Technical data
11 Technical data
11.1 Engine number
11.2 Engine data
1Removing and installing engine
31 Removing and installing engine
31.1 Removing engine
31.2 Removing engine from scissor-type assembly platform VAS 6131
141.3 Securing engine on engine and gearbox support VAS 6095
151.4 Notes on installing
16Crankshaft group
181 Dismantling and assembling engine
181.1 Assembly overview - components in the V space
181.2 Assembly overview - gear train assembly
201.3 Removing and installing gear train assembly
211.4 Removing and installing engine mounting and engine support (left and right)
241.5 Removing and installing drive plate
252 Balancer shaft
272.1 Assembly overview - balance shaft
273 Crankshaft
283.1 Assembly overview - crankshaft
283.2 Removing and installing bearing saddle for crankshaft
293.3 Crankshaft dimensions
314 Sealing flange, seals and vibration damper
324.1 Assembly overview - front sealing flange and vibration damper
324.2 Renewing crankshaft oil seal, vibration damper end
334.3 Renewing crankshaft oil seal - engine timing end
344.4 Renewing alternator shaft oil seal
365 Valve timing housing
395.1 Assembly overview - timing housing
396 Pistons and conrods
416.1 Assembly overview - pistons and conrods
416.2 Checking piston projection at TDC
426.3 Piston and cylinder dimensions
426.4 Piston rings, cylinder bore and piston installation position
43Cylinder head, valve gear
451 Cylinder head
451.1 Assembly overview - cylinder head
451.2 Removing and installing camshaft compensating gear and drive gear wheel
471.3 Checking valve timing
521.4 Adjusting valve timing
541.5 Removing and installing cylinder heads
561.6 Checking compression
582 Valve gear
622.1 Assembly overview - valve gear
622.2 Reworking valve seats
652.3 Checking valve guides
662.4 Renewing valve stem seals
672.5 Removing and installing camshaft
69Lubrication
711 Engine oil:
711.1 Oil capacities
711.2 Checking engine oil level
712 Oil pan
722.1 Assembly overview - sump
722.2 Applying sealant
753 Assembly overview - oil supply lines
763.1 Oil supply line for turbocharger, cylinder bank 1
763.2 Oil supply line for turbocharger, cylinder bank 2
774 Oil pump, oil filter housing and oil pressure
794.1 Assembly overview - oil pump
794.2 Assembly overview - oil filter housing
814.3 Removing and installing oil filter housing
824.4 Checking oil pressure and oil pressure switch
824.5 Checking oil pressure at front of engine
84Cooling
861 Parts of cooling system
861.1 Assembly overview - radiator
871.2 Assembly overview - fans
891.3 Parts of cooling system, body side
901.4 Parts of cooling system engine side and top
911.5 Parts of alternator and fuel cooling
921.7 Assembly overview - thermostat housing
931.8 Assembly overview - coolant pump
951.9 Coolant hose schematic diagram (vehicles with engine codes AYH, BKW)
961.10 Coolant hose schematic diagram (vehicles with engine codes BLE and BWF)
971.11 Draining and adding coolant
981.12 Removing and installing fan support
1001.13 Removing and installing radiator
1011.14 Removing and installing coolant connection
1021.15 Removing and installing coolant pump
103Fuel supply system
1061 Parts of fuel supply system
1061.1 Safety regulations for working on fuel supply
1071.2 Rules for cleanliness
1071.3 Assembly overview - fuel tank with attachments
1071.4 Assembly overview - fuel filter (vehicles with engine codes AYH, BKW)
1101.5 Assembly overview - fuel filter (vehicles with engine codes BLE and BWF)
1111.6 Schematic diagram of fuel lines and components in fuel tank
1131.9 Emptying fuel tank
1161.11 Removing and installing fuel tank with attached components
1211.12 Removing and installing fuel filter (vehicles with engine codes AYH, BKW)
1251.13 Checking fuel pumps
1271.14 Checking tandem pump and fuel pump
1291.15 Removing and installing tandem pump and fuel pump
1311.16 Assembly overview - accelerator mechanism
1332 Additive tank (vehicles with engine code BLE)
1352.1 Safety precautions when working on additive tank
1352.2 Assembly overview - additive tank
1352.3 Removing and installing additive tank
137Turbocharging/supercharging
1401 Charge air system with turbocharger
1401.1 Safety precautions
1401.2 Rules for cleanliness
1401.3 Installing hose connections with plug-in connectors
1411.4 Assembly overview - turbocharger
1421.5 Assembly overview - parts of charge air cooling
1441.6 Checking charge air system for leaks
145Mixture preparation - injection
1481 Repairing diesel direct injection system
1481.1 Safety precautions
1481.2 Rules for cleanliness
1491.3 Removing and installing intake manifold
1491.6 Assembly overview - air filter
1531.7 Assembly overview - unit injector
1551.8 Removing and installing unit injector
1561.9 Checking and adjusting position of pump plungers in unit injectors
1581.10 Renewing O-rings for unit injectors
1602 Engine control units
1632.1 Reading and clearing fault memory of engine control units
1632.2 Adapting functions and components
1642.3 Engine control units
165Exhaust system
1691 Removing and installing parts of exhaust system
1691.1 Assembly overview - exhaust manifold
1701.4 Metering pumps for post-injection (engine code BWF)
1741.5 Assembly overview - silencer with mountings (vehicles with engine codes AYH and BKW)
1751.6 Assembly overview - silencer with mountings (vehicles with engine codes BLE and BWF)
1772 Exhaust gas recirculation system
1802.1 Safety precautions
1802.2 Rules for cleanliness
1802.3 Assembly overview - exhaust gas recirculation (vehicles with engine codes AYH, BKW)
1812.4 Assembly overview - exhaust gas recirculation (vehicles with engine codes BLE and BWF)
1822.6 Removing and installing bypass flap with exhaust gas recirculation cooler
1862.7 Vacuum hose schematic diagram (vehicles with engine codes AYH, BKW)
1872.9 Checking exhaust gas recirculation valve (vehicles with engine codes AYH, BKW)
189Glow plug system
1911 Glow plugs
1911.1 Removing, installing and checking glow plugs (vehicles with engine code AYH)
191