Volkswagen CJDA Workshop Manual Download Page 502 | Manualshive

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Special tools and workshop equipment required

◆

Adapter -3400-

Test prerequisite

● Poly V-belt tension OK and alternator secured properly

Test procedure

– Remove protective cap from poly V-belt pulley with free-

wheel.

– Insert adapter -3400- in poly V-belt pulley (with freewheel)

on alternator.

– Using a 17 mm ring spanner on adapter -3400-, turn drive

shaft of alternator anti-clockwise via poly V-belt pulley.

If only the drive shaft in the poly V-belt pulley turns and the con-
tact surface of the pulley remains stationary:

– Renew poly V-belt pulley with freewheel clutch

,

removing and installing poly V-belt pulley.

If the contact surface of the poly V-belt pulley turns along with
the drive shaft in poly V-belt:

– Clip protective cap onto poly V-belt pulley with freewheel.

– Check alternator -C- and voltage regulator -C1-

3

Current flow diagrams

Note

◆

The current flow diagrams below are only examples for cir-
cuits, since due to the various use cases of industrial en-
gines it is not possible to specify common circuits.

◆

The specified cross-section values are minimum values. De-
pending on the relevant unit, larger cross-sections may ap-
ply and must be adhered to accordingly when performing
any repair work.

WARNING

Always disconnect the battery earth strap before working
on the electrical system.

Observe safety precautions

Observe rules for cleanliness

Current flow diagrams:

◆

Vehicles/machines compliant with emission standard (97/68
stage 3a), engine codes CPYA, CPYB,CPYC, CPYD, CPYE

.

◆

Vehicles/machines compliant with emission standard (97/68
stage 3b), engine codes CPYA, CPYB, CPYC, CPYD, CPYE

.

3

Industriemotoren - Industrial Engines 2009

▶

Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015

486

Repair Group 27 - Starter, current supply, CCS

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Summary of Contents for CJDA

Page 1: ...al Industriemotoren Industrial Engines 2009 Workshop Manual for Diesel Engine 2 0 l 36 75 kW_EA 189 Edition 05 2015 Engine code CJDA CJDD CPYA CPYB CPYC CPYD CPYE Service 3 Service Department Technica...

Page 2: ...Bulletins 00 Technical data 01 Vehicle self diagnosis 10 Removing and installing engine 13 Crankshaft group 15 Cylinder head valve gear 17 Lubrication 19 Cooling 20 Fuel supply system 21 Turbocharging...

Page 3: ...amage 18 4 4 2 Perform road test 18 4 4 3 Add on parts on the engine peripherals 19 5 Warranty 19 5 1 Repair work important information 19 5 2 Warranty terms 19 Vehicle self diagnosis 22 1 Vehicle sel...

Page 4: ...oup 12 Status 99 5 3 9 Display group 13 Smooth running control 1 101 5 3 10 Display group 20 Fuel rail values 3 101 5 3 11 Display group 30 Pedal encoder 102 5 3 12 Display group 34 Charge pressure po...

Page 5: ...filter exhaust gas temperature sender pressure differential sender 121 6 3 21 Display group 104 122 6 3 22 Display group 108 diesel particulate filter regeneration 8 123 6 3 23 Display group 245 124 6...

Page 6: ...d belt drive engine codes CPYA CPYB CPYC CPYE with crankshaft seal 149 1 10 Removing and installing toothed belt guard with inspection cover for checking tension of toothed belt 150 1 11 Performing vi...

Page 7: ...ds 182 4 1 Assembly overview pistons and conrods 183 4 2 Separating new conrods 185 4 3 Bearing shells installation position 186 4 4 Checking piston projection at TDC 187 4 5 Piston and cylinder dimen...

Page 8: ...2 1 2 Engine codes CPYA CPYB CPYC CPYD CPYE 254 2 2 Removing and installing sump 257 2 2 1 Removing 258 2 2 2 Installing 259 3 Oil filter bracket oil cooler and oil pressure switch 260 3 1 Oil filter...

Page 9: ...ply system 298 1 Removing and installing parts of fuel supply system 298 1 1 Safety precautions when working on fuel supply system 299 1 2 Rules for cleanliness 300 1 3 Procedure when filling with inc...

Page 10: ...80 337 2 4 Testing vacuum system 338 2 4 1 Checking supply line and non return valve engine codes CJDA CJDD only 338 2 4 2 Checking control line to turbocharger engine codes CJDA CJDD CPYA CPYB CPYC C...

Page 11: ...2 Removing and installing fuel pressure regulating valve N276 377 1 13 Removing and installing fuel pressure sender G247 379 1 14 Removing and installing high pressure pump 380 1 15 Filling and bleedi...

Page 12: ...PXD CPYE 435 3 Checking components and functions 436 3 1 Checking exhaust gas recirculation system 436 3 2 Checking exhaust gas recirculation valve N18 437 3 3 Checking Lambda probe G39 439 3 4 Checki...

Page 13: ...g voltage regulator C1 Bosch 478 2 4 2 Removing and installing voltage regulator C1 Valeo 479 2 5 Removing and installing poly V belt pulley 480 2 5 1 Removing and installing poly V belt pulley withou...

Page 14: ...oltage supply relay engine control unit fuses 505 3 2 4 Jumpers charge pressure sender intake air temperature sender air mass meter engine control unit 506 3 2 5 Accelerator position sender accelerato...

Page 15: ...gas temperature sender 1 exhaust gas temperature sender 3 exhaust gas temperature sender 4 engine control unit 527 3 3 10 Lambda probe exhaust gas pressure sensor 1 engine control unit lambda probe he...

Page 16: ...3 Industriemotoren Industrial Engines 2009 Workshop Manual for Diesel Engine 2 0 l 36 75 kW_EA 189 05 2015 xvi Contents...

Page 17: ...associated with it 2 Important notes for repair work on the engine Note The procedures described in this workshop manual must on ly be carried out by personnel which has undergone the ap propriate tr...

Page 18: ...e manual that comply with Volks wagen specifications The use of makeshift tools wrong components as well as proceeding in the wrong way results in improper repair work Part numbers stated in this manu...

Page 19: ...me medicine or pharmaceutical products may impair your concentration and reactivity Make sure to illuminate your work environment properly and safely Use a portable safety lamp when working in side or...

Page 20: ...ARNING When working on the electrical system or the fuel system of the vehicle machine always disconnect the negative battery cable from the battery of the vehicle machine Never smoke or perform any w...

Page 21: ...r heavy components 3 Technical data Engine number engine code Page 5 Engine data Page 6 In the event of any queries claims complaints and when order ing replacement parts always indicate the engine de...

Page 22: ...e Diesel engine Diesel engine Displacement cyl inders l number 2 0 4 2 0 4 Output kW at rpm 55 2700 44 2700 Torque Nm at rpm 240 1750 200 1750 Bore Diameter mm 81 0 81 0 Stroke mm 95 5 95 5 Weight wit...

Page 23: ...fil 97 68 EC category 3a 97 68 EC category 3a Particulate filter no no Exhaust gas recircula tion yes yes Turbocharging super charging yes yes Charge air cooler yes yes Upper idling speed rpm 3400 340...

Page 24: ...with 97 68 EC category 3a Engine codes CPYG Manufactured 08 14 Engine designation TDI 2 0 436 MC CR Engine type Diesel engine Displacement l 2 0 4 Output kW at rpm 36 2700 Torque Nm at rpm 200 1750 Bo...

Page 25: ...with out attach ments and diesel partic ulate filter kg 140 kg 140 kg Compression ratio 16 5 16 5 Fuel min Diesel in accord ance with DIN EN 590 with min 51 CN Diesel in accord ance with DIN EN 590 wi...

Page 26: ...d in this manual we strongly recommend that you have the work performed exclusively in a qualified workshop This recommendation also applies in cases where individu als and workshops are not equipped...

Page 27: ...service are indicated whichever occurs first Depending on the conditions under which the vehicle is used extra service work must be performed in addition to the interval service inspection service or...

Page 28: ...content in fuel Page 12 Change engine oil Every 300 operating hours 1 year whichever occurs first Engines operated under normal operat ing conditions Page 14 Interval service Every 600 operating hours...

Page 29: ...ervice intervals This is applicable in particular for the air filter toothed belt fuel filter diesel particulate filter and engine oil The following are severe operating conditions Deviation from note...

Page 30: ...f service ap ply In this case the engine oil must be changed every 600 oper ating hours or after 1 year Page 11 Volkswagen recommends to double the frequency of service work according to the operating...

Page 31: ...cooling fins for leaks and soiling on the outside Check exhaust system for leaks damage and whether it is secured firmly Renew air filter Check hoses clamps and renew as necessary Check air lines for...

Page 32: ...on diesel particulate filter CPYA CPYB CPYC CPYD CPYE CPYF CPYG Page 454 1 Applicable for diesel engines only in some countries the sulphur content in diesel fuel exceeds 2000 ppm The high sulphur con...

Page 33: ...CPYB CPYC CPYD CPYE CPYF CPYG CJDA CJDD Page 430 Page 465 As necessary Additional work Engine code Page Drain water from fuel filter CPYA CPYB CPYC CPYD CPYE CPYF CPYG CJDA CJDD Page 307 Exhaust emiss...

Page 34: ...ents for leaks damage and whether they are secured firmly Check lines hoses and connections of exhaust system fuel system cooling and heating system engine oil circuit air conditioning system intake s...

Page 35: ...drive the vehicle to the workshop If this is not possible you can request a mechanic to provide assistance For complex repair work provide the removed and cleaned en gine to the certified workshop Th...

Page 36: ...become the property of the vendor If the remedies require any additional service work prescribed by the Volkswagen Group the ven dor will bear any costs for said service work including the costs for...

Page 37: ...to a breach of the agreement 7 The warranty claims mentioned above become invalid after the warranty period has elapsed in accordance with para graph 1 If a warranty claim has been asserted within the...

Page 38: ...d with the addendum sporadic fault SP The cause of sporadic faults can be for example a loose contact or a brief open cir cuit If a sporadic fault does not occur again within 50 engine starts it will...

Page 39: ...es yes yes 014 Long adaptation yes yes no 015 Access permissions yes yes no Only carry out with ignition switched on and when engine does not start 1 3 Connecting vehicle diagnostic tester and selecti...

Page 40: ...not match Check control unit coding Select diagnostic function All the available diagnosis functions are shown on the display Press key on display for the desired function Note For the function 011 Me...

Page 41: ...598 39 1 Prerequisites Ignition switched off All electrical consumers must be switched off Procedure Pull 60 pin connector off engine control unit J623 Using adapter cable V A G 1598 39 1 connect test...

Page 42: ...ector off engine control unit J623 Using adapter cable V A G 1598 39 2 connect test box V A G 1598 42 to wiring harness of engine control unit and to connections A and B of test box The engine control...

Page 43: ...one or more static faults are stored in the event memory it is recommended in agreement with the customer to rectify these faults using Guided fault finding Sporadic faults If only sporadic faults or...

Page 44: ...e displayed as well For additional information on the fault types e g Open cir cuit Short to Earth refer to the Operating manual for vehicle diagnosis testing and information system VAS 5051 If compon...

Page 45: ...at are not always present e g loose contact Fault code 00022 P0016 00146 P0092 Page 30 00256 P0100 01687 P0697 Page 34 04110 P100E 05784 P1693 Page 64 08194 P2002 09780 P2634 Page 70 12256 P33C8 13093...

Page 46: ...Hall sender 2 G40 on page 403 Use tester to check valve timing camshaft position Check operation of camshaft adjuster check control valves shaft adjuster oil pressure Check valve timing Page 210 Remov...

Page 47: ...ng fill level of fuel tank Checking fuel system for leaks Page 384 Check supplementary fuel pump V393 Page 314 Checking fuel pres sure regulating valve N276 Page 391 Check return flow rate from fuel p...

Page 48: ...for leaks Page 384 Check supplementary fuel pump V393 Page 314 Checking fuel pres sure regulating valve N276 Page 391 Check return flow rate from fuel pressure regulating valve N276 Page 377 Checking...

Page 49: ...arth Wiring short to earth N290 defective Failure of metering unit and engine Check fuel metering valve N290 Page 388 Pull connector off ac tuator and read event memory again If in addition MeUnOL ren...

Page 50: ...ther there is an electrical fault in wire or wiring harness short to positive or to earth or open circuit If not renew sensor After road test fault in event memory re new ECU there is no other way to...

Page 51: ...42 Implausible signal Open circuit or line short circuit G42 defective No limitation Check intake air tem perature sender G42 Page 404 Comparison of all temperatures with completely cooled down engine...

Page 52: ...measure reference volt age 3 3 V on signal line measured value block Air_uRawT CACDs approx refer ence voltage con nect signal line to earth If sensor raw voltage in measured value block 0 V sensor de...

Page 53: ...or raw voltage 00279 P0117 Coolant temperature sender G62 Signal too low Wiring open circuit or wiring short to posi tive G62 defective Alternative values are used for coolant alter native values are...

Page 54: ...e to ECU Wire to ECU OK ECU defective 00289 P0121 Throttle valve potentiom eter G69 Implausible signal Open circuit or line short circuit Throttle valve potenti ometer G69 defec tive No limitations Ch...

Page 55: ...robe 1 Electrical fault in current circuit Open circuit or line short circuit Lambda probe G39 defective Zero quantity calibra tion calculation of die sel particulate filter load exhaust gas temperatu...

Page 56: ...60 65 ohm Warning termi nal 15 Off for this if measuring resistor is defective renew lambda probe Check voltage supply dis connect universal lambda probe and measure on contacts of coupling between vi...

Page 57: ...Fuel temperature sender G81 Open circuit short to pos itive Wiring open circuit or wiring short to posi tive G81 defective Changes to alterna tive value RB_FuelT_TransStg Dfl_C Regeneration is locked...

Page 58: ...itched off Engine fails N30 Check Page 398 Check for short to positive on injector 1 high and low wire If OK check injector If OK renew ECU 00514 P0202 Injector for cyl 2 N31 Electr fault in circuit O...

Page 59: ...nosis Checking charge pressure control Page 333 Checking charge air system for leaks Page 331 00567 P0237 Charge pressure sender G31 Signal too low Open circuit or line short circuit G31 defective Tor...

Page 60: ...ection quanti ty on cyl 1 Adaption values do not match adaption value specified on in jector Glow period warning lamp K29 lights up Incorrect injection quantity Check injector deliv ery calibration va...

Page 61: ...U defec tive If an additional fault is stored which indicates a defective EEProm renew ECU 00617 P0269 Incorrect injection quanti ty on cyl 3 Adaption values do not match adaption value specified on i...

Page 62: ...defec tive Leak in charge air system Torque limiting regen eration is locked Check N75 Page 89 final control diagnosis Checking charge air system for leaks Page 331 Checking charge pressure control Pa...

Page 63: ...sion Page 218 Check injector for cyl 4 N33 Page 398 Compare learnt val ues for zero quantity calibration ZFC 00801 P0321 Engine speed sender G28 Implausible signal Wire open circuit or wire has short...

Page 64: ...hub or Hall sender G40 Too much clearance between Hall sender G40 hub Hub with sender wheel on camshaft is twisted or loose Engine is operated via crankshaft signal EPC is activated be cause detectio...

Page 65: ...ions Check exhaust gas re circulation system Page 436 01025 P0401 Exhaust gas recirculation system Insufficient throughput Exhaust gas recircu lation system clogged Leak in exhaust gas recirculation s...

Page 66: ...re to excluded 01029 P0405 Exhaust gas recirculation sender Signal too low Wiring open circuit or wiring short to posi tive G212 defective Particulate filter re generation locked Check G212 Page 437 c...

Page 67: ...n nector on exhaust gas recirculation valve is OK On wiring harness check feedback line for short circuit to bat tery voltage and to sensor 5V supply voltage Check feed back line for open load On exha...

Page 68: ...sensors ahead of tur bine and downstream from diesel oxidising catalytic converter for plausibility If OK check air mass meter for plausibility If OK check exhaust system for leaks If OK check injecti...

Page 69: ...Torque reduction Check components for working speed control Page 486 current flow diagram Check electrical con nection to sensor if OK sensor defec tive electrical or read event memory of vehicle con...

Page 70: ...age 417 Possible open circuit on terminal 87 01538 P0602 Control unit coding Malfunction Invalid control unit coding for engine control unit J623 Several effects possi ble since ECU is co ded incorrec...

Page 71: ...tion locked Calculation of diesel particulate filter load Exhaust gas tempera ture regulation FMO Regeneration of NOx storage catalytic con verter is locked J623 Renew Page 418 01576 P0628 Electric f...

Page 72: ...88 P0634 Control unit temperature shut off Overload on output stage s in J623 Glow plug control module is switched off Very high ambient temperature Engine control unit not installed correctly Interna...

Page 73: ...r in take manifold flap dif ferential pressure die sel particulate filter pedal encoder 1 G28 Check Checking engine speed sender G28 on page 400 G31 Check Checking charge pressure sender G31 on page 3...

Page 74: ...s star ted Check J179 Page 89 final control diagnosis After a while the fault should stored Rectify fault glow plug control unit does not match engine control unit Has one of the control units been re...

Page 75: ...uator con trol flap charge pres sure probe pedal en coder 2 G28 Check Checking engine speed sender G28 on page 400 G31 Check Checking charge pressure sender G31 on page 343 G79 Check Checking accelera...

Page 76: ...to auto matic glow period con trol unit J179 Page 486 current flow diagrams Electr test of glow plug connector Pull off glow plug and read entry in event memory If entry is still stored in event memor...

Page 77: ...g to auto matic glow period con trol unit J179 Page 486 current flow diagrams Electrical test of glow plug connector wire to glow plug control unit Pull off glow plug and check resistance Check glow p...

Page 78: ...ow plug control unit Pull off glow plug and check resistance Page 536 If resistance is not in finite check wire and connector 01658 P067A Glow plug for cylinder 4 Short to earth Wire open circuit or w...

Page 79: ...ly Open circuit or line short circuit Defective terminal 30 voltage supply relay J317 Engine stops Engine control unit switched off Check wires to J317 Page 486 current flow diagrams Renew main relay...

Page 80: ...ressure regu lating valve N276 Page 377 N276 Check Page 391 04663 P1237 Injector for cyl 1 N30 Open circuit Open circuit or line short circuit N30 defective Irregular idling or en gine stalls Cylinder...

Page 81: ...renew ECU 04999 P1387 Control unit defective Engine control unit J623 defective Reduced performance Increased exhaust emissions Replicate fault fault is stored on ignition ON Motorsteuerger t J623 Ren...

Page 82: ...ilter No limitation Check N18 Page 89 final control diagnosis Check wiring of DC motor EGR valve short circuit between M and M Disconnect EGR valve clear event memo ry fault stored again ECU defective...

Page 83: ...aust gas recir culation system is shut off and constant specified values are output No limitation Check exhaust gas re circulation system for leaks Page 433 Check N18 Page 89 final control diagnosis 0...

Page 84: ...ore Check electrical con nection to actuator J623 Renew Page 418 05642 P160A Control unit defective Internal defect in en gine control unit J623 Engine does not start or is difficult to start J623 Ren...

Page 85: ...ol unit J623 ECU performs reset J623 Renew Page 418 05778 P1692 Self diagnosis warning lamp K83 Short to earth Wire open circuit or wire has short to earth Check K83 Page 89 final control diagnosis Ch...

Page 86: ...n circuit or line short circuit J388 defective No regeneration of diesel particulate filter Check J338 Page 89 final control diagnosis J338 Check Page 414 Check electrical con nection to actuator 0845...

Page 87: ...ry The sensor may be defective as well 08482 P2122 Accelerator pedal posi tion sender Signal too low Wiring open circuit or wiring short to posi tive G79 defective Torque is considerably reduced above...

Page 88: ...enewed 08518 P2146 Voltage supply of injec tor s A Open circuit Open circuit or line short circuit N30 N33 defective Engine stalls N30 N33 Check Page 398 Check wires high and low of injectors for shor...

Page 89: ...meter defective offset in fuel rail 08598 P2196 Lambda probe 1 bank 1 Signal too rich Wiring open circuit Lambda probe G39 defective Regeneration of NOx storage catalytic con verter is locked G39 Chec...

Page 90: ...this if measuring resistor is defective renew lambda probe Check voltage supply dis connect universal lambda probe and measure on contacts of coupling between virtual earth IPN and body earth V 2 3 V...

Page 91: ...l 15 OFF for this if measuring resistor is defective renew lambda probe Check voltage supply dis connect universal lambda probe and measure on contacts of coupling between virtual earth IPN and body e...

Page 92: ...between virtual earth IPN and body earth V 2 3 V Warning terminal 15 ON for this if there is no volt age check wire for open circuit and re new it as necessary Check wires for pump current APE virtua...

Page 93: ...gu lating valve N276 defective Failure of pressure regulating valve Engine stalls N276 Check Page 391 Pull connector off actua tor and read event mem ory again if in addition PCVOL renew actua tor oth...

Page 94: ...V sensor de fective sensor raw voltage in measured value block ap prox 0 V check sensor wire to ECU Wire to ECU OK ECU defective 09259 P242B Exhaust gas temperature sender 3 bank 1 Implausible signal...

Page 95: ...defective No service regenera tion possible anymore Renew diesel particu late filter 09298 P2452 Diesel particulate filter pressure differential sender Electrical fault Open circuit or line short cir...

Page 96: ...icu late filter CPYA CPYB CPYC CPYD CPYE Page 454 Check proper connec tion of hoses on pres sure differential send er leaks clogged etc perform electr test on sensor wire 1 Pull off pressure sensor se...

Page 97: ...late filter CJDA CJDD Page 460 Check diesel particu late filter CPYA CPYB CPYC CPYD CPYE Page 454 Pull off pressure sen sor sensor raw voltage in measured value block reference voltage 5V sen sor defe...

Page 98: ...engine codes CJDA CJDD on page 460 Check diesel particu late filter and note en gine code Emergency regeneration must be performed on diesel particulate filter An emergency regen eration must be per f...

Page 99: ...Implausible signal Open circuit or line short circuit G648 defective No limitation G648 Check Page 444 Comparison of all temperatures with completely cooled down engine and ter minal 15 ON engine OFF...

Page 100: ...OK diesel oxidising cata lytic converter may be defective 09571 P2563 Position sender for charge pressure position er Implausible signal Open circuit or short circuit in wire G581 defective G581 Check...

Page 101: ...o high Open circuit or short circuit in wire G581 defective Limp mode Regeneration of die sel particulate filter locked regular and emergency regenera tion G581 Check Page 345 Terminal 15 ON read even...

Page 102: ...pres sure fuel system too low Check J49 Page 89 final control diagnosis Check wiring to J49 Page 486 current flow diagrams Check terminal 15 On and 12V on relay KL85 Pull off relay connector and chec...

Page 103: ...ystem Statutory long term event memory entry the entry only occurs in conjunction with an other EGR fault In correct EGR through put 3 5 Fault code 13256 P33C8 13257 P33C9 Indicated on display Possibl...

Page 104: ...ulate filter After the service re generation the en gine oil must be changed There may be a fault in the fol lowing components EGR cooler air mass meter turbocharger charge pressure in jection quantit...

Page 105: ...5 Glow period warning lamp K29 if fitted 6 Exhaust emissions warning lamp K83 if fitted 7 Warning lamp for diesel particle filter K231 8 Radiator fan control unit J293 radiator fan activation as semb...

Page 106: ...d Check exhaust gas recirculation Page 436 Activating charge pressure control solenoid valve N75 Press button The charge pressure control solenoid valve N75 is activated The displays in display zones...

Page 107: ...e valve module is activated If the engine is not switched off Proceed with final control diagnosis until completed Switch off ignition Check throttle valve module Page 414 Activating glow period warni...

Page 108: ...1 according to cur rent flow diagram Page 486 current flow diagrams Activating automatic glow period control unit J179 Press button The automatic glow period control unit J179 is activated The contro...

Page 109: ...DA CJDD Observe safety precautions Page 93 Read measured value block Page 94 Evaluate measured value blocks At idling speed Page 95 At full load Page 106 5 1 Safety precautions WARNING When doing any...

Page 110: ...y as an overview Test prerequisites Fuses must be OK The battery voltage must be at least 11 5 V Earth connections OK All electrical consumers must be switched off No faults must be stored in event me...

Page 111: ...trol Page 99 12 Status Page 99 13 Smooth running control Page 101 20 Fuel rail values 3 Page 101 30 Pedal encoder Page 102 34 Charge pressure positioner Page 103 99 Exhaust gas temperature sender Page...

Page 112: ...ding fuel system Page 383 Injectors for cylinders 1 4 N30 N33 defective N30 N33 Check Page 398 5 3 2 Display group 2 Idling speed Test prerequisites Engine running at idling speed Engine warm coolant...

Page 113: ...tem Page 436 Unmetered air Check intake system for leaks Above specification Engine too cold Run engine at increased speed to warm up and repeat test Insufficient exhaust gas recirculation Engine run...

Page 114: ...uation Display group 7 display zone 1 fuel tempera ture Display shows Possible cause of fault Fault remedy Large deviation from ambient tem perature Short circuit or fuel temperature send er G81 defec...

Page 115: ...e 316 5 3 7 Display group 11 Charge pressure control Test prerequisites Engine running at idling speed Engine warm coolant temperature not below 80 C Intake air temperature 40 C Display zone Operating...

Page 116: ...nce if display 1 Dis play show s Glow plug system status 0000 0000 Waiting for coolant temperature 0001 0000 Pre heating 1011 0000 Post heating 1111 0000 Intermediate heating 0011 0000 Standby heating...

Page 117: ...w rate compressions etc which are recognised and compensated for by selective injection quantities Recognition at idling speed is via the signal from the engine speed sender If the signals are deliver...

Page 118: ...sure in high pressure fuel system Display shows Possible cause of fault Fault remedy Deviation from specification Fuel pressure regulating valve N276 defective N276 Check Page 391 5 3 11 Display group...

Page 119: ...Checking charge pressure control Page 333 G581 Check Page 345 Evaluation display group 34 display zone 4 charge pres sure control Display shows Possible cause of fault Fault remedy Deviation from spe...

Page 120: ...00 200 C Page 104 2 Exhaust gas temperature downstream of diesel particulate filter 100 250 C Page 104 3 Diesel particulate filter pressure differen tial sender adapted 0 20 mbar Page 104 4 Diesel par...

Page 121: ...uisites Secure vehicle machine Engine running at idling speed Engine warm coolant temperature not below 80 C Intake air temperature 40 C Display zone Operating mode or component Specification Evaluati...

Page 122: ...recautions Page 93 Read measured value block Page 94 Note Due to the various use cases of industrial engines check whether the engine attains full load under the respective operat ing conditions befor...

Page 123: ...Check fuel supply system Page 298 removing and installing parts of fuel supply system Bleeding fuel system Page 383 Injectors for cylinders 1 4 N30 N33 defective N30 N33 Check Page 398 5 4 3 Display...

Page 124: ...lation valve Display shows Possible cause of fault Fault remedy Below specification Excessive exhaust gas recirculation Check exhaust gas recirculation sys tem Page 436 Unmetered air Check intake syst...

Page 125: ...lay zone 3 charge pres sure actual Display shows Possible cause of fault Fault remedy Below specification Leaks between turbocharger and en gine charge air system Charge pressure control defective Che...

Page 126: ...ed without starting e g to check compression pull connector A off injectors Disconnecting and connecting the battery must only be done with the ignition switched off otherwise the engine control unit...

Page 127: ...Lower Press button Skip Press button If the specifications are attained in all display zones Exit diagnosis function Switch off ignition 6 3 Evaluating measured value blocks at idling speed Always fo...

Page 128: ...0 0 C Evaluation Display group 1 display zone 2 quantity injec ted Display shows Possible cause of fault Fault remedy Below specification Injectors for cylinders 1 4 N30 N33 defective N30 N33 Check Pa...

Page 129: ...0 mg stroke 3 Intaken air mass actual 190 320 mg stroke1 Page 113 4 Duty cycle of exhaust gas recirculation valve 45 70 1 The specification applies for deactivated exhaust gas recirculation system Dut...

Page 130: ...n engine at increased speed to warm up and repeat test 6 3 5 Display group 5 Display zone Operating mode or component Value range Evaluation 1 Engine speed 0 5865 rpm 2 Engine start quantity on start...

Page 131: ...Fault remedy Large deviation from ambient tem perature Short circuit or defective coolant tem perature sender G62 G62 Check Page 407 6 3 7 Display group 10 Air quantities Test prerequisites Engine run...

Page 132: ...m coolant temperature not below 80 C Intake air temperature 40 C Display zone Operating mode or component Specification Evaluation 1 Glow plug system status 1111 1111 Page 116 2 Glow period in seconds...

Page 133: ...emperature 40 C Display zone Operating mode or component Specification Evaluation 1 Injection quantity for smooth running con trol through injector cylinder 1 N30 2 80 2 80 mg H Page 117 2 Injection q...

Page 134: ...s therefore supplied with less fuel 6 3 11 Display group 20 Fuel rail values 3 Test prerequisites Engine running at idling speed Engine warm coolant temperature not below 80 C Intake air temperature 4...

Page 135: ...accelerator position Display shows Possible cause of fault Fault remedy 1 0 100 0 Defective accelerator position sender G79 Open circuit in wiring to G79 G79 Check Page 316 6 3 13 Display group 32 Di...

Page 136: ...Fault remedy Deviation from specification Position sender for charge pressure positioner G581 defective Leaks between turbocharger and en gine charge air system Charge pressure control defective Chec...

Page 137: ...r temperature 40 C Display zone Operating mode or component Specification Evaluation 1 Engine speed 880 1090 rpm 2 Exhaust gas temperature ahead of turbo charger 150 370 C Page 121 3 4 Exhaust gas tem...

Page 138: ...gas temperature Display shows Possible cause of fault Fault remedy Deviation from specification Exhaust temperature sender 4 G648 defective G648 Check Page 444 Evaluation display group 100 display zon...

Page 139: ...cation Ash deposit mass too high Renew diesel particulate filter Page 430 Evaluation display group 108 display zone 2 diesel par ticulate filter regeneration Display shows Possible cause of fault Faul...

Page 140: ...11111 6 3 24 Display group 246 Display zone Operating mode or component Value range Evaluation 1 Ratio between thermal management and regular engine operation only CPYA and CPYB 0 100 2 Test status fo...

Page 141: ...ge Evaluation 1 Engine speed 0 5865 rpm 2 Status of regeneration and ash deposit mass adaptation only CPYA and CPYB 0 255 CAN available 1 in doc for commission ing coding request message Vehicle is se...

Page 142: ...read at an engine speed of 2500 rpm 2nd person required Test prerequisites Engine warm coolant temperature not below 80 C Engine speed 2200 2800 rpm Engine at full load Display zone Operating mode or...

Page 143: ...luation 1 Engine speed 2200 2800 rpm 2 Intaken air mass specified 620 830 mg stroke 3 Intaken air mass actual Approx intaken air mass specified Page 113 4 Duty cycle of exhaust gas recirculation valve...

Page 144: ...component Specification Evaluation 1 Engine speed 2200 2800 rpm 2 Desired torque xxx Nm 3 Torque limit xxx Nm 4 Smoke limiting xxx Nm 6 4 5 Display group 11 Charge pressure control Note To perform the...

Page 145: ...ne code CPYB Note conditions for measurements at full load Page 129 Display group 1 Injected quantity Page 130 3 Exhaust gas recirculation Page 130 8 Torque limit 1 Page 131 11 Charge pressure control...

Page 146: ...lay shows Possible cause of fault Fault remedy Below specification Injectors for cylinders 1 4 N30 N33 defective N30 N33 Check Page 398 Above specification Engine too cold Run engine at increased spee...

Page 147: ...tion Give burst on throttle Defective air mass meter G70 G70 Check Page 411 Evaluation display group 3 display zone 4 duty cycle of exhaust gas recirculation valve Display shows Possible cause of faul...

Page 148: ...Engine speed 2200 2450 rpm 2 Charge pressure specified 1620 1750 mbar 3 Charge pressure actual 1620 1800 mbar Page 132 4 Duty cycle of charge pressure control sol enoid valve 40 70 Evaluation display...

Page 149: ...ecial tools and workshop equipment required Lifting tackle 3033 Hose clamps up to 25 mm 3094 Support clamp VW 313 Drip tray V A G 1306 or drip tray VAS 6208 Torque wrench 5 50 Nm V A G 1331 Torque wre...

Page 150: ...assembly stand Page 136 Notes on installing Page 136 Specified torques Page 137 Additional information and assembly work for power units with air conditioner Page 137 1 1 Notes on removing Note The p...

Page 151: ...d refrigerant brake fluid and vacuum and electrical wiring in their original positions Ensure that there is sufficient clearance to all moving or hot components Tools are to be checked for damage and...

Page 152: ...ocedure Attach lifting tackle 3033 as shown and raise engine using workshop hoist V A G 1202 A or workshop hoist VAS 6100 Flywheel end Position 4 Vibration damper end Position 8 Engine can now be move...

Page 153: ...ening of the refrigerant circuit can only be carried out in workshops which have trained personnel and the neces sary range of tools and workshop equipment To prevent damage to condenser or to refrige...

Page 154: ...adhere to the safety instructions from the manufacturer There is a risk of injuries if maintenance locations are difficult to access This risk can be reduced by in stalling the engine in an appropria...

Page 155: ...ving and installing poly V belt Page 141 Assembly overview poly V belt drive without air conditioner compressor Page 141 Checking poly V belt Page 143 Removing and installing poly V belt tensioner eng...

Page 156: ...new q Do not additionally oil or grease the threads and shoul der q Turning further can be done in several stages 6 Poly V belt tensioning element q Swing to slacken poly V belt q Removing and in stal...

Page 157: ...5 Poly V belt q Check for wear Page 143 q Removing and in stalling Page 141 1 3 Removing and installing or renewing poly V belt Example with air conditioner compressor Special tools and workshop equip...

Page 158: ...poly V belt check direction of belt rotation and proper seating of belt in pulleys Fit poly V belt on pulleys 1 Crankshaft 2 Tensioning element 3 Alternator 4 Air conditioner compressor After completi...

Page 159: ...es cross sectional breaks Delamination top cover cord strands Eruptions on bottom cover Fraying of cord strands Flank wear material abrasion frayed flanks flank hardening glass like flanks surface cra...

Page 160: ...essure pump Page 380 Remove alternator Page 471 WARNING The air conditioner refrigerant circuit must not be opened If fitted unbolt air conditioner compressor from ancillary bracket and tie it up free...

Page 161: ...ing angle Insert securing bolts for ancillary bracket as follows Bolts 1 and 2 Bolts 3 and 4 Bolts 5 and 6 Tighten securing bolts for ancillary bracket in sequence 1 6 in 2 stages as follows 1 Screw a...

Page 162: ...done in several stages 3 Crankshaft toothed belt pulley 4 20 Nm 5 Idler pulley 6 20 Nm 1 8 turn 45 further q Renew 7 Tensioning roller q If fitted remove en gine bracket to remove and install 8 20 Nm...

Page 163: ...t guard lower part 26 Toothed belt guard centre part 27 10 Nm q Renew 28 10 Nm 1 4 turn 90 further q Renew 29 Belt pulley and vibration damper q Can only be installed in one position holes are offset...

Page 164: ...by the engine falling tipping over etc Installing Tightening sequence for securing engine bracket to cylin der block if fitted Caution The tightening sequence and specified torques for the en gine bra...

Page 165: ...n 45 further q Renew 8 Camshaft pulley 9 25 Nm 10 100 Nm 11 Hub q Use counterhold tool T10051 to loosen and tighten q To remove use puller T10052 q Removing and installing Page 138 Removing and instal...

Page 166: ...offset 33 5 Nm 34 35 Protective plate 36 40 Nm 1 2 turn 180 further q Renew q Observe tightening sequence Fig on page 148 37 Engine bracket 38 180 Nm 3 8 turn 135 further q Renew q Use counterhold to...

Page 167: ...sender wheel is free to move There may be grinding noise Slight grinding noises should disappear after the en gine has been running for a while If the clearance is too small rework toothed belt guard...

Page 168: ...may become detached during operation 1 12 Assessing wear on tensioning roller and belt pulleys Toothed belt und pulleys 1 Worn 2 New 3 Operation time The toothed belt tension must be checked as part...

Page 169: ...serve indicator position on tensioning roller Assess whether the toothed belt will exceed the wear limit before the next service interval taking the operating hours in to account The toothed belt must...

Page 170: ...be renewed This must be assessed for each individual case Example 3 inspection at 1800 operating hours 1 Worn 2400 operating hours 2 New 3 3 4 of measuring field If the dashed indicator is still ahead...

Page 171: ...nly be installed in one position holes are offset Push locking lug 7 of guide 5 precisely onto respective locking peg 8 on toothed belt pulley 6 Fit lower part of toothed belt guard 4 and renew bolts...

Page 172: ...s diagonal ly 5 Bracket 6 10 Nm 7 Connection q For 4 2 way valve q Removing and in stalling 4 2 way valve Page 290 8 15 Nm 9 O ring q Renew 10 4 2 way valve q Removing and installing 4 2 way valve Pag...

Page 173: ...ng and as sembling pistons and conrods Page 138 2 Guide tube q Renew O ring 3 Spreader clip 4 Gaskets q Renew q May not be lubrica ted with oil q Fit into lugs on oil filter bracket 5 Oil filter brack...

Page 174: ...amage results Volkswagen is exempt from any liability and warranty claims WARNING Adhere to the general safety regulations and the notes on repair work on the engine Page 1 Note Before carrying out re...

Page 175: ...pter must be carried out in a Volkswagen dealership only If these instructions are not adhered to and damage results Volkswagen is exempt from any liability and warranty claims Industriemotoren Indust...

Page 176: ...talling re move oil residue from crankshaft journal using a clean cloth q Renewing crank shaft oil seal belt pulley end Page 161 4 Sealing flange q Must seat on dowel pins q Removing and installing Pa...

Page 177: ...pair work described in this chapter must be carried out in a Volkswagen dealership only Go to a Volkswagen deal ership If these instructions are not adhered to and damage results Volkswagen is exempt...

Page 178: ...oothed belt pul ley using counterhold 3415 To guide oil seal extractor 3203 screw central bolt by hand to stop into crankshaft Unscrew inner part of oil seal extractor by 20 mm from outer part making...

Page 179: ...itionally oiled or greased Remove oil residue from crankshaft journal using clean cloth Place guide sleeve T10053 1 onto crankshaft journal Slide oil seal over guide sleeve onto crankshaft journal Pre...

Page 180: ...t Page 210 2 3 Removing and installing crankshaft sealing flange pulley end WARNING Always adhere to the following instructions The repair work described in this chapter must be carried out in a Volks...

Page 181: ...illustrated Silicone sealant D176404 A Hand drill with plastic brush attachment Flat scraper Eye protection Removing Page 165 Installing Page 166 2 3 1 Removing Remove toothed belt Page 210 Industrie...

Page 182: ...tection Clean sealing surfaces They must be free of oil and grease 2 3 2 Installing Note Note the expiry date of the sealant The sealing flange must be installed within 5 minutes of ap plying silicone...

Page 183: ...t pulley us ing counterhold 3415 Tighten new central bolt to 120 Nm and 1 4 turn 90 further turning further can be done in several stages Note Thread and shoulder must be free of oil and grease How to...

Page 184: ...upply from Volkswagen Adhere to the manufacturing specifications when performing any maintenance and repair work 6 Intermediate plate q Must seat on dowel sleeves q Do not damage or bend when assembli...

Page 185: ...notes on repair work on the engine Page 1 WARNING Always adhere to the following instructions The repair work described in this chapter must be carried out in a Volkswagen dealership only If these ins...

Page 186: ...ing flange with sender wheel Page 172 A Assembling seal with sender wheel on assembly tool T10134 Page 172 B Installing assembly tool T10134 with sealing flange to crankshaft flange Page 174 C Bolting...

Page 187: ...l regulations for disposal Remove sump Page 244 Remove engine speed sender G28 arrow using a com mercially available ball ended hex key socket Unscrew sealing flange securing bolts Note Sealing flange...

Page 188: ...must only be renewed together with the sender wheel The assembly device T10134 is held in its position relative to the crankshaft by a guide pin inserted into a hole in the crankshaft Assembly tool T...

Page 189: ...Note The sender wheel must not be taken out of the sealing flange or twisted Locating hole A on sender wheel C must align with mark ing B on sealing flange Place sealing flange with front side downwar...

Page 190: ...When installing sealing flange ensure that sender wheel re mains fixed in assembly device 2 5 4 B Installing assembly tool T10134 with sealing flange to crankshaft flange Crankshaft flange must be fre...

Page 191: ...ontacts crankshaft A Push guide pin for diesel engines black knob D into hole in crankshaft This ensures that the sender wheel reaches its final installation position Note The guide pin for petrol eng...

Page 192: ...n socket head bolts Screw the three knurled screws B out of sealing flange Remove assembly tool T10134 Remove sealing lip support ring The sender wheel is in the correct installation position on the c...

Page 193: ...nge Screw hexagon nut E onto threaded spindle by hand until it lies on assembly housing C Tighten hexagon nut of assembly tool T10134 to 40 Nm us ing torque wrench V A G 1331 and tool insert 24 mm V A...

Page 194: ...ler using hose clamp and pull off hoses Remove oil filter bracket Page 260 Assembly overview oil filter bracket and engine oil cooler Pull 3 pin connector off engine speed sender G28 Using a commercia...

Page 195: ...S 6095 1 using universal mounting VAS 6095 Finding metal shavings or a large quantity of small metal particles during engine repair could indicate that the crank shaft bearings or conrod bearings are...

Page 196: ...ng caps must align 4 Thrust washer q For bearing cap 3 q Note fixing arrange ment 5 Needle bearing q Not installed on all engines q Pulling out and driving in Page 181 6 Crankshaft q Axial clearance n...

Page 197: ...ll en gines Special tools and workshop equipment required Puller T10055 With adapter T10055 3 Centring mandrel 3176 or drift VW 207 C Puller e g Kukko 21 2 Pulling out Page 181 Driving in Page 182 3 3...

Page 198: ...hese instructions are not adhered to and damage results Volkswagen is exempt from any liability and warranty claims WARNING Adhere to the general safety regulations and the notes on repair work on the...

Page 199: ...q Arrow on piston crown points to belt pulley end q Install using piston ring clamp q If piston skirt is cracked renew pis ton q Checking piston projection at TDC Page 187 3 Piston pin q If difficult...

Page 200: ...conrod q Separate new conrod Page 185 9 Oil spray jet q For piston cooling 10 25 Nm q Insert without sealant 11 Conrod bolt 30 Nm 1 4 turn 90 further q Renew q Oil threads and contact surface q Use ol...

Page 201: ...Difference between actual and nominal diameter max 0 10 mm Note The cylinder bores must not be measured when the cylinder block is mounted on a repair stand with engine and gearbox support VAS 6095 a...

Page 202: ...er carefully knock against conrod bearing cap in direction of arrow until it is loose 4 3 Bearing shells installation position Bearing shell 1 with oil hole arrow for conrod Bearing shell 2 without oi...

Page 203: ...ket depending upon piston projection according to fol lowing table Note Turn engine clockwise to measure piston projection at TDC If different values are determined during the projection measurement u...

Page 204: ...the seal is renewed ensure that the designation matches Piston projection at TDC must be determined when installing new pistons or a short engine Page 187 4 5 Piston and cylinder dimensions Honing di...

Page 205: ...ects in the engine compartment such as cleaning cloths or tools Many engine components become hot during opera tion risk of burns If necessary provide appropriate protective means Servicing materials...

Page 206: ...w cylinder head 1 Cylinder head q Check for distortion Fig on page 191 q Removing and in stalling Page 220 q After renewing re new entire coolant 2 Washer q For cylinder head bolt 3 Cylinder head bolt...

Page 207: ...issible Cylinder head gasket identification Part number arrow 1 Holes arrow 2 Production control code arrow 3 can be disregarded Note Different thicknesses of cylinder head gasket are fitted de pendin...

Page 208: ...hed belt from idler pulley high pressure pump pulley To do this remove toothed belt Page 212 Engine codes CJDA CJDD Disconnect connector for Hall sender G40 in centre Detach plug from its retainer Eng...

Page 209: ...cylinder head and guide its plug through repair aperture in toothed belt guard Installing Install in reverse order Observe the following Seal repair aperture in toothed belt guard using the respec ti...

Page 210: ...on page 195 q Attach Fig on page 195 q Lock Fig on page 196 5 5 Nm 6 Injector cover 7 Bush q For securing fuel rail q Renew if damaged 8 10 Nm 9 Clamping piece q Note installation position 10 Cable g...

Page 211: ...to see whether they are fractured or have broken off Always replace damaged fuel return lines A damaged fuel return line that becomes loose when en gine is running causes damage to injection valve pi...

Page 212: ...ver hand tight in the sequence 1 to 7 Tighten bolts to 10 Nm in the sequence 1 7 1 3 1 Removing and installing cylinder head cov er Special tools and workshop equipment required Torque wrench V A G 14...

Page 213: ...sconnecting the connectors Otherwise the whole wiring harness will need to be renewed Do not compress the pli ers 3314 too firmly to separate the connectors otherwise the support sleeve may be damaged...

Page 214: ...disconnecting check the 4 catches arrow to see whether they are fractured or have broken off Always replace damaged fuel return lines A damaged fuel return line that becomes loose when en gine is runn...

Page 215: ...rrow off turbocharger and guide wiring out of retainers Pull connector off fuel pressure regulating valve N276 arrow Remove wiring harness from rail and lay to one side Pull off vacuum line at the cyl...

Page 216: ...e that cylinder head cover is correctly clipped to tooth ed belt guard Note For reasons of clarity the camshaft sprocket has been left out To do this press toothed belt guard using a screwdriver if ne...

Page 217: ...wnwards as far as they will go arrows After fuel return line has been pushed on completely press locking pin downwards arrow Industriemotoren Industrial Engines 2009 Workshop Manual for Diesel Engine...

Page 218: ...page 204 q Lock Fig on page 204 4 Injector piezo injec tors q When removing and installing always renew the following components and seals O rings copper seal O ring for injector bore O ring for inje...

Page 219: ...d installing Page 205 19 O ring q Renew if damaged or leaking 20 Pipe assembly q For crankcase breather q Press release buttons to remove 21 Sealing bush for fuel rail q Renew if damaged or leaking 22...

Page 220: ...damage to injection valve piezo injector The injection valve piezo injector must then be replaced Attach fuel return line Apply a thin coat of diesel fuel to new O rings on return line connections Att...

Page 221: ...0 Nm in the sequence 1 6 1 4 1 Removing and installing cylinder head cov er Special tools and workshop equipment required Torque wrench V A G 1410 Socket T40055 Removing Industriemotoren Industrial En...

Page 222: ...ow Unscrew bolts 3 Unscrew union nuts 1 using socket T40055 and remove fuel line 2 Place removed high pressure line on a clean surface 3 Industriemotoren Industrial Engines 2009 Workshop Manual for Di...

Page 223: ...tions Disconnecting fuel return lines Caution Carefully pull fuel return lines upwards vertically when disconnecting as the 4 catches arrow can fracture After disconnecting check the 4 catches arrow t...

Page 224: ...ew bolts 6 from fuel rail Remove fuel rail 3 to right Guide fuel return line arrow past fuel lines when doing this Ensure cleanliness No dirt may get into the injector holes on the cylinder head cover...

Page 225: ...O rings on return line connections Attach fuel return line and press the two clips downwards as far as they will go arrows After fuel return line has been pushed on completely press locking pin downwa...

Page 226: ...ork on the engine Page 1 Note In general the toothed belt does not need to be renewed be fore the next change interval is due Especially cracks on the rear do not affect the service life and cannot be...

Page 227: ...ounterhold T10172 Counterhold tool adapt er T10172 4 Counterhold tool adapt er T10172 8 Angle driver T10264 Locking tool T10265 Torque wrench 5 50 Nm V A G 1331 Industriemotoren Industrial Engines 200...

Page 228: ...lines e g for fuel hydraulics cool ant and refrigerant brake fluid and vacuum and electri cal wiring in their original positions Ensure that there is sufficient clearance to all moving or hot componen...

Page 229: ...he crankshaft pulley 2 and the crankshaft stop T10050 1 must align At the same time the pin of the crankshaft stop T10050 must engage in the drilling in the seal ing flange Mark direction of rotation...

Page 230: ...e tensioning element varies de pending on the engine temperature If the tensioning roller is to be renewed the engine bracket must be removed Renew securing bolts for camshaft pulley and high pressure...

Page 231: ...3359 To do this slide locking pin into adjustment hole outside toothed belt pulley Turn camshaft pulley and toothed belt pulley of high pres sure pump in their elongated holes clockwise to stop Fit to...

Page 232: ...under tension In this position tighten securing bolts 1 of camshaft pulley initially by hand and then to 20 Nm Then tighten bolts 45 further In addition tighten securing bolts of toothed belt pul ley...

Page 233: ...sitioned on left next to hole Turn crankshaft in engine direction of rotation until crank shaft stop pin engages in sealing flange whilst turning Tighten securing bolts of camshaft toothed belt pulley...

Page 234: ...here to specified torques and tightening sequence for en gine bracket if fitted 1 6 Checking compression WARNING Adhere to the general safety regulations and the notes on repair work on the engine Pag...

Page 235: ...limit 19 bar Maximum permissible difference between all cylinders 5 bar Install glow plug using U J extension and socket 10 mm 3220 Page 535 Note Faults will have been stored because the connectors fo...

Page 236: ...red Guide pins 3070 Diesel injection pump locking pin 3359 Crankshaft stop T10050 Counterhold T10051 Puller T10052 Bit XZN 10 T10385 3 Industriemotoren Industrial Engines 2009 Workshop Manual for Dies...

Page 237: ...ies Notes on removing Page 221 Notes on installing Page 225 1 7 1 Notes on removing Note The procedure described below provides only general instruc tions for removing and installing cylinder heads si...

Page 238: ...stalling toothed belt Pull connector 2 off throttle valve module J338 Wires or coolant fuel and air lines may impair the repair work Remove these wires in lines It may be sufficient to loosen the fast...

Page 239: ...es off coolant connection of cylinder head Unscrew bolt of oil supply line arrow and remove oil supply line Engine codes CPYA CPYB CPXC CPYD CPYE Caution Exhaust gas temperature sender 1 G235 must not...

Page 240: ...is lifted out The oil return line of the turbocharger is pulled out of the support when the cylinder head is lifted out The cylinder head must be guided carefully to prevent dam age Guide cylinder he...

Page 241: ...ine rotation until all pistons are nearly uniformly below TDC Cylinder head gasket must lie with identification facing up wards Note Note identification on cylinder head gasket Fig on page 191 To cent...

Page 242: ...t memory of engine control unit and clear event memory if necessary Page 26 read event memory 1 8 Removing and installing vacuum pump Special tools and workshop equipment required Torque wrench V A G...

Page 243: ...Volkswagen deal ership If these instructions are not adhered to and damage results Volkswagen is exempt from any liability and warranty claims WARNING Adhere to the general safety regulations and the...

Page 244: ...amshaft 7 Roller rocker finger q Mark installation po sition q Do not interchange q Check roller bearing for ease of movement q Oil contact surface 8 Hydraulic compensation element q Mark installation...

Page 245: ...and workshop equipment required Universal dial gauge bracket VW 387 Dial gauge Insert new valve into guide The end of the valve stem must be flush with the guide On account of differing stem diame te...

Page 246: ...3 1 Procedure Remove all glow plugs using U J extension and socket 3220 Page 536 Remove camshafts Page 233 Fit guide plate VAS 5161 23 onto cylinder head Secure guide plate on intake manifold side wit...

Page 247: ...connection piece and apply con stant air pressure Minimum pressure 6 bar Attach pressure fork VAS 5161 2 to snap in device and push assembly cartridge down At the same time turn knurled screw of asse...

Page 248: ...into cylinder head If valve cotters have been removed from assembly cartridge they need to be put into insertion device VAS 5161 18 first Note Larger diameter of valve cotters faces upwards Press asse...

Page 249: ...ensure that none of the valves make con tact when the starter is operated 2 4 Removing and installing camshaft Special tools and workshop equipment required Diesel injection pump locking pin 3359 Coun...

Page 250: ...ling and tensioning toothed belt Remove cylinder head cover Remove securing bolts for camshaft toothed belt pulley 1 Detach camshaft pulley from hub Counterhold hub with counterhold T10051 and loosen...

Page 251: ...176 501 A1 Caution The camshafts may only be installed with the camshaft fit ting tool T40094 as described below The axial bearings in the bearing frame will otherwise be damaged beyond repair and the...

Page 252: ...lled F First position inlet camshaft as illustrated Ensure that inden tation arrow for cylinder head bolt faces outwards Set 0 50 mm feeler gauge in place and push support T40094 8 into groove on inle...

Page 253: ...e camshafts Set clamping tool T40095 in place as illustrated in order to hold camshafts in position in retaining frame Remove cover T40094 11 Pull support T40094 8 out of inlet camshaft groove Cut off...

Page 254: ...ove clamping tool T40095 and camshaft fitting tool T40096 1 Renew camshaft oil seal Page 239 Using a suitable drift knock new sealing cap core plug Item 15 on page 229 in cylinder head until flush Per...

Page 255: ...position using locking pin 3359 Install toothed belt and adjust timing Install vacuum pump Install cylinder head cover 2 5 Removing and installing camshaft oil seal Note As of 09 2009 a new gasket B...

Page 256: ...re pump Removing installing and tensioning toothed belt Remove camshaft toothed belt pulley and hub Page 233 Removing and installing camshaft Insert thrust piece 3240 1 into camshaft Unscrew inner par...

Page 257: ...er groove in taper of camshaft e g with Sellotape Fit guide sleeve of fitting tool 10 203 onto camshaft as shown in illustration Carefully slide oil seal 1 over guide sleeve onto camshaft Press seal i...

Page 258: ...d belt Remove camshaft toothed belt pulley and hub Page 233 Removing and installing camshaft Caution If turned back too far the internal pressure plate moves off the pressure screw In this case the pr...

Page 259: ...camshaft journal using a clean cloth Fit guide sleeve of fitting tool 10 203 onto camshaft as shown in illustration The inscription on the seal faces out wards Carefully slide oil seal 1 over guide s...

Page 260: ...mental regulations for disposal Pull dipstick out again and read engine oil level If a dipstick is present A Engine oil is not to be topped up B Engine oil may be replenished The oil level may increas...

Page 261: ...filter element a valve is opened the oil in the filter housing automatically flows into crank case The oil drain plug is fitted with a captive seal Therefore the oil drain plug must always be renewed...

Page 262: ...ental regulations for disposal Oil new O rings before installing Unclip solenoid changeover valve 1 Loosen sealing cap 2 using for example a suitable ring spanner or socket Note Before draining or ext...

Page 263: ...rd 507 00 1 1 2 3 Replenishing engine oil Engine oil specifications and engine oil capacity Note Depending on the installation position of the engine the re quired engine oil capacity may be different...

Page 264: ...be as far as it will go in order to prevent any engine oil from escaping when the en gine is running After refilling screw the oil filler cap back on correctly After replenishing with oil wait at leas...

Page 265: ...e correct Incorrect service flu ids can cause serious functional problems and damage to the engine The engine oil level must never be above segment A Oth erwise engine oil could be drawn in through th...

Page 266: ...engine in an appropriate location and by avoiding sharp edges Route all the various lines e g for fuel hydraulics coolant and refrigerant brake fluid and vacuum and electrical wiring in their original...

Page 267: ...ngine codes CJDA CJDD Page 251 Engine codes CPYA CPYB CPYC CPYD CPYE Page 254 2 1 1 Engine codes CJDA CJDD Assembly overview oil filter bracket and oil cooler Industriemotoren Industrial Engines 2009...

Page 268: ...ling pretension spring and fit 4 Oil dipstick q The oil level must not be above the max mark q Markings 5 Dipstick guide 6 Guide tube 7 Dowel sleeves 8 O ring q Renew 9 15 Nm 10 Suction line q Clean s...

Page 269: ...ature sender G266 wiring harness if fitted 22 20 Nm 1 4 turn 90 further 23 Chain 24 25 Nm q Insert without sealant 25 Oil spray jet q For piston cooling Fig on page 253 Oil spray jet and pressure reli...

Page 270: ...s CPYA CPYB CPYC CPYD CPYE Assembly overview oil filter bracket and oil cooler 3 Industriemotoren Industrial Engines 2009 Workshop Manual for Diesel Engine 2 0 l 36 75 kW_EA 189 05 2015 254 Repair Gro...

Page 271: ...s is not a fault and does not neces sarily mean belt needs replacing 4 10 Nm 5 Oil dipstick q The oil level must not be above the max mark q Markings 6 Guide tube q Renew O ring 7 Clip 8 Dowel sleeves...

Page 272: ...Renew 20 10 Nm 21 Oil level and oil temperature sender G266 q Black 3 pin connector q Removing and installing Fig on page 257 22 Seal q Renew 23 Oil level and oil temperature sender G266 wiring harne...

Page 273: ...this chapter must be carried out in a Volkswagen dealership only Go to a Volkswagen deal ership If these instructions are not adhered to and damage results Volkswagen is exempt from any liability and...

Page 274: ...2 Hand drill with plastic brush Eye protection Flat scraper Removing Page 258 Installing Page 259 2 2 1 Removing Drain engine oil Page 245 Note Observe environmental regulations for disposal If fitted...

Page 275: ...of the sealant Install sump within 5 minutes of applying silicone sealant Cut off tube nozzle at front marking nozzle diameter approx 3 mm Apply silicone sealant as shown to clean sump sealing sur fac...

Page 276: ...ations and the notes on repair work on the engine Page 1 Caution Finding metal shavings or a large quantity of small metal particles during engine repair could indicate that the crank shaft bearings o...

Page 277: ...ng Page 262 4 Seal q Renew 5 Connecting piece 30 Nm 6 Oil supply line 22 Nm q To turbocharger 7 Oil pressure switch F1 22 Nm q 0 7 bar switch brown q If seal is leaking nip open and renew q Checking P...

Page 278: ...gether with oil cooler Special tools and workshop equipment required Assembly tool T10118 Oil drip tray Removing Drain coolant Detach any required wiring harnesses and connectors and lay them to one s...

Page 279: ...cket If neces sary counterhold with an open ended spanner Place oil drip tray below engine Unscrew securing bolts arrows and remove oil filter brack et Installing Installation is carried out in the re...

Page 280: ...uxiliary measuring set V A G 1594 A Test prerequisites Check whether oil level OK Engine oil temperature at least 80 C Test procedure Note Functional check and repair of the optical oil pressure gauge...

Page 281: ...obtained Rectify any mechanical damage e g damaged bearings Renew oil filter bracket with pressure relief valve or renew oil pump At higher engine speeds the oil pressure must not exceed 7 0 bar If th...

Page 282: ...cooler Caution Seals 11 and 14 must not be lubricated with oil The coolant seals would otherwise swell up 3 Industriemotoren Industrial Engines 2009 Workshop Manual for Diesel Engine 2 0 l 36 75 kW_E...

Page 283: ...not be lubrica ted with oil q Fit into lugs on en gine oil cooler 12 14 Nm 1 2 turn 180 further q Renew q First fit upper left and lower right bolts and then tighten all 4 bolts in diagonal sequence 1...

Page 284: ...workshop equipment required Removal lever 80 200 Torque wrench V A G 1410 Used oil collection and extraction unit V A G 1782 Hose clip pliers VAS 6362 3 Industriemotoren Industrial Engines 2009 Worksh...

Page 285: ...tube Drain coolant Push clip 3 off guide tube 1 for oil dipstick with removal lever 80 200 Industriemotoren Industrial Engines 2009 Workshop Manual for Diesel Engine 2 0 l 36 75 kW_EA 189 05 2015 3 3...

Page 286: ...s which conform to production standard Bolt on oil filter bracket hand tight in the sequence 1 4 Tighten bolts in the sequence 1 4 Specified torque 14 Nm 1 2 turn 180 further Bolt on dipstick guide tu...

Page 287: ...50 Body front Lock carrier service position Drain coolant In addition to draining coolant from engine pull coolant hose from oil filter bracket arrow Remove oil filter element 3 Industriemotoren Indus...

Page 288: ...t Carefully slide engine oil cooler onto centring pins Press oil cooler on until it is flush 1 with end of centring pins Start new bolts and screw them in until heads make contact Tighten bolts arrows...

Page 289: ...al and installation must be carried out from right hand side behind cylinder head If appropriate remove any relevant components and service fluid lines or detach line retainers to allow for laying lin...

Page 290: ...t V A G 1594 C Test prerequisites Check whether oil level OK Engine oil temperature at least 80 C Test procedure Note Functional check and repair of the optical oil pressure gauge current flow diagram...

Page 291: ...wly From 0 30 0 60 bar the LED must light up otherwise renew oil pressure switch F1 Checking oil pressure Prerequisite Oil pressure tester V A G 1342 is connected Test procedure Increase engine speed...

Page 292: ...tective means Servicing materials such as fuel engine oils or cool ant additive are harmful substances adhere to the safety instructions from the manufacturer There is a risk of injuries if maintenanc...

Page 293: ...eakage test of cooling system using cooling system tester V A G 1274 and adapters V A G 1274 8 and V A G 1274 9 Page 292 Parts of cooling system engine side Page 278 Coolant hose schematic diagram Pag...

Page 294: ...r G62 q For engine control unit J623 q Before removing release pressure in cooling system if necessary q Check Page 407 6 O ring q Renew 7 Centre hex stud 9 Nm 8 40 Nm 9 13 Nm 10 Coolant pipe q Coolan...

Page 295: ...q For engine control unit J623 q Before removing release pressure in cooling system if necessary q Check Page 407 6 O ring q Renew 7 Centre hex stud 9 Nm 8 40 Nm 9 13 Nm 10 Coolant pipe q Coolant hose...

Page 296: ...at with 4 2 way valve 10 4 2 way valve q Removing and in stalling 4 2 way valve Page 290 11 Coolant pump 12 Breather pipe q To expansion tank 1 4 Cooling system Check frost protection and coolant leve...

Page 297: ...olant improves en gine reliability under heavy loads particularly in countries with tropical climates Frost protection is required down to about 25 C in coun tries with arctic climates down to about 3...

Page 298: ...ox 40 C otherwise frost protection and cooling effectiveness are reduced again If frost protection is insufficient drain coolant and top up with coolant additive G 12 Page 282 Note Observe environment...

Page 299: ...ale and also raise the boiling point Therefore the cooling system must be filled all year round with frost and corrosion protection additives Because of its higher boiling point the coolant improves e...

Page 300: ...rated Cooling system charge unit VAS 6096 Coolant additive G 12 according to TL VW 774 F Draining Page 284 Filling Page 285 1 5 1 Draining Make sure to catch any escaping coolant Place a drip tray V A...

Page 301: ...neralised or distilled water to standard VDE 0510 Tap water must no longer be used Note The water used in the coolant mixture has a great influence on its effectiveness Because the water quality diffe...

Page 302: ...seasons and in warmer countries The coolant additive concentration must be at least 40 If a stronger anti freeze mixture is necessary due to harsher weather conditions it can be increased using G 12...

Page 303: ...096 Fit expansion tank cap Start engine and maintain an engine speed of about 2 000 rpm for about 3 minutes Run engine until radiator fan cuts in WARNING Hot steam may escape when expansion tank is op...

Page 304: ...drip tray VAS 6208 Torque wrench 5 50 Nm V A G 1331 Spring type clip pliers VAS 5024 Removing Note Always renew seals and gaskets Drain coolant Remove poly V belt Remove toothed belt Removing install...

Page 305: ...new O ring 3 with coolant Insert coolant pump 2 in cylinder block and tighten secur ing bolts 1 to 15 Nm Note The coolant pump plug faces downwards Install and tension toothed belt Install poly V bel...

Page 306: ...ocated within the 4 2 way valve and cannot be replaced individually Drain coolant Page 284 Remove alternator Page 471 Remove any required coolant lines coolant pipes compo nents of the charge air syst...

Page 307: ...sealing surfaces Renew gaskets and seals First seat 2 way valve with connection C on coolant pipe then insert into cylinder block Insert securing bolts 3 and tighten them to 15 Nm Connect coolant hose...

Page 308: ...scape when expansion tank is opened Wear eye protection and protective clothing to avoid eye inju ries and scalding Cover cap with cloth and open careful ly Open filler cap on coolant expansion tank S...

Page 309: ...ter for cooling system tester V A G 1274 9 Clamp connector V A G 1274 B 1 into adapter for cooling system tester V A G 1274 9 Using connecting hose supplied join connection piece V A G 1274 B 1 to coo...

Page 310: ...8 Spring type clip pliers VAS 5024 A Drip tray V A G 1306 or drip tray VAS 6208 Not illustrated Torque wrench 5 50 Nm V A G 1331 Expansion tank 1K0 121 407 A bzw 6Q0 121 407 A bzw 1J0 121 407 B Plug...

Page 311: ...ling system tester V A G 1274 with cooling sys tem tester adapter V A G 1274 8 to expansion tank Use hand pump on tester to create a pressure of about 1 6 bar Watch pressure drop on pressure gauge A p...

Page 312: ...ip tray for work shop hoist VAS 6208 Torque wrench 5 50 Nm V A G 1331 Not illustrated Expansion tank 1K0 121 407 A or expansion tank 1J0 121 407 B Plug 191 211 343 Cap 1J0 121 324 Coolant hose 251 265...

Page 313: ...tester V A G 1274 with adapter for cool ing system tester V A G 1274 8 on coolant expansion tank 1 Using hand pump on tester build up a pressure of approx 1 6 bar Observe pressure drop on pressure ga...

Page 314: ...rotective means Servicing materials such as fuel engine oils or cool ant additive are harmful substances adhere to the safety instructions from the manufacturer There is a risk of injuries if maintena...

Page 315: ...erant brake fluid and vacuum and electrical wiring in their original positions Ensure that there is sufficient clearance to all moving or hot components The fuel and the fuel lines in the fuel system...

Page 316: ...s and surrounding areas before disconnecting Place removed parts on a clean surface and cover Use only lint free cloths Carefully cover opened components or seal if repairs cannot be carried out immed...

Page 317: ...incorrect fuel Empty fuel tank as far as possible via fuel filler neck using fuel extractor VAS 5190 Engine codes CJDA CJDD Pull off fuel supply line to high pressure pump ahead of strainer Engine co...

Page 318: ...sis Note The fuel pump is now activated Repeat procedure if necessary until fuel tank is completely empty Fill fuel tank with 5 litres of diesel fuel Completely empty fuel tank again as described abov...

Page 319: ...high pressure pump or Check fuel metering valve N290 and high pressure pump for metal particles Metal particles found Yes Step 5 There are filings in high pressure pump on page 303 No Step 6 There ar...

Page 320: ...Assembly overview fuel filter Note safety precautions before beginning work Page 299 Observe rules for cleanliness Page 300 Renew fuel filter Page 308 Engine codes CJDA CJDD Page 304 Engine codes CPYA...

Page 321: ...y seated q Connection over view Page 305 7 Upper part of fuel fil ter q Observe various types Page 305 q Connection over view Page 305 q Removing and in stalling Page 305 8 Filter insert 9 Lower part...

Page 322: ...ne white or white marking Check for secure seating 6 Fuel return line from engine blue or blue marking Check for secure seating Fuel filter upper part type B 1 5 Nm 2 Fuel return line to fuel tank blu...

Page 323: ...com ponents between fuel tank and high pressure fuel pump Page 383 Unclip fuel filter 1 from fuel filter bracket Take fuel filter 1 upwards out of fuel filter bracket Fuel lines remain connected to f...

Page 324: ...icle with prescribed fuel Page 6 Switch ignition on Connect vehicle diagnostic tester and carry out guided func tion Fuel pump activation checking fuel pump Note The fuel pump is now activated for 30...

Page 325: ...sel comes into contact with other components in the engine compartment If necessary clean immediately Note Observe environmental regulations for disposal Carry out the following work sequence Unscrew...

Page 326: ...If the filter needs to be renewed remove filter 3 from lower part of fuel filter Remove old seal 2 from upper part of fuel filter 1 by lever ing seal out of respective groove arrow Caution Remove any...

Page 327: ...torque of 5 Nm in sequence shown illustration This procedure prevents the seal from being damaged Bleeding fuel system Procedure Note If there is any air left in the fuel system the engine may switch...

Page 328: ...posal Removing Caution Ensure that no diesel comes into contact with other components in the engine compartment If necessary clean immediately Carry out the following work sequence Release and pull of...

Page 329: ...t memory 1 7 Removing and installing supplementary fuel pump V393 inline electronic fuel pump Special tools and workshop equipment required Hose clip pliers VAS 6340 Torque wrench V A G 1331 Removing...

Page 330: ...n the engine Page 1 The described component checks and functional checks are ap plicable for the series components and the current flow dia grams as of page Page 486 current flow diagrams If component...

Page 331: ...to fuel supply line 1 Connect other adapter 3 of K Jetronic pressure tester V A G 1318 to open connection on high pressure pump Note The K Jetronic pressure tester V A G 1318 must be inserted as an in...

Page 332: ...and accelerator posi tion sender 2 G185 are installed in one common housing Only gold plated contacts may be used when repairing the contacts in the connector of the accelerator position sender Switch...

Page 333: ...easure voltage Switch on ignition Specification at least 4 8 5 2 V Switch off ignition Check wiring of accelerator position sender as follows Using adapter cable V A G 1598 39 2 connect test box V A G...

Page 334: ...5 Pull connectors off any components which are connected to this voltage supply line Page 486 current flow diagrams Check voltage supply and wires on these components If no wiring fault is detected a...

Page 335: ...from the manufacturer There is a risk of injuries if maintenance locations are difficult to access This risk can be reduced by in stalling the engine in an appropriate location and by avoiding sharp e...

Page 336: ...o ses for dirt soiling Check the whole charge air path and charge air cooler for foreign objects If foreign objects are found in the charge air system the charged air routing must be cleaned and the c...

Page 337: ...nstalling the oil supply line fill turbocharger with en gine oil through connecting piece engine codes CJDA CJDD only Before installing the turbocharger fill the oil supply channel smaller diameter wi...

Page 338: ...er G581 Page 449 5 Connector q To position sender for charge pressure positioner G581 Page 449 6 Heat protection q Renew if damaged 7 Gasket q Renew 8 Connecting pipe q To exhaust gas recirculation co...

Page 339: ...allation position of exhaust gas temperature sender with angled cable guide Note When installing the exhaust gas temperature sender with an gled cable guide it is absolutely necessary to keep to dimen...

Page 340: ...Nm 7 Heat shield 8 Turbocharger q Can only be re newed complete with exhaust mani fold and vacuum unit q Removing and in stalling Page 326 9 Retaining ring q Installation possible in one position only...

Page 341: ...20 Nm 23 Support q For turbocharger q Before installing oil supply line ensure that it is not blocked q Before installing fill turbocharger with engine oil through oil supply line connection 24 Bolt...

Page 342: ...as temperature sender with an gled cable guide adhere to dimension a of 3 5 mm from the threaded connection of the turbocharger support 1 4 Removing and installing turbocharger WARNING Adhere to the g...

Page 343: ...for cleanliness Page 320 Pull off connector of position sender for charge pressure po sitioner G581 on turbocharger Page 321 Pull vacuum hose off vacuum unit on turbocharger Disconnect connector for...

Page 344: ...faces down wards and remove turbocharger downwards Engine codes CPYA CPYB CPYC CPYD CPYE Pull charge air pipe connecting hose off turbocharger Loosen clamp for turbocharger diesel particulate filter I...

Page 345: ...bocharger before instal ling Note Renew seals and gaskets Renew self locking nuts Before installing the oil supply line fill turbocharger with en gine oil through connecting piece to prevent a dry sta...

Page 346: ...he manu facturing specifications when performing any maintenance and repair work All hose connections are secured Charge air system must be free of leaks When making repairs remove oil from connection...

Page 347: ...s Page 320 Remove intake hose 1 from air filter Connect adapter 1687 10 in intake hose 1 and secure with clip Prepare charge air system tester V A G 1687 as follows Unscrew pressure regulating valve 2...

Page 348: ...e test circuit is filled If neces sary readjust pressure to 0 5 bar Check the charge air system for leaks by listening and touching with commercially available leak detector spray or using ultrasonic...

Page 349: ...display zones 2 3 and 4 must fluctuate within following control range Display zone 2 OFF Specification in display zone 3 900 1150 mbar Specification in display zone 4 90 100 Display zone 2 ON Specific...

Page 350: ...have been checked for leaks the en gine must be restarted Check position sender for charge pressure positioner G581 Page 345 If the charge pressure difference between OFF and ON in display zone 3 is...

Page 351: ...Air filter q Optional 4 Charge pressure con trol solenoid valve N75 5 Vacuum unit 6 Exhaust system 7 Non return valve q Note installation po sition 8 Vacuum pump 9 Cylinder head cover 10 Charge air co...

Page 352: ...er head cover 8 Charge air cooler 2 3 3 Intake system installation position 0 Note The proper position alignment of the air mass meter is critical for the proper operation of the engine and the diesel...

Page 353: ...r a proper alignment when installing 1 2 Connector position of air mass meter 3 Air mass meter 4 90 elbow of intake connecting pipe 5 Intake connecting pipe 2 3 4 Intake system installation position 1...

Page 354: ...ystem and turbocharger Page 320 Observe rules for cleanliness Page 320 Follow these instructions before starting work and while working on system 2 4 1 Checking supply line and non return valve engine...

Page 355: ...ed vacuum hoses Check control line to turbocharger Page 339 2 4 2 Checking control line to turbocharger en gine codes CJDA CJDD CPYA CPYB CPYC CPYD CPYE Pull off vacuum hose on connecting piece of cha...

Page 356: ...urrent flow dia grams as of page Page 486 current flow diagrams If components and electric circuits differ observe the notes of the respective industrial engine customer Check charge pressure control...

Page 357: ...ting and information system VAS 5051 B using diagnostic cable VAS 5051B 1 Hand multimeter V A G 1526 or multimeter V A G 1715 Auxiliary measuring set V A G 1594D Test box V A G 1598 42 with adapter ca...

Page 358: ...n read event memory of engine control unit and clear event memory if necessary Page 26 read event memory If specification is attained Checking voltage supply Connect multimeter to connector contact 1...

Page 359: ...nsumers must be switched off Earth connections OK Test procedure Note The charge pressure sender G31 and intake air tempera ture sender G42 are installed in one common housing in the charge air pipe O...

Page 360: ...test box and connector for open cir cuit referring to current flow diagram Contact 3 socket 17 Contact 4 socket 83 Cable resistance max 2 0 Also check wiring for short to one another short to battery...

Page 361: ...activate charge pres sure control solenoid valve N75 Page 89 final control di agnosis The displays in display zones 2 3 and 4 must fluctuate within following control range Note The display zones may b...

Page 362: ...socket 25 Cable resistance max 2 0 Also check wiring for short to one another short to battery earth engine earth and short to battery positive Specifica tion If no wiring fault is detected and volta...

Page 363: ...select engine control unit Page 23 Select diagnosis function 011 Read measured value block Select Display group 99 Indicated on display Note The display zones may be shown one below the other or next...

Page 364: ...s temperature sender 1 G235 ex haust gas temperature sender ahead of turbocharger and wiring to sender as follows Exit diagnosis function Switch off ignition Checking resistance Disconnect 2 pin conne...

Page 365: ...max 2 0 Also check wiring for short to one another short to battery earth engine earth and short to battery positive Specifica tion If no fault in lines is detected Renew engine control unit J623 Pag...

Page 366: ...he safety instructions from the manufacturer There is a risk of injuries if maintenance locations are difficult to access This risk can be reduced by in stalling the engine in an appropriate location...

Page 367: ...y overview fuel system Page 362 Correction values for injectors Page 368 Checking for injectors that are jammed open Page 369 Removing and installing injector piezo injector Page 370 Install high pres...

Page 368: ...rp objects of any kind If high pressure lines are not renewed they must be labelled on removal High pressure fuel lines must always be re in stalled in their original positions i e on the same cylinde...

Page 369: ...r the hoses must be cleaned immediately Damaged hoses must be renewed 1 2 To avoid any risk of injuries to persons and or the destruction of the injection and glow plug system the following must be no...

Page 370: ...the following if testers and measuring instruments have to be used during a road test The test and measuring equipment must always be secured and operated by a 2nd person 1 4 Rules for cleanliness Wh...

Page 371: ...PYB CPYC CPYD CPYE Page 356 Removing and installing intake manifold Page 357 1 5 1 Engine codes CJDA CJDD 1 Intake manifold q Must not be disman tled q Removing and in stalling Page 357 2 8 Nm 3 Gaske...

Page 372: ...6 Clamp 5 Nm q Renew 7 Connection q For exhaust gas re circulation 8 8 Nm 9 Seal q Renew 10 Throttle valve mod ule J338 q Checking Page 89 final control diagnosis 11 8 Nm 12 8 Nm 13 Clip 14 Guide tub...

Page 373: ...cting the connectors Otherwise the whole wiring harness will need to be renewed Do not compress the pli ers 3314 too firmly to separate the connectors otherwise the support sleeve may be damaged Posit...

Page 374: ...ing bolts from the intake manifold from the outside to the inside in diagonal sequence with hexagon key extension T40159 Remove intake manifold from engine Installing Installation is carried out in th...

Page 375: ...er q With pre heating valve q Assembly overview fuel filter Page 304 3 Supplementary fuel pump V393 q Removing and in stalling Page 313 q Checking Page 314 4 Filter strainer 5 Fuel temperature sender...

Page 376: ...iezo injectors q The pressure retention valve may only be renewed together with the fuel return lines q After replacement engine must be run at idling speed for approx 2 minutes to bleed fuel system q...

Page 377: ...e regulating valve Page 391 q Checking return flow rate Page 377 q Removing and installing Page 377 9 Fuel rail 10 Fuel pressure sender G247 q Removing and installing Page 379 q Checking Page 394 11 P...

Page 378: ...a final control diagnosis to bleed the fuel system If a fuel pump fuel line or the fuel filter is removed or re newed the fuel pump must be activated via the final control diagnosis for at least 60 s...

Page 379: ...k taper seat of respective high pressure line for deformation and cracks The inside of the line must not be deformed con stricted or dam aged Corroded lines should no longer be used q Do not interchan...

Page 380: ...s and seals O rings copper seal O ring for injector bore O ring for injector return connection q Removed injectors must always be reinstalled in their original location on the same cylinder q Before r...

Page 381: ...lec tronic Parts Catalogue to connect overflow oil line B with riffled section DO NOT use a clamp to connect over flow oil line Industriemotoren Industrial Engines 2009 Workshop Manual for Diesel Engi...

Page 382: ...391 q Removing and installing Page 377 5 O ring q Renew 6 Injector piezo injectors q Do not interchange q When removing and installing an injector always renew the following components and seals O ri...

Page 383: ...n valve has the task of always maintaining a residual pressure control volume of approx 10 bar in the fuel return lines The injectors require this control volume to function q The pressure retention v...

Page 384: ...values for injectors serves to correct the injection rates for each cylinder of a com mon rail system individually across the entire ignition map range The 7 digit correction values 1 details in illu...

Page 385: ...available cold cleaning solvent before removing Note Make sure all parts are clean no dirt must be allowed to en ter the fuel system Check all cylinders in turn Dry all components after cleaning Start...

Page 386: ...serve pressure loss at hand vac uum pump VAS 6213 Renew defective injectors Page 370 1 10 Removing and installing injector piezo injector Special tools and workshop equipment required Puller T10055 As...

Page 387: ...inder numbers on injectors They must always be re installed on the same cylinders Observe rules for cleanliness when working on the in jection system Plug open connections with suitable sealing caps i...

Page 388: ...union nuts of relevant high pressure line 1 to 4 and remove corresponding high pressure line Unscrew securing bolts for cover Item 16 on page 364 of injectors to be removed Slightly lift cover and tu...

Page 389: ...when reusing high pres sure lines The high pressure lines may be re used after the following checks Check taper seat of respective high pressure line for defor mation and cracks The inside of the line...

Page 390: ...or into injector bore Specified torque Page 366 Continuation for all engine codes Install high pressure lines Page 375 Note After renewing one or more injectors the injector delivery cali bration valu...

Page 391: ...se the respective line to break in the long term Note This section describes how to install new injection lines If al ready fitted injection lines are to be used again perform the following checks Apa...

Page 392: ...ds to be installed adopt the same pro cedure for all 4 injection lines Slide all securing clamps over fuel line and observe align ment Screw in clamp securing bolts about 3 turns Retighten fuel rail W...

Page 393: ...ained the fuel pressure regulating valve N276 is defective 1 12 Removing and installing fuel pressure regulating valve N276 The fuel pressure regulating valve is located in the fuel rail The valves en...

Page 394: ...valve N276 Counterhold at housing hexagon and loosen union nut Then unscrew and remove by hand Extract dirt from fuel rail bore threads and sealing surface Do not use tools or other instruments for th...

Page 395: ...from the engine control unit In back up function the maximum engine speed is limited to approx 3 000 rpm Special tools and workshop equipment required Engine bung set VAS 6122 Removing Caution Always...

Page 396: ...n accelerating to full throttle at least once Check high pressure part of fuel system again for leaks Finally read event memory of engine control unit again Page 26 read event memory 1 14 Removing and...

Page 397: ...with T40064 1 Torque wrench V A G 1331 Pliers 3314 Removing Remove toothed belt from camshaft and high pressure pump Page 210 Industriemotoren Industrial Engines 2009 Workshop Manual for Diesel Engine...

Page 398: ...g bolts and lay lines to one side Position pliers 3314 with groove arrow A on shoulder of support sleeve arrow B and pull connectors off glow plugs Pull fuel return line off high pressure pump 4 Disco...

Page 399: ...ues for toothed belt drive Page 146 Caution Risk of irreparable damage to high pressure pump if al lowed to run dry The high pressure pump must first be filled with fuel be fore the engine is started...

Page 400: ...ond time switch off ignition and switch it back on Perform final control diagnosis again and activate fuel pump for 120 seconds Then start engine After filling fuel system leave engine running at mode...

Page 401: ...is any air left in the fuel system the engine may switch to the limp mode during the road test test run Switch off the en gine and clear the event memory Page 26 read event memo ry Then continue road...

Page 402: ...eturn line connection of cylinder no 1 e g with com mercially available cold cleaning solvent before removing Dry return line connection of cylinder no 1 Cover return line connection on cylinder no 1...

Page 403: ...or the series components and the current flow dia grams as of page Page 486 current flow diagrams If components and electric circuits differ observe the notes of the respective industrial engine custo...

Page 404: ...ay Note The display zones may be shown one below the other or next to each other on the display of the vehicle diagnostic tester Observe display zone 4 For the check below the coolant temperature must...

Page 405: ...e and if the pressure difference does not ex ceed 40 bar No fault was detected Then read event memory of engine control unit and clear event memory if necessary Page 26 read event memory If the displa...

Page 406: ...short circuit and transfer resistance at contacts referring to current flow dia gram If specification is attained Checking wiring Check wiring of fuel metering valve N290 as follows Using adapter cab...

Page 407: ...display of the vehicle diagnostic tester Observe display zone 4 For the check below the coolant temperature must be at least 80 C Check fuel rail pressure as follows Select Display group 20 Indicated...

Page 408: ...ed Check return flow rate of fuel pressure regulating valve N276 Page 377 Then read event memory of engine control unit and clear event memory if necessary Page 26 read event memory If the display zon...

Page 409: ...nd transfer resistance at contacts referring to current flow dia gram If specification is attained Checking wiring Check wiring of fuel pressure regulating valve N276 as fol lows Using adapter cable V...

Page 410: ...arts Allow engine to idle Connect vehicle diagnostic tester and select engine control unit Page 23 Select diagnosis function 011 Read measured value block Select Display group 7 Indicated on display N...

Page 411: ...fuel system specified 320 780 bar Display zone 3 pressure in high pressure fuel system ac tual 320 780 bar Display zone 4 duty cycle specified 25 42 Continuation for all engine codes If the specified...

Page 412: ...been attained Check fuel pressure while starting Page 397 If specification has been attained Fuel supply to high pressure pump is OK Then check fuel rail pressure while starting Start engine and run...

Page 413: ...Have a second person start the engine and observe pres sure tester while the engine is started While doing this close shut off tap of pressure tester slowly and carefully until a pressure of max 8 bar...

Page 414: ...e earth and short to battery positive Specifica tion If no wiring fault is detected and voltage was present between contacts 1 3 Renew fuel pressure sender G247 Then read event memory of engine contro...

Page 415: ...uxiliary measuring set V A G 1594D to measure re sistance Specification 50 0 700 0 k If the specification is not attained Renew the defective injector Then read event memory of engine control unit and...

Page 416: ...4 N33 contact 2 socket 16 Cable resistance max 2 0 Additionally check wiring for the following Short to positive Specification Short to earth Specification Short to one another Specification If no fa...

Page 417: ...arth connections OK Test procedure Note Only gold plated contacts may be used when repairing the con tacts in the connectors of the engine speed sender Clamp off coolant hoses at oil cooler using hose...

Page 418: ...specification is not attained Check wiring of engine speed sender as follows Using adapter cable V A G 1598 39 1 connect test box V A G 1598 42 to wiring harness of control unit Page 24 The engine con...

Page 419: ...these components Renew engine control unit J623 Page 418 2 6 Checking Hall sender 2 G40 Special tools and workshop equipment required Hand multimeter V A G 1526 or multimeter V A G 1715 Auxiliary meas...

Page 420: ...d voltage was present between contacts 1 3 Renew hall sender G40 Then read event memory of engine control unit and clear event memory if necessary Page 26 read event memory Pull connectors off any com...

Page 421: ...t to each other on the display of the vehicle diagnostic tester Check intake air temperature value in display zone 3 The temperature value must correspond approx to ambient tem perature If the value i...

Page 422: ...pply Connect multimeter to contacts 1 3 of connector using test leads from V A G 1594 to measure voltage Switch on ignition Specification at least 4 8 5 2 V Switch off ignition Check wiring of intake...

Page 423: ...est box V A G 1598 42 with adapter cable V A G 1598 39 1 Current flow diagram Test prerequisites Fuses must be OK The battery voltage must be at least 11 5 V All electrical consumers must be switched...

Page 424: ...erature is displayed as a substitute Check coolant tem perature sender and wiring connections to sender as follows Exit diagnosis function Switch off ignition Checking resistance Pull 2 pin connector...

Page 425: ...ed by this action Check wiring between test box and connector for open cir cuit referring to current flow diagram Contact 1 socket 53 Contact 2 socket 54 Cable resistance max 2 0 Also check wiring for...

Page 426: ...next to each other on the display of the vehicle diagnostic tester Check fuel temperature value in display zone 1 The temper ature value must correspond approx to ambient tempera ture If the value in...

Page 427: ...42 to wiring harness of control unit Page 24 The engine control unit is not connected by this action Check wiring between test box and connector for open cir cuit referring to current flow diagram Con...

Page 428: ...tored in event memory Page 26 read event memory Check whether charge pressure control is OK Page 333 Check whether exhaust gas recirculation system is OK Page 436 Coolant temperature must be at least...

Page 429: ...ring to current flow diagram Contact 1 socket 18 Contact 2 socket 23 Contact 4 socket 39 Contact 5 socket 87 Cable resistance max 2 0 Check wiring between contact 5 of 5 pin connector and fuse referri...

Page 430: ...e referring to current flow diagram Page 486 Also check wiring for short to one another short to battery earth engine earth and short to battery positive Specifica tion If no fault in lines is detecte...

Page 431: ...diagnosis until completed Exit diagnosis function Switch off ignition If the engine did not stop when the throttle valve module was activated Pull 5 pin connector 4 off throttle valve module Checking...

Page 432: ...low diagrams Check voltage supply and wires on these components If no wiring fault is detected and no voltage was present on these components Renew engine control unit J623 Page 418 3 Engine control u...

Page 433: ...t test box V A G 1598 42 to wiring harness and to control unit Page 24 Connect multimeter to following test box contacts using test leads from V A G 1594 to measure voltage 1 87 2 87 4 87 Specificatio...

Page 434: ...calibration val ues injector voltage calibration values and storing them in engine control unit on page 421 To verify whether the correct injectors are installed note in jector delivery calibration co...

Page 435: ...ating time of the diesel particulate filter However based on the mileage or the oper ating hours since the last change of the diesel particulate fil ter this data can be restored approximately Log in...

Page 436: ...ead measured value block The ignition must be switched on for this purpose Select Display group 100 Indicated on display Note The display zones may be shown one below the other or next to each other o...

Page 437: ...ose Select respective channel numbers for injectors N30 N33 Channel number 71 for injector 1 N30 Channel number 72 for injector 2 N31 Channel number 73 for injector 3 N32 Channel number 74 for injecto...

Page 438: ...must be at least 11 5 V Earth connections OK All electrical consumers must be switched off Procedure Connect vehicle diagnostic tester and select engine control unit Page 23 Select diagnosis function...

Page 439: ...he on screen keyboard enter the value 1 Press button Press Confirm button to reset the learnt value Then read event memory of engine control unit and clear event memory if necessary Page 26 read event...

Page 440: ...n procedure Function The engine control unit uses the CAN bus to communicate with all bus enabled control units These bus enabled components are connected via twisted pair data bus wires CAN_High and...

Page 441: ...using test leads from V A G 1594 to measure resistance 67 68 Specification 60 72 If the specification is not attained Renew engine control unit J623 Page 418 If specification is attained Eliminate th...

Page 442: ...s This risk can be reduced by in stalling the engine in an appropriate location and by avoiding sharp edges Route all the various lines e g for fuel hydraulics coolant and refrigerant brake fluid and...

Page 443: ...s of probe body q To remove use socket AF 22 mm for lambda probe T10491 q Checking Page 439 5 Gasket q Renew q Note installation po sition 6 Clamp 7 Nm q Make sure it is firm ly seated 7 Exhaust gas t...

Page 444: ...adaptation value for ash deposit mass must be set to 0 Page 460 check diesel particulate filter 13 Bracket q Bolted to cylinder head 14 25 Nm 15 25 Nm 1 1 2 Engine codes CPYA CPYB CPYC CPYD CPYE Remo...

Page 445: ...sel particulate filter q Grease thread of sender using high temperature paste G 052 112 A3 q Checking Page 442 6 Diesel particulate filter q Check diesel particulate filter Page 460 q Removing and ins...

Page 446: ...codes CPYA CPYB CPYC CPYD CPYE Special tools and workshop equipment required Socket AF 22 mm for lambda probe T 10491 Torque wrench V A G 1331 Note If the diesel particulate filter has to be renewed b...

Page 447: ...iculate filter 6 Installing Install in reverse order Renew seal 4 Join diesel particulate filter 6 and oxidising catalytic con verter 3 using clamp 5 and seal 4 Note installation posi tion of clamp 5...

Page 448: ...ed by a new und unused diesel particulate filter the adaptation value for ash deposit mass must be set to 0 Page 459 If the diesel particulate filter is replaced by a used diesel partic ulate filter p...

Page 449: ...5 mm to bolting of turbocharger support Electrical connections and routing Current flow diagrams Electrical fault finding and Fitting locations 2 Exhaust gas recirculation sys tem WARNING Adhere to t...

Page 450: ...gas re circulation 5 Connecting pipe Caution Ensure that decou pling element of con necting pipe is not bent and thus stretched There is a danger of cracking 6 23 Nm 7 Exhaust gas recircu lation valv...

Page 451: ...g 7 9 Nm q 8 Clamp 5 Nm 9 Exhaust gas recircu lation cooler q With integrated ex haust gas recircula tion valve N18 with exhaust gas recircu lation potentiometer G212 10 9 Nm 11 Gasket q Renew 12 Gask...

Page 452: ...r 4 G648 exhaust gas temperature sender downstream of diesel particulate filter Page 444 Checking exhaust gas pressure sensor 1 G450 Page 446 Check diesel particulate filter engine codes CJDA CJDD Pag...

Page 453: ...ivate exhaust gas recirculation valve N18 Page 89 final control diagnosis The displays in display zones 3 and 4 must fluctuate within fol lowing control range Specification in display zone 3 180 370 m...

Page 454: ...Access permissions Carry out final control diagnosis and activate exhaust gas recirculation valve N18 Page 89 final control diagnosis The displays in display zones 3 and 4 must fluctuate within fol lo...

Page 455: ...Renew exhaust gas recirculation valve N18 with exhaust gas recirculation potentiometer G212 Adapt exhaust gas recirculation valve N18 Page 423 Then read event memory of engine control unit and clear...

Page 456: ...basic voltage after approx 8 sec onds Specification 0 4 0 5 V Switch off ignition If the specification is not attained Check wiring of lambda probe as follows Using adapter cable V A G 1598 39 2 conn...

Page 457: ...probe heater Z19 and lambda probe G39 are installed in one common housing Only gold plated contacts may be used when repairing con tacts in connector of lambda probe and lambda probe heat er Disconnec...

Page 458: ...open cir cuit referring to current flow diagram Contact 3 socket 73 Cable resistance max 2 0 Additionally check wires for short to one another Specifica tion If no wiring fault is detected and voltage...

Page 459: ...er ahead of diesel particulate filter in display zone 1 and from exhaust gas temperature sender 4 G648 ex haust gas temperature sensor downstream from diesel par ticulate filter in display zone 2 Note...

Page 460: ...this action Check wiring between test box and connector for open cir cuit referring to current flow diagram Contact 1 socket 89 Contact 2 socket 32 Cable resistance max 2 0 Also check wiring for short...

Page 461: ...f temperature value in display zone 2 With the engine speed being increased select Display group 100 Indicated on display Check exhaust gas temperature value from exhaust gas temperature sender 3 G495...

Page 462: ...26 read event memory If specification is attained Check wiring of exhaust gas temperature sender 4 G648 as follows Using adapter cable V A G 1598 39 2 connect test box V A G 1598 42 to wiring harness...

Page 463: ...ated on display Note The display zones may be shown one below the other or next to each other on the display of the vehicle diagnostic tester Check differential exhaust gas pressure in display zone 3...

Page 464: ...rt to one another short to battery earth engine earth and short to battery positive Specifica tion If no wiring fault is detected and voltage was present between contacts 1 2 Renew exhaust gas pressur...

Page 465: ...parts kit is available for renewing the vacuum unit with position sender for charge pressure positioner G581 Electronic Parts Catalogue ETKA Removing Remove air filter housing with air mass meter and...

Page 466: ...14 mm open ended wrench for counterholding 14 mm open end wrench for counterholding connecting piece of oil supply line A 110 mm B 25 mm Counterhold connecting piece with 14 mm open end wrench and uns...

Page 467: ...re move the vacuum unit A Caution Only use new bolts and nuts from the spare parts kit If necessary remove lower securing nut of control rod from vacuum unit Screw locknut by hand onto the control ro...

Page 468: ...120 and confirm entry with the Q key Connect hand vacuum pump VAS 6213 to vacuum unit Observe the lowest value of the measured value block and set a voltage of 0 760 V by causing a partial vacuum Cau...

Page 469: ...locknut B Coun terhold locknut B turn securing nut A in opposite direc tion and tighten it with socket AF 10 mm T10422 Press locking plate by hand onto control rod and turn it 90 in direction of arro...

Page 470: ...Diesel particulate filter has been renewed If the diesel particulate filter is replaced by a new und unused diesel particulate filter the adaptation value for ash deposit mass must be set to 0 Page 4...

Page 471: ...2 or 3 exceeds 35 g Exit diagnosis function Switch off ignition Renew diesel particulate filter Page 430 If the soot loading is between 0 35 g Perform a regeneration of the diesel particulate filter P...

Page 472: ...ect 015 2 Security Access automatic Enter following access code Access code 40809 Confirm access code Press button 3 times to go back to diagnosis function menu Select diagnosis function 014 Long adap...

Page 473: ...regeneration has been completed and the display zone of display group 254 does not show 1 the oxidising catalytic converter is presumably defective Then read event memory of engine control unit and cl...

Page 474: ...must be performed after each re generation By adapting the ash deposit mass the calculated ash de posit mass in the engine control unit will be recalibrated The ash deposit mass must be adapted right...

Page 475: ...filter must be performed before hand Caution Allow the engine to run for another 2 to 3 minutes after the adaptation of the ash deposit mass has been completed This helps to cool down the engine and...

Page 476: ...ensor 1 G450 3 10 Checking diesel particulate filter en gine codes CJDA CJDD Note If the diesel particulate filter is renewed the adaptation value for the ash deposit mass must be set to 0 renew diese...

Page 477: ...s to 60 000 km Evaluating filter status Start engine Press button Select Display group 1 Indicated on display Increase engine speed to 1200 1500 rpm Keep engine running at increased engine speed for a...

Page 478: ...rocedure Press button Select Display group 108 Indicated on display Check ash deposit mass in display zone 1 Specification 500 ml for large diesel particulate filter Check calculated soot loading in d...

Page 479: ...least 161 C The regeneration takes 20 min Start engine and run at idling speed Connect vehicle diagnostic tester and select engine control unit Page 23 Select diagnosis function 011 Read measured valu...

Page 480: ...ase Check soot loading in display zones 2 and 3 Specification 5 g If specification is attained Press button back Select Display group 104 Indicated on display If display zone 2 shows FF02 the regenera...

Page 481: ...k Press Confirm button to reset the learnt value Exit diagnosis function Switch ignition off and after 60 seconds switch it on again Select Display group 108 011 Read measured value block Indicated on...

Page 482: ...s value Now the ash deposit mass has been recalculated and stored ignore error message Select Display group 108 011 Read measured value block Indicated on display Check condition of diesel particulate...

Page 483: ...rminal 50 from ignition starter switch D 3 Connection for coil 1 2 Starter B not turning Special tools and workshop equipment required Auxiliary measuring set V A G 1594 Hand multimeter V A G 1526 or...

Page 484: ...on starter switch and check the voltage Speci fication at least 8 0 V If the specification is not attained Renew ignition starter switch D If specification is attained Check wiring between Ignition st...

Page 485: ...Removing and installing starter B Special tools and workshop equipment required Torque wrench 5 50 Nm V A G 1331 Torque wrench 40 200 Nm V A G 1332 Removing Page 469 Installing Page 471 Specified torq...

Page 486: ...securing bolt of starter arrow Unscrew securing bolt of starter arrow Unscrew securing nut 1 from lower securing bolt of starter Remove line retainer 2 3 Industriemotoren Industrial Engines 2009 Works...

Page 487: ...f starter M8 15 Nm 2 Alternator C WARNING Adhere to the general safety regulations and the notes on repair work on the engine Page 1 Observe rules for cleanliness Page 354 Assembly overview alternator...

Page 488: ...nator C Note Removing and installing bracket for ancillary units Page 144 3 Industriemotoren Industrial Engines 2009 Workshop Manual for Diesel Engine 2 0 l 36 75 kW_EA 189 05 2015 472 Repair Group 27...

Page 489: ...heck Page 474 checking alternator C and voltage reg ulator C1 q Removing and in stalling Page 475 q Removing and in stalling poly V belt pulley Page 138 q Checking operation of freewheel clutch Page 4...

Page 490: ...nits due to excessive voltage With ignition switched off disconnect earth strap from bat tery Tighten securing nut of B1 wire arrow Specified torque 15 Nm 2 2 Checking alternator C and voltage reg ula...

Page 491: ...G 1715 display does not show OK Renew voltage regulator C1 Page 477 removing and in stalling voltage regulator C1 Repeat the test procedure If the multimeter V A G 1715 display again does not show OK...

Page 492: ...the descriptions of work from the respective manufacturer Note safety precautions before beginning work Page 354 Observe rules for cleanliness Page 354 Remove poly V belt Page 138 Disconnect connector...

Page 493: ...o not damage threaded sleeves while driving them out Secure line retainer arrow in 3 o clock position on back of alternator Tighten threaded connections to specified torque given in assembly overview...

Page 494: ...nd securing bolt arrow B of protective cap and remove protective cap Unscrew securing bolts arrows of voltage regulator and re move voltage regulator Installing Install in reverse order In the process...

Page 495: ...V A G 1783 Removing Page 479 Installing Page 479 Removing Remove alternator C Page 475 Remove spring clips arrows and remove protective cap from alternator Unscrew securing bolts and securing nut arro...

Page 496: ...rnator to 2 Nm Push protective cap into guides arrows until it can be heard to engage Install alternator C Page 475 2 5 Removing and installing poly V belt pul ley Removing and installing poly V belt...

Page 497: ...alternator in a vice at mounting points Use socket VAS 3310 to unscrew poly V belt pulley secur ing nut from alternator shaft Installing Installation is carried out in the reverse order When installin...

Page 498: ...o alternator shaft Loosen threaded connection by turning clockwise Counter hold with ring spanner when doing this Hold poly V belt pulley with freewheel by hand Turn drive shaft of alternator until po...

Page 499: ...nto alternator shaft Counterhold using adapter 3400 and 17 mm ring spanner Tighten poly V belt with freewheel by turning drive shaft of alternator anti clockwise using torque wrench V A G 1332 Tighten...

Page 500: ...lling Page 485 Removing Remove alternator C Page 475 Clamp alternator in a vice at mounting points Remove protective cap from poly V belt pulley with free wheel Insert adapter 3400 with 17 mm ring spa...

Page 501: ...ve 1 and pull off grip 2 Turn grip 2 of torque wrench through 180 degrees and re insert socket Set direction of rotation of torque wrench to anti clockwise on socket drive Insert TORX key V A G 1603 1...

Page 502: ...d voltage regulator C1 Page 474 3 Current flow diagrams Note The current flow diagrams below are only examples for cir cuits since due to the various use cases of industrial en gines it is not possibl...

Page 503: ...ol unit Page 494 Exhaust gas recirculation potentiometer exhaust gas tempera ture sender 1 fuel pressure sender engine control unit exhaust gas recirculation valve Page 495 Brake light switch brake pe...

Page 504: ...age regulator D Ignition starter switch S5 Fuse q 15 A q In fuse holder S8 Fuse q 5 A q In fuse holder S10 Fuse q 5 A q In fuse holder B M Battery earth en gine earth 3 Industriemotoren Industrial Eng...

Page 505: ...Glow plug 1 Q11 Glow plug 2 Q12 Glow plug 3 Q13 Glow plug 4 S1 Fuse q 20 A q In fuse holder S3 Fuse q 50 A q In fuse holder T4a 4 pin connector T11 11 pin connector T14 14 pin connector V393 Suppleme...

Page 506: ...S9 Fuse q 5 A q In fuse holder T14 14 pin connector T60 60 pin connector T94 94 pin connector 131 Earth connection 2 in engine compart ment wiring harness D180 Connection 87a in engine compart ment wi...

Page 507: ...rge air pres sure sender G42 Intake air tempera ture sender G70 Air mass meter J623 Engine control unit T4 4 pin connector T94 94 pin connector B M Battery earth en gine earth Industriemotoren Industr...

Page 508: ...r 2 J623 Engine control unit N30 Injector cylinder 1 N31 Injector cylinder 2 N32 Injector cylinder 3 N33 Injector cylinder 4 T6a 6 pin connector T60 60 pin connector T94 94 pin connector B M Battery e...

Page 509: ...lant tempera ture sender J623 Engine control unit N276 Fuel pressure reg ulating valve N290 Fuel metering valve T3 3 pin connector T14 14 pin connector T60 60 pin connector B M Battery earth en gine e...

Page 510: ...rature sender G581 Position sender for charge pressure positioner J338 Throttle valve module J623 Engine control unit T60 60 pin connector 220 Earth connection sender earth in en gine wiring harness D...

Page 511: ...uel pressure sender J623 Engine control unit N18 Exhaust gas recir culation valve T2a 2 pin connector T6 6 pin connector T60 60 pin connector T94 94 pin connector 220 Earth connection sender earth in...

Page 512: ...l unit N75 Charge pressure control solenoid valve N79 Heater element for crankcase breather q If installed S12 Fuse q 10 A q In fuse holder q If installed T1 1 pin connector T14 14 pin connector T60 6...

Page 513: ...but ton E433 Preset speed 1 switch E434 Preset speed 2 switch F36 Clutch pedal switch J623 Engine control unit T14 14 pin connector T60 60 pin connector T94 94 pin connector A143 Connection work ing s...

Page 514: ...tor K29 Glow period warn ing lamp K83 Exhaust emissions warning lamp T94 94 pin connector A143 Connection work ing speed control in dash panel wiring harness D52 Positive connec tion 15a in engine com...

Page 515: ...peed control decrease speed button E429 Working speed control increase speed button E604 Working speed governor switch 2 J623 Engine control unit K158 Working speed control warning lamp T14 14 pin con...

Page 516: ...n fuse holder S42 Radiator fan single fuse q Fuse rating de pends on used radi ator fan used T14 14 pin connector T60 60 pin connector T94 94 pin connector V7 Radiator fan B M Battery earth en gine ea...

Page 517: ...B compliant with emission standard 97 68 stage 3b Battery starter alternator voltage regulator ignition starter switch fuses Page 503 Electric fuel pump 2 relay automatic glow period control unit glow...

Page 518: ...ve heater element for crankcase breather Page 512 Working speed control switch working speed control resume button preset speed switch 1 and 2 clutch pedal switch engine control unit Page 513 Preset s...

Page 519: ...or C1 Voltage regulator D Ignition starter switch S5 Fuse q 15 A q In fuse holder S8 Fuse q 5 A q In fuse holder S10 Fuse q 5 A q In fuse holder B M Battery earth en gine earth Industriemotoren Indust...

Page 520: ...g 1 Q11 Glow plug 2 Q12 Glow plug 3 Q13 Glow plug 4 S1 Fuse q 20 A q In fuse holder S3 Fuse q 50 A q In fuse holder T4a 4 pin connector T11 11 pin connector T14 14 pin connector V393 Supplementary fue...

Page 521: ...q 5 A q In fuse holder S11 Fuse q 10 A q In fuse holder T14 14 pin connector T60 60 pin connector T94 94 pin connector 131 Earth connection 2 in engine compart ment wiring harness D180 Connection 87a...

Page 522: ...Air mass meter J623 Engine control unit T4 4 pin connector T94 94 pin connector B M Battery earth en gine earth 3 2 5 Accelerator position sender accelerator position sender 2 engine control unit in j...

Page 523: ...lant tempera ture sender J623 Engine control unit N276 Fuel pressure reg ulating valve N290 Fuel metering valve T3 3 pin connector T14 14 pin connector T60 60 pin connector B M Battery earth en gine e...

Page 524: ...rature sender G581 Position sender for charge pressure positioner J338 Throttle valve module J623 Engine control unit T60 60 pin connector 220 Earth connection sender earth in en gine wiring harness D...

Page 525: ...der J623 Engine control unit N18 Exhaust gas recir culation valve T6 6 pin connector T60 60 pin connector 220 Earth connection sender earth in en gine wiring harness D101 Connection 1 in engine compar...

Page 526: ...nder 3 G648 Exhaust gas tem perature sender 4 J623 Engine control unit T2a 2 pin connector T2b 2 pin connector T2c 2 pin connector T94 94 pin connector 327 Earth connection sender earth in en gine wir...

Page 527: ...probe G450 Exhaust gas pres sure sensor 1 J623 Engine control unit Z19 Lambda probe heater T6b 6 pin connector T94 94 pin connector B M Battery earth en gine earth Industriemotoren Industrial Engines...

Page 528: ...ol unit N75 Charge pressure control solenoid valve N79 Heater element for crankcase breather q If installed S12 Fuse q 10 A q In fuse holder q If installed T1 1 pin connector T14 14 pin connector T60...

Page 529: ...but ton E433 Preset speed 1 switch E434 Preset speed 2 switch F36 Clutch pedal switch J623 Engine control unit T14 14 pin connector T60 60 pin connector T94 94 pin connector A143 Connection work ing s...

Page 530: ...ing lamp K83 Exhaust emissions warning lamp K231 Warning lamp for diesel particle filter T14 14 pin connector T60 60 pin connector T94 94 pin connector A143 Connection work ing speed control in dash...

Page 531: ...peed control decrease speed button E429 Working speed control increase speed button E604 Working speed governor switch 2 J623 Engine control unit K158 Working speed control warning lamp T14 14 pin con...

Page 532: ...n fuse holder S42 Radiator fan single fuse q Fuse rating de pends on used radi ator fan used T14 14 pin connector T60 60 pin connector T94 94 pin connector V7 Radiator fan B M Battery earth en gine ea...

Page 533: ...CJDA CJDD compliant with emission standard EU5 Battery starter alternator voltage regulator ignition starter switch Page 519 Electric fuel pump 2 relay automatic glow period control unit glow plugs f...

Page 534: ...ve heater element for crankcase breather Page 529 Working speed control switch working speed control resume button preset speed switch 1 and 2 clutch pedal switch engine control unit Page 530 Preset s...

Page 535: ...or C1 Voltage regulator D Ignition starter switch S5 Fuse q 15 A q In fuse holder S8 Fuse q 5 A q In fuse holder S10 Fuse q 5 A q In fuse holder B M Battery earth en gine earth Industriemotoren Indust...

Page 536: ...g 1 Q11 Glow plug 2 Q12 Glow plug 3 Q13 Glow plug 4 S1 Fuse q 20 A q In fuse holder S3 Fuse q 50 A q In fuse holder T4a 4 pin connector T11 11 pin connector T14 14 pin connector V393 Supplementary fue...

Page 537: ...q 5 A q In fuse holder S11 Fuse q 10 A q In fuse holder T14 14 pin connector T60 60 pin connector T94 94 pin connector 131 Earth connection 2 in engine compart ment wiring harness D180 Connection 87a...

Page 538: ...es sure sender G42 Intake air tempera ture sender G70 Air mass meter J623 Engine control unit T5 5 pin connector T94 94 pin connector B M Battery earth en gine earth 3 Industriemotoren Industrial Engi...

Page 539: ...tion sender 2 J623 Engine control unit N30 Injector cylinder 1 N31 Injector cylinder 2 N32 Injector cylinder 3 N33 Injector cylinder 4 T6a 6 pin connector T60 60 pin connector T94 94 pin connector B M...

Page 540: ...ra ture sender J623 Engine control unit N276 Fuel pressure reg ulating valve N290 Fuel metering valve T3 3 pin connector T14 14 pin connector T60 60 pin connector B M Battery earth en gine earth 3 Ind...

Page 541: ...Fuel temperature sender G581 Position sender for charge pressure positioner J338 Throttle valve module J623 Engine control unit T60 60 pin connector 220 Earth connection sender earth in en gine wiring...

Page 542: ...Engine control unit N18 Exhaust gas recir culation valve T6 6 pin connector T60 60 pin connector 220 Earth connection sender earth in en gine wiring harness D101 Connection 1 in engine compartment wir...

Page 543: ...rature sender 3 G648 Exhaust gas tem perature sender 4 J623 Engine control unit T2a 2 pin connector T2b 2 pin connector T2c 2 pin connector T94 94 pin connector 327 Earth connection sender earth in en...

Page 544: ...50 Exhaust gas pres sure sensor 1 J623 Engine control unit Z19 Lambda probe heater T6b 6 pin connector T94 94 pin connector B M Battery earth en gine earth 3 Industriemotoren Industrial Engines 2009 W...

Page 545: ...ine control unit N75 Charge pressure control solenoid valve N79 Heater element for crankcase breather q If installed S12 Fuse q 10 A q In fuse holder q If installed T1 1 pin connector T14 14 pin conne...

Page 546: ...433 Preset speed 1 switch E434 Preset speed 2 switch F36 Clutch pedal switch J623 Engine control unit T14 14 pin connector T60 60 pin connector T94 94 pin connector A143 Connection work ing speed cont...

Page 547: ...eriod warn ing lamp K83 Exhaust emissions warning lamp K231 Warning lamp for diesel particle filter T14 14 pin connector T60 60 pin connector T94 94 pin connector A143 Connection work ing speed contro...

Page 548: ...rol decrease speed button E429 Working speed control increase speed button E604 Working speed governor switch 2 J623 Engine control unit K158 Working speed control warning lamp T14 14 pin connector T6...

Page 549: ...q 5 A q In fuse holder S42 Radiator fan single fuse q Fuse rating de pends on used radi ator fan used T14 14 pin connector T60 60 pin connector T94 94 pin connector V7 Radiator fan B M Battery earth e...

Page 550: ...e control unit K3 Oil pressure warn ing lamp S Fuse q 5 A q In fuse holder T14 14 pin connector T16 16 pin connector q Diagnostic connec tion T94 94 pin connector Customer specific Speed signal output...

Page 551: ...uch as fuel engine oils or cool ant additive are harmful substances adhere to the safety instructions from the manufacturer There is a risk of injuries if maintenance locations are difficult to access...

Page 552: ...ts of coolant line arrows from intake manifold and set down coolant line in front of intake manifold Caution Make sure that no wiring connections are damaged when disconnecting the connectors Otherwis...

Page 553: ...tool U J extension and 10 mm socket 3220 Installing Installation is carried out in the reverse order When installing note the following To tighten glow plugs use special tool U J extension and 10 mm s...

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