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
  3
• 1 Removing and installing engine
  3
• 1.1 Removing engine
  3
• 1.2 Removing engine from scissor-type assembly platform VAS 6131
  14
• 1.3 Securing engine on engine and gearbox support VAS 6095
  15
• 1.4 Notes on installing
  16
• Crankshaft group
  18
• 1 Dismantling and assembling engine
  18
• 1.1 Assembly overview - components in the V space
  18
• 1.2 Assembly overview - gear train assembly
  20
• 1.3 Removing and installing gear train assembly
  21
• 1.4 Removing and installing engine mounting and engine support (left and right)
  24
• 1.5 Removing and installing drive plate
  25
• 2 Balancer shaft
  27
• 2.1 Assembly overview - balance shaft
  27
• 3 Crankshaft
  28
• 3.1 Assembly overview - crankshaft
  28
• 3.2 Removing and installing bearing saddle for crankshaft
  29
• 3.3 Crankshaft dimensions
  31
• 4 Sealing flange, seals and vibration damper
  32
• 4.1 Assembly overview - front sealing flange and vibration damper
  32
• 4.2 Renewing crankshaft oil seal, vibration damper end
  33
• 4.3 Renewing crankshaft oil seal - engine timing end
  34
• 4.4 Renewing alternator shaft oil seal
  36
• 5 Valve timing housing
  39
• 5.1 Assembly overview - timing housing
  39
• 6 Pistons and conrods
  41
• 6.1 Assembly overview - pistons and conrods
  41
• 6.2 Checking piston projection at TDC
  42
• 6.3 Piston and cylinder dimensions
  42
• 6.4 Piston rings, cylinder bore and piston installation position
  43
• Cylinder head, valve gear
  45
• 1 Cylinder head
  45
• 1.1 Assembly overview - cylinder head
  45
• 1.2 Removing and installing camshaft compensating gear and drive gear wheel
  47
• 1.3 Checking valve timing
  52
• 1.4 Adjusting valve timing
  54
• 1.5 Removing and installing cylinder heads
  56
• 1.6 Checking compression
  58
• 2 Valve gear
  62
• 2.1 Assembly overview - valve gear
  62
• 2.2 Reworking valve seats
  65
• 2.3 Checking valve guides
  66
• 2.4 Renewing valve stem seals
  67
• 2.5 Removing and installing camshaft
  69
• Lubrication
  71
• 1 Engine oil:
  71
• 1.1 Oil capacities
  71
• 1.2 Checking engine oil level
  71
• 2 Oil pan
  72
• 2.1 Assembly overview - sump
  72
• 2.2 Applying sealant
  75
• 3 Assembly overview - oil supply lines
  76
• 3.1 Oil supply line for turbocharger, cylinder bank 1
  76
• 3.2 Oil supply line for turbocharger, cylinder bank 2
  77
• 4 Oil pump, oil filter housing and oil pressure
  79
• 4.1 Assembly overview - oil pump
  79
• 4.2 Assembly overview - oil filter housing
  81
• 4.3 Removing and installing oil filter housing
  82
• 4.4 Checking oil pressure and oil pressure switch
  82
• 4.5 Checking oil pressure at front of engine
  84
• Cooling
  86
• 1 Parts of cooling system
  86
• 1.1 Assembly overview - radiator
  87
• 1.2 Assembly overview - fans
  89
• 1.3 Parts of cooling system, body side
  90
• 1.4 Parts of cooling system engine side and top
  91
• 1.5 Parts of alternator and fuel cooling
  92
• 1.7 Assembly overview - thermostat housing
  93
• 1.8 Assembly overview - coolant pump
  95
• 1.9 Coolant hose schematic diagram (vehicles with engine codes AYH, BKW)
  96
• 1.10 Coolant hose schematic diagram (vehicles with engine codes BLE and BWF)
  97
• 1.11 Draining and adding coolant
  98
• 1.12 Removing and installing fan support
  100
• 1.13 Removing and installing radiator
  101
• 1.14 Removing and installing coolant connection
  102
• 1.15 Removing and installing coolant pump
  103
• Fuel supply system
  106
• 1 Parts of fuel supply system
  106
• 1.1 Safety regulations for working on fuel supply
  107
• 1.2 Rules for cleanliness
  107
• 1.3 Assembly overview - fuel tank with attachments
  107
• 1.4 Assembly overview - fuel filter (vehicles with engine codes AYH, BKW)
  110
• 1.5 Assembly overview - fuel filter (vehicles with engine codes BLE and BWF)
  111
• 1.6 Schematic diagram of fuel lines and components in fuel tank
  113
• 1.9 Emptying fuel tank
  116
• 1.11 Removing and installing fuel tank with attached components
  121
• 1.12 Removing and installing fuel filter (vehicles with engine codes AYH, BKW)
  125
• 1.13 Checking fuel pumps
  127
• 1.14 Checking tandem pump and fuel pump
  129
• 1.15 Removing and installing tandem pump and fuel pump
  131
• 1.16 Assembly overview - accelerator mechanism
  133
• 2 Additive tank (vehicles with engine code BLE)
  135
• 2.1 Safety precautions when working on additive tank
  135
• 2.2 Assembly overview - additive tank
  135
• 2.3 Removing and installing additive tank
  137
• Turbocharging/supercharging
  140
• 1 Charge air system with turbocharger
  140
• 1.1 Safety precautions
  140
• 1.2 Rules for cleanliness
  140
• 1.3 Installing hose connections with plug-in connectors
  141
• 1.4 Assembly overview - turbocharger
  142
• 1.5 Assembly overview - parts of charge air cooling
  144
• 1.6 Checking charge air system for leaks
  145
• Mixture preparation - injection
  148
• 1 Repairing diesel direct injection system
  148
• 1.1 Safety precautions
  148
• 1.2 Rules for cleanliness
  149
• 1.3 Removing and installing intake manifold
  149
• 1.6 Assembly overview - air filter
  153
• 1.7 Assembly overview - unit injector
  155
• 1.8 Removing and installing unit injector
  156
• 1.9 Checking and adjusting position of pump plungers in unit injectors
  158
• 1.10 Renewing O-rings for unit injectors
  160
• 2 Engine control units
  163
• 2.1 Reading and clearing fault memory of engine control units
  163
• 2.2 Adapting functions and components
  164
• 2.3 Engine control units
  165
• Exhaust system
  169
• 1 Removing and installing parts of exhaust system
  169
• 1.1 Assembly overview - exhaust manifold
  170
• 1.4 Metering pumps for post-injection (engine code BWF)
  174
• 1.5 Assembly overview - silencer with mountings (vehicles with engine codes AYH and BKW)
  175
• 1.6 Assembly overview - silencer with mountings (vehicles with engine codes BLE and BWF)
  177
• 2 Exhaust gas recirculation system
  180
• 2.1 Safety precautions
  180
• 2.2 Rules for cleanliness
  180
• 2.3 Assembly overview - exhaust gas recirculation (vehicles with engine codes AYH, BKW)
  181
• 2.4 Assembly overview - exhaust gas recirculation (vehicles with engine codes BLE and BWF)
  182
• 2.6 Removing and installing bypass flap with exhaust gas recirculation cooler
  186
• 2.7 Vacuum hose schematic diagram (vehicles with engine codes AYH, BKW)
  187
• 2.9 Checking exhaust gas recirculation valve (vehicles with engine codes AYH, BKW)
  189
• Glow plug system
  191
• 1 Glow plugs
  191
• 1.1 Removing, installing and checking glow plugs (vehicles with engine code AYH)
  191