5-cylinder diesel engine

Kapitelübersicht

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  1
• 2 Safety instructions
  2
• 2.1 Safety precautions when working on fuel supply system
  2
• 2.3 Safety precautions when working on cooling system
  3
• 3 General repair notes
  4
• 3.1 Rules for cleanliness
  4
• 3.2 Foreign objects in engine
  4
• Removing and installing engine
  5
• 1 Removing and installing engine
  5
• 1.1 Removing engine
  5
• 1.2 Removing engine from scissor-type assembly platform
  13
• 1.3 Securing engine to assembly stand
  15
• 1.4 Additional information and assembly work for vehicles with air conditioner
  16
• 1.5 Installing engine
  17
• 2 Assembly mountings
  18
• 2.1 Assembly overview - engine mountings
  18
• 2.2 Specified torques - Assembly mountings
  18
• Crankshaft group
  19
• 1 Dismantling and assembling engine
  19
• 1.1 Dismantling and assembling engine, parts I-III
  19
• 1.2 Removing and installing crankshaft
  24
• 1.3 Removing and installing drive plate
  25
• 1.4 Crankshaft bearing cap identification
  26
• 1.5 Crankshaft dimensions
  27
• 1.6 Renewing crankshaft oil seal - engine timing end
  27
• 1.7 Renewing alternator shaft oil seal
  28
• 2 Dismantling and assembling pistons and conrods
  30
• 2.1 Assembly overview - pistons and conrods
  30
• 2.2 Separating new conrods
  31
• 2.3 Installation position and allocation of piston to cylinder
  32
• 2.4 Checking piston ring gap
  32
• 2.5 Checking ring-to-groove clearance
  32
• 2.6 Checking cylinder bores
  33
• 2.7 Piston and cylinder dimensions
  33
• Cylinder head, valve gear
  34
• 1 Overview - cylinder head
  34
• 1.1 Assembly overview - cylinder head
  34
• 1.2 Renewing pipe connection for coolant
  36
• 1.3 Removing and installing camshaft drive gear
  37
• 1.4 Setting engine to TDC No. 1 cylinder
  41
• 1.5 Removing and installing cylinder head
  42
• 1.6 Checking compression
  44
• 2 Repairing valve gear
  47
• 2.1 Assembly overview - valve gear
  47
• 2.2 Reworking valve seats
  51
• 2.3 Checking valve guides
  53
• 2.4 Renewing valve stem seals
  53
• 2.5 Removing and installing camshaft
  55
• Lubrication
  57
• 1 Engine oil
  57
• 1.1 Oil capacities
  57
• 1.2 Checking engine oil level
  57
• 2 Parts of lubrication system
  58
• 2.1 Assembly overview - oil pump, sump
  58
• 2.2 Assembly overview - oil filter housing
  59
• 2.3 Removing and installing oil sump
  62
• 2.4 Checking oil pressure and oil pressure switch
  64
• Cooling
  67
• 1 Removing and installing parts of cooling system
  67
• 1.1 Parts of cooling system, body side
  68
• 1.2 Assembly overview - radiator fan
  69
• 1.3 Removing and installing fan support
  69
• 1.4 Parts of cooling system, engine side
  70
• 1.5 Coolant hose schematic diagram
  72
• 1.6 Draining and filling coolant
  72
• 1.7 Removing and installing radiator
  75
• 1.8 Removing and installing coolant pump
  77
• 1.9 Checking oil cooler for leaks
  82
• Fuel supply system
  85
• 1 Removing and installing parts of fuel supply system
  85
• 1.1 Rules for cleanliness
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• 1.2 Safety precautions when working on fuel supply system
  86
• 1.3 Assembly overview - fuel tank with attachments (► model year 08)
  86
• 1.4 Assembly overview - fuel tank with attachments (model year 08 ►)
  88
• 1.5 Assembly overview - fuel filter with fuel cooler
  90
• 1.6 Emptying fuel tank
  91
• 1.9 Removing and installing fuel tank with attached components
  99
• 1.10 Checking fuel pumps
  102
• 1.11 Checking tandem pump
  104
• 1.12 Removing and installing tandem pump
  107
• 1.13 Assembly overview - accelerator mechanism
  109
• Turbocharging/supercharging
  110
• 1 Charge air system with turbocharger
  110
• 1.1 Rules for cleanliness
  110
• 1.2 Turbocharger with attachments for engine codes BAC and BLK
  110
• 1.3 Removing and installing turbocharger for engine codes BAC and BLK
  111
• 1.4 Turbocharger with attachments (engine codes BPD and BPE)
  114
• 1.5 Removing and installing turbocharger (engine codes BPD and BPE)
  116
• 1.6 Removing and installing parts of charge air cooling
  119
• 1.7 Checking charge air system for leaks
  120
• 1.8 Hose connections
  122
• 1.9 Vacuum hose schematic diagram
  123
• Mixture preparation - injection
  126
• 1 Repairing diesel direct injection system
  126
• 1.1 Safety precautions
  126
• 1.2 Rules for cleanliness
  127
• 1.3 Removing and installing wiring harness for unit injectors
  127
• 1.4 Removing and installing unit injector
  130
• 1.5 Assembly overview - unit injector
  133
• 1.6 Removing and installing O-rings for unit injector
  134
• 1.7 Assembly overview - intake manifold and fuel rail
  135
• 1.8 Repairing intake manifold flap
  137
• 1.9 Dismantling and assembling air filter
  139
• 2 Engine control unit
  140
• 2.1 Reading and deleting engine control unit event memory
  140
• 2.2 Removing and installing engine control unit J623
  141
• 2.3 Removing and installing anti-theft engine control unit J623
  141
• Exhaust system
  145
• 1 Exhaust system
  145
• 1.1 Assembly overview - front exhaust pipe with catalytic converters
  145
• 1.2 Assembly overview - front exhaust pipe with particulate filter
  146
• 1.3 Removing and installing particulate filter
  148
• 1.4 Assembly overview - exhaust manifold (engine codes BPD, BPE)
  149
• 1.5 Removing and installing exhaust manifold (engine codes BPD, BPE)
  151
• 1.6 Silencer with mountings
  153
• 2 Exhaust gas recirculation system
  155
• 2.1 Assembly overview - exhaust gas recirculation
  155
• 2.2 Checking exhaust gas recirculation valve (mechanical)
  159
• Glow plug system
  161
• 1 Glow plug system
  161
• 1.1 Characteristics of glow plugs
  161
• 1.2 Checking metal glow plugs
  161
• 1.3 Removing, installing and checking ceramic glow pin plugs
  162