5-cylinder diesel engine

Chapter overview

• Technical data
  1
• 1 Identification
  1
• 1.1 Engine number/engine data
  1
• 2 Safety information
  2
• 2.2 Safety precautions when working on the cooling system
  2
• 2.3 Safety regulations for working on fuel supply
  3
• 2.4 Safety precautions when working on injection system
  4
• 3 Repair instructions
  5
• 3.1 Rules for cleanliness during work on fuel system
  5
• 3.2 Rules for cleanliness when working on fuel supply system
  5
• 3.3 Rules for cleanliness when working on injection system
  6
• 3.4 Foreign objects in engine
  6
• Removing and installing engine
  7
• 1 Removing and installing engine
  7
• 1.1 Removing engine
  7
• 1.2 Securing engine to assembly stand
  13
• 1.3 Installing engine
  14
• 2 Assembly mountings
  17
• 2.1 Assembly overview - assembly mountings
  17
• 2.2 Removing and installing front torque reaction support
  18
• Crankshaft group
  20
• 1 Cylinder block (pulley end)
  20
• 1.1 Assembly overview - crankcase
  20
• 1.2 Crankcase - attachments
  22
• 1.3 Removing and installing sealing flange on pulley end
  24
• 1.4 Renewing seal for timing housing cover
  25
• 1.5 Renewing alternator shaft oil seal
  26
• 1.6 Removing and installing thread insert for tie bolt
  29
• 2 Cylinder block, gearbox end
  30
• 2.1 Assembly overview – valve timing housing cover
  30
• 2.2 Removing and installing drive plate
  32
• 2.3 Removing and installing flywheel
  33
• 3 Crankshaft
  36
• 3.1 Assembly overview - crankshaft
  36
• 3.2 Basic settings for gear train
  38
• 3.3 Crankshaft bearing cap identification
  40
• 3.4 Crankshaft dimensions
  41
• 3.5 Measuring axial clearance of crankshaft
  41
• 3.6 Measuring radial clearance of crankshaft
  42
• 4 Pistons and conrods
  43
• 4.1 Assembly overview - pistons and conrods
  43
• 4.2 Installation position and allocation of piston to cylinder
  45
• 4.3 Measuring piston projection at TDC
  45
• 4.4 Checking piston ring gap
  46
• 4.5 Checking ring-to-groove clearance
  47
• 4.6 Checking cylinder bores
  47
• 4.7 Piston and cylinder dimensions
  48
• Cylinder head, valve gear
  49
• 1 Cylinder head
  49
• 1.1 Assembly overview - cylinder head
  49
• 1.2 Removing and installing cylinder head
  54
• 1.3 Checking valve timing
  58
• 1.4 Checking compression
  60
• 2 Valve gear
  62
• 2.1 Assembly overview - valve gear
  62
• 2.2 Measuring axial play of camshaft
  65
• 2.3 Removing and installing camshaft
  66
• 2.4 Removing and installing camshaft drive gear
  67
• 2.5 Removing and installing valve stem seals
  72
• 3 Inlet and exhaust valves
  75
• 3.1 Reworking valve seats
  75
• 3.2 Checking valve guides
  76
• 3.3 Valve dimensions
  77
• Lubrication
  79
• 1 Sump, oil pump
  79
• 1.1 Assembly overview - sump/oil pump
  79
• 1.2 Removing and installing oil sump
  81
• 1.3 Engine oil:
  83
• 2 Oil filter, oil pressure switch
  85
• 2.1 Assembly overview - oil filter housing
  85
• 2.2 Removing and installing oil filter housing
  86
• 2.3 Checking oil pressure and oil pressure switch
  90
• 2.4 Measuring oil consumption
  92
• Cooling
  93
• 1 Cooling system/coolant
  93
• 1.1 Connection diagram - coolant hoses
  93
• 1.2 Draining and adding coolant
  93
• 1.3 Checking cooling system for leaks
  101
• 2 Coolant pump, regulation of cooling system
  103
• 2.1 Assembly overview - coolant pump, thermostat
  103
• 2.2 Removing and installing coolant temperature sender G62
  105
• 2.3 Removing and installing thermostat housing
  107
• 2.4 Removing and installing coolant pump
  107
• 2.5 Removing and installing coolant union
  112
• 2.6 Renewing pipe connection for coolant
  113
• 3 Radiator, radiator fan
  115
• 3.1 Assembly overview - radiator, radiator fan
  115
• 3.2 Assembly overview – fan support
  117
• 3.3 Removing and installing radiator
  117
• Turbocharging/supercharging
  120
• 1 Turbocharger
  120
• 1.1 Assembly overview - turbocharger
  120
• 1.2 Assembly overview - turbocharger
  122
• 1.3 Removing and installing turbocharger
  124
• 1.4 Removing and installing turbocharger
  126
• 2 Charge air system
  131
• 2.1 Assembly overview - charge air system
  131
• 2.2 Checking charge air system for leaks
  132
• 2.3 Installing hose connections with plug-in connectors
  135
• Mixture preparation - injection
  137
• 1 Injection system
  137
• 1.1 Bleeding fuel system
  137
• 2 Injectors
  138
• 2.1 Assembly overview - unit injector
  138
• 2.2 Removing and installing unit injector
  138
• 2.3 Removing and installing wiring harness for unit injectors
  142
• 2.4 Removing and installing O-rings for unit injector
  145
• 2.5 Visual inspection of unit injector
  147
• 3 Vacuum system
  148
• 3.1 Vacuum hose schematic diagram
  148
• 3.2 Vacuum hose schematic diagram
  148
• 4 Senders and sensors
  150
• 4.1 Removing and installing fuel temperature sender G81
  150
• 5 Intake manifold
  151
• 5.1 Assembly overview – intake manifold
  151
• 5.2 Assembly overview – intake manifold flap
  151
• 5.3 Assembly overview – intake manifold flap
  152
• 6 Air filter
  154
• 6.1 Assembly overview - air filter
  154
• 7 Engine control unit
  155
• 7.1 Removing and installing engine control unit
  155
• Exhaust system
  157
• 1 Exhaust pipes and silencers
  157
• 1.1 Assembly overview – silencers
  157
• 1.2 Assembly overview – silencers
  159
• 1.3 Separating front and rear silencers
  160
• 1.4 Installation position of clamps
  162
• 1.5 Checking exhaust system for leaks
  162
• 2 Emission control
  163
• 2.1 Assembly overview - particulate filter
  163
• 2.2 Removing and installing particulate filter
  165
• 3 Exhaust gas temperature regulation
  173
• 3.1 Removing and installing exhaust gas temperature sender 1 G235
  173
• 3.2 Removing and installing exhaust gas temperature sender 2 G448
  174
• 3.3 Removing and installing exhaust gas temperature sender 3 G495
  176
• 4 Exhaust gas recirculation
  178
• 4.1 Assembly overview – exhaust gas recirculation
  178
• 4.2 Checking mechanical exhaust gas recirculation valve
  181
• 4.3 Checking electronic exhaust gas recirculation valve
  182
• Glow plug system
  184
• 1 Glow plug system
  184
• 1.1 Removing and installing glow plugs Q10/Q14
  184
• 1.2 Checking glow plugs Q10/Q14
  186
• 1.3 Removing and installing engine speed sender G28
  189