10-cylinder diesel engine

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  1
• Removing and installing engine
  2
• 1 Removing and installing engine
  2
• 1.1 Removing engine
  2
• 1.2 Notes on installing
  14
• 1.3 Specified torques
  14
• Crankshaft group
  15
• 1 Dismantling and assembling engine
  15
• 1.1 Assembly overview - components in the V space
  15
• 1.2 Assembly overview - gear train assembly
  17
• 1.3 Removing and installing gear train assembly
  18
• 1.4 Removing and installing drive plate
  21
• 2 Balancer shaft
  22
• 2.1 Assembly overview - balancer shaft
  22
• 3 Crankshaft
  23
• 3.1 Assembly overview - crankshaft
  23
• 3.2 Removing and installing bearing saddle for crankshaft
  24
• 3.3 Crankshaft dimensions
  26
• 4 Sealing flanges, seals and vibration dampers
  27
• 4.1 Assembly overview - front sealing flange and vibration damper
  27
• 4.2 Renewing crankshaft oil seal, vibration damper end
  28
• 4.3 Crankshaft oil seal - engine timing end
  29
• 4.4 Alternator shaft oil seal
  31
• 5 Valve timing housing
  34
• 5.1 Assembly overview - valve timing housing
  34
• 6 Pistons and conrods
  36
• 6.1 Assembly overview - pistons and conrods
  36
• 6.2 Checking piston projection at TDC
  37
• 6.3 Piston and cylinder dimensions
  37
• 6.4 Piston rings, cylinder bore and piston installation position
  38
• Cylinder head, valve gear
  40
• 1 Cylinder head
  40
• 1.1 Assembly overview - cylinder head
  40
• 1.2 Removing and installing camshaft compensating gear and drive gear wheel
  42
• 1.3 Checking valve timing
  47
• 1.4 Adjusting valve timing
  47
• 1.5 Removing and installing cylinder heads
  50
• 1.6 Checking compression
  52
• 2 Valve gear
  55
• 2.1 Assembly overview - valve gear
  55
• 2.2 Reworking valve seats
  58
• 2.3 Checking valve guides
  59
• 2.4 Renewing valve stem seals
  59
• 2.5 Removing and installing camshaft
  61
• Lubrication
  63
• 1 Engine oil
  63
• 1.1 Oil capacities
  63
• 1.2 Checking engine oil level
  63
• 2 Oil sump
  64
• 2.1 Assembly overview - lower part of sump
  64
• 2.2 Assembly overview - upper part of sump
  65
• 2.3 Applying sealant
  66
• 3 Assembly overview - oil filter housing
  67
• 4 Assembly overview - oil pump
  68
• 5 Checking oil pressure
  69
• 5.1 Assembly overview - oil pressure switch
  69
• 5.2 Check oil pressure in V space and and oil pressure switch
  70
• 5.3 Checking oil pressure at front of engine
  71
• 6 Assembly overview - oil supply lines
  72
• 6.1 Oil supply line for turbocharger of cylinder bank 1
  72
• 6.2 Oil supply line for turbocharger of cylinder bank 2
  73
• Cooling
  75
• 1 Parts of cooling system
  75
• 1.1 Assembly overview - radiator
  75
• 1.2 Removing and installing fan support
  76
• 1.3 Assembly overview - fans
  77
• 1.4 Parts of cooling system, body side
  78
• 1.5 Checking cooling system for leaks
  79
• 1.6 Removing and installing coolant connection
  80
• 1.7 Assembly overview - thermostat housing
  80
• 1.8 Parts of cooling system - engine side and at top
  82
• 1.9 Coolant hose schematic diagram
  83
• 1.10 Draining and filling coolant
  84
• 1.11 Removing and installing radiator
  86
• 1.12 Assembly overview - coolant pump
  87
• Turbocharging/supercharging
  91
• 1 Charge air system with turbocharger
  91
• 1.1 Removing and installing turbocharger with attachments
  91
• 1.2 Removing and installing parts of charge air cooling
  93
• 1.3 Rules for cleanliness
  93
• Mixture preparation - injection
  95
• 1 Repairing diesel direct injection system
  95
• 1.1 Safety precautions
  95
• 1.2 Rules for cleanliness
  96
• 1.3 Removing and installing intake manifold
  96
• 1.4 Assembly overview - intake connecting pipe
  97
• 1.5 Assembly overview - unit injector
  98
• 1.6 Removing and installing unit injector
  99
• 1.7 Checking and adjusting position of pump plungers in unit injectors
  101
• 1.8 Removing and installing O-rings for unit injector
  103
• 1.9 Assembly overview - air filter
  104
• 2 Engine control units
  106
• 2.1 Reading and deleting engine control unit fault memory
  106
• 2.2 Adapting functions and components
  107
• 2.3 Removing and installing engine control units
  107
• Exhaust system
  109
• 1 Removing and installing parts of exhaust system
  109
• 1.1 Removing and installing exhaust manifold
  109
• 1.2 Front exhaust pipe and catalytic converter with attachments
  111
• 1.3 Silencer with mountings
  112
• 2 Exhaust gas recirculation system
  114
• 2.1 Assembly overview - parts of exhaust gas recirculation
  114
• 2.2 Checking exhaust gas recirculation valve (mechanical)
  115
• 2.3 Vacuum hose schematic diagram
  116
• Glow plug system
  118
• 1 Removing, installing and checking glow plugs
  118