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Workshop Manual for Industrial Diesel Engine (2.0 l / 36-75 kW EA 189)
Engine code CJDA, CJDD, CPYA, CPYB, CPYC, CPYD, CPYE
Edition 05.2015
Repair Group
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/supercharging
23 Mixture preparation - injection
26 Exhaust system
27 Starter, current supply, CCS
28 Glow plug system
Contents:
Technical data . . . . . 1
1 Description of symbols. . . . . 1
2 Important notes for repair work on the engine. . . . . 1
2.1 General safety notes. . . . . 3
3 Technical data. . . . . 5
3.1 Engine number/engine code. . . . . 5
3.2 Engine data. . . . . 6
4 Service work. . . . . 10
4.1 Entries in service history book. . . . . 10
4.2 Service intervals. . . . . 11
4.2.1 Countries with high sulphur content in diesel fuel. . . . . 12
4.2.2 Severe operating conditions. . . . . 13
4.2.3 Extended service intervals. . . . . 13
4.3 Scope of interval service. . . . . 14
4.3.1 General scopes of service. . . . . 14
4.3.2 Additional work. . . . . 16
4.3.3 Scopes of service for gas systems. . . . . 17
4.4 Descriptions of work, engine, general. . . . . 18
4.4.1 Engine and add-on parts in engine compartment (from above and below): perform visual check for leaks and damage. . . . . 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 self-diagnosis. . . . . 22
1.1 Features of vehicle self-diagnosis. . . . . 22
1.2 Technical data of vehicle self-diagnosis. . . . . 22
1.2.1 Read version of engine control unit. . . . . 22
1.2.2 Available diagnosis functions when using the vehicle diagnosis, testing and information system. . . . . 23
1.3 Connecting vehicle diagnostic tester and selecting engine control unit . . . . . 23
1.4 Connecting test box to check lines. . . . . 24
1.4.1 Connecting test box -V.A.G 1598/42- using adapter cable -V.A.G 1598/39-1- . . . . . 25
1.4.2 Connecting test box -V.A.G 1598/42- using adapter cable -V.A.G 1598/39-2- . . . . . 26
2 Event memory. . . . . 26
2.1 Reading event memory. . . . . 26
2.2 Clearing event memory. . . . . 27
3 List of fault codes. . . . . 28
3.1 Fault code: 00022/P0016...00146/P0092. . . . . 30
3.2 Fault code: 00257/P0101...01687/P0697. . . . . 34
3.3 Fault code: 04110/P100E...05779/P1693. . . . . 64
3.4 Fault code: 08320/P2080 ... 11179 ... P2BAB. . . . . 70
3.5 Fault code: 13256/P33C8...13257/P33C9. . . . . 87
3.6 Fault code: 49153/U0001...54282/U140A. . . . . 88
4 Final control diagnosis. . . . . 89
4.1 Performing final control diagnosis. . . . . 89
5 Measured value blocks, engine codes CJDA, CJDD. . . . . 93
5.1 Safety precautions. . . . . 93
5.2 Reading measured value block. . . . . 94
5.3 Evaluating measured value blocks at idling speed. . . . . 95
5.3.1 Display group 1 - Injected quantity. . . . . 95
5.3.2 Display group 2 - Idling speed. . . . . 96
5.3.3 Display group 3 - Exhaust gas recirculation. . . . . 97
5.3.4 Display group 4 - Activation of injectors -N30...N33-. . . . . 97
5.3.5 Display group 7 - Temperatures. . . . . 98
5.3.6 Display group 10 - Air quantities. . . . . 98
5.3.7 Display group 11 - Charge pressure control. . . . . 99
5.3.8 Display group 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 positioner. . . . . 103
5.3.13 Display group 99 - exhaust gas temperature sender. . . . . 103
5.3.14 Display group 100 - diesel particulate filter, exhaust gas temperature sender, pressure differential sender. . . . . 104
5.3.15 Display group 106 - diesel particulate filter, regeneration 6. . . . . 105
5.3.16 Display group 108 - diesel particulate filter, regeneration 8. . . . . 105
5.4 Evaluating measured value blocks at full load. . . . . 106
5.4.1 Conditions for measurements at full load. . . . . 106
5.4.2 Display group 1 - Injected quantity. . . . . 106
5.4.3 Display group 3 - Exhaust gas recirculation. . . . . 107
5.4.4 Display group 8 - torque limit 1. . . . . 108
5.4.5 Display group 11 - Charge pressure control. . . . . 109
6 Measured value blocks, engine codes CPYA, CPYB, CPYC, CPYD, CPYE, CPYF, CPYG. . . . . 109
6.1 Safety precautions. . . . . 110
6.2 Reading measured value block. . . . . 110
6.3 Evaluating measured value blocks at idling speed. . . . . 111
6.3.1 Display group 1 - Injected quantity. . . . . 112
6.3.2 Display group 2 - Idling speed. . . . . 112
6.3.3 Display group 3 - Exhaust gas recirculation. . . . . 113
6.3.4 Display group 4 - Activation of injectors -N30...N33-. . . . . 114
6.3.5 Display group 5. . . . . 114
6.3.6 Display group 7 - Temperatures. . . . . 114
6.3.7 Display group 10 - Air quantities. . . . . 115
6.3.8 Display group 11 - Charge pressure control. . . . . 116
6.3.9 Display group 12 - Status. . . . . 116
6.3.10 Display group 13 - Smooth running control 1. . . . . 117
6.3.11 Display group 20 - Fuel rail values 3. . . . . 118
6.3.12 Display group 30 - Pedal encoder. . . . . 119
6.3.13 Display group 32. . . . . 119
6.3.14 Display group 34 - Charge pressure positioner. . . . . 119
6.3.15 Display group 38. . . . . 120
6.3.16 Display group 39. . . . . 120
6.3.17 Display group 85. . . . . 121
6.3.18 Display group 97. . . . . 121
6.3.19 Display group 99 - exhaust gas temperature sender. . . . . 121
6.3.20 Display group 100 - diesel particulate 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
6.3.24 Display group 246. . . . . 124
6.3.25 Display group 248. . . . . 124
6.3.26 Display group 250. . . . . 125
6.3.27 Display group 253. . . . . 125
6.3.28 Display group 254. . . . . 125
6.4 Evaluating measured value blocks at full load (engine code CPYA). . . . . 125
6.4.1 Conditions for measurements at full load. . . . . 125
6.4.2 Display group 1 - Injected quantity. . . . . 126
6.4.3 Display group 3 - Exhaust gas recirculation. . . . . 127
6.4.4 Display group 8 - torque limit 1. . . . . 128
6.4.5 Display group 11 - Charge pressure control. . . . . 128
6.5 Evaluating measured value blocks at full load (engine code CPYB). . . . . 129
6.5.1 Conditions for measurements at full load. . . . . 129
6.5.2 Display group 1 - Injected quantity. . . . . 130
6.5.3 Display group 3 - Exhaust gas recirculation. . . . . 130
6.5.4 Display group 8 - torque limit 1. . . . . 131
6.5.5 Display group 11 - Charge pressure control. . . . . 132
10 Removing and installing engine. . . . . 133
1 Removing and installing engine. . . . . 133
1.1 Notes on removing. . . . . 134
1.2 Securing engine to assembly stand. . . . . 136
1.3 Notes on installing. . . . . 136
1.4 Specified torques. . . . . 137
1.5 Additional information and assembly work for power units with air conditioning system . . . 137
Crankshaft group. . . . . 138
1 Dismantling and assembling engine. . . . . 138
1.1 Assembly overview - poly V-belt drive, with air conditioner compressor . . . . . 140
1.2 Assembly overview - poly V-belt drive, without air conditioner compressor . . . . . 141
1.3 Removing and installing or renewing poly V-belt. . . . . 141
1.4 Poly V-belt: Check condition. . . . . 143
1.5 Removing and installing poly V-belt tensioner, engines with air conditioner compressor only. . . . . 143
1.6 Removing and installing ancillary bracket. . . . . 144
1.7 Assembly overview - toothed belt drive, engine codes CJDA, CJDD, without crankshaft seal. . . . . 146
1.8 Removing and installing engine bracket. . . . . 148
1.9 Assembly overview - toothed 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 visual check of toothed belt tension. . . . . 151
1.12 Assessing wear on tensioning roller and belt pulleys. . . . . 152
1.13 Wear of high-pressure pump pulley. . . . . 152
1.14 Assessing wear. . . . . 153
1.15 Removing and installing crankshaft protective cover. . . . . 155
1.16 Assembly overview - crankcase, engine codes CJDA, CJDD. . . . . 156
1.17 Assembly overview - crankcase, engine codes CPYA, CPYB, CPYC, CPYD, CPYE . . . . . 157
2 Removing and installing sealing flange and flywheel. . . . . 158
2.1 Assembly overview - Sealing flange, belt pulley end. . . . . 159
2.2 Renewing crankshaft oil seal - pulley end. . . . . 161
2.2.1 Removing. . . . . 162
2.2.2 Installing. . . . . 163
2.3 Removing and installing crankshaft sealing flange, pulley end. . . . . 164
2.3.1 Removing. . . . . 165
2.3.2 Installing. . . . . 166
2.4 Assembly overview - sealing flanges and flywheel. . . . . 167
2.5 Renewing crankshaft sealing flange - flywheel end. . . . . 169
2.5.1 Pressing out sealing flange with sender wheel. . . . . 171
2.5.2 Pressing in sealing flange with sender wheel. . . . . 172
2.5.3 A - Assembling seal with sender wheel on assembly tool -T10134-. . . . . 172
2.5.4 B - Installing assembly tool -T10134- with sealing flange to crankshaft flange . . . . . 174
2.5.5 C - Bolting assembly tool -T10134- to crankshaft flange. . . . . 175
2.5.6 D - Pressing sender wheel onto crankshaft flange using assembly tool -T10134- . . . . . 176
2.5.7 E - Checking installation position of sender wheel on crankshaft. . . . . 176
2.5.8 F - Re-pressing sender wheel. . . . . 177
2.6 Removing and installing engine speed sender -G28-. . . . . 178
2.6.1 Removing. . . . . 178
2.6.2 Installing. . . . . 178
3 Removing and installing crankshaft. . . . . 179
3.1 Assembly overview - crankshaft. . . . . 180
3.2 Crankshaft dimensions. . . . . 180
3.3 Pulling needle bearing, if fitted, out of and driving into crankshaft. . . . . 181
3.3.1 Pulling out. . . . . 181
3.3.2 Driving in. . . . . 182
4 Dismantling and assembling pistons and conrods. . . . . 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 dimensions. . . . . 188
Cylinder head, valve gear. . . . . 189
1 Cylinder head. . . . . 189
1.1 Assembly overview - cylinder head. . . . . 190
1.2 Removing and installing Hall sender -G40-. . . . . 191
1.3 Assembly overview - cylinder head cover, engine codes CJDA, CJDD . . . . . 194
1.3.1 Removing and installing cylinder head cover. . . . . 196
1.4 Assembly overview - cylinder head cover, engine codes CPYA, CPYB, CPYC, CPYD, CPYE. . . . . 202
1.4.1 Removing and installing cylinder head cover. . . . . 205
1.5 Renewing toothed belt and toothed belt tensioning roller for camshaft drive, engine codes CJDA, CJDD, CPYA, CPYB, CPYC, CPYD, CPYE. . . . . 210
1.5.1 Removing. . . . . 212
1.5.2 Installing, tensioning. . . . . 214
1.6 Checking compression. . . . . 218
1.7 Removing and installing cylinder head. . . . . 220
1.7.1 Notes on removing. . . . . 221
1.7.2 Notes on installing. . . . . 225
1.8 Removing and installing vacuum pump. . . . . 226
Repairing valve gear. . . . . 227
2.1 Assembly overview - valve gear. . . . . 228
2.2 Valves. . . . . 229
2.2.1 Valve dimensions. . . . . 229
2.2.2 Checking valve guides. . . . . 229
2.3 Renewing valve stem seals. . . . . 230
2.4 Removing and installing camshaft. . . . . 233
2.4.1 Removing. . . . . 234
2.4.2 Installing. . . . . 235
2.5 Removing and installing camshaft oil seal. . . . . 239
2.5.1 Engines up to 08.09. . . . . 240
2.5.2 Engines as of 09.09. . . . . 242
Lubrication. . . . . 244
1 Engine oil. . . . . 244
1.1 Engine oil level: Check. . . . . 244
1.2 Engine oil: draining or extracting; Renewing oil filter and replenishing engine oil . . . . . 244
1.2.1 Draining or extracting engine oil. . . . . 245
1.2.2 Renewing engine oil filter, engine codes CJDA, CJDD, CPYA, CPYB, CPYC, CPYD, CPYE. . . . . 246
1.2.3 Replenishing engine oil. . . . . 247
2 Parts of lubrication system. . . . . 249
2.1 Assembly overview - oil pump, sump. . . . . 250
2.1.1 Engine codes CJDA, CJDD. . . . . 251
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 bracket, oil cooler and oil pressure switch, engine codes CJDA, CJDD . . . . . 260
3.1.1 Assembly overview - oil filter bracket and oil cooler. . . . . 261
3.1.2 Removing and installing oil filter bracket together with oil cooler. . . . . 262
3.1.3 Checking oil pressure and oil pressure switch -F1-. . . . . 264
3.2 Oil filter bracket, oil cooler and oil pressure switch, engine codes CPYA, CPYB, CPYC, CPYD, CPYE. . . . . 265
3.2.1 Assembly overview - oil filter bracket, oil cooler. . . . . 266
3.2.2 Removing and installing oil filter bracket with engine oil cooler. . . . . 268
3.2.3 Removing and installing oil cooler. . . . . 270
3.2.4 Removing and installing oil pressure switch -F1-. . . . . 273
3.2.5 Checking oil pressure and oil pressure switch -F1-. . . . . 274
Cooling. . . . . 276
1 Removing and installing parts of cooling system. . . . . 276
1.1 Parts of cooling system, engine side, engine codes CJDA, CJDD. . . . . 278
1.2 Parts of cooling system, engine side, engine codes CPYA, CPYB, CPYC, CPYD, CPYE . 279
1.3 Coolant hose schematic diagram. . . . . 280
1.4 Cooling system: Check frost protection and coolant level. . . . . 280
1.4.1 Checking frost protection, replenishing coolant additive if necessary . . . . . 281
1.4.2 Checking coolant level, replenishing coolant additive if necessary. . . . . 282
1.4.3 Mixture ratio:. . . . . 283
1.5 Draining and filling coolant. . . . . 284
1.5.1 Draining. . . . . 284
1.5.2 Filling. . . . . 285
1.6 Renewing coolant pump, engine codes CJDA, CJDD, CPYA, CPYB, CPYC, CPYD, CPYE. . . . . 287
1.6.1 Renewing coolant pump, engine codes CJDA, CJDD, CPYA, CPYB, CPYC, CPYD, CPYE. . . . . 288
1.7 Removing and installing 4/2-way valve with thermostat. . . . . 290
1.8 Checking cooling system for leaks. . . . . 292
1.9 Checking oil cooler for leaks. . . . . 293
1.9.1 Engine codes CJDA, CJDD. . . . . 294
1.9.2 Engine codes CPYA, CPYB, CPYC, CPYD, CPYE. . . . . 296
Fuel supply 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 incorrect fuel. . . . . 301
1.3.1 Step 1 (Engine was started with incorrect fuel). . . . . 301
1.3.2 Step 2 (Engine was not started with incorrect fuel). . . . . 302
1.3.3 Step 3 (There are filings in fuel tank and strainer). . . . . 302
1.3.4 Step 4 (There are no filings in fuel tank and strainer). . . . . 303
1.3.5 Step 5 (There are filings in high-pressure pump). . . . . 303
1.3.6 Step 6 (There are no filings in high-pressure pump). . . . . 304
1.4 Assembly overview - fuel filter. . . . . 304
1.4.1 Engine codes CJDA, CJDD. . . . . 304
1.4.2 Upper part of fuel filter. . . . . 305
1.4.3 Engine codes CPYA, CPYB, CPYC, CPYD, CPYE. . . . . 307
1.5 Draining water from fuel filter/fuel tank. . . . . 307
1.6 Renewing fuel filter. . . . . 308
1.6.1 Renewing fuel filter or upper part of fuel filter CJDA, CJDD. . . . . 309
1.6.2 Renewing fuel filter, engine codes CPYA, CPYB, CPYC, CPYD, CPYE . . . . . 312
1.7 Removing and installing supplementary fuel pump -V393- (inline electronic fuel pump) . . . 313
2 Checking components and functions. . . . . 314
2.1 Checking supplementary fuel pump -V393- (inline electronic fuel pump) . . . . . 314
2.2 Checking accelerator pedal position sender -G79-, if fitted. . . . . 316
Turbocharging/supercharging. . . . . 319
1 Charge air system with turbocharger. . . . . 319
1.1 Safety precautions when working on charge air system with turbocharger . . . . . 320
1.2 Rules for cleanliness. . . . . 320
1.3 Assembly overview - turbocharger with attachments. . . . . 321
1.3.1 Engine codes CJDA, CJDD. . . . . 322
1.3.2 Engine codes CPYA, CPYB, CPYC, CPYD, CPYE. . . . . 324
1.4 Removing and installing turbocharger. . . . . 326
1.4.1 Removing. . . . . 327
1.4.2 Installing. . . . . 329
2 Checking charge air system. . . . . 330
2.1 Checking charge air system for leaks. . . . . 331
2.2 Checking charge pressure control. . . . . 333
2.3 Connection for vacuum hoses. . . . . 334
2.3.1 Engine codes CJDA, CJDD. . . . . 335
2.3.2 Engine codes CPYA, CPYB, CPYC, CPYD, CPYE. . . . . 336
2.3.3 Intake system, installation position 0°. . . . . 336
2.3.4 Intake system, installation position 180°. . . . . 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, CPYD, CPYE. . . . . 339
2.4.3 Checking vacuum hoses. . . . . 340
3 Checking components and functions. . . . . 340
3.1 Markings on air mass meter and on elbow of the intake connecting pipe, view from turbocharger end. . . . . 341
3.2 Checking charge pressure control solenoid valve -N75-, engine codes CJDA, CJDD, CPYA, CPYB, CPYC, CPYD, CPYE. . . . . 341
3.3 Checking charge pressure sender -G31-. . . . . 343
3.4 Checking position sender for charge pressure positioner -G581-. . . . . 345
3.5 Checking exhaust gas temperature sender 1 -G235- (exhaust gas temperature sender ahead of turbocharger). . . . . 347
Mixture preparation - injection. . . . . 350
1 Repairing diesel direct injection system. . . . . 350
1.1 Instructions for working on fuel system. . . . . 351
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 noted. . . . . 353
1.3 Observe safety precautions when working on diesel direct injection fuel system . . . . . 354
1.4 Rules for cleanliness. . . . . 354
1.5 Assembly overview - intake manifold with attachments. . . . . 355
1.5.1 Engine codes CJDA, CJDD. . . . . 355
1.5.2 Engine codes CPYA, CPYB, CPYC, CPYD, CPYE. . . . . 356
1.5.3 Removing and installing intake manifold. . . . . 357
1.6 Fuel system. . . . . 358
1.6.1 Fuel system, engine codes CJDA, CJDD. . . . . 359
1.6.2 Fuel system, engine codes CPYA, CPYB, CPYC, CPYD, CPYE. . . . . 361
1.7 Assembly overview - fuel system. . . . . 362
1.7.1 Engine codes CJDA, CJDD. . . . . 363
1.7.2 Engine codes CPYA, CPYB, CPYC, CPYD, CPYE. . . . . 366
1.8 Correction values for injectors. . . . . 368
1.9 Checking for injectors sticking open. . . . . 369
1.10 Removing and installing injector (piezo injector). . . . . 370
1.10.1 Removing. . . . . 371
1.10.2 Installing. . . . . 373
1.10.3 Installing high-pressure lines. . . . . 375
1.11 Checking return flow rate from fuel pressure regulating valve -N276- . . . . . 377
1.12 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 bleeding fuel system. . . . . 383
1.16 Checking fuel system for leaks. . . . . 384
1.17 Checking pressure retention valve in fuel return line. . . . . 385
2 Checking components and functions. . . . . 387
2.1 Checking fuel metering valve -N290-. . . . . 388
2.2 Checking fuel pressure regulating valve -N276-. . . . . 391
2.3 Checking fuel pressure sender -G247-. . . . . 394
2.4 Checking injectors, cylinders 1...4 -N30...N33-. . . . . 398
2.5 Checking engine speed sender -G28-. . . . . 400
2.6 Checking Hall sender 2 -G40-. . . . . 403
2.7 Checking intake air temperature sender -G42-. . . . . 404
2.8 Checking coolant temperature sender -G62-. . . . . 407
2.9 Checking fuel temperature sender -G81-. . . . . 409
2.10 Checking air mass meter -G70-. . . . . 411
2.11 Checking throttle valve module -J338-. . . . . 414
3 Engine control unit -J623-. . . . . 416
3.1 Checking voltage supply for engine control unit. . . . . 417
3.2 Renewing engine control unit. . . . . 418
3.3 Adapting exhaust gas pressure sensor 1 -G450-. . . . . 420
3.4 Reading injector delivery calibration values/injector voltage calibration values, and storing them in engine control unit. . . . . 421
3.5 Adapting engine control unit -J623- to position sender for charge pressure positioner -G581-. . . . . 422
3.6 Adapting engine control unit -J623- to exhaust gas recirculation valve . . . . . 423
3.7 Adapting engine control unit -J623- to throttle valve module -J338-. . . . . 423
3.8 Checking data bus. . . . . 424
Exhaust system. . . . . 426
1 Removing and installing parts of exhaust system. . . . . 426
1.1 Assembly overview - diesel particulate filter. . . . . 427
1.1.1 Engine codes CJDA, CJDD. . . . . 427
1.1.2 Engine codes CPYA, CPYB, CPYC, CPYD, CPYE. . . . . 428
1.2 Renewing diesel particulate filter, engine codes CPYA, CPYB, CPYC, CPYD, CPYE . . . . . 430
1.3 Removing and installing exhaust gas temperature sender 1 -G235-. . . . . 432
2 Exhaust gas recirculation system. . . . . 433
2.1 Assembly overview - exhaust gas recirculation cooler. . . . . 434
2.1.1 Engine codes CJDA, CJDD. . . . . 434
2.1.2 Engine codes CPYA, CPYB, CPYC, CPXD, 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 Checking lambda probe heater -Z19-. . . . . 441
3.5 Checking exhaust gas temperature sender 3 -G495- (exhaust gas temperature sender
ahead of diesel particulate filter). . . . . 442
3.6 Checking exhaust gas temperature sender 4 -G648- (exhaust gas temperature sender
downstream of diesel particulate filter). . . . . 444
3.7 Checking exhaust gas pressure sensor 1 -G450-. . . . . 446
3.8 Renewing vacuum unit with position sender for charge pressure positioner -G581- . . . . . 449
3.9 Performing service work on diesel particulate filter, engine codes CPYA, CPYB, CPYC, CPYD, CPYE. . . . . 454
3.9.1 Checking diesel particulate filter, engine codes CPYA, CPYB, CPYC, CPYD, CPYE . . . . . 454
3.9.2 Regeneration of diesel particulate filter, engine codes CPYA, CPYB, CPYC, CPYD, CPYE. . . . . 455
3.9.3 Cancelling regeneration of diesel particulate filter, engine codes CPYA, CPYB, CPYC, CPYD, CPYE. . . . . 457
3.9.4 Adapting ash deposit mass of diesel particulate filter, engine codes CPYA, CPYB, CPYC, CPYD, CPYE. . . . . 458
3.9.5 Setting adaptation value for ash deposit mass to “0”, engine codes CPYA, CPYB, CPYC, CPYD, CPYE. . . . . 459
3.10 Checking diesel particulate filter, engine codes CJDA, CJDD. . . . . 460
3.11 Checking diesel particulate filter, engine codes CPYA, CPYB. . . . . 462
3.12 Regeneration of diesel particulate filter, engine codes CJDA, CJDD . . . . . 463
3.13 Renewing diesel particulate filter, engine codes CJDA, CJDD. . . . . 465
Starter, current supply, CCS. . . . . 467
1 Starter -B-. . . . . 467
1.1 Connections on solenoid switch. . . . . 467
1.2 Starter -B- not turning. . . . . 467
1.3 Starter -B- turning too slowly and not cranking engine properly. . . . . 468
1.4 Removing and installing starter -B-. . . . . 469
1.4.1 Removing. . . . . 469
1.4.2 Installing. . . . . 471
1.4.3 Specified torques. . . . . 471
2 Alternator -C-. . . . . 471
2.1 Assembly overview - alternator -C-. . . . . 472
2.2 Checking alternator -C- and voltage regulator -C1-. . . . . 474
2.3 Removing and installing alternator -C-. . . . . 475
2.3.1 Removing. . . . . 476
2.3.2 Installing. . . . . 477
2.4 Removing and installing voltage regulator -C1-. . . . . 477
2.4.1 Removing and installing 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 without freewheel. . . . . 481
2.5.2 Removing and installing poly V-belt pulley with freewheel, Bosch. . . . . 482
2.5.3 Removing and installing poly V-belt pulley with freewheel, Valeo. . . . . 484
2.6 Checking operation of freewheel clutch. . . . . 485
3 Current flow diagrams. . . . . 486
3.1 Current flow diagrams, engine codes CPYA, CPYB, compliant with emission standard (97/68 stage 3a). . . . . 487
3.1.1 Battery, starter, alternator, voltage regulator, ignition/starter switch fuses . . . . . 488
3.1.2 Electric fuel pump 2 relay, automatic glow period control unit, glow plugs, fuses, supplementary fuel pump. . . . . 489
3.1.3 Terminal 30 voltage supply relay, engine control unit, fuses. . . . . 490
3.1.4 Jumpers, charge pressure sender, intake air temperature sender, air mass meter, engine control unit. . . . . 491
3.1.5 Accelerator position sender, accelerator position sender 2, engine control unit, injectors, cylinders 1 - 4. . . . . 492
3.1.6 Hall sender, coolant temperature sender, engine control unit, fuel pressure regulating valve, fuel metering valve. . . . . 493
3.1.7 Engine speed sender, throttle valve potentiometer, fuel temperature sender, position sender for charge pressure positioner, throttle valve module, engine control unit . . . . . 494
3.1.8 Exhaust gas recirculation potentiometer, exhaust gas temperature sender 1, fuel pressure sender, engine control unit, exhaust gas recirculation valve. . . . . 495
3.1.9 Brake light switch, brake pedal switch, engine control unit, charge pressure control solenoid valve, heater element for crankcase breather. . . . . 496
3.1.10 Working speed control switch, working speed control, resume button, preset speed switch 1 and 2, clutch pedal switch, engine control unit. . . . . 497
3.1.11 Preset speed switch 3, engine control unit, alternator warning lamp, glow period warning lamp, exhaust emissions warning lamp. . . . . 498
3.1.12 Working speed control, safety contact switch, working speed control, decrease speed button, working speed control, increase speed button, working speed control switch 2, engine control unit, working speed warning lamp. . . . . 499
3.1.13 Jumpers, radiator fan relay, engine control unit, radiator fan single fuse, radiator fan . . . . . 500
3.1.14 Diagnostic connection, oil pressure switch, engine control unit, oil pressure warning lamp .501
3.2 Current flow diagrams, engine codes CPYA, CPYB, compliant with emission standard (97/68 stage 3b). . . . . 501
3.2.1 Battery, starter, alternator, voltage regulator, ignition/starter switch fuses . . . . . 503
3.2.2 Electric fuel pump 2 relay, automatic glow period control unit, glow plugs, fuses, supplementary fuel pump. . . . . 504
3.2.3 Terminal 30 voltage 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, accelerator position sender 2, engine control unit, injectors, cylinders 1 - 4. . . . . 506
3.2.6 Hall sender, coolant temperature sender, engine control unit, fuel pressure regulating valve, fuel metering valve. . . . . 507
3.2.7 Engine speed sender, throttle valve potentiometer, fuel temperature sender, position sender for charge pressure positioner, throttle valve module, engine control unit . . . . . 508
3.2.8 Exhaust gas recirculation potentiometer, fuel pressure sender, engine control unit, exhaust gas recirculation valve. . . . . 509
3.2.9 Exhaust gas temperature sender 1, exhaust gas temperature sender 3, exhaust gas temperature sender 4, engine control unit. . . . . 510
3.2.10 Lambda probe, exhaust gas pressure sensor 1, engine control unit, lambda probe heater .511
3.2.11 Brake light switch, brake pedal switch, engine control unit, charge pressure control solenoid valve, heater element for crankcase breather. . . . . 512
3.2.12 Working speed control switch, working speed control, resume button, preset speed switch 1 and 2, clutch pedal switch, engine control unit. . . . . 513
3.2.13 Preset speed 3 switch, engine control unit, alternator warning lamp, glow period warning lamp, exhaust emissions warning lamp, diesel particulate filter warning lamp . . . . . 514
3.2.14 Working speed control, safety contact switch, working speed control, decrease speed button, working speed control, increase speed button, working speed control switch 2, engine control unit, working speed warning lamp. . . . . 515
3.2.15 Jumpers, radiator fan relay, engine control unit, radiator fan single fuse, radiator fan . . . . . 516
3.2.16 Diagnostic connection, oil pressure switch, engine control unit, oil pressure warning lamp .517
3.3 Current flow diagrams, engine codes CJDA, CJDD, compliant with emission standard (EU5). . . . . 517
3.3.1 Battery, starter, alternator, voltage regulator, ignition/starter switch fuses . . . . . 519
3.3.2 Electric fuel pump 2 relay, automatic glow period control unit, glow plugs, fuses, supplementary fuel pump. . . . . 520
3.3.3 Terminal 30 voltage supply relay, engine control unit, fuses. . . . . 521
3.3.4 Jumpers, charge pressure sender, intake air temperature sender, air mass meter, engine control unit. . . . . 522
3.3.5 Accelerator position sender, accelerator position sender 2, engine control unit, injectors, cylinders 1 - 4. . . . . 523
3.3.6 Hall sender, coolant temperature sender, engine control unit, fuel pressure regulating valve, fuel metering valve. . . . . 524
3.3.7 Engine speed sender, throttle valve potentiometer, fuel temperature sender, position sender for charge pressure positioner, throttle valve module, engine control unit . . . . . 525
3.3.8 Exhaust gas recirculation potentiometer, fuel pressure sender, engine control unit, exhaust gas recirculation valve. . . . . 526
3.3.9 Exhaust 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 heater. . . . . 528
3.3.11 Brake light switch, brake pedal switch, engine control unit, charge pressure control solenoid valve, heater element for crankcase breather. . . . . 529
3.3.12 Working speed control switch, working speed control, resume button, preset speed switch 1 and 2, clutch pedal switch, engine control unit. . . . . 530
3.3.13 Preset speed 3 switch, engine control unit, alternator warning lamp, glow period warning lamp, exhaust emissions warning lamp, diesel particulate filter warning lamp . . . . . 531
3.3.14 Working speed control, safety contact switch, working speed control, decrease speed button, working speed control, increase speed button, working speed control switch 2, engine control unit, working speed warning lamp. . . . . 532
3.3.15 Jumpers, radiator fan relay, engine control unit, radiator fan single fuse, radiator fan . . . . . 533
3.3.16 Diagnostic connection, oil pressure switch, engine control unit, oil pressure warning lamp .534
Glow plug system. . . . . 535
1 Glow plug system. . . . . 535
1.1 Removing, installing and checking glow plugs. . . . . 53
Engine code CJDA, CJDD, CPYA, CPYB, CPYC, CPYD, CPYE
Edition 05.2015
Repair Group
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/supercharging
23 Mixture preparation - injection
26 Exhaust system
27 Starter, current supply, CCS
28 Glow plug system
Contents:
Technical data . . . . . 1
1 Description of symbols. . . . . 1
2 Important notes for repair work on the engine. . . . . 1
2.1 General safety notes. . . . . 3
3 Technical data. . . . . 5
3.1 Engine number/engine code. . . . . 5
3.2 Engine data. . . . . 6
4 Service work. . . . . 10
4.1 Entries in service history book. . . . . 10
4.2 Service intervals. . . . . 11
4.2.1 Countries with high sulphur content in diesel fuel. . . . . 12
4.2.2 Severe operating conditions. . . . . 13
4.2.3 Extended service intervals. . . . . 13
4.3 Scope of interval service. . . . . 14
4.3.1 General scopes of service. . . . . 14
4.3.2 Additional work. . . . . 16
4.3.3 Scopes of service for gas systems. . . . . 17
4.4 Descriptions of work, engine, general. . . . . 18
4.4.1 Engine and add-on parts in engine compartment (from above and below): perform visual check for leaks and damage. . . . . 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 self-diagnosis. . . . . 22
1.1 Features of vehicle self-diagnosis. . . . . 22
1.2 Technical data of vehicle self-diagnosis. . . . . 22
1.2.1 Read version of engine control unit. . . . . 22
1.2.2 Available diagnosis functions when using the vehicle diagnosis, testing and information system. . . . . 23
1.3 Connecting vehicle diagnostic tester and selecting engine control unit . . . . . 23
1.4 Connecting test box to check lines. . . . . 24
1.4.1 Connecting test box -V.A.G 1598/42- using adapter cable -V.A.G 1598/39-1- . . . . . 25
1.4.2 Connecting test box -V.A.G 1598/42- using adapter cable -V.A.G 1598/39-2- . . . . . 26
2 Event memory. . . . . 26
2.1 Reading event memory. . . . . 26
2.2 Clearing event memory. . . . . 27
3 List of fault codes. . . . . 28
3.1 Fault code: 00022/P0016...00146/P0092. . . . . 30
3.2 Fault code: 00257/P0101...01687/P0697. . . . . 34
3.3 Fault code: 04110/P100E...05779/P1693. . . . . 64
3.4 Fault code: 08320/P2080 ... 11179 ... P2BAB. . . . . 70
3.5 Fault code: 13256/P33C8...13257/P33C9. . . . . 87
3.6 Fault code: 49153/U0001...54282/U140A. . . . . 88
4 Final control diagnosis. . . . . 89
4.1 Performing final control diagnosis. . . . . 89
5 Measured value blocks, engine codes CJDA, CJDD. . . . . 93
5.1 Safety precautions. . . . . 93
5.2 Reading measured value block. . . . . 94
5.3 Evaluating measured value blocks at idling speed. . . . . 95
5.3.1 Display group 1 - Injected quantity. . . . . 95
5.3.2 Display group 2 - Idling speed. . . . . 96
5.3.3 Display group 3 - Exhaust gas recirculation. . . . . 97
5.3.4 Display group 4 - Activation of injectors -N30...N33-. . . . . 97
5.3.5 Display group 7 - Temperatures. . . . . 98
5.3.6 Display group 10 - Air quantities. . . . . 98
5.3.7 Display group 11 - Charge pressure control. . . . . 99
5.3.8 Display group 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 positioner. . . . . 103
5.3.13 Display group 99 - exhaust gas temperature sender. . . . . 103
5.3.14 Display group 100 - diesel particulate filter, exhaust gas temperature sender, pressure differential sender. . . . . 104
5.3.15 Display group 106 - diesel particulate filter, regeneration 6. . . . . 105
5.3.16 Display group 108 - diesel particulate filter, regeneration 8. . . . . 105
5.4 Evaluating measured value blocks at full load. . . . . 106
5.4.1 Conditions for measurements at full load. . . . . 106
5.4.2 Display group 1 - Injected quantity. . . . . 106
5.4.3 Display group 3 - Exhaust gas recirculation. . . . . 107
5.4.4 Display group 8 - torque limit 1. . . . . 108
5.4.5 Display group 11 - Charge pressure control. . . . . 109
6 Measured value blocks, engine codes CPYA, CPYB, CPYC, CPYD, CPYE, CPYF, CPYG. . . . . 109
6.1 Safety precautions. . . . . 110
6.2 Reading measured value block. . . . . 110
6.3 Evaluating measured value blocks at idling speed. . . . . 111
6.3.1 Display group 1 - Injected quantity. . . . . 112
6.3.2 Display group 2 - Idling speed. . . . . 112
6.3.3 Display group 3 - Exhaust gas recirculation. . . . . 113
6.3.4 Display group 4 - Activation of injectors -N30...N33-. . . . . 114
6.3.5 Display group 5. . . . . 114
6.3.6 Display group 7 - Temperatures. . . . . 114
6.3.7 Display group 10 - Air quantities. . . . . 115
6.3.8 Display group 11 - Charge pressure control. . . . . 116
6.3.9 Display group 12 - Status. . . . . 116
6.3.10 Display group 13 - Smooth running control 1. . . . . 117
6.3.11 Display group 20 - Fuel rail values 3. . . . . 118
6.3.12 Display group 30 - Pedal encoder. . . . . 119
6.3.13 Display group 32. . . . . 119
6.3.14 Display group 34 - Charge pressure positioner. . . . . 119
6.3.15 Display group 38. . . . . 120
6.3.16 Display group 39. . . . . 120
6.3.17 Display group 85. . . . . 121
6.3.18 Display group 97. . . . . 121
6.3.19 Display group 99 - exhaust gas temperature sender. . . . . 121
6.3.20 Display group 100 - diesel particulate 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
6.3.24 Display group 246. . . . . 124
6.3.25 Display group 248. . . . . 124
6.3.26 Display group 250. . . . . 125
6.3.27 Display group 253. . . . . 125
6.3.28 Display group 254. . . . . 125
6.4 Evaluating measured value blocks at full load (engine code CPYA). . . . . 125
6.4.1 Conditions for measurements at full load. . . . . 125
6.4.2 Display group 1 - Injected quantity. . . . . 126
6.4.3 Display group 3 - Exhaust gas recirculation. . . . . 127
6.4.4 Display group 8 - torque limit 1. . . . . 128
6.4.5 Display group 11 - Charge pressure control. . . . . 128
6.5 Evaluating measured value blocks at full load (engine code CPYB). . . . . 129
6.5.1 Conditions for measurements at full load. . . . . 129
6.5.2 Display group 1 - Injected quantity. . . . . 130
6.5.3 Display group 3 - Exhaust gas recirculation. . . . . 130
6.5.4 Display group 8 - torque limit 1. . . . . 131
6.5.5 Display group 11 - Charge pressure control. . . . . 132
10 Removing and installing engine. . . . . 133
1 Removing and installing engine. . . . . 133
1.1 Notes on removing. . . . . 134
1.2 Securing engine to assembly stand. . . . . 136
1.3 Notes on installing. . . . . 136
1.4 Specified torques. . . . . 137
1.5 Additional information and assembly work for power units with air conditioning system . . . 137
Crankshaft group. . . . . 138
1 Dismantling and assembling engine. . . . . 138
1.1 Assembly overview - poly V-belt drive, with air conditioner compressor . . . . . 140
1.2 Assembly overview - poly V-belt drive, without air conditioner compressor . . . . . 141
1.3 Removing and installing or renewing poly V-belt. . . . . 141
1.4 Poly V-belt: Check condition. . . . . 143
1.5 Removing and installing poly V-belt tensioner, engines with air conditioner compressor only. . . . . 143
1.6 Removing and installing ancillary bracket. . . . . 144
1.7 Assembly overview - toothed belt drive, engine codes CJDA, CJDD, without crankshaft seal. . . . . 146
1.8 Removing and installing engine bracket. . . . . 148
1.9 Assembly overview - toothed 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 visual check of toothed belt tension. . . . . 151
1.12 Assessing wear on tensioning roller and belt pulleys. . . . . 152
1.13 Wear of high-pressure pump pulley. . . . . 152
1.14 Assessing wear. . . . . 153
1.15 Removing and installing crankshaft protective cover. . . . . 155
1.16 Assembly overview - crankcase, engine codes CJDA, CJDD. . . . . 156
1.17 Assembly overview - crankcase, engine codes CPYA, CPYB, CPYC, CPYD, CPYE . . . . . 157
2 Removing and installing sealing flange and flywheel. . . . . 158
2.1 Assembly overview - Sealing flange, belt pulley end. . . . . 159
2.2 Renewing crankshaft oil seal - pulley end. . . . . 161
2.2.1 Removing. . . . . 162
2.2.2 Installing. . . . . 163
2.3 Removing and installing crankshaft sealing flange, pulley end. . . . . 164
2.3.1 Removing. . . . . 165
2.3.2 Installing. . . . . 166
2.4 Assembly overview - sealing flanges and flywheel. . . . . 167
2.5 Renewing crankshaft sealing flange - flywheel end. . . . . 169
2.5.1 Pressing out sealing flange with sender wheel. . . . . 171
2.5.2 Pressing in sealing flange with sender wheel. . . . . 172
2.5.3 A - Assembling seal with sender wheel on assembly tool -T10134-. . . . . 172
2.5.4 B - Installing assembly tool -T10134- with sealing flange to crankshaft flange . . . . . 174
2.5.5 C - Bolting assembly tool -T10134- to crankshaft flange. . . . . 175
2.5.6 D - Pressing sender wheel onto crankshaft flange using assembly tool -T10134- . . . . . 176
2.5.7 E - Checking installation position of sender wheel on crankshaft. . . . . 176
2.5.8 F - Re-pressing sender wheel. . . . . 177
2.6 Removing and installing engine speed sender -G28-. . . . . 178
2.6.1 Removing. . . . . 178
2.6.2 Installing. . . . . 178
3 Removing and installing crankshaft. . . . . 179
3.1 Assembly overview - crankshaft. . . . . 180
3.2 Crankshaft dimensions. . . . . 180
3.3 Pulling needle bearing, if fitted, out of and driving into crankshaft. . . . . 181
3.3.1 Pulling out. . . . . 181
3.3.2 Driving in. . . . . 182
4 Dismantling and assembling pistons and conrods. . . . . 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 dimensions. . . . . 188
Cylinder head, valve gear. . . . . 189
1 Cylinder head. . . . . 189
1.1 Assembly overview - cylinder head. . . . . 190
1.2 Removing and installing Hall sender -G40-. . . . . 191
1.3 Assembly overview - cylinder head cover, engine codes CJDA, CJDD . . . . . 194
1.3.1 Removing and installing cylinder head cover. . . . . 196
1.4 Assembly overview - cylinder head cover, engine codes CPYA, CPYB, CPYC, CPYD, CPYE. . . . . 202
1.4.1 Removing and installing cylinder head cover. . . . . 205
1.5 Renewing toothed belt and toothed belt tensioning roller for camshaft drive, engine codes CJDA, CJDD, CPYA, CPYB, CPYC, CPYD, CPYE. . . . . 210
1.5.1 Removing. . . . . 212
1.5.2 Installing, tensioning. . . . . 214
1.6 Checking compression. . . . . 218
1.7 Removing and installing cylinder head. . . . . 220
1.7.1 Notes on removing. . . . . 221
1.7.2 Notes on installing. . . . . 225
1.8 Removing and installing vacuum pump. . . . . 226
Repairing valve gear. . . . . 227
2.1 Assembly overview - valve gear. . . . . 228
2.2 Valves. . . . . 229
2.2.1 Valve dimensions. . . . . 229
2.2.2 Checking valve guides. . . . . 229
2.3 Renewing valve stem seals. . . . . 230
2.4 Removing and installing camshaft. . . . . 233
2.4.1 Removing. . . . . 234
2.4.2 Installing. . . . . 235
2.5 Removing and installing camshaft oil seal. . . . . 239
2.5.1 Engines up to 08.09. . . . . 240
2.5.2 Engines as of 09.09. . . . . 242
Lubrication. . . . . 244
1 Engine oil. . . . . 244
1.1 Engine oil level: Check. . . . . 244
1.2 Engine oil: draining or extracting; Renewing oil filter and replenishing engine oil . . . . . 244
1.2.1 Draining or extracting engine oil. . . . . 245
1.2.2 Renewing engine oil filter, engine codes CJDA, CJDD, CPYA, CPYB, CPYC, CPYD, CPYE. . . . . 246
1.2.3 Replenishing engine oil. . . . . 247
2 Parts of lubrication system. . . . . 249
2.1 Assembly overview - oil pump, sump. . . . . 250
2.1.1 Engine codes CJDA, CJDD. . . . . 251
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 bracket, oil cooler and oil pressure switch, engine codes CJDA, CJDD . . . . . 260
3.1.1 Assembly overview - oil filter bracket and oil cooler. . . . . 261
3.1.2 Removing and installing oil filter bracket together with oil cooler. . . . . 262
3.1.3 Checking oil pressure and oil pressure switch -F1-. . . . . 264
3.2 Oil filter bracket, oil cooler and oil pressure switch, engine codes CPYA, CPYB, CPYC, CPYD, CPYE. . . . . 265
3.2.1 Assembly overview - oil filter bracket, oil cooler. . . . . 266
3.2.2 Removing and installing oil filter bracket with engine oil cooler. . . . . 268
3.2.3 Removing and installing oil cooler. . . . . 270
3.2.4 Removing and installing oil pressure switch -F1-. . . . . 273
3.2.5 Checking oil pressure and oil pressure switch -F1-. . . . . 274
Cooling. . . . . 276
1 Removing and installing parts of cooling system. . . . . 276
1.1 Parts of cooling system, engine side, engine codes CJDA, CJDD. . . . . 278
1.2 Parts of cooling system, engine side, engine codes CPYA, CPYB, CPYC, CPYD, CPYE . 279
1.3 Coolant hose schematic diagram. . . . . 280
1.4 Cooling system: Check frost protection and coolant level. . . . . 280
1.4.1 Checking frost protection, replenishing coolant additive if necessary . . . . . 281
1.4.2 Checking coolant level, replenishing coolant additive if necessary. . . . . 282
1.4.3 Mixture ratio:. . . . . 283
1.5 Draining and filling coolant. . . . . 284
1.5.1 Draining. . . . . 284
1.5.2 Filling. . . . . 285
1.6 Renewing coolant pump, engine codes CJDA, CJDD, CPYA, CPYB, CPYC, CPYD, CPYE. . . . . 287
1.6.1 Renewing coolant pump, engine codes CJDA, CJDD, CPYA, CPYB, CPYC, CPYD, CPYE. . . . . 288
1.7 Removing and installing 4/2-way valve with thermostat. . . . . 290
1.8 Checking cooling system for leaks. . . . . 292
1.9 Checking oil cooler for leaks. . . . . 293
1.9.1 Engine codes CJDA, CJDD. . . . . 294
1.9.2 Engine codes CPYA, CPYB, CPYC, CPYD, CPYE. . . . . 296
Fuel supply 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 incorrect fuel. . . . . 301
1.3.1 Step 1 (Engine was started with incorrect fuel). . . . . 301
1.3.2 Step 2 (Engine was not started with incorrect fuel). . . . . 302
1.3.3 Step 3 (There are filings in fuel tank and strainer). . . . . 302
1.3.4 Step 4 (There are no filings in fuel tank and strainer). . . . . 303
1.3.5 Step 5 (There are filings in high-pressure pump). . . . . 303
1.3.6 Step 6 (There are no filings in high-pressure pump). . . . . 304
1.4 Assembly overview - fuel filter. . . . . 304
1.4.1 Engine codes CJDA, CJDD. . . . . 304
1.4.2 Upper part of fuel filter. . . . . 305
1.4.3 Engine codes CPYA, CPYB, CPYC, CPYD, CPYE. . . . . 307
1.5 Draining water from fuel filter/fuel tank. . . . . 307
1.6 Renewing fuel filter. . . . . 308
1.6.1 Renewing fuel filter or upper part of fuel filter CJDA, CJDD. . . . . 309
1.6.2 Renewing fuel filter, engine codes CPYA, CPYB, CPYC, CPYD, CPYE . . . . . 312
1.7 Removing and installing supplementary fuel pump -V393- (inline electronic fuel pump) . . . 313
2 Checking components and functions. . . . . 314
2.1 Checking supplementary fuel pump -V393- (inline electronic fuel pump) . . . . . 314
2.2 Checking accelerator pedal position sender -G79-, if fitted. . . . . 316
Turbocharging/supercharging. . . . . 319
1 Charge air system with turbocharger. . . . . 319
1.1 Safety precautions when working on charge air system with turbocharger . . . . . 320
1.2 Rules for cleanliness. . . . . 320
1.3 Assembly overview - turbocharger with attachments. . . . . 321
1.3.1 Engine codes CJDA, CJDD. . . . . 322
1.3.2 Engine codes CPYA, CPYB, CPYC, CPYD, CPYE. . . . . 324
1.4 Removing and installing turbocharger. . . . . 326
1.4.1 Removing. . . . . 327
1.4.2 Installing. . . . . 329
2 Checking charge air system. . . . . 330
2.1 Checking charge air system for leaks. . . . . 331
2.2 Checking charge pressure control. . . . . 333
2.3 Connection for vacuum hoses. . . . . 334
2.3.1 Engine codes CJDA, CJDD. . . . . 335
2.3.2 Engine codes CPYA, CPYB, CPYC, CPYD, CPYE. . . . . 336
2.3.3 Intake system, installation position 0°. . . . . 336
2.3.4 Intake system, installation position 180°. . . . . 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, CPYD, CPYE. . . . . 339
2.4.3 Checking vacuum hoses. . . . . 340
3 Checking components and functions. . . . . 340
3.1 Markings on air mass meter and on elbow of the intake connecting pipe, view from turbocharger end. . . . . 341
3.2 Checking charge pressure control solenoid valve -N75-, engine codes CJDA, CJDD, CPYA, CPYB, CPYC, CPYD, CPYE. . . . . 341
3.3 Checking charge pressure sender -G31-. . . . . 343
3.4 Checking position sender for charge pressure positioner -G581-. . . . . 345
3.5 Checking exhaust gas temperature sender 1 -G235- (exhaust gas temperature sender ahead of turbocharger). . . . . 347
Mixture preparation - injection. . . . . 350
1 Repairing diesel direct injection system. . . . . 350
1.1 Instructions for working on fuel system. . . . . 351
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 noted. . . . . 353
1.3 Observe safety precautions when working on diesel direct injection fuel system . . . . . 354
1.4 Rules for cleanliness. . . . . 354
1.5 Assembly overview - intake manifold with attachments. . . . . 355
1.5.1 Engine codes CJDA, CJDD. . . . . 355
1.5.2 Engine codes CPYA, CPYB, CPYC, CPYD, CPYE. . . . . 356
1.5.3 Removing and installing intake manifold. . . . . 357
1.6 Fuel system. . . . . 358
1.6.1 Fuel system, engine codes CJDA, CJDD. . . . . 359
1.6.2 Fuel system, engine codes CPYA, CPYB, CPYC, CPYD, CPYE. . . . . 361
1.7 Assembly overview - fuel system. . . . . 362
1.7.1 Engine codes CJDA, CJDD. . . . . 363
1.7.2 Engine codes CPYA, CPYB, CPYC, CPYD, CPYE. . . . . 366
1.8 Correction values for injectors. . . . . 368
1.9 Checking for injectors sticking open. . . . . 369
1.10 Removing and installing injector (piezo injector). . . . . 370
1.10.1 Removing. . . . . 371
1.10.2 Installing. . . . . 373
1.10.3 Installing high-pressure lines. . . . . 375
1.11 Checking return flow rate from fuel pressure regulating valve -N276- . . . . . 377
1.12 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 bleeding fuel system. . . . . 383
1.16 Checking fuel system for leaks. . . . . 384
1.17 Checking pressure retention valve in fuel return line. . . . . 385
2 Checking components and functions. . . . . 387
2.1 Checking fuel metering valve -N290-. . . . . 388
2.2 Checking fuel pressure regulating valve -N276-. . . . . 391
2.3 Checking fuel pressure sender -G247-. . . . . 394
2.4 Checking injectors, cylinders 1...4 -N30...N33-. . . . . 398
2.5 Checking engine speed sender -G28-. . . . . 400
2.6 Checking Hall sender 2 -G40-. . . . . 403
2.7 Checking intake air temperature sender -G42-. . . . . 404
2.8 Checking coolant temperature sender -G62-. . . . . 407
2.9 Checking fuel temperature sender -G81-. . . . . 409
2.10 Checking air mass meter -G70-. . . . . 411
2.11 Checking throttle valve module -J338-. . . . . 414
3 Engine control unit -J623-. . . . . 416
3.1 Checking voltage supply for engine control unit. . . . . 417
3.2 Renewing engine control unit. . . . . 418
3.3 Adapting exhaust gas pressure sensor 1 -G450-. . . . . 420
3.4 Reading injector delivery calibration values/injector voltage calibration values, and storing them in engine control unit. . . . . 421
3.5 Adapting engine control unit -J623- to position sender for charge pressure positioner -G581-. . . . . 422
3.6 Adapting engine control unit -J623- to exhaust gas recirculation valve . . . . . 423
3.7 Adapting engine control unit -J623- to throttle valve module -J338-. . . . . 423
3.8 Checking data bus. . . . . 424
Exhaust system. . . . . 426
1 Removing and installing parts of exhaust system. . . . . 426
1.1 Assembly overview - diesel particulate filter. . . . . 427
1.1.1 Engine codes CJDA, CJDD. . . . . 427
1.1.2 Engine codes CPYA, CPYB, CPYC, CPYD, CPYE. . . . . 428
1.2 Renewing diesel particulate filter, engine codes CPYA, CPYB, CPYC, CPYD, CPYE . . . . . 430
1.3 Removing and installing exhaust gas temperature sender 1 -G235-. . . . . 432
2 Exhaust gas recirculation system. . . . . 433
2.1 Assembly overview - exhaust gas recirculation cooler. . . . . 434
2.1.1 Engine codes CJDA, CJDD. . . . . 434
2.1.2 Engine codes CPYA, CPYB, CPYC, CPXD, 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 Checking lambda probe heater -Z19-. . . . . 441
3.5 Checking exhaust gas temperature sender 3 -G495- (exhaust gas temperature sender
ahead of diesel particulate filter). . . . . 442
3.6 Checking exhaust gas temperature sender 4 -G648- (exhaust gas temperature sender
downstream of diesel particulate filter). . . . . 444
3.7 Checking exhaust gas pressure sensor 1 -G450-. . . . . 446
3.8 Renewing vacuum unit with position sender for charge pressure positioner -G581- . . . . . 449
3.9 Performing service work on diesel particulate filter, engine codes CPYA, CPYB, CPYC, CPYD, CPYE. . . . . 454
3.9.1 Checking diesel particulate filter, engine codes CPYA, CPYB, CPYC, CPYD, CPYE . . . . . 454
3.9.2 Regeneration of diesel particulate filter, engine codes CPYA, CPYB, CPYC, CPYD, CPYE. . . . . 455
3.9.3 Cancelling regeneration of diesel particulate filter, engine codes CPYA, CPYB, CPYC, CPYD, CPYE. . . . . 457
3.9.4 Adapting ash deposit mass of diesel particulate filter, engine codes CPYA, CPYB, CPYC, CPYD, CPYE. . . . . 458
3.9.5 Setting adaptation value for ash deposit mass to “0”, engine codes CPYA, CPYB, CPYC, CPYD, CPYE. . . . . 459
3.10 Checking diesel particulate filter, engine codes CJDA, CJDD. . . . . 460
3.11 Checking diesel particulate filter, engine codes CPYA, CPYB. . . . . 462
3.12 Regeneration of diesel particulate filter, engine codes CJDA, CJDD . . . . . 463
3.13 Renewing diesel particulate filter, engine codes CJDA, CJDD. . . . . 465
Starter, current supply, CCS. . . . . 467
1 Starter -B-. . . . . 467
1.1 Connections on solenoid switch. . . . . 467
1.2 Starter -B- not turning. . . . . 467
1.3 Starter -B- turning too slowly and not cranking engine properly. . . . . 468
1.4 Removing and installing starter -B-. . . . . 469
1.4.1 Removing. . . . . 469
1.4.2 Installing. . . . . 471
1.4.3 Specified torques. . . . . 471
2 Alternator -C-. . . . . 471
2.1 Assembly overview - alternator -C-. . . . . 472
2.2 Checking alternator -C- and voltage regulator -C1-. . . . . 474
2.3 Removing and installing alternator -C-. . . . . 475
2.3.1 Removing. . . . . 476
2.3.2 Installing. . . . . 477
2.4 Removing and installing voltage regulator -C1-. . . . . 477
2.4.1 Removing and installing 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 without freewheel. . . . . 481
2.5.2 Removing and installing poly V-belt pulley with freewheel, Bosch. . . . . 482
2.5.3 Removing and installing poly V-belt pulley with freewheel, Valeo. . . . . 484
2.6 Checking operation of freewheel clutch. . . . . 485
3 Current flow diagrams. . . . . 486
3.1 Current flow diagrams, engine codes CPYA, CPYB, compliant with emission standard (97/68 stage 3a). . . . . 487
3.1.1 Battery, starter, alternator, voltage regulator, ignition/starter switch fuses . . . . . 488
3.1.2 Electric fuel pump 2 relay, automatic glow period control unit, glow plugs, fuses, supplementary fuel pump. . . . . 489
3.1.3 Terminal 30 voltage supply relay, engine control unit, fuses. . . . . 490
3.1.4 Jumpers, charge pressure sender, intake air temperature sender, air mass meter, engine control unit. . . . . 491
3.1.5 Accelerator position sender, accelerator position sender 2, engine control unit, injectors, cylinders 1 - 4. . . . . 492
3.1.6 Hall sender, coolant temperature sender, engine control unit, fuel pressure regulating valve, fuel metering valve. . . . . 493
3.1.7 Engine speed sender, throttle valve potentiometer, fuel temperature sender, position sender for charge pressure positioner, throttle valve module, engine control unit . . . . . 494
3.1.8 Exhaust gas recirculation potentiometer, exhaust gas temperature sender 1, fuel pressure sender, engine control unit, exhaust gas recirculation valve. . . . . 495
3.1.9 Brake light switch, brake pedal switch, engine control unit, charge pressure control solenoid valve, heater element for crankcase breather. . . . . 496
3.1.10 Working speed control switch, working speed control, resume button, preset speed switch 1 and 2, clutch pedal switch, engine control unit. . . . . 497
3.1.11 Preset speed switch 3, engine control unit, alternator warning lamp, glow period warning lamp, exhaust emissions warning lamp. . . . . 498
3.1.12 Working speed control, safety contact switch, working speed control, decrease speed button, working speed control, increase speed button, working speed control switch 2, engine control unit, working speed warning lamp. . . . . 499
3.1.13 Jumpers, radiator fan relay, engine control unit, radiator fan single fuse, radiator fan . . . . . 500
3.1.14 Diagnostic connection, oil pressure switch, engine control unit, oil pressure warning lamp .501
3.2 Current flow diagrams, engine codes CPYA, CPYB, compliant with emission standard (97/68 stage 3b). . . . . 501
3.2.1 Battery, starter, alternator, voltage regulator, ignition/starter switch fuses . . . . . 503
3.2.2 Electric fuel pump 2 relay, automatic glow period control unit, glow plugs, fuses, supplementary fuel pump. . . . . 504
3.2.3 Terminal 30 voltage 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, accelerator position sender 2, engine control unit, injectors, cylinders 1 - 4. . . . . 506
3.2.6 Hall sender, coolant temperature sender, engine control unit, fuel pressure regulating valve, fuel metering valve. . . . . 507
3.2.7 Engine speed sender, throttle valve potentiometer, fuel temperature sender, position sender for charge pressure positioner, throttle valve module, engine control unit . . . . . 508
3.2.8 Exhaust gas recirculation potentiometer, fuel pressure sender, engine control unit, exhaust gas recirculation valve. . . . . 509
3.2.9 Exhaust gas temperature sender 1, exhaust gas temperature sender 3, exhaust gas temperature sender 4, engine control unit. . . . . 510
3.2.10 Lambda probe, exhaust gas pressure sensor 1, engine control unit, lambda probe heater .511
3.2.11 Brake light switch, brake pedal switch, engine control unit, charge pressure control solenoid valve, heater element for crankcase breather. . . . . 512
3.2.12 Working speed control switch, working speed control, resume button, preset speed switch 1 and 2, clutch pedal switch, engine control unit. . . . . 513
3.2.13 Preset speed 3 switch, engine control unit, alternator warning lamp, glow period warning lamp, exhaust emissions warning lamp, diesel particulate filter warning lamp . . . . . 514
3.2.14 Working speed control, safety contact switch, working speed control, decrease speed button, working speed control, increase speed button, working speed control switch 2, engine control unit, working speed warning lamp. . . . . 515
3.2.15 Jumpers, radiator fan relay, engine control unit, radiator fan single fuse, radiator fan . . . . . 516
3.2.16 Diagnostic connection, oil pressure switch, engine control unit, oil pressure warning lamp .517
3.3 Current flow diagrams, engine codes CJDA, CJDD, compliant with emission standard (EU5). . . . . 517
3.3.1 Battery, starter, alternator, voltage regulator, ignition/starter switch fuses . . . . . 519
3.3.2 Electric fuel pump 2 relay, automatic glow period control unit, glow plugs, fuses, supplementary fuel pump. . . . . 520
3.3.3 Terminal 30 voltage supply relay, engine control unit, fuses. . . . . 521
3.3.4 Jumpers, charge pressure sender, intake air temperature sender, air mass meter, engine control unit. . . . . 522
3.3.5 Accelerator position sender, accelerator position sender 2, engine control unit, injectors, cylinders 1 - 4. . . . . 523
3.3.6 Hall sender, coolant temperature sender, engine control unit, fuel pressure regulating valve, fuel metering valve. . . . . 524
3.3.7 Engine speed sender, throttle valve potentiometer, fuel temperature sender, position sender for charge pressure positioner, throttle valve module, engine control unit . . . . . 525
3.3.8 Exhaust gas recirculation potentiometer, fuel pressure sender, engine control unit, exhaust gas recirculation valve. . . . . 526
3.3.9 Exhaust 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 heater. . . . . 528
3.3.11 Brake light switch, brake pedal switch, engine control unit, charge pressure control solenoid valve, heater element for crankcase breather. . . . . 529
3.3.12 Working speed control switch, working speed control, resume button, preset speed switch 1 and 2, clutch pedal switch, engine control unit. . . . . 530
3.3.13 Preset speed 3 switch, engine control unit, alternator warning lamp, glow period warning lamp, exhaust emissions warning lamp, diesel particulate filter warning lamp . . . . . 531
3.3.14 Working speed control, safety contact switch, working speed control, decrease speed button, working speed control, increase speed button, working speed control switch 2, engine control unit, working speed warning lamp. . . . . 532
3.3.15 Jumpers, radiator fan relay, engine control unit, radiator fan single fuse, radiator fan . . . . . 533
3.3.16 Diagnostic connection, oil pressure switch, engine control unit, oil pressure warning lamp .534
Glow plug system. . . . . 535
1 Glow plug system. . . . . 535
1.1 Removing, installing and checking glow plugs. . . . . 53
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