6-cylinder diesel engine (3.0 l engine, common rail)

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  1
• Removing and installing engine
  3
• 1 Removing and installing engine
  3
• 1.1 Removing engine
  3
• 1.2 Notes on installing
  15
• 1.3 Specified torques
  16
• 1.4 Front engine mounting
  16
• Crankshaft group
  18
• 1 Dismantling and assembling engine
  18
• 1.1 Assembly overview - poly V-belt drive
  20
• 1.2 Removing and installing poly V-belt
  23
• 1.3 Renewing crankshaft oil seal - belt pulley end
  24
• 1.4 Removing and installing front sealing flange
  26
• 1.5 Assembly overview - drive plate/dual-mass flywheel
  29
• 1.6 Removing and installing dual-mass flywheel
  30
• 1.7 Extracting and driving in needle roller bearing for dual-mass flywheel
  31
• 1.8 Removing and installing drive plate
  32
• 1.9 Renewing crankshaft oil seal on timing chain end
  33
• 1.10 Assembly overview - timing chain covers
  35
• 1.11 Removing and installing timing chain covers
  36
• 1.12 Assembly overview - balancer shaft
  43
• 1.13 Removing and installing balancer shaft
  44
• 2 Chain drive (engine code BMK)
  47
• 2.1 Assembly overview - drive chain for valve gear
  47
• 2.2 Removing and installing drive chain for valve gear
  48
• 2.3 Assembly overview - chain for balancer shaft and oil pump
  49
• 2.4 Removing and installing chain for balancer shaft and oil pump
  51
• 3 Chain drive (engine codes CARA, CEXA, CEXB)
  55
• 3.1 Assembly overview - drive chain for valve gear
  55
• 3.2 Removing and installing drive chain for valve gear
  56
• 3.3 Assembly overview - chain for balancer shaft and oil pump
  57
• 3.4 Removing and installing chain for balancer shaft and oil pump
  59
• 4 Removing and installing crankshaft
  63
• 4.1 Assembly overview - crankshaft
  63
• 4.2 Crankshaft dimensions
  65
• 4.3 Measuring axial clearance
  65
• 4.4 Measuring radial clearance
  66
• 5 Pistons and conrods
  67
• 5.1 Assembly overview - pistons and conrods
  67
• 5.2 Checking piston projection at TDC
  70
• 5.3 Piston and cylinder dimensions
  71
• 5.4 Checking radial clearance of conrods
  71
• Cylinder head, valve gear
  72
• 1 Cylinder head
  72
• 1.1 Assembly overview - cylinder head
  72
• 1.2 Assembly overview - cylinder head cover
  75
• 1.3 Removing and installing cylinder head cover
  78
• 1.4 Removing and installing cylinder head
  84
• 1.5 Checking compression
  91
• 1.6 Assembly overview - vacuum pump
  93
• 2 Valve gear
  95
• 2.1 Assembly overview - valve gear
  95
• 2.2 Checking axial clearance of camshafts
  96
• 2.3 Renewing camshaft oil seal
  97
• 2.4 Removing and installing camshafts
  100
• 2.5 Renewing valve stem seals
  104
• 2.6 Checking hydraulic valve compensation elements
  108
• 2.7 Valve dimensions
  110
• 2.8 Checking valve guides
  110
• 3 Chain drive for camshafts
  112
• 3.1 Camshaft timing chains (engine code BMK)
  112
• 3.2 Camshaft timing chains (engine codes CARA, CEXA, CEXB)
  131
• Lubrication
  151
• 1 Engine oil
  151
• 1.1 Oil capacities
  151
• 1.2 Checking engine oil level
  151
• 2 Parts of lubrication system
  152
• 2.1 Assembly overview - oil pump, lower part of sump
  152
• 2.2 Removing and installing lower part of sump
  153
• 2.3 Removing and installing oil pump
  155
• 2.4 Assembly overview - upper part of sump
  156
• 2.5 Removing and installing upper part of sump
  157
• 3 Oil cooler, pressure control valve and oil filter housing
  161
• 3.1 Assembly overview - oil cooler, pressure control valve, and oil filter housing
  161
• 3.2 Removing and installing oil cooler
  162
• 3.3 Removing and installing oil filter housing
  163
• 3.7 Checking oil pressure and oil pressure switch
  167
• Cooling
  170
• 1 Parts of cooling system
  170
• 1.1 Assembly overview - radiator
  170
• 1.2 Removing and installing fan support
  171
• 1.3 Assembly overview - fans
  172
• 1.4 Checking cooling system for leaks
  173
• 1.5 Draining and filling coolant
  173
• 1.6 Assembly overview - coolant pump and thermostat
  177
• 1.7 Removing and installing coolant pump
  177
• 1.8 Removing and installing continued coolant circulation pump V51
  178
• 1.9 Removing and installing hose connection with thermostat
  179
• 1.10 Assembly overview - pump for exhaust gas recirculation cooler V400
  180
• 1.11 Removing and installing pump for exhaust gas recirculation cooler V400
  181
• 1.12 Assembly overview - coolant pipes
  182
• 1.13 Removing and installing coolant pipes
  185
• 1.14 Removing and installing coolant temperature sender G62
  192
• Turbocharging/supercharging
  194
• 1 Charge air system with turbocharger
  194
• 1.1 Rules for cleanliness
  194
• 1.2 Assembly overview - turbocharger (engine code BMK)
  194
• 1.3 Removing and installing turbocharger (engine code BMK)
  196
• 1.4 Assembly overview - turbocharger (engine codes CARA, CEXA und CEXB)
  198
• 1.5 Removing and installing turbocharger (engine codes CARA, CEXA und CEXB)
  200
• 1.6 Removing and installing turbocharger 1 control unit J724
  204
• 1.7 Assembly overview - parts of charge air cooling
  213
• 1.8 Removing and installing charge air cooler
  214
• Mixture preparation - injection
  216
• 1 Diesel direct injection system
  217
• 1.1 Safety precautions
  218
• 1.2 Rules for cleanliness and instructions for working on fuel system
  218
• 1.3 Schematic overview of fuel system (engine code BMK)
  219
• 1.4 Schematic overview of fuel system (engine codes CARA, CEXA und CEXB)
  221
• 1.5 Assembly overview - fuel system (engine code BMK)
  223
• 1.6 Assembly overview - fuel system (engine codes CARA, CEXA und CEXB)
  225
• 1.7 Assembly overview - intake manifold
  228
• 1.8 Removing and installing intake manifold upper part
  232
• 1.9 Removing and installing intake manifold flap motor V157 or intake manifold flap 2 motor V275
  236
• 1.10 Removing and installing lower parts of intake manifold (engine code BMK)
  243
• 1.12 Removing and installing injectors (piezo injectors)
  253
• 1.13 Checking fuel pressure regulating valve N276
  259
• 1.14 Removing and installing fuel pressure regulating valve N276
  259
• 1.15 Removing and installing fuel pressure sender G247
  261
• 1.16 Checking return flow rate of injectors (piezo injectors) with engine running
  262
• 1.17 Checking return flow rate of injectors (piezo injectors) at starting speed
  265
• 1.18 Checking for injectors sticking open (piezo injectors)
  266
• 1.19 Installing high-pressure lines
  267
• 1.20 Checking pressure retention valve in fuel return
  270
• 1.21 Assembly overview - toothed belt for high-pressure pump (engine code BMK)
  271
• 1.23 Assembly overview - high-pressure pump (engine code BMK)
  277
• 1.24 Removing and installing high-pressure pump (engine code BMK)
  280
• 1.29 Bleeding fuel system
  294
• 1.30 Assembly overview - air filter
  295
• 2 Engine control unit
  298
• 2.1 Reading and clearing engine control unit fault memory
  298
• 2.2 Adapting functions and components
  299
• 2.3 Removing and installing engine control unit
  300
• 2.4 Fitting locations
  300
• Exhaust system
  303
• 1 Parts of the exhaust system
  303
• 1.1 Assembly overview - exhaust system
  303
• 1.2 Assembly overview - front exhaust pipe and catalytic converter
  306
• 1.3 Assembly overview - exhaust manifold and intermediate pipes
  307
• 2 Exhaust gas recirculation system, engine code BMK
  308
• 2.1 Assembly overview - exhaust gas recirculation system
  308
• 2.2 Checking mechanical exhaust gas recirculation valve
  309
• 2.3 Removing and installing mechanical exhaust gas recirculation valve
  310
• 2.4 Removing and installing exhaust gas recirculation cooler
  310
• 3 Exhaust gas recirculation, engine codes CARA, CEXA, CEXB
  312
• 3.1 Assembly overview - exhaust gas recirculation system
  312
• 3.2 Removing and installing exhaust gas recirculation control motor V338
  313
• 3.3 Removing and installing exhaust gas recirculation cooler
  314
• 3.4 Removing and installing exhaust gas recirculation temperature sensor G98
  316
• Glow plug system
  318
• 1 Glow plug system
  318
• 1.1 Glow plug characteristics
  318
• 1.2 Removing, installing and checking ceramic glow pin plugs
  318
• 1.3 Removing and installing metal glow plugs
  320
• 1.4 Checking metal glow plugs
  321