6-cylinder diesel engine

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  1
• Removing and installing engine
  2
• 1 Removing and installing engine
  2
• 1.1 Removing engine
  2
• 1.2 Procedure
  4
• 1.3 Notes on installing
  8
• 1.4 Torque settings
  10
• 1.5 Front engine mounting
  11
• 1.6 Electrohydraulic engine mounting, left and right
  13
• 1.7 Pneumatic engine mounting, left and right
  15
• 1.8 Additional information and removal instructions for vehicles with air conditioner
  16
• Crankshaft group
  18
• 1 Dismantling and assembling engine
  18
• 1.1 Overview
  18
• 1.2 Removing and installing poly-V-belt
  24
• 1.3 Removing and installing bracket for vane pump and oil cooler
  26
• 2 Removing and installing sealing flanges and flywheel or drive plate
  29
• 2.1 Renewing crankshaft oil seal - belt pulley end
  31
• 2.2 Removing and installing front sealing flange
  32
• 2.3 Removing and installing dual-mass flywheel
  35
• 2.4 Removing and installing drive plate
  36
• 3 Removing and installing crankshaft
  38
• 3.1 Crankshaft dimensions
  40
• 3.2 Removing and installing chain sprocket
  40
• 4 Dismantling and assembling pistons and conrods
  42
• 4.1 Checking piston projection at TDC
  45
• 4.2 Piston and cylinder dimensions
  46
• Cylinder head, valve gear
  47
• 1 Removing and installing cylinder head
  47
• 1.2 Removing and installing front intake manifold, engine code BDG
  51
• 1.3 Torque settings
  52
• 1.4 Removing, installing and tensioning toothed belt
  52
• 1.5 Removing toothed belt from camshaft pulleys
  59
• 1.6 Removing and installing left intake manifold
  67
• 1.7 Removing and installing right intake manifold
  69
• 1.8 Removing and installing left cylinder head cover
  70
• 1.9 Removing and installing right cylinder head cover
  72
• 1.10 Removing left cylinder head
  75
• 1.11 Removing right cylinder head
  77
• 1.12 Installing cylinder head
  80
• 1.13 Checking compression
  84
• 2 Repairing valve gear
  86
• 2.1 Checking axial clearance of camshafts
  88
• 2.2 Renewing camshaft oil seal
  89
• 2.3 Removing and installing camshafts
  90
• 2.4 Checking hydraulic valve compensation elements
  94
• 2.5 Renewing valve stem seals
  94
• 2.6 Checking valve guides
  96
• Lubrication
  97
• 1 Removing and installing parts of lubrication system
  97
• 1.1 Engine oil
  97
• 1.2 Removing and installing oil filter bracket
  101
• 1.3 Removing and installing lower part of sump
  103
• 1.4 Removing and installing oil pump
  105
• 1.5 Removing and installing upper part of sump
  108
• 1.6 Renewing oil check valve
  112
• 1.7 Removing and installing oil cooler
  113
• 1.8 Checking oil pressure and oil pressure switch
  115
• Cooling
  118
• 1 Removing and installing parts of cooling system
  118
• 1.1 Parts of cooling system - body side
  118
• 1.2 Coolant pump and thermostat
  120
• 1.3 Overview - coolant pipes
  121
• 1.4 Draining and filling coolant
  122
• 1.5 Removing and installing coolant pump
  125
• 1.6 Removing and installing thermostat
  126
• 1.7 Removing and installing front coolant pipe
  131
• 1.8 Removing and installing left upper and lower coolant pipes
  132
• 1.9 Removing and installing right coolant pipe
  134
• 1.10 Removing and installing radiator
  134
• Fuel supply system
  137
• 1 Removing and installing parts of fuel supply system
  137
• 1.1 Safety precautions when working on fuel supply system
  137
• 1.2 Rules for cleanliness
  138
• 1.3 Removing and installing fuel tank with attachments
  138
• 1.4 Repairing fuel filter
  147
• 1.5 Emptying fuel tank
  147
• 1.6 Removing and installing fuel tank
  148
• 1.7 Checking low fuel level sender
  150
• 1.8 Removing and installing fuel gauge sender
  152
• 1.9 Removing and installing fuel delivery unit
  154
• 1.10 Removing and installing suction-jet pump
  158
• 1.11 Checking fuel pump
  160
• 1.12 Bleeding fuel system
  162
• 2 Accelerator mechanism
  165
• 2.1 Repairing accelerator mechanism
  165
• 2.2 Adjusting pedal position sender
  166
• 2.3 Function of EPC system
  167
• Turbocharging/supercharging
  169
• 1 Charge air system with turbocharger
  169
• 1.1 Rules for cleanliness
  169
• 1.2 Removing and installing turbocharger with attachments
  169
• 1.3 Removing and installing turbocharger with attachments
  171
• 1.4 Removing and installing turbocharger
  172
• 1.5 Removing and installing compensator
  174
• 1.6 Removing and installing parts of charge air cooling
  176
• 1.7 Removing and installing charge air cooler
  177
• 1.8 Charge pressure control hose routing diagram
  177
• 1.9 Charge pressure control hose routing diagram
  179
• Mixture preparation - injection
  180
• 1 Repairing diesel direct injection system
  180
• 1.1 Safety precautions
  180
• 1.2 Rules for cleanliness
  180
• 1.3 Repairing injection pump
  181
• 1.4 Removing and installing injection pump
  183
• 1.5 Dynamically checking and adjusting commencement of injection
  186
• 1.6 Checking injectors
  189
• 1.7 Removing and installing injectors
  190
• 1.8 Repairing injectors
  192
• 1.9 Adapting idling speed
  192
• 1.10 Identification of injection pump
  194
• 1.11 Removing and installing intake manifold flap
  195
• 2 Engine control unit
  196
• 2.1 Reading and erasing engine control unit fault memory
  196
• 2.2 Adapting functions and components
  197
• 2.3 Removing and installing engine control unit
  198
• Exhaust system
  199
• 1 Removing and installing parts of exhaust system
  199
• 1.1 Front exhaust pipe with catalytic converter, middle silencer, rear silencer and attachments
  199
• 1.2 Front exhaust pipe with catalytic converter and attachments
  202
• 1.3 Silencer with mountings
  205
• 1.4 Removing and installing left exhaust manifold with front exhaust pipe
  206
• 1.5 Removing and installing right exhaust manifold with front exhaust pipe
  208
• 2 Exhaust gas recirculation system
  210
• 2.1 Vacuum hose schematic diagram
  210
• 2.2 Checking exhaust gas recirculation valve
  211
• 2.3 Removing and installing exhaust gas recirculation valve
  212
• Glow plug system
  215
• 1 Glow plug system
  215
• 1.1 Checking glow plug system
  215
• 1.2 Checking glow plugs
  215