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
  2
• Removing and installing engine
  3
• 1 Removing and installing engine
  3
• 1.1 Removing engine
  5
• 1.2 Removing engine from scissor-type assembly platform VAS 6131
  13
• 1.3 Securing engine to assembly stand
  14
• 1.4 Notes on installing
  15
• 1.5 Assembly overview - engine mountings
  16
• 1.6 Removing and installing engine mounting
  16
• Crankshaft group
  22
• 1 Dismantling and assembling engine
  22
• 1.1 Assembly overview - poly V-belt drive
  23
• 1.2 Removing and installing poly-V belt
  27
• 1.3 Renewing crankshaft oil seal - pulley end
  29
• 1.4 Removing and installing front sealing flange
  31
• 1.5 Assembly overview - drive plate/dual-mass flywheel
  35
• 1.6 Removing and installing drive plate
  36
• 1.7 Removing and installing dual-mass flywheel
  37
• 1.8 Extracting and driving in needle roller bearing for dual-mass flywheel
  39
• 1.9 Renewing crankshaft oil seal (timing chain end)
  40
• 1.10 Assembly overview - timing chain covers
  42
• 1.11 Removing and installing timing chain covers
  43
• 1.12 Assembly overview - balance shaft
  52
• 1.13 Removing and installing balance shaft
  53
• 2 Chain drive (engine codes BKS, BUN)
  57
• 2.1 Assembly overview - drive chain for valve gear
  57
• 2.2 Removing and installing drive chain for valve gear
  59
• 2.3 Assembly overview - chain for balance shaft and oil pump
  60
• 2.4 Removing and installing chain for balance shaft and oil pump
  61
• 3 Chain drive (engine codes CASA, CASB, CASC, CATA)
  67
• 3.1 Assembly overview - drive chain for valve gear
  67
• 3.2 Removing and installing drive chain for valve gear
  69
• 3.3 Assembly overview - chain for balance shaft and oil pump
  70
• 3.4 Removing and installing chain for balance shaft and oil pump
  71
• 4 Removing and installing crankshaft
  77
• 4.1 Assembly overview - crankshaft
  77
• 4.2 Crankshaft dimensions
  81
• 4.3 Measuring axial clearance
  81
• 4.4 Measuring radial clearance
  82
• 5 Pistons and conrods
  83
• 5.1 Assembly overview - pistons and conrods
  83
• 5.2 Checking piston projection at TDC
  88
• 5.3 Piston and cylinder dimensions
  90
• 5.4 Checking radial clearance of conrods
  90
• Cylinder head, valve gear
  91
• 1 Cylinder head
  91
• 1.1 Assembly overview - cylinder head
  91
• 1.2 Assembly overview - cylinder head cover
  94
• 1.3 Removing and installing cylinder head cover
  97
• 1.4 Removing and installing cylinder head
  104
• 1.5 Checking compression
  113
• 1.6 Assembly overview - vacuum pump
  115
• 2 Assembly overview - valve gear
  117
• 2.1 Checking axial clearance of camshafts
  119
• 2.2 Renewing camshaft oil seal
  120
• 2.3 Removing and installing camshafts
  123
• 2.4 Renewing valve stem seals
  136
• 2.5 Checking hydraulic valve compensation elements
  141
• 2.6 Valve dimensions
  143
• 2.7 Checking valve guides
  143
• 3 Chain drive for camshafts
  145
• 3.1 Camshaft timing chain (engine codes BKS, BUN)
  145
• 3.2 Camshaft timing chain (engine codes CASA, CASB, CASC, CATA)
  171
• Lubrication
  198
• 1 Engine oil:
  198
• 1.1 Oil capacities
  198
• 1.2 Checking engine oil level
  198
• 2 Parts of lubrication system
  200
• 2.1 Assembly overview - oil pump, lower part of sump
  200
• 2.2 Removing and installing lower part of sump
  203
• 2.3 Removing and installing oil pump
  211
• 2.4 Assembly overview - upper part of sump
  212
• 2.5 Removing and installing oil pressure switch F1 (engine code CATA)
  217
• 2.6 Removing and installing oil pressure control valve N428 (engine code CATA)
  217
• 2.7 Removing and installing upper part of sump
  218
• 3 Oil cooler, pressure control valve and oil filter housing
  222
• 3.1 Assembly overview - oil cooler, pressure control valve, and oil filter housing
  222
• 3.2 Removing and installing oil cooler
  224
• 3.3 Removing and installing oil filter housing
  225
• 3.4 Removing and installing pressure control valve for crankcase breather system
  227
• 3.7 Checking oil pressure and oil pressure switch
  230
• Cooling
  233
• 1 Parts of cooling system
  233
• 1.1 Assembly overview - radiator
  234
• 1.2 Assembly overview - fan support
  235
• 1.3 Assembly overview - thermostat and coolant pump
  236
• 1.4 Coolant hose connection diagram
  238
• 1.5 Removing and installing fan support
  241
• 1.6 Draining and adding coolant
  241
• 1.7 Removing and installing radiator
  245
• 1.8 Removing and installing coolant pump
  246
• 1.9 Removing and installing thermostat
  248
• 1.10 Assembly overview - pump for exhaust gas recirculation cooler V400
  249
• 1.11 Removing and installing pump for exhaust gas recirculation cooler V400
  250
• 1.12 Assembly overview - coolant pipes
  250
• 1.13 Removing and installing coolant pipes
  253
• 1.14 Removing and installing coolant temperature sender G62
  266
• 1.15 Checking cooling system for leaks
  267
• 1.16 Checking coolant pump V36/fuel cooling pump V166
  269
• Fuel supply system
  271
• 1 Parts of fuel supply system
  271
• 1.1 Safety regulations for working on fuel supply
  271
• 1.2 Rules for cleanliness
  272
• 1.3 Procedure in event of misfuelling
  272
• 1.4 Assembly overview - fuel tank with attachments
  275
• 1.5 Emptying fuel tank
  277
• 1.6 Removing and installing fuel tank with attached components
  281
• 1.8 Assembly overview - fuel filter with fuel cooler
  286
• 1.9 Assembly overview - supplementary fuel pump V393
  288
• 1.10 Checking fuel pump
  290
• 1.11 Bleeding fuel system
  310
• 1.12 Checking for leaks in the fuel system
  310
• 1.13 Repairing accelerator mechanism
  311
• Turbocharging/supercharging
  312
• 1 Charge air system with turbocharger
  312
• 1.1 Rules for cleanliness
  312
• 1.2 Assembly overview - turbocharger (engine codes BKS, BUN)
  312
• 1.3 Removing and installing turbocharger (engine codes BKS, BUN)
  314
• 1.4 Assembly overview - turbocharger (engine codes CASA, CASB, CASC)
  317
• 1.5 Removing and installing turbocharger (engine codes CASA, CASB, CASC)
  319
• 1.6 Assembly overview - turbocharger (engine code CATA)
  324
• 1.7 Removing and installing turbocharger (engine code CATA)
  326
• 1.8 Removing and installing turbocharger 1 control unit J724
  333
• 1.9 Removing and installing parts of charge air cooling
  346
• 1.10 Assembly overview - parts of charge air cooling system, left side
  346
• 1.11 Assembly overview - parts of right charge air cooling
  347
• 1.12 Parts of charge air cooling (engine code CATA)
  348
• Mixture preparation - injection
  351
• 1 Repairing diesel direct injection system
  351
• 1.1 Safety precautions
  353
• 1.2 Rules for cleanliness and instructions for working on fuel system
  353
• 1.3 Schematic overview of fuel system (engine codes BKS, BUN)
  354
• 1.4 Assembly overview - fuel system (engine codes BKS, BUN)
  355
• 1.5 Assembly overview - intake manifold (engine codes BKS, BUN)
  357
• 1.6 Removing and installing upper part of intake manifold (engine codes BKS, BUN)
  359
• 1.8 Removing and installing lower part of intake manifold (engine codes BKS, BUN)
  375
• 1.9 Schematic overview of fuel system (engine codes CASA, CASB, CASC, CATA)
  381
• 1.10 Assembly overview - fuel system (engine codes CASA, CASB, CASC, CATA)
  384
• 1.11 Assembly overview - intake manifold (engine codes CASA, CASB, CASC, CATA)
  387
• 1.14 Removing and installing injectors (piezo injectors)
  396
• 1.15 Checking return flow rate of injectors (piezo injectors) with engine running
  402
• 1.16 Checking return flow rate of injectors (piezo injectors) at cranking speed
  404
• 1.17 Checking for injectors sticking open (piezo injectors)
  407
• 1.18 Installing high-pressure lines
  408
• 1.19 Checking pressure retention valve in fuel return line
  411
• 1.24 Assembly overview - high-pressure pump (engine codes BKS, BUN)
  431
• 1.25 Removing and installing high-pressure pump (engine codes BKS, BUN)
  436
• 1.28 Removing and installing fuel pressure regulating valve N276
  444
• 1.29 Removing and installing fuel pressure sender G247
  446
• 1.30 Assembly overview - air filter
  447
• 1.31 Removing and installing exhaust gas pressure sensor 1 G450
  449
• 2 Engine control unit
  451
• 2.1 Removing and installing engine control unit
  451
• 2.2 Removing and installing anti-theft engine control unit
  451
• Exhaust system
  455
• 1 Parts of the exhaust system
  455
• 1.3 Removing and installing starter catalytic converter
  460
• 1.4 Removing and installing particulate filter
  464
• 1.5 Removing and installing reduction catalytic converter
  467
• 1.6 Assembly overview - exhaust gas temperature regulator (engine code CATA)
  468
• 1.7 Silencer with mountings
  469
• 1.8 Replacing tail pipes
  470
• 1.9 Aligning exhaust system free of stress
  471
• 1.10 SCR system (selective catalytic reduction)
  472
• 1.11 Assembly overview - exhaust manifold with intermediate pipe
  494
• 1.12 Removing and installing left exhaust manifold
  495
• 1.13 Removing and installing right exhaust manifold
  498
• 1.14 Removing and installing intermediate pipe (left side)
  501
• 1.15 Removing and installing intermediate pipe (right side)
  502
• 2 Exhaust gas recirculation system (engine codes BKS, BUN)
  506
• 2.1 Assembly overview - exhaust gas recirculation system
  506
• 2.2 Checking mechanical exhaust gas recirculation valve
  508
• 2.3 Removing and installing mechanical exhaust gas recirculation valve
  508
• 2.4 Removing and installing exhaust gas recirculation cooler
  509
• 3 Exhaust gas recirculation (engine codes CASA, CASB, CASC)
  512
• 3.1 Assembly overview - exhaust gas recirculation system
  512
• 3.2 Removing and installing exhaust gas recirculation control motor V338
  514
• 3.3 Removing and installing exhaust gas recirculation cooler
  516
• 3.4 Removing and installing exhaust gas recirculation temperature sensor G98
  518
• 4 Exhaust gas recirculation (engine code CATA)
  520
• 4.1 Assembly overview - exhaust gas recirculation system
  520
• 4.2 Assembly overview - supplementary cooler for exhaust gas recirculation system
  522
• 4.3 Removing and installing exhaust gas recirculation control motor V338
  522
• 4.4 Removing and installing exhaust gas recirculation cooler
  524
• 4.6 Removing and installing exhaust gas recirculation temperature sensor G98
  530
• Glow plug system
  532
• 1 Checking glow plug system
  532
• 1.1 Assembly overview - Glow plugs, Hall sender, engine speed sender
  532
• 1.2 Characteristics of ceramic glow plugs
  533
• 1.3 Removing, installing and checking ceramic glow plugs
  533
• 1.4 Removing and installing glow plugs, engine code CATA
  535
• 1.5 Removing and installing metal glow plugs
  537
• 1.6 Checking metal glow plugs
  538
• 1.7 Removing and installing engine speed sender G28
  539
• 1.8 Removing and installing Hall sender G40
  540