6-cylinder common rail engine (3.0 l, 4V, EA 897 Gen II, 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 start/stop system
  1
• 1.4 Safety measures when working on cooling system
  2
• 1.5 Safety measures when working on exhaust system
  2
• 1.6 Safety precautions when working on the SCR system
  3
• 1.7 Safety regulations for working on glow plug system
  4
• 1.8 Safety measures when working on subframe
  4
• 2 Identification
  5
• 2.1 Engine number/engine data
  5
• 3 Repair notes
  7
• 3.1 Rules for cleanliness
  7
• 3.2 General information
  7
• 3.3 General repair notes
  8
• 3.4 Adapting learnt value for SCR system
  9
• 3.5 Foreign objects in engine
  9
• 3.6 Contact corrosion
  10
• 3.7 Routing and attachment of lines
  10
• 3.8 Installing radiators and condensers
  10
• 3.9 Checking vacuum system
  10
• Removing and installing engine
  12
• 1 Removing and installing motor
  12
• 1.1 Removing motor
  12
• 1.2 Separating engine and gearbox
  34
• 1.3 Securing engine on engine and gearbox support
  41
• 1.4 Installing engine
  45
• 2 Assembly mountings
  50
• 2.1 Assembly overview - assembly mountings
  50
• 2.2 Removing and installing engine mounting
  53
• 2.3 Removing and installing gearbox mountings
  59
• 2.4 Supporting engine in installation position
  60
• 3 Engine cover panel
  64
• 3.1 Removing and installing engine cover
  64
• Crankshaft group
  68
• 1 Cylinder block (pulley end)
  68
• 1.1 Assembly overview - cylinder block (pulley end)
  68
• 1.2 Assembly overview - sealing flange, belt pulley end
  71
• 1.3 Removing and installing poly-V belt
  73
• 1.4 Removing and installing tensioner for poly V-belt
  75
• 1.5 Removing and installing vibration damper
  75
• 1.6 Removing and installing bracket for ancillaries
  78
• 1.7 Removing and installing engine support
  80
• 1.8 Renewing crankshaft oil seal - belt pulley end
  81
• 1.9 Removing and installing sealing flange on pulley end
  83
• 2 Cylinder block, gearbox end
  88
• 2.1 Assembly overview - cylinder block, gearbox end
  88
• 2.2 Removing and installing drive plate
  88
• 2.3 Renewing crankshaft oil seal (gearbox end)
  91
• 3 Crankshaft
  94
• 3.1 Assembly overview - crankshaft
  94
• 3.2 Crankshaft dimensions
  96
• 3.3 Allocation of main bearing shells
  97
• 3.4 Measuring axial clearance of crankshaft
  98
• 3.5 Measuring radial clearance of crankshaft
  99
• 3.6 Checking sender wheel
  99
• 4 Balancer shaft
  101
• 4.1 Assembly overview - balance shaft
  101
• 4.2 Removing and installing balance shaft
  101
• 5 Pistons and conrods
  110
• 5.1 Assembly overview - pistons and conrods
  110
• 5.2 Removing and installing pistons
  114
• 5.3 Measuring piston projection at TDC
  115
• 5.4 Checking pistons and cylinder bores
  118
• 5.5 Checking radial clearance of conrods
  120
• Cylinder head, valve gear
  121
• 1 Cylinder head
  121
• 1.1 Assembly overview - cylinder head
  121
• 1.2 Assembly overview - cylinder head cover
  124
• 1.3 Removing and installing cylinder head
  127
• 1.4 Removing and installing cylinder head cover
  136
• 1.5 Removing and installing injector seals
  142
• 1.6 Checking compression
  143
• 2 Cover for timing chain
  145
• 2.1 Assembly overview - cover for timing chain
  145
• 2.2 Removing and installing timing chain cover
  149
• 3 Chain drive
  162
• 3.1 Assembly overview - camshaft timing chains
  162
• 3.2 Assembly overview - drive chain for high pressure pump
  164
• 3.3 Assembly overview - drive chain for oil pump
  165
• 3.4 Assembly overview - intermediate drive
  165
• 3.5 Removing camshaft timing chain from camshafts
  166
• 3.6 Removing and installing camshaft timing chain
  179
• 3.7 Removing and installing drive chain for high-pressure pump
  191
• 3.8 Installing intermediate drive
  193
• 4 Valve gear
  202
• 4.1 Assembly overview - valve gear
  202
• 4.2 Measuring axial play of camshaft
  210
• 4.3 Measuring radial play of camshaft
  212
• 4.4 Removing and installing camshaft
  212
• 4.5 Checking hydraulic compensation elements
  228
• 4.6 Removing and installing valve stem seals
  230
• 5 Inlet and exhaust valves
  240
• 5.1 Reworking valve seats
  240
• 5.2 Checking valve guides
  240
• 5.3 Checking valves
  241
• 5.4 Valve dimensions
  241
• Lubrication
  242
• 1 Sump, oil pump
  242
• 1.1 Assembly overview - sump/oil pump
  242
• 1.2 Engine oil:
  247
• 1.3 Removing and installing lower part of sump
  249
• 1.4 Removing and installing upper part of sump
  252
• 1.5 Removing and installing oil pump
  255
• 1.6 Removing and installing oil level and oil temperature sender G266
  258
• 2 Engine oil cooler
  259
• 2.1 Assembly overview - engine oil cooler
  259
• 2.2 Removing and installing engine oil cooler
  261
• 2.3 Removing and installing temperature regulator for engine oil cooler
  262
• 3 Crankcase ventilation
  264
• 3.1 Assembly overview - crankcase breather system
  264
• 3.2 Removing and installing oil separator
  265
• 4 Oil filter, oil pressure switch
  266
• 4.1 Assembly overview - oil filter
  266
• 4.2 Removing and installing oil pressure sender G10
  268
• 4.3 Checking oil pressure
  269
• 4.4 Removing and installing oil filter housing
  269
• 4.5 Removing and installing oil pressure regulating valve N428
  272
• 4.6 Removing and installing oil temperature sender 2 G664
  272
• Cooling
  274
• 1 Cooling system/coolant
  274
• 1.1 Connection diagram - coolant hoses
  274
• 1.2 Checking cooling system for leaks
  278
• 1.3 Draining and adding coolant
  281
• 2 Coolant pump, regulation of cooling system
  292
• 2.1 Assembly overview - coolant pump
  292
• 2.2 Assembly overview - electric coolant pump
  294
• 2.3 Assembly overview - thermostat
  294
• 2.4 Assembly overview - coolant temperature sender
  296
• 2.5 Removing and installing electric coolant pump
  297
• 2.6 Removing and installing coolant pump
  299
• 2.7 Removing and installing thermostat housing
  301
• 2.8 Removing and installing thermostat
  303
• 2.9 Removing and installing coolant temperature sender G62
  303
• 2.11 Removing and installing coolant temperature sender 2 G802
  306
• 2.12 Removing and installing coolant valves
  307
• 3 Coolant pipes
  310
• 3.1 Assembly overview - coolant pipes
  310
• 3.2 Removing and installing coolant pipes
  315
• 4 Radiator, radiator fan
  328
• 4.1 Assembly overview - radiator/radiator fan
  328
• 4.2 Assembly overview - auxiliary radiator
  331
• 4.3 Removing and installing radiator
  332
• 4.4 Removing and installing radiator cowl
  338
• 4.5 Removing and installing radiator fan V7
  341
• 4.6 Removing and installing auxiliary radiator
  341
• Turbocharging/supercharging
  344
• 1 Turbocharger
  344
• 1.1 Assembly overview - turbocharger
  344
• 1.2 Removing and installing turbocharger
  349
• 2 Charge air system
  354
• 2.1 Assembly overview - charge air system
  354
• 2.2 Assembly overview - charge-air hose connections
  355
• 2.3 Removing and installing charge air cooler
  356
• 2.4 Removing and installing charge pressure sender G31
  359
• 2.5 Checking charge air system for leaks
  359
• Mixture preparation - injection
  364
• 1 Injection system
  364
• 1.1 Schematic overview - fuel system
  364
• 1.2 Overview of fitting locations - injection system
  365
• 1.3 Filling/bleeding fuel system
  372
• 1.4 Checking fuel system for leaks
  373
• 2 Vacuum system
  374
• 2.1 Connection diagram - vacuum system
  374
• 2.2 Checking vacuum system
  374
• 3 Injectors/high-pressure accumulator (rail)
  376
• 3.1 Assembly overview - injectors
  376
• 3.2 Testing injectors
  380
• 3.3 Adapting correction values for injectors
  381
• 3.4 Checking return flow rate of injectors with engine running
  382
• 3.5 Checking return flow rate of injectors at starter speed
  385
• 3.6 Testing jammed-open injectors
  388
• 3.7 Check pressure retention valve in fuel return line
  392
• 3.8 Removing and installing injectors
  393
• 3.9 Removing and installing high-pressure lines
  399
• 3.10 Removing and installing fuel rail
  401
• 4 Air filter
  406
• 4.1 Assembly overview - air filter housing
  406
• 4.2 Removing and installing air filter housing
  408
• 5 Intake manifold
  411
• 5.1 Assembly overview - intake manifold
  411
• 5.2 Removing and installing intake manifold upper part
  415
• 5.3 Removing and installing lower part of intake manifold
  420
• 5.4 Removing and installing intake manifold flap motor V157
  421
• 5.5 Removing and installing throttle valve module J338
  424
• 6 Senders and sensors
  426
• 6.1 Checking fuel pressure regulating valve N276
  426
• 6.2 Removing and installing fuel pressure regulating valve N276
  428
• 6.3 Removing and installing fuel pressure sender G247
  430
• 6.4 Removing and installing air mass meter G70
  433
• 6.5 Removing and installing pressure differential sender G505
  433
• 6.6 Removing and installing pressure differential sender 2 G524
  435
• 6.7 Removing and installing NOx sender G295
  436
• 6.8 Removing and installing NOx sender 2 G687
  438
• 6.9 Removing and installing particle sensor G784
  439
• 6.11 Removing and installing fuel temperature sender G81
  441
• 6.12 Removing and installing fuel pressure sender for low-pressure G410
  441
• 7 Engine control unit
  443
• 7.1 Assembly overview – motor control unit
  443
• 7.2 Removing and installing engine control unit J623
  443
• 8 High-pressure pump
  445
• 8.1 Assembly overview - high-pressure pump
  445
• 8.2 Removing and installing high-pressure pump
  448
• 9 Lambda probe
  454
• 9.1 Assembly overview - Lambda probe
  454
• 9.2 Removing and installing Lambda probe
  456
• Exhaust system
  458
• 1 Exhaust pipes and silencers
  458
• 1.1 Assembly overview - silencers
  458
• 1.2 Removing and installing front exhaust pipe
  460
• 1.3 Separating exhaust pipes from silencers
  465
• 1.4 Removing and installing silencer
  466
• 1.5 Aligning exhaust system free of stress
  468
• 1.6 Checking exhaust system for leaks
  469
• 2 Emission control
  470
• 2.1 Assembly overview - emission control
  470
• 2.2 Removing and installing emission control module
  473
• 2.3 Removing and installing trap catalytic converter
  477
• 2.4 Removing and installing exhaust flap control unit J883
  479
• 3 SCR system (selective catalytic reduction)
  481
• 3.1 Assembly overview - tank for reducing agent
  481
• 3.2 Assembly overview - reducing agent supply line
  483
• 3.3 Assembly overview - control unit for reducing agent metering system
  484
• 3.4 Relieving pressure in SCR system
  485
• 3.5 Draining reducing agent tank
  486
• 3.6 Removing and installing reducing agent tank
  487
• 3.7 Removing and installing injector for reduction agent N474
  489
• 3.8 Assembly overview - injector for reducing agent
  491
• 3.9 Removing and installing control unit for reducing agent metering system J880
  492
• 3.10 Removing and installing reducing agent quality sensor G849
  493
• 4 Exhaust gas temperature regulation
  494
• 4.1 Assembly overview - exhaust gas temperature regulation
  494
• 4.2 Removing and installing exhaust gas temperature sender 1 G235
  495
• 4.3 Removing and installing exhaust gas temperature sender 2 G448
  497
• 4.4 Removing and installing exhaust gas temperature sender 3 G495
  498
• 4.5 Removing and installing exhaust gas temperature sender 4 G648
  500
• 5 Exhaust gas recirculation
  502
• 5.1 Assembly overview - exhaust gas recirculation
  502
• 5.2 Removing and installing exhaust gas recirculation valve
  507
• 5.3 Removing and installing exhaust gas recirculation cooler
  510
• 5.4 Removing and installing exhaust gas recirculation control motor 2 V339
  514
• 5.5 Removing and installing exhaust gas recirculation temperature sensor G98
  515
• 6 Exhaust manifold
  517
• 6.1 Assembly overview - exhaust manifold
  517
• 6.2 Removing and installing exhaust manifold
  518
• Glow plug system
  523
• 1 Glow plug system
  523
• 1.1 Assembly overview - glow plug system
  523
• 1.2 Removing and installing glow plug
  525
• 1.3 Removing and installing automatic glow period control unit J179
  528
• 1.4 Removing and installing Hall sender G40
  529
• 1.5 Removing and installing engine speed sender G28
  529