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Volkswagen CJDA User Manual

Volkswagen CJDA
553 pages
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Workshop Manual
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. Technical Information

Table of Contents

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Volkswagen CJDA Specifications

General IconGeneral
Engine CodeCJDA
TurbochargedYes
AspirationTurbocharged
Valves per Cylinder4
Fuel SystemDirect Injection
Engine TypeInline 4-cylinder
Compression Ratio10:1
Displacement1.4L (1395 cc)

Summary

00 - Technical data

2 Important notes for repair work on the engine

Procedures must only be carried out by trained personnel; dealership-specific work noted.

3 Technical data

Details engine specifications, including displacement, output, torque, and emissions.

01 - Vehicle self-diagnosis

1 Vehicle self-diagnosis

The engine control unit is equipped with an event memory for storing faults.

1.1 Features of vehicle self-diagnosis

Details how faults are stored, displayed, and cleared from the event memory.

1.2 Technical data of vehicle self-diagnosis

Provides information on control unit identification, coding, and available diagnosis functions.

1.3 Connecting vehicle diagnostic tester and selecting engine control unit

Steps to connect diagnostic tester and select the engine control unit for diagnosis.

1.4 Connecting test box to check lines

Instructions for connecting a test box to check lines between components and the engine control unit.

04 - Service work

4.1 Entries in service history book

Recording component changes and their impact on service intervals.

4.2 Service intervals

Details service intervals based on operating hours or time, including conditions affecting them.

4.3 Scope of interval service

Contains service tables and specifications for the Volkswagen brand.

4.4 Descriptions of work, engine, general

Covers service scopes not assigned to specific repair groups, with cross-references.

10 - Removing and installing engine

1 Removing and installing engine

General safety regulations and notes for engine removal and installation procedures.

1.1 Notes on removing

General instructions for removing industrial engines due to varied use cases.

1.2 Securing engine to assembly stand

Procedures for securing the engine to an assembly stand using specific tools.

13 - Crankshaft group

1 Dismantling and assembling engine

Safety regulations and notes for dismantling and assembling the engine.

1.1 Assembly overview - poly V-belt drive, with air conditioner compressor

Component overview of the poly V-belt drive system including air conditioner compressor.

1.2 Assembly overview - poly V-belt drive, without air conditioner compressor

Component overview of the poly V-belt drive system excluding air conditioner.

1.3 Removing and installing or renewing poly V-belt

Step-by-step guide for removing, installing, or renewing the poly V-belt.

15 - Cylinder head, valve gear

1 Cylinder head

Information and procedures related to the cylinder head.

1.1 Assembly overview - cylinder head

Detailed assembly overview of the cylinder head components.

17 - Lubrication

1 Engine oil

Safety precautions and information regarding engine oil.

1.1 Engine oil level: Check

Procedure for checking the engine oil level using the dipstick.

1.2 Engine oil: draining or extracting; Renewing oil filter and replenishing engine oil

Instructions for draining, extracting, renewing oil filter and refilling engine oil.

19 - Cooling

1 Removing and installing parts of cooling system

Safety precautions and general instructions for removing/installing cooling system parts.

1.4 Cooling system: Check frost protection and coolant level

Procedure for checking frost protection and coolant level.

20 - Fuel supply system

1 Removing and installing parts of fuel supply system

Safety precautions and general instructions for working on the fuel supply system.

1.1 Safety precautions when working on fuel supply system

Specific safety measures for working on the fuel system.

1.3 Procedure when filling with incorrect fuel

Steps to follow if the engine was started with incorrect fuel.

21 - Turbocharging/supercharging

1 Charge air system with turbocharger

Safety precautions and overview of the charge air system with turbocharger.

1.1 Safety precautions when working on charge air system with turbocharger

Safety measures specific to working on the charge air system with turbocharger.

1.2 Rules for cleanliness

Cleanliness rules for working on the turbocharger to prevent damage.

23 - Mixture preparation - injection

1 Repairing diesel direct injection system

Safety and general instructions for repairing the diesel direct injection system.

1.1 Instructions for working on fuel system

Important steps to ensure correct engine start after fuel system repairs.

26 - Exhaust system

1 Removing and installing parts of exhaust system

General instructions for removing and installing exhaust system components.

1.1 Assembly overview - diesel particulate filter

Component overview of the diesel particulate filter for specific engine codes.

1.2 Renewing diesel particulate filter, engine codes CPYA, CPYB, CPYC, CPYD, CPYE

Procedure for renewing the diesel particulate filter for specific engine codes.

27 - Starter, current supply, CCS

1 Starter -B-

Safety regulations and notes for working on the starter.

1.1 Connections on solenoid switch

Details the terminal connections on the starter solenoid switch.

1.2 Starter -B- not turning

Troubleshooting steps for a starter that does not turn or cranks slowly.

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