5-cylinder diesel engine

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number/engine data
  1
• 2 Safety information
  3
• 2.1 Safety measures when working on fuel supply
  3
• 2.3 Safety precautions when working on the cooling system
  4
• 2.4 Safety precautions when working on charge air system
  5
• 2.5 Safety precautions when working on injection system
  5
• 2.6 Safety precautions when working on the SCR system
  6
• 3 Repair instructions
  7
• 3.1 Rules for cleanliness when working on fuel supply system
  7
• 3.2 Rules for cleanliness during work on fuel system
  7
• 3.3 Rules for cleanliness and instructions for working on injection system
  7
• 3.4 General notes on the lubrication system
  9
• 3.5 Foreign objects in engine
  9
• Removing and installing engine
  10
• 1 Removing and installing engine
  10
• 1.1 Removing engine
  10
• 1.2 Installing engine
  14
• 1.3 Securing engine on engine and gearbox support VAS 6095
  16
• Crankshaft group
  17
• 1 Cylinder block (pulley end)
  17
• 1.1 Assembly overview - cylinder block (pulley end)
  17
• 1.2 Assembly overview – poly V-belt drive
  18
• 1.3 Removing and installing poly-V belt
  19
• 1.4 Removing and installing tensioner for poly V-belt
  20
• 1.5 Renewing crankshaft oil seal - belt pulley end
  21
• 2 Cylinder block, gearbox end
  24
• 2.1 Assembly overview - flywheel
  24
• 2.2 Removing and installing sealing flange on gearbox side
  26
• 2.3 Removing and installing flywheel
  34
• 2.4 Renewing needle bearing
  35
• 3 Power take-off
  37
• 3.1 Engine power take-off
  37
• 3.2 Removing and installing poly V-belt for power take-off
  37
• 4 Crankshaft
  40
• 4.1 Assembly overview - crankshaft
  40
• 4.2 Crankshaft dimensions
  41
• 5 Pistons and conrods
  42
• 5.1 Assembly overview - pistons and conrods
  42
• 5.2 Checking pistons and cylinder bores
  43
• 5.3 Measuring piston projection at TDC
  44
• 5.4 Piston and cylinder dimensions
  45
• Cylinder head, valve gear
  46
• 1 Cylinder head
  46
• 1.1 Assembly overview - cylinder head
  46
• 1.2 Removing and installing cylinder head
  49
• 1.3 Removing and installing cylinder head cover
  53
• 1.4 Checking compression
  54
• 2 Toothed belt drive
  56
• 2.1 Assembly overview - toothed belt
  56
• 2.2 Removing and installing toothed belt
  58
• 3 Valve gear
  64
• 3.1 Assembly overview - valve gear
  64
• 3.2 Measuring axial play of camshaft
  65
• 3.3 Removing and installing camshaft
  66
• 3.4 Removing and installing valve stem seals
  67
• 4 Inlet and exhaust valves
  70
• 4.1 Reworking valve seats
  70
• 4.2 Checking valve guides
  71
• 4.3 Removing and installing valve guides
  71
• 4.4 Valve dimensions
  73
• Lubrication
  74
• 1 Sump, oil pump
  74
• 1.1 Assembly overview - sump/oil pump
  74
• 1.2 Removing and installing sump
  76
• 1.3 Removing and installing oil pump
  80
• 1.4 Measuring oil consumption
  83
• 1.5 Engine oil:
  83
• 2 Engine oil cooler
  85
• 2.1 Checking engine oil cooler for leaks
  85
• 3 Oil filter, oil pressure switch
  87
• 3.1 Checking oil pressure and oil pressure switch
  87
• Cooling
  89
• 1 Cooling system/coolant
  89
• 1.1 Connection diagram - coolant hoses
  89
• 1.2 Coolant hose schematic diagram, vehicles with auxiliary heater
  90
• 1.3 Coolant hose schematic diagram, vehicles with auxiliary heater and 2nd heat exchanger
  91
• 1.4 Checking cooling system for leaks
  91
• 1.5 Draining and adding coolant
  93
• 2 Coolant pump, regulation of cooling system
  101
• 2.1 Assembly overview - coolant pump, thermostat
  101
• 2.2 Removing and installing coolant pump
  103
• 2.3 Removing and installing thermostat
  104
• 3 Radiator, radiator fan
  106
• 3.1 Assembly overview - radiator/radiator fan
  106
• 3.2 Removing and installing radiator
  107
• 3.3 Removing and installing viscous fan
  108
• Turbocharging/supercharging
  110
• 1 Turbocharger
  110
• 1.1 Assembly overview - turbocharger (engine codes BJJ, BJK, BJL, BJM)
  110
• 1.2 Assembly overview - turbocharger (engine codes CEBA, CEBB, CECA, CECB)
  112
• 1.3 Removing and installing turbocharger (engine codes BJJ, BJK, BJL, BJM)
  114
• 2 Charge air system
  118
• 2.1 Assembly overview - charge air system
  118
• 2.2 Checking charge air system for leaks
  118
• Mixture preparation - injection
  122
• 1 Injection system
  122
• 1.1 Schematic overview - fuel system
  122
• 1.2 Assembly overview - fuel system
  123
• 1.3 Filling fuel system
  126
• 1.4 Checking fuel system for leaks
  126
• 2 Injectors/high-pressure accumulator (rail)
  128
• 2.1 Check pressure retention valve in fuel return line
  128
• 2.2 Removing and installing injectors (piezo injectors)
  129
• 2.3 Removing and installing fuel overflow valve
  132
• 3 Vacuum system
  136
• 3.1 Connection diagram - vacuum system
  136
• 4 High-pressure pump
  137
• 4.1 Removing and installing high-pressure pump
  137
• 5 Senders and sensors
  140
• 5.1 Removing and installing fuel pressure regulating valve N276
  140
• 5.2 Checking fuel pressure regulating valve N276
  142
• 5.3 Removing and installing fuel pressure sender G247
  142
• 5.4 Removing and installing fuel metering valve N290
  144
• 5.5 Removing and installing air mass meter G70
  149
• 6 Intake manifold
  150
• 6.1 Assembly overview - intake manifold
  150
• 6.2 Removing and installing intake manifold
  151
• 7 Air filter
  153
• 7.1 Assembly overview - air filter
  153
• 8 Engine control unit
  154
• 8.1 Removing and installing engine control unit J623
  154
• Exhaust system
  155
• 1 Exhaust pipes and silencers
  155
• 1.1 Assembly overview - silencer (engine codes BJJ, BJK, BJL, BJM)
  155
• 1.3 Checking exhaust system for leaks
  157
• 2 Emission control
  158
• 2.1 Assembly overview - diesel particulate filter (engine codes CEBA, CEBB, CECA, CECB)
  158
• 2.2 Assembly overview - diesel particulate filter (engine codes BJJ, BJK, BJL, BJM)
  160
• 2.5 Removing and installing catalytic converter (engine codes BJJ, BJK, BJL, BJM)
  169
• 3 SCR system (selective catalytic reduction)
  172
• 3.1 AdBlue® technology
  172
• 3.2 Assembly overview - tank for reducing agent (Crafter panel van and Crafter window van)
  172
• 3.4 Removing and installing injector for reduction agent N474
  176
• 3.5 Removing and installing reducing agent supply line
  177
• 3.7 Removing and installing filler neck for reducing agent (panel van and window van)
  181
• 3.8 Removing and installing reducing agent tank (panel van and window van)
  181
• 3.9 Removing and installing reducing agent tank (platform van and chassis)
  183
• 3.10 Emptying reducing agent tank (panel van and window van)
  184
• 3.11 Emptying reducing agent tank (platform van and chassis)
  185
• 3.12 Removing and installing heater element (heater cup)
  187
• 4 Exhaust gas recirculation
  190
• 4.1 Assembly overview - exhaust gas recirculation
  190
• Glow plug system
  192
• 1 Glow plug system
  192
• 1.1 Handling ceramic glow plugs
  192
• 1.2 Checking glow plugs (installed)
  192
• 1.3 Checking glow plugs (removed)
  192
• 1.4 Removing and installing glow plugs
  193
• 1.5 Removing and installing engine speed sender G28
  197