12-cylinder injection engine

Chapter overview

• Technical data
  1
• 1 Engine number
  1
• 2 Engine data
  2
• Removing and installing engine
  3
• 1 Removing and installing engine
  3
• 1.1 Removing engine
  5
• 1.2 Securing engine on engine and gearbox support VAS 6095
  15
• 1.3 Installing engine
  16
• 1.4 Specified torques
  18
• 2 Assembly mountings
  19
• 2.1 Assembly overview - assembly mountings
  19
• 2.2 Supporting engine in installation position
  20
• 2.3 Removing and installing engine carrier
  22
• 2.4 Removing and installing left engine mounting
  24
• 2.5 Removing and installing right engine mounting
  25
• 2.6 Removing and installing left engine support
  26
• 2.7 Removing and installing right engine support
  26
• Crankshaft group
  28
• 1 Assembly overview - dismantling and assembling engine
  28
• 1.1 Removing and installing poly V-belt
  30
• 2 Removing and installing sealing flange and drive plate
  32
• 2.1 Renewing crankshaft oil seal, vibration damper end
  34
• 2.2 Removing and installing drive plate
  35
• 2.3 Renewing crankshaft oil seal - drive plate side
  37
• Cylinder head, valve gear
  39
• 1 Cylinder heads
  39
• 1.1 Assembly overview - cylinder bank 1
  40
• 1.2 Assembly overview - cylinder bank 2
  43
• 1.3 Removing and installing cylinder head cover (cylinder banks 1 and 2)
  45
• 1.4 Removing and installing cylinder head (cylinder banks 1 and 2)
  47
• 1.5 Checking compression
  54
• 2 Chain drive
  57
• 2.1 Parts of chain drive system - engine codes BAN and BAP
  57
• 2.2 Parts of chain drive system - engine codes BRN, BRP and BTT
  61
• 2.3 Adjusting valve timing - engine codes BAN and BAP
  63
• 2.4 Adjusting valve timing, engine codes BRN, BRP and BTT
  72
• 3 Valve gear
  82
• 3.1 Valve gear (cylinder bank 1 and 2) - assembly overview
  82
• 3.2 Reworking valve seats
  87
• 3.3 Removing and installing camshaft control valves
  88
• 3.4 Removing and installing camshafts
  90
• 3.5 Checking valve guides
  99
• 3.6 Renewing valve stem seals
  99
• Lubrication
  102
• 1 Parts of lubrication system
  102
• 1.1 Engine oil
  102
• 1.2 Oil capacities
  103
• 1.3 Checking engine oil level
  103
• 1.4 Assembly overview - sump (vehicles with engine codes BAN and BAP)
  104
• 1.5 Assembly overview - sump (vehicles with engine codes BRN, BRP and BTT)
  107
• 1.6 Removing and installing lower part of sump
  108
• 1.7 Removing and installing upper part of sump
  110
• 1.8 Assembly overview - oil pump
  114
• 1.9 Removing and installing oil pump
  116
• 1.10 Assembly overview - oil filter housing (vehicles with engine codes BAN and BAP)
  118
• 1.12 Checking oil pressure and oil pressure switch
  121
• Cooling
  123
• 1 Parts of cooling system
  123
• 1.1 Assembly overview - radiator
  124
• 1.2 Assembly overview - fans
  126
• 1.3 Assembly overview - parts of cooling system, body side
  126
• 1.4 Assembly overview - cooling system, engine side, top
  127
• 1.5 Assembly overview - cooling system, engine side, rear and side
  128
• 1.6 Parts of cooling system engine side, front
  130
• 1.7 Coolant hose schematic diagram
  131
• 1.8 Draining and filling coolant
  133
• 1.9 Removing and installing radiator
  137
• 1.10 Removing and installing coolant pump
  139
• 1.11 Checking cooling system for leaks
  141
• Fuel supply system
  143
• 1 Parts of fuel supply system
  143
• 1.1 Safety precautions when working on fuel supply system
  143
• 1.2 Rules for cleanliness
  144
• 1.3 Assembly overview - fuel tank with fuel filter
  144
• 1.4 Assembly overview - right side fuel delivery unit, fuel gauge sender and suction-jet pump
  146
• 1.5 Assembly overview - left side fuel delivery unit, fuel gauge sender and suction-jet pump
  148
• 1.6 Schematic diagram of fuel lines and components in fuel tank
  150
• 1.7 Emptying fuel tank
  152
• 1.9 Removing and installing fuel delivery unit, fuel gauge sender and suction-jet pump, left side
  158
• 1.10 Removing and installing fuel tank with attachments and fuel filter
  162
• 1.11 Checking fuel pumps
  165
• 2 Electronic power control (EPC)
  174
• 2.1 Function of EPC system
  174
• 2.2 Assembly overview - accelerator mechanism
  174
• 3 Activated charcoal filter system (vehicles with engine code BAN and BRN)
  176
• 3.1 Function of activated charcoal filter system
  176
• 3.2 Assembly overview - activated charcoal filter system
  176
• 3.3 Checking activated charcoal filter system for leaks
  178
• 4 Activated charcoal filter system (vehicles with engine code BAP and BRP)
  181
• 4.1 Function of activated charcoal filter system
  181
• 4.2 Assembly overview - activated charcoal filter system
  182
• Mixture preparation - injection
  184
• 1 Injection system
  184
• 1.1 General notes on injection
  184
• 1.2 Safety precautions
  185
• 1.3 Rules for cleanliness
  185
• 1.7 Assembly overview - fuel rail with injectors
  190
• 1.8 Assembly overview - air filter
  192
• 1.9 Technical data
  193
• 2.1 Removing and installing Lambda probe G39 and Lambda probe 2 G108
  194
• 2.2 Removing and installing Lambda probe 3 G285 and Lambda probe 4 G286
  197
• 2.3 Removing and installing Lambda probe after catalytic converter G130
  198
• 2.4 Removing and installing Lambda probe 2 after catalytic converter G131
  199
• 4 after catalytic converter G288
  201
• 3 Checking components
  204
• 3.1 Checking injectors
  204
• 3.2 Checking fuel pressure regulator and holding pressure
  206
• 4 Engine control units
  211
• 4.1 Removing and installing engine control units
  211
• Exhaust system
  212
• 1 Parts of the exhaust system
  212
• 1.2 Removing and installing starter catalytic converter for exhaust bank 1 of cylinders 1 … 3
  216
• 1.3 Removing and installing starter catalytic converter for exhaust bank 2 of cylinders 4 … 6
  216
• 1.4 Removing and installing exhaust manifold for exhaust bank 1 of cylinders 1 … 3
  217
• 1.5 Removing and installing exhaust manifold for exhaust bank 2 of cylinders 4 … 6
  217
• 1.7 Removing and installing starter catalytic converter for exhaust bank 3 of cylinders 7 … 9
  221
• 1.8 Removing and installing starter catalytic converter for exhaust bank 4 of cylinders 10 … 12
  221
• 1.9 Removing and installing exhaust manifold for exhaust bank 3 of cylinders 7 … 9
  222
• 1.10 Removing and installing exhaust manifold for exhaust bank 4 of cylinders 10 … 12
  222
• 1.11 Aligning starter catalytic converter with exhaust pipes
  223
• 1.12 Assembly overview - silencers with mountings
  224
• 2 Secondary air system
  227
• 2.1 Function of the secondary air system
  227
• 2.2 Assembly overview - secondary air system on body side
  228
• 2.3 Assembly overview - secondary air system on engine side
  229
• 2.4 Checking combination valves (vehicles with engine codes BAN and BAP)
  230
• Ignition system
  232
• 1 Repairing ignition system
  232
• 1.1 Assembly overview - ignition system
  232
• 1.2 Safety precautions
  234
• 1.3 Test data, spark plugs
  234
• 1.4 Removing and installing ignition coils with final output stages, engine codes BAN and BAP
  235