6-cylinder common rail engine (3.0 l, 4V, EA 897 Gen III, turbocharger)

Chapter overview

• Technical data
  1
• 1 Identification
  1
• 1.1 Engine number/engine data
  1
• 2 Safety information
  2
• 2.1 Safety precautions when working on fuel system
  2
• 2.2 Safety measures when working on vehicles with a start/stop system
  2
• 2.4 Safety precautions when working on the cooling system
  3
• 2.5 Safety precautions when working on exhaust system
  3
• 2.6 Safety precautions when working on the SCR system
  4
• 3 Repair notes
  6
• 3.1 Identification labels
  6
• 3.2 Using impact drivers
  6
• 3.3 Rules for cleanliness
  7
• 3.4 General notes
  7
• 3.5 General repair notes
  9
• 3.6 Foreign objects in engine
  10
• 3.7 Contact corrosion
  11
• 3.8 Routing and attachment of lines
  11
• 3.9 Fitting radiator and condensers
  11
• 3.10 Adapting after component replacement
  12
• Removing and installing engine
  13
• 1 Removing and installing engine
  13
• 1.1 Removing engine
  13
• 1.2 Separating engine and gearbox
  36
• 1.3 Securing engine on engine and gearbox support
  42
• 1.4 Installing engine
  46
• 2 Assembly mountings
  50
• 2.1 Assembly overview - assembly mountings
  50
• 2.2 Removing and installing engine mounting
  54
• 2.3 Removing and installing gearbox mounting
  59
• 2.4 Supporting engine in installation position
  60
• 2.5 Removing and installing power unit mounting senders
  64
• 2.6 Removing and installing power unit mounting control unit J931
  64
• 2.7 Calibrating electrohydraulic engine mounting
  65
• 3 Engine cover panel
  67
• 3.1 Removing and installing engine cover
  67
• Crankshaft group
  69
• 1 Cylinder block (pulley end)
  69
• 1.1 Assembly overview - cylinder block (pulley end)
  69
• 1.2 Assembly overview - sealing flange, belt pulley end
  76
• 1.3 Removing and installing poly-V belt
  79
• 1.4 Removing and installing tensioner for poly V-belt
  83
• 1.5 Removing and installing vibration damper
  86
• 1.6 Removing and installing bracket for ancillaries
  93
• 1.7 Removing and installing engine support
  97
• 1.8 Renewing crankshaft oil seal - belt pulley end
  98
• 1.9 Removing and installing sealing flange on pulley end
  99
• 2 Cylinder block, gearbox end
  105
• 2.1 Assembly overview - cylinder block, gearbox end
  105
• 2.2 Removing and installing drive plate
  105
• 2.3 Renewing crankshaft oil seal (gearbox end)
  108
• 3 Crankshaft
  111
• 3.1 Assembly overview - crankshaft
  111
• 3.2 Crankshaft dimensions
  114
• 3.3 Allocation of main bearing shells
  114
• 3.4 Measuring axial clearance of crankshaft
  115
• 3.5 Measuring radial clearance of crankshaft
  116
• 3.6 Checking sender wheel
  117
• 4 Balancer shaft
  119
• 4.1 Assembly overview - balance shaft
  119
• 4.2 Removing and installing balance shaft
  120
• 4.3 Renewing roller bearing
  128
• 5 Pistons and conrods
  131
• 5.1 Assembly overview - pistons and conrods
  131
• 5.2 Removing and installing pistons
  135
• 5.3 Measuring piston projection at TDC
  136
• 5.4 Checking pistons and cylinder bores
  138
• 5.5 Checking radial clearance of conrods
  140
• Cylinder head, valve gear
  142
• 1 Cover for timing chain
  142
• 1.1 Assembly overview - cover for timing chain
  142
• 1.2 Removing and installing timing chain cover
  147
• 2 Chain drive
  158
• 2.1 Assembly overview - camshaft timing chains
  158
• 2.2 Assembly overview - drive chain
  160
• 2.3 Removing camshaft timing chain from camshafts
  162
• 2.4 Removing and installing camshaft timing chain
  174
• 2.5 Removing and installing drive chain for high-pressure pump
  185
• 2.6 Installing intermediate drive
  187
• 3 Cylinder head
  196
• 3.1 Assembly overview - cylinder head
  196
• 3.2 Assembly overview - cylinder head cover
  199
• 3.3 Removing and installing cylinder head
  202
• 3.4 Removing and installing cylinder head cover
  211
• 3.5 Removing and installing injector seals
  216
• 3.6 Checking compression
  217
• 4 Valve gear
  219
• 4.1 Assembly overview - valve gear
  219
• 4.2 Measuring axial play of camshaft
  228
• 4.3 Measuring radial play of camshaft
  230
• 4.4 Removing and installing camshaft
  231
• 4.5 Removing and installing valve stem seals
  247
• 5 Inlet and exhaust valves
  257
• 5.1 Reworking valve seats
  257
• 5.2 Checking valve guides
  257
• 5.3 Checking valves
  258
• 5.4 Valve dimensions
  258
• Lubrication
  259
• 1 Sump, oil pump
  259
• 1.1 Assembly overview - sump/oil pump
  259
• 1.2 Engine oil:
  263
• 1.3 Removing and installing lower part of sump
  263
• 1.4 Removing and installing upper part of sump
  267
• 1.5 Removing and installing oil pump
  270
• 1.6 Removing and installing oil level and oil temperature sender G266
  272
• 2 Engine oil cooler
  274
• 2.1 Assembly overview - engine oil cooler
  274
• 2.2 Removing and installing engine oil cooler
  276
• 2.3 Removing and installing temperature regulator for engine oil cooler
  277
• 3 Oil filter, oil pressure switch
  279
• 3.1 Assembly overview - oil filter
  279
• 3.2 Removing and installing oil filter housing
  281
• 3.3 Removing and installing oil pressure sender G10
  283
• 3.4 Checking oil pressure
  284
• 3.5 Removing and installing oil pressure regulating valve N428
  285
• 3.6 Removing and installing oil temperature sender 2 G664
  285
• Cooling
  288
• 1 Cooling system/coolant
  288
• 1.1 Connection diagram - coolant hoses
  288
• 1.2 Assembly overview – coolant expansion tank
  292
• 1.3 Checking cooling system for leaks
  293
• 1.4 Draining and adding coolant
  297
• 2 Coolant pump, regulation of cooling system
  306
• 2.1 Assembly overview - coolant pump
  306
• 2.2 Assembly overview - electric coolant pump
  307
• 2.3 Assembly overview - thermostat
  309
• 2.4 Assembly overview – coolant valves
  311
• 2.5 Assembly overview - coolant temperature sender
  314
• 2.6 Removing and installing electric coolant pump
  316
• 2.7 Removing and installing coolant pump
  319
• 2.8 Removing and installing map-controlled engine cooling thermostat F265
  322
• 2.10 Removing and installing coolant temperature sender G62
  323
• 2.12 Removing and installing coolant temperature sender 2 G802
  326
• 2.13 Removing and installing coolant temperature sender for charge air cooler G1130
  327
• 2.14 Removing and installing coolant valves
  329
• 3 Coolant pipes
  335
• 3.1 Assembly overview - coolant pipes
  335
• 3.2 Removing and installing coolant pipes
  340
• 3.3 Removing and installing coolant line
  360
• 4 Radiator, radiator fan
  362
• 4.1 Assembly overview - radiator/radiator fan
  362
• 4.2 Assembly overview – radiator cowl and radiator fan
  365
• 4.3 Assembly overview - radiator blind
  366
• 4.4 Assembly overview - auxiliary radiator
  367
• 4.5 Removing and installing radiator
  368
• 4.6 Removing and installing radiator blind
  372
• 4.7 Removing and installing radiator blind control motor V544
  373
• 4.8 Removing and installing water radiator for charge air cooling circuit
  375
• 4.9 Removing and installing radiator cowl
  377
• 4.10 Removing and installing radiator fan
  380
• 4.11 Removing and installing auxiliary radiator
  381
• Turbocharging/supercharging
  384
• 1 Turbocharger
  384
• 1.1 Assembly overview - turbocharger
  384
• 1.2 Removing and installing turbocharger
  388
• 2 Charge air system
  392
• 2.1 Assembly overview - charge air system
  392
• 2.2 Assembly overview - charge-air hose connections
  394
• 2.3 Removing and installing charge air cooler
  395
• 2.4 Removing and installing charge pressure sender G31
  398
• 2.5 Removing and installing charge air temperature sender
  399
• 2.6 Checking charge air system for leaks
  400
• Mixture preparation - injection
  405
• 1 Injection system
  405
• 1.1 Schematic overview - fuel system
  405
• 1.2 Overview of fitting locations - injection system
  406
• 1.3 Filling/bleeding fuel system
  413
• 1.4 Checking fuel system for leaks
  414
• 2 Vacuum system
  415
• 2.1 Connection diagram – vacuum system
  415
• 2.2 Checking vacuum system
  415
• 3 Air filter
  417
• 3.1 Assembly overview - air filter housing
  417
• 3.2 Removing and installing air filter housing
  419
• 4 Intake manifold
  423
• 4.1 Assembly overview – intake manifold
  423
• 4.2 Removing and installing intake manifold upper part
  426
• 4.3 Removing and installing lower part of intake manifold
  430
• 4.4 Removing and installing intake manifold flap control unit GX14
  431
• 4.5 Removing and installing throttle valve module GX3
  432
• 5 Injectors/high-pressure accumulator (rail)
  434
• 5.1 Assembly overview - injectors
  434
• 5.2 Testing injectors
  439
• 5.3 Adapting correction values for injectors
  439
• 5.4 Checking return flow rate of injectors with engine running
  440
• 5.5 Checking return flow rate of injectors at starter speed
  445
• 5.6 Removing and installing injectors
  450
• 5.7 Removing and installing high-pressure lines
  462
• 5.8 Removing and installing fuel rail
  464
• 6 Senders and sensors
  470
• 6.1 Removing and installing air mass meter G70
  470
• 6.2 Removing and installing fuel temperature sender G81
  471
• 6.3 Removing and installing fuel pressure sender G247
  472
• 6.4 Removing and installing fuel pressure sender for low-pressure G410
  474
• 6.5 Checking fuel pressure regulating valve N276
  475
• 6.6 Removing and installing fuel pressure regulating valve N276
  477
• 6.7 Removing and installing pressure differential sender
  480
• 6.8 Removing and installing NOx sender
  482
• 6.9 Removing and installing particle sensor G784
  486
• 7 High-pressure pump
  489
• 7.1 Assembly overview - high-pressure pump
  489
• 7.2 Removing and installing high-pressure pump
  491
• 8 Lambda probe
  496
• 8.1 Assembly overview - Lambda probe
  496
• 8.2 Removing and installing Lambda probe
  499
• 9 Engine control unit
  503
• 9.1 Assembly overview – engine/motor control unit
  503
• 9.2 Removing and installing engine control unit J623
  503
• Exhaust system
  505
• 1 Exhaust pipes and silencers
  505
• 1.1 Assembly overview – silencers
  505
• 1.2 Removing and installing front exhaust pipe
  507
• 1.3 Separating exhaust pipes from silencers
  510
• 1.4 Removing and installing silencer
  512
• 1.5 Aligning exhaust system free of stress
  514
• 1.6 Checking exhaust system for leaks
  515
• 1.7 Installation position of clamp
  516
• 2 Emission control
  518
• 2.1 Assembly overview – emission control
  518
• 2.2 Removing and installing emission control module
  521
• 2.3 Removing and installing trap catalytic converter
  525
• 2.4 Removing and installing exhaust flap control unit J883
  527
• 3 SCR system (selective catalytic reduction)
  529
• 3.1 Assembly overview – reducing agent tank
  529
• 3.2 Assembly overview - injector for reducing agent
  532
• 3.3 Assembly overview - reducing agent supply line
  535
• 3.4 Relieving pressure in SCR system
  536
• 3.5 Disconnecting reducing agent supply line
  537
• 3.6 Draining reducing agent tank
  539
• 3.7 Removing and installing reducing agent tank
  541
• 3.8 Removing and installing injector for reduction agent N474
  543
• 3.9 Removing and installing injector 2 for reducing agent N758
  545
• 3.10 Removing and installing control unit for reducing agent metering system J880
  547
• 3.11 Removing and installing reducing agent quality sensor G849
  548
• 3.12 Removing and installing pump for reducing agent V437
  548
• 3.14 Removing and installing connection for SCR supply line
  553
• 4 Exhaust gas temperature regulation
  556
• 4.1 Assembly overview – exhaust gas temperature regulation
  556
• 4.2 Removing and installing exhaust gas temperature sender 1 G235
  557
• 4.3 Removing and installing exhaust gas temperature sender 2 G448
  559
• 4.4 Removing and installing exhaust gas temperature sender 3 G495
  560
• 4.5 Removing and installing exhaust gas temperature sender 4 G648
  561
• 5 Exhaust gas recirculation
  564
• 5.1 Assembly overview – exhaust gas recirculation
  564
• 5.2 Removing and installing exhaust gas recirculation cooler
  568
• 5.3 Removing and installing exhaust gas recirculation valve 2 GX6
  573
• 5.4 Removing and installing exhaust gas recirculation temperature sensor G98
  574
• 6 Exhaust manifold
  576
• 6.1 Assembly overview - exhaust manifold
  576
• 6.2 Removing and installing exhaust manifold
  577
• Ignition system
  581
• 1 Glow plug system
  581
• 1.1 Assembly overview - glow plug system
  581
• 1.2 Removing and installing glow plug
  583
• 1.3 Removing and installing automatic glow period control unit J179
  587
• 1.4 Removing and installing Hall sender G40
  588
• 1.5 Removing and installing engine speed sender G28
  589