6-cyl. common rail engine (3.0 l, 4V, EA 897, turbocharger)

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety measures when working on fuel system
  1
• 1.2 Safety measures when working on vehicles with a start/stop system
  1
• 1.4 Safety precautions when working on the cooling system
  2
• 1.5 Safety precautions when working on exhaust system
  2
• 1.6 Safety regulations for working on glow plug system
  3
• 1.7 Safety precautions when working on subframe
  3
• 2 Identification
  4
• 2.1 Engine number/engine data
  4
• 3 Repair instructions
  5
• 3.1 Rules for cleanliness
  5
• 3.2 General information
  5
• 3.3 General repair notes
  6
• 3.4 Foreign objects in engine
  7
• 3.5 Contact corrosion
  7
• 3.6 Routing and attachment of lines
  7
• 3.7 Fitting radiator and condensers
  8
• 3.8 Checking vacuum system
  8
• Removing and installing engine
  9
• 1 Removing and installing engine
  9
• 1.1 Removing engine
  9
• 1.2 Separating engine and gearbox
  30
• 1.3 Securing engine on engine and gearbox support
  36
• 1.4 Installing engine
  39
• 2 Assembly mountings
  44
• 2.1 Assembly overview – assembly mountings
  44
• 2.2 Removing and installing engine mounting
  47
• 2.3 Removing and installing gearbox mounting
  53
• 2.4 Supporting engine in installation position
  54
• 3 Engine cover panel
  58
• 3.1 Removing and installing engine cover
  58
• Crankshaft group
  62
• 1 Cylinder block (pulley end)
  62
• 1.1 Assembly overview - cylinder block (pulley end)
  62
• 1.2 Assembly overview - sealing flange, belt pulley end
  65
• 1.3 Removing and installing poly-V belt
  67
• 1.4 Removing and installing tensioner for poly V-belt
  69
• 1.5 Removing and installing vibration damper
  69
• 1.6 Removing and installing bracket for ancillaries
  72
• 1.7 Removing and installing engine support
  74
• 1.8 Renewing crankshaft oil seal - belt pulley end
  75
• 1.9 Removing and installing sealing flange on pulley end
  77
• 2 Cylinder block, gearbox end
  82
• 2.1 Assembly overview - cylinder block, gearbox end
  82
• 2.2 Removing and installing drive plate
  82
• 2.3 Renewing crankshaft oil seal (gearbox end)
  85
• 3 Crankshaft
  88
• 3.1 Assembly overview - crankshaft
  88
• 3.2 Crankshaft dimensions
  90
• 3.3 Allocation of main bearing shells
  91
• 3.4 Measuring axial clearance of crankshaft
  92
• 3.5 Measuring radial clearance of crankshaft
  93
• 3.6 Checking sender wheel
  93
• 4 Balancer shaft
  95
• 4.1 Assembly overview - balance shaft
  95
• 4.2 Removing and installing balance shaft
  95
• 5 Pistons and conrods
  104
• 5.1 Assembly overview - pistons and conrods
  104
• 5.2 Removing and installing pistons
  108
• 5.3 Measuring piston projection at TDC
  109
• 5.4 Checking pistons and cylinder bores
  112
• 5.5 Checking radial clearance of conrods
  114
• Cylinder head, valve gear
  115
• 1 Cylinder head
  115
• 1.1 Assembly overview - cylinder head
  115
• 1.2 Assembly overview - cylinder head cover
  118
• 1.3 Removing and installing cylinder head
  121
• 1.4 Removing and installing cylinder head cover
  130
• 1.5 Removing and installing injector seals
  136
• 1.6 Checking compression
  137
• 2 Cover for timing chain
  139
• 2.1 Assembly overview - cover for timing chain
  139
• 2.2 Removing and installing timing chain cover
  143
• 3 Chain drive
  156
• 3.1 Assembly overview - camshaft timing chains
  156
• 3.2 Assembly overview - drive chain for high pressure pump
  158
• 3.3 Assembly overview - drive chain for oil pump
  159
• 3.4 Assembly overview - intermediate drive
  159
• 3.5 Removing camshaft timing chain from camshafts
  160
• 3.6 Removing and installing camshaft timing chain
  173
• 3.7 Removing and installing drive chain for high-pressure pump
  185
• 3.8 Installing intermediate drive
  187
• 4 Valve gear
  196
• 4.1 Assembly overview - valve gear
  196
• 4.2 Measuring axial play of camshaft
  204
• 4.3 Measuring radial play of camshaft
  206
• 4.4 Removing and installing camshaft
  206
• 4.5 Checking hydraulic compensation elements
  222
• 4.6 Removing and installing valve stem seals
  224
• 5 Inlet and exhaust valves
  234
• 5.1 Reworking valve seats
  234
• 5.2 Checking valve guides
  234
• 5.3 Checking valves
  235
• 5.4 Valve dimensions
  235
• Lubrication
  236
• 1 Sump, oil pump
  236
• 1.1 Assembly overview - sump/oil pump
  236
• 1.2 Engine oil:
  241
• 1.3 Removing and installing lower part of sump
  243
• 1.4 Removing and installing upper part of sump
  245
• 1.5 Removing and installing oil pump
  249
• 1.6 Removing and installing oil level and oil temperature sender G266
  252
• 2 Engine oil cooler
  253
• 2.1 Assembly overview - engine oil cooler
  253
• 2.2 Removing and installing engine oil cooler
  255
• 2.3 Removing and installing temperature regulator for engine oil cooler
  256
• 3 Crankcase ventilation
  258
• 3.1 Assembly overview - crankcase breather system
  258
• 3.2 Removing and installing oil separator
  259
• 4 Oil filter, oil pressure switch
  260
• 4.1 Assembly overview - oil filter
  260
• 4.2 Removing and installing oil pressure sender G10
  262
• 4.3 Checking oil pressure
  263
• 4.4 Removing and installing oil filter housing
  263
• 4.5 Removing and installing oil pressure regulating valve N428
  266
• 4.6 Removing and installing oil temperature sender 2 G664
  266
• Cooling
  268
• 1 Cooling system/coolant
  268
• 1.1 Connection diagram - coolant hoses
  268
• 1.2 Checking cooling system for leaks
  272
• 1.3 Draining and adding coolant
  275
• 2 Coolant pump, regulation of cooling system
  286
• 2.1 Assembly overview - coolant pump
  286
• 2.2 Assembly overview - electric coolant pump
  288
• 2.3 Assembly overview - thermostat
  288
• 2.4 Assembly overview - coolant temperature sender
  290
• 2.5 Removing and installing coolant circulation pump V50
  291
• 2.6 Removing and installing coolant pump
  292
• 2.7 Removing and installing thermostat housing
  295
• 2.8 Removing and installing map-controlled engine cooling thermostat F265
  296
• 2.9 Removing and installing coolant temperature sender G62
  297
• 2.11 Removing and installing coolant temperature sender 2 G802
  299
• 2.12 Removing and installing coolant valves
  300
• 3 Coolant pipes
  303
• 3.1 Assembly overview - coolant pipes
  303
• 3.2 Removing and installing coolant pipes
  306
• 4 Radiator, radiator fan
  316
• 4.1 Assembly overview - radiator, radiator fan
  316
• 4.2 Removing and installing radiator
  319
• 4.3 Removing and installing radiator cowl
  325
• 4.4 Removing and installing radiator fan V7
  327
• Turbocharging/supercharging
  329
• 1 Turbocharger
  329
• 1.1 Assembly overview - turbocharger
  329
• 1.2 Removing and installing turbocharger
  334
• 2 Charge air system
  339
• 2.1 Assembly overview - charge air system
  339
• 2.2 Assembly overview - charge-air hose connections
  341
• 2.3 Removing and installing charge air cooler
  342
• 2.4 Removing and installing charge pressure sender G31
  345
• 2.6 Checking charge air system for leaks
  346
• Mixture preparation - injection
  350
• 1 Injection system
  350
• 1.1 Schematic overview - fuel system
  350
• 1.2 Overview of fitting locations - injection system
  351
• 1.3 Filling/bleeding fuel system
  357
• 1.4 Checking fuel system for leaks
  358
• 2 Vacuum system
  359
• 2.1 Connection diagram - vacuum system
  359
• 2.2 Checking vacuum system
  359
• 3 Injectors/high-pressure accumulator (rail)
  361
• 3.1 Assembly overview - injectors
  361
• 3.2 Testing injectors
  365
• 3.3 Adapting correction values for injectors
  366
• 3.4 Checking return flow rate of injectors with engine running
  367
• 3.5 Checking return flow rate of injectors at starter speed
  370
• 3.6 Testing jammed-open injectors
  373
• 3.7 Check pressure retention valve in fuel return line
  377
• 3.8 Removing and installing injectors
  378
• 3.9 Removing and installing high-pressure lines
  384
• 3.10 Removing and installing fuel rail
  386
• 4 Air filter
  391
• 4.1 Assembly overview - air filter housing
  391
• 4.2 Removing and installing air filter housing
  393
• 5 Intake manifold
  396
• 5.1 Assembly overview – intake manifold
  396
• 5.2 Removing and installing intake manifold upper part
  400
• 5.3 Removing and installing lower part of intake manifold
  404
• 5.4 Removing and installing intake manifold flap motor V157
  406
• 5.5 Removing and installing throttle valve module J338
  408
• 6 Senders and sensors
  410
• 6.1 Checking fuel pressure regulating valve N276
  410
• 6.2 Removing and installing fuel pressure regulating valve N276
  412
• 6.3 Removing and installing fuel pressure sender G247
  414
• 6.4 Removing and installing air mass meter G70
  416
• 6.5 Removing and installing pressure differential sender G505
  417
• 6.6 Removing and installing fuel temperature sender G81
  418
• 6.7 Removing and installing fuel pressure sender for low-pressure G410
  419
• 7 Engine control unit
  420
• 7.1 Assembly overview – motor control unit
  420
• 7.2 Removing and installing engine control unit J623
  420
• 8 High-pressure pump
  422
• 8.1 Assembly overview - high-pressure pump
  422
• 8.2 Removing and installing high-pressure pump
  425
• 9 Lambda probe
  431
• 9.1 Assembly overview - Lambda probe
  431
• 9.2 Removing and installing Lambda probe
  432
• Exhaust system
  434
• 1 Exhaust pipes and silencers
  434
• 1.1 Assembly overview – silencers
  434
• 1.2 Removing and installing front exhaust pipe
  436
• 1.3 Separating exhaust pipes from silencers
  441
• 1.4 Removing and installing silencer
  442
• 1.5 Aligning exhaust system free of stress
  443
• 1.6 Checking exhaust system for leaks
  445
• 2 Emission control
  446
• 2.1 Assembly overview – emission control
  446
• 2.2 Removing and installing emission control module
  449
• 2.3 Removing and installing catalytic converter
  452
• 3 Exhaust gas temperature regulation
  454
• 3.1 Assembly overview – exhaust gas temperature regulation
  454
• 3.2 Removing and installing exhaust gas temperature sender 1 G235
  455
• 3.3 Removing and installing exhaust gas temperature sender 2 G448
  457
• 3.4 Removing and installing exhaust gas temperature sender 3 G495
  458
• 3.5 Removing and installing exhaust gas temperature sender 4 G648
  460
• 4 Exhaust gas recirculation
  462
• 4.1 Assembly overview – exhaust gas recirculation
  462
• 4.2 Removing and installing exhaust gas recirculation valve
  465
• 4.3 Removing and installing exhaust gas recirculation cooler
  468
• 4.4 Removing and installing exhaust gas recirculation temperature sensor G98
  470
• 5 Exhaust manifold
  472
• 5.1 Assembly overview - exhaust manifold
  472
• 5.2 Removing and installing exhaust manifold
  473
• Glow plug system
  478
• 1 Glow plug system
  478
• 1.1 Assembly overview - glow plug system
  478
• 1.2 Removing and installing glow plug
  480
• 1.3 Removing and installing automatic glow period control unit J179
  483
• 1.4 Removing and installing Hall sender G40
  483
• 1.5 Removing and installing engine speed sender G28
  484