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

Chapter overview

• Technical data
  1
• 1 Identification
  1
• 1.1 Engine number/engine data
  1
• 2 Safety information
  3
• 2.1 Safety precautions during work on fuel system
  3
• 2.2 Safety measures when working on vehicles with a start/stop system
  3
• 2.4 Safety precautions when working on the cooling system
  4
• 2.5 Safety precautions when working on the SCR system
  5
• 2.6 Safety precautions when working on exhaust system
  6
• 3 Repair instructions
  7
• 3.1 Rules for cleanliness
  7
• 3.2 Adapting learnt value for SCR system
  7
• 3.3 Foreign objects in engine
  7
• 3.4 Contact corrosion
  8
• 3.5 Routing and attachment of lines
  8
• 3.6 Fitting radiator and condensers
  8
• Removing and installing engine
  9
• 1 Removing and installing engine
  9
• 1.1 Removing engine
  9
• 1.2 Separating engine and gearbox
  25
• 1.3 Securing engine on engine and gearbox support
  35
• 1.4 Installing engine
  39
• 2 Assembly mountings
  44
• 2.1 Assembly overview – assembly mountings
  44
• 2.2 Removing and installing engine mounting
  46
• 2.3 Removing and installing engine mounting
  48
• 2.4 Supporting engine in installation position
  50
• 3 Engine cover panel
  53
• 3.1 Removing and installing engine cover
  53
• Crankshaft group
  54
• 1 Cylinder block (pulley end)
  54
• 1.1 Assembly overview - poly V-belt drive
  54
• 1.2 Assembly overview - sealing flange, belt pulley end
  58
• 1.3 Removing and installing poly-V belt
  64
• 1.4 Removing and installing tensioner for poly V-belt
  66
• 1.5 Removing and installing vibration damper
  66
• 1.6 Removing and installing bracket for ancillaries
  67
• 1.7 Renewing crankshaft oil seal - belt pulley end
  67
• 1.8 Removing and installing sealing flange on pulley end
  69
• 1.9 Removing and installing cover for sealing flange (pulley end)
  73
• 2 Cylinder block, gearbox end
  75
• 2.1 Assembly overview - drive plate
  75
• 2.2 Removing and installing drive plate
  75
• 2.3 Removing and installing sender wheel
  77
• 2.4 Checking sender wheel
  77
• 2.5 Renewing crankshaft oil seal (gearbox end)
  78
• 3 Crankshaft
  81
• 3.1 Assembly overview - crankshaft
  81
• 3.2 Crankshaft dimensions
  83
• 3.3 Allocation of main bearing shells
  84
• 3.4 Measuring axial clearance of crankshaft
  85
• 3.5 Measuring radial clearance of crankshaft
  86
• 4 Balancer shaft
  87
• 4.1 Assembly overview - balance shaft
  87
• 4.2 Renewing roller bearing for balance shaft
  87
• 4.3 Removing and installing balance shaft
  89
• 5 Pistons and conrods
  92
• 5.1 Assembly overview - pistons and conrods
  92
• 5.2 Measuring piston projection at “TDC”
  96
• 5.3 Checking pistons and cylinder bores
  98
• 5.4 Checking radial clearance of conrods
  100
• Cylinder head, valve gear
  101
• 1 Cylinder head
  101
• 1.1 Assembly overview - cylinder head
  101
• 1.2 Assembly overview - cylinder head cover
  105
• 1.3 Removing and installing cylinder head
  108
• 1.4 Removing and installing cylinder head cover
  115
• 1.5 Removing and installing injector seals
  121
• 1.6 Checking compression
  121
• 2 Cover for timing chain
  124
• 2.1 Assembly overview - cover for timing chain
  124
• 2.2 Removing and installing timing chain cover
  128
• 3 Chain drive
  137
• 3.1 Assembly overview - camshaft timing chains
  137
• 3.2 Assembly overview - drive chain for oil pump and high-pressure pump
  139
• 3.3 Removing and installing camshaft timing chain
  140
• 3.4 Removing camshaft timing chain from camshafts
  153
• 3.5 Removing and installing drive chain for oil pump and high-pressure pump
  164
• 4 Valve gear
  168
• 4.1 Assembly overview - valve gear
  168
• 4.2 Measuring axial play of camshaft
  171
• 4.3 Measuring radial play of camshaft
  172
• 4.4 Removing and installing camshaft
  173
• 4.5 Checking hydraulic compensation elements
  205
• 4.6 Removing and installing valve stem oil seals
  207
• 5 Inlet and exhaust valves
  217
• 5.1 Reworking valve seats
  217
• 5.2 Checking valve guides
  217
• 5.3 Checking valves
  218
• 5.4 Valve dimensions
  218
• Lubrication
  220
• 1 Sump, oil pump
  220
• 1.1 Assembly overview - sump/oil pump
  220
• 1.2 Engine oil:
  225
• 1.3 Removing and installing lower part of sump
  227
• 1.4 Removing and installing upper part of sump
  232
• 1.5 Removing and installing oil pump
  236
• 1.6 Removing and installing oil level and oil temperature sender
  238
• 2 Oil filter, oil pressure switch
  240
• 2.1 Assembly overview - oil filter housing, oil pressure switch
  240
• 2.2 Removing and installing oil filter housing
  242
• 2.3 Removing and installing oil pressure regulating valve N428
  244
• 2.4 Checking oil pressure and oil pressure switch
  244
• 2.5 Removing and installing oil pressure switch
  246
• 3 Engine oil cooler
  248
• 3.1 Assembly overview - engine oil cooler
  248
• 3.2 Removing and installing engine oil cooler
  249
• 3.3 Removing and installing mounting plate for engine oil cooler/coolant shut-off valve
  250
• 3.4 Removing and installing temperature regulator for engine oil cooler
  251
• Cooling
  253
• 1 Cooling system/coolant
  253
• 1.1 Connection diagram - coolant hoses
  253
• 1.2 Checking cooling system for leaks
  255
• 1.3 Draining and adding coolant
  257
• 1.4 Draining cooling system
  265
• 1.5 Checking filling quality
  267
• 2 Coolant pump, regulation of cooling system
  269
• 2.1 Assembly overview - coolant pump
  269
• 2.2 Assembly overview - coolant shut-off valve
  270
• 2.3 Assembly overview - coolant temperature sender
  270
• 2.4 Removing and installing coolant pump
  271
• 2.5 Removing and installing thermostat
  272
• 2.6 Removing and installing coolant temperature sender G62
  273
• 2.7 Removing and installing radiator outlet coolant temperature sender G83
  273
• 2.9 Removing and installing coolant shut-off valve
  276
• 3 Coolant pipes
  277
• 3.1 Assembly overview - coolant pipes
  277
• 3.2 Removing and installing coolant pipes
  281
• 4 Radiator, radiator fan
  291
• 4.1 Assembly overview - radiator/radiator fan
  291
• 4.2 Removing and installing radiator cowl with radiator fan
  292
• 4.3 Removing and installing radiator module
  293
• 4.4 Dismantling radiator module
  297
• Turbocharging/supercharging
  299
• 1 Turbocharger
  299
• 1.1 Assembly overview - turbocharger
  299
• 1.2 Removing and installing turbocharger
  302
• 1.3 Removing and installing turbocharger 1 control unit J724
  309
• 2 Charge air system
  324
• 2.1 Assembly overview - charge air system
  324
• 2.2 Assembly overview - charge-air hose connections
  325
• 2.3 Removing and installing charge air cooler
  327
• 2.4 Removing and installing charge pressure sender G31
  329
• 2.5 Removing and installing air intake pipe
  330
• 2.6 Checking charge air system for leaks
  333
• Mixture preparation - injection
  341
• 1 Injection system
  341
• 1.1 Schematic overview - fuel system
  341
• 1.2 Overview of fitting locations - injection system
  344
• 1.3 Filling/bleeding fuel system
  349
• 1.4 Checking fuel system for leaks
  349
• 2 Vacuum system
  350
• 2.1 Connection diagram – vacuum system
  350
• 3 Injectors/high-pressure accumulator (rail)
  351
• 3.1 Assembly overview - injectors
  351
• 3.2 Adapting correction values for injectors
  354
• 3.3 Checking return flow rate of injectors with engine running
  354
• 3.4 Checking return flow rate of injectors at starter speed
  356
• 3.5 Checking open injectors
  359
• 3.6 Checking restrictor in fuel return line
  361
• 3.7 Removing and installing injectors
  362
• 3.8 Removing and installing high-pressure lines
  367
• 4 Air filter
  370
• 4.1 Assembly overview - air filter housing
  370
• 4.2 Removing and installing air filter housing
  370
• 5 Intake manifold
  373
• 5.1 Assembly overview – intake manifold
  373
• 5.2 Removing and installing intake manifold
  376
• 5.3 Removing and installing intake manifold flap motor V157
  381
• 5.4 Removing and installing throttle valve module J338
  383
• 6 Senders and sensors
  385
• 6.1 Removing and installing fuel pressure regulating valve N276
  385
• 6.2 Removing and installing fuel pressure sender G247
  387
• 6.3 Removing and installing air mass meter G70
  390
• 6.4 Removing and installing pressure differential sender G505
  391
• 6.5 Removing and installing NOx sender G295
  392
• 6.6 Removing and installing NOx sender 2 G687
  393
• 6.7 Removing and installing particle sensor G784
  394
• 7 Engine control unit
  396
• 7.1 Removing and installing engine (motor) control unit J623 with protective housing
  396
• 8 High-pressure pump
  398
• 8.1 Assembly overview - high-pressure pump
  398
• 8.2 Removing and installing high-pressure pump
  400
• 9 Lambda probe
  407
• 9.1 Assembly overview - Lambda probe
  407
• 9.2 Removing and installing Lambda probe 1 before catalytic converter GX10
  413
• Exhaust system
  415
• 1 Exhaust pipes and silencers
  415
• 1.1 Assembly overview – silencers
  415
• 1.2 Replacing tail pipes
  417
• 1.3 Aligning exhaust system free of stress
  418
• 1.4 Checking exhaust system for leaks
  419
• 2 Emission control
  420
• 2.1 Assembly overview – emission control
  420
• 2.2 Removing and installing catalytic converter
  427
• 2.3 Removing and installing particulate filter
  429
• 2.4 Removing and installing reduction catalytic converter
  433
• 3 SCR system (selective catalytic reduction)
  434
• 3.1 Assembly overview – reducing agent tank
  434
• 3.2 Assembly overview - delivery module for reducing agent
  434
• 3.3 Assembly overview - reducing agent supply line
  436
• 3.4 Draining reducing agent tank
  438
• 3.5 Removing and installing reducing agent tank
  442
• 3.6 Removing and installing reducing agent supply line
  445
• 3.7 Removing and installing injector for reduction agent N474
  448
• 3.8 Removing and installing pump for reducing agent V437
  452
• 3.9 Removing and installing heater element (heater cup)
  454
• 3.10 Disconnecting reducing agent supply line
  457
• 4 Exhaust manifold
  461
• 4.1 Assembly overview - exhaust manifold
  461
• 4.2 Removing and installing exhaust manifold
  462
• 5 Exhaust gas temperature regulation
  467
• 5.1 Assembly overview – exhaust gas temperature regulation
  467
• 5.2 Removing and installing parts of exhaust gas temperature regulation
  474
• 6 Exhaust gas recirculation
  483
• 6.1 Assembly overview – exhaust gas recirculation
  483
• 6.2 Removing and installing exhaust gas recirculation control motor V338
  487
• 6.3 Removing and installing exhaust gas recirculation cooler
  488
• 6.4 Removing and installing exhaust gas recirculation temperature sensor G98
  489
• Glow plug system
  491
• 1 Glow plug system
  491
• 1.1 Assembly overview – glow plug system
  491
• 1.2 Removing and installing glow plug
  491
• 1.3 Removing and installing engine speed sender G28
  493
• 1.4 Removing and installing Hall sender G40
  493