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 Engine and gearbox
  3
• 1.1 Removing and installing engine cover
  3
• 1.2 Removing engine
  3
• 1.3 Separating engine and gearbox
  17
• 1.4 Removing engine from scissor-type assembly platform VAS 6131
  24
• 1.5 Securing engine to assembly stand
  24
• 1.6 Notes on installing
  26
• 1.7 Supporting engine in installation position
  28
• 2 Assembly mountings
  31
• 2.1 Assembly overview - assembly mountings
  31
• 2.2 Removing and installing engine mounting
  32
• 2.3 Removing and installing engine mounting
  33
• Crankshaft group
  35
• 1 Dismantling and assembling engine
  35
• 1.1 Assembly overview - poly V-belt drive
  36
• 1.2 Removing and installing poly-V belt
  40
• 1.3 Renewing crankshaft oil seal – belt pulley end
  42
• 1.4 Removing and installing front sealing flange
  43
• 1.5 Assembly overview - drive plate
  46
• 1.6 Removing and installing drive plate
  48
• 1.7 Renewing crankshaft oil seal – timing chain end
  48
• 1.8 Assembly overview - timing chain covers
  50
• 1.9 Removing and installing timing chain cover (left)
  52
• 1.10 Removing and installing timing chain cover (right)
  54
• 1.11 Removing and installing timing chain cover (bottom)
  57
• 1.12 Assembly overview - balance shaft
  63
• 1.13 Removing and installing balance shaft
  63
• 2 Chain drive
  67
• 2.1 Assembly overview - drive chain for valve gear
  67
• 2.2 Removing and installing drive chain for valve gear
  68
• 2.3 Assembly overview - chain for balance shaft and oil pump
  69
• 2.4 Removing and installing chain for balance shaft and oil pump
  71
• 3 Removing and installing crankshaft
  75
• 3.1 Assembly overview - crankshaft
  75
• 3.2 Crankshaft dimensions
  77
• 3.3 Measuring axial clearance
  77
• 3.4 Measuring radial clearance
  78
• 4 Pistons and conrods
  79
• 4.1 Assembly overview - pistons and conrods
  79
• 4.2 Checking piston projection at TDC
  82
• 4.3 Piston and cylinder dimensions
  84
• 4.4 Checking radial clearance of conrods
  84
• Cylinder head, valve gear
  85
• 1 Cylinder head
  85
• 1.1 Assembly overview - cylinder head
  85
• 1.2 Assembly overview - cylinder head cover
  88
• 1.3 Removing and installing cylinder head cover
  90
• 1.4 Removing and installing cylinder head
  95
• 1.5 Checking compression
  102
• 1.6 Assembly overview - vacuum pump
  103
• 2 Assembly overview - valve gear
  105
• 2.1 Checking axial clearance of camshafts
  106
• 2.2 Renewing camshaft oil seal
  107
• 2.3 Removing and installing camshafts
  110
• 2.4 Renewing valve stem seals
  116
• 2.5 Checking hydraulic valve compensation elements
  120
• 2.6 Valve dimensions
  121
• 2.7 Checking valve guides
  121
• 3 Chain drive for camshafts
  123
• 3.1 Camshaft timing chains
  123
• Lubrication
  142
• 1 Engine oil:
  142
• 1.1 Oil capacities
  142
• 1.2 Using tester to check engine oil level
  142
• 2 Parts of lubrication system
  144
• 2.1 Assembly overview - oil pump, lower part of sump
  144
• 2.2 Removing and installing lower part of sump
  146
• 2.3 Removing and installing oil pump
  149
• 2.4 Assembly overview - upper part of sump
  150
• 2.5 Removing and installing oil pressure switch F22
  152
• 2.6 Removing and installing oil pressure regulating valve N428
  152
• 2.7 Removing and installing upper part of sump
  153
• 3 Engine oil cooler, pressure control valve and oil filter housing
  156
• 3.1 Assembly overview - engine oil cooler, pressure control valve and oil filter housing
  156
• 3.2 Removing and installing engine oil cooler
  157
• 3.3 Removing and installing oil filter housing
  158
• 3.7 Checking oil pressure and oil pressure switch
  161
• Cooling
  164
• 1 Cooling system
  164
• 1.1 Coolant hose connection diagram
  164
• 1.2 Assembly overview - coolant pipes
  166
• 1.3 Removing and installing coolant pipes
  170
• 1.4 Removing and installing coolant temperature sender G62
  183
• 1.5 Removing and installing radiator outlet coolant temperature sender G83
  184
• 1.6 Assembly overview - pump for exhaust gas recirculation cooler V400
  185
• 1.7 Removing and installing pump for exhaust gas recirculation cooler V400
  186
• 2 Coolant
  187
• 2.1 Draining coolant
  187
• 2.2 Draining cooling system
  188
• 2.3 Filling with coolant
  189
• 2.4 Checking filling quality
  192
• 2.5 Checking cooling system for leaks
  193
• 3 Radiator module and radiator fan
  196
• 3.1 Assembly overview - radiator module and radiator fan
  196
• 3.2 Removing and installing radiator cowl and radiator fan
  197
• 3.3 Removing, installing and dismantling radiator module
  197
• 4 Coolant pump and thermostat
  203
• 4.2 Assembly overview - coolant pump and thermostat (engine code CATA)
  204
• 4.3 Removing and installing coolant pump
  204
• 4.5 Removing and installing thermostat with union (engine code CATA)
  206
• Turbocharging/supercharging
  209
• 1 Turbocharger
  209
• 1.1 Rules for cleanliness
  209
• 1.2 Assembly overview - turbocharger
  209
• 1.3 Removing and installing turbocharger
  212
• 1.4 Removing and installing turbocharger 1 control unit J724
  217
• 2 Charge air cooling
  229
• 2.1 Removing and installing parts of charge air cooling
  229
• 2.2 Charge air cooler parts
  229
• 2.3 Checking charge air system for leaks
  230
• Mixture preparation - injection
  233
• 1 Safety precautions and rules for cleanliness
  233
• 1.1 Safety precautions
  233
• 1.2 Rules for cleanliness and instructions for working on fuel system
  234
• 2 Diesel direct injection system
  236
• 2.1 Schematic overview of the fuel system
  236
• 2.2 Assembly overview - fuel system
  239
• 2.3 Removing and installing injectors (piezo injectors)
  242
• 2.4 Installing high-pressure lines
  247
• 2.5 Testing injectors
  249
• 2.6 Checking and setting injector correction values
  249
• 2.7 Checking return flow rate of injectors (piezo injectors) with engine running
  250
• 2.8 Checking return flow rate of injectors (piezo injectors) at cranking speed
  251
• 2.9 Checking for injectors sticking open (piezo injectors)
  253
• 2.10 Checking throttle in fuel return line
  255
• 2.11 Assembly overview - toothed belt for high-pressure pump
  255
• 2.12 Removing and installing toothed belt for high-pressure pump
  257
• 2.13 Assembly overview - high-pressure pump
  264
• 2.14 Removing and installing high-pressure pump
  266
• 2.15 Removing and installing fuel pressure regulating valve N276
  267
• 2.16 Checking fuel pressure regulating valve N276
  269
• 2.17 Removing and installing fuel pressure sender G247
  270
• 2.18 Bleeding fuel system/filling tank with fuel for first time
  271
• 2.19 Checking fuel system for leaks
  272
• 3 Intake manifolds
  273
• 3.1 Assembly overview - intake manifold
  273
• 3.2 Removing and installing intake manifold upper part
  274
• 3.3 Removing and installing lower parts of intake manifold
  276
• 4 Air filter
  281
• 4.1 Assembly overview - air filter
  281
• 5 Engine (motor) control unit
  282
• 5.1 Removing and installing engine control unit J623
  282
• Exhaust system
  284
• 1 Parts of the exhaust system
  284
• 1.3 Removing and installing starter catalytic converter
  288
• 1.4 Removing and installing particulate filter
  291
• 1.5 Removing and installing reduction catalytic converter
  294
• 1.7 Assembly overview - exhaust gas temperature regulation (engine code CATA)
  300
• 1.8 Silencer with mountings
  311
• 1.9 SCR system (selective catalytic reduction)
  312
• 1.10 Replacing tail pipes
  330
• 1.11 Aligning exhaust system free of stress
  330
• 1.12 Checking exhaust system for leaks
  331
• 1.13 Assembly overview - exhaust manifold with intermediate pipe
  331
• 1.14 Removing and installing left exhaust manifold
  332
• 1.15 Removing and installing right exhaust manifold
  334
• 1.16 Removing and installing intermediate pipe (left side)
  336
• 1.17 Removing and installing intermediate pipe (right side)
  338
• 2 Exhaust gas temperature regulation (engine codes CASA and CASD)
  340
• 2.1 Assembly overview - exhaust gas recirculation system
  340
• 2.2 Removing and installing exhaust gas recirculation control motor V338
  341
• 2.3 Removing and installing exhaust gas recirculation cooler
  342
• 2.4 Removing and installing exhaust gas recirculation temperature sensor G98
  345
• 3 Exhaust gas recirculation (engine code CATA)
  347
• 3.1 Assembly overview - exhaust gas recirculation system
  347
• 3.2 Assembly overview - supplementary cooler for exhaust gas recirculation system
  349
• 3.3 Removing and installing exhaust gas recirculation control motor V338
  349
• 3.4 Removing and installing exhaust gas recirculation cooler
  350
• 3.6 Removing and installing exhaust gas recirculation temperature sensor G98
  355
• Glow plug system
  356
• 1 Glow plug system
  356
• 1.1 Assembly overview - Glow plugs, Hall sender, engine speed sender
  356
• 1.2 Removing and installing glow plugs
  356
• 1.3 Removing and installing engine speed sender G28
  358
• 1.4 Removing and installing Hall sender G40
  359