8-cyl. common rail engine (4.0 l, 4V, EA 898, turbocharger)

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety measures when working on fuel system
  1
• 1.2 Safety measures when working on vehicles with a start/stop system
  1
• 1.4 Safety precautions when working on the cooling system
  2
• 1.5 Safety precautions when working on exhaust system
  2
• 1.6 Safety precautions when working on the SCR system
  3
• 1.7 Safety regulations for working on glow plug system
  5
• 1.8 Safety precautions when working on subframe
  5
• 2 Identification
  6
• 2.1 Engine number/engine data
  6
• 3 Repair instructions
  8
• 3.1 Rules for cleanliness
  8
• 3.2 General information
  8
• 3.3 General repair notes
  9
• 3.4 Adapting learnt value for SCR system
  10
• 3.5 Foreign objects in engine
  10
• 3.6 Contact corrosion
  10
• 3.7 Routing and attachment of lines
  11
• 3.8 Fitting radiator and condensers
  11
• 3.9 Checking vacuum system
  11
• Removing and installing engine
  12
• 1 Removing and installing engine
  12
• 1.1 Removing engine
  12
• 1.2 Separating engine and gearbox
  34
• 1.3 Securing engine on engine and gearbox support
  40
• 1.4 Installing engine
  44
• 2 Assembly mountings
  52
• 2.1 Assembly overview – assembly mountings
  52
• 2.2 Removing and installing engine mounting
  56
• 2.3 Removing and installing gearbox mounting
  57
• 2.4 Supporting engine in installation position
  61
• 2.5 Removing and installing power unit mounting senders
  63
• 2.6 Removing and installing power unit mounting control unit J931
  64
• 2.7 Calibrating electrohydraulic engine mounting
  66
• 3 Engine cover panel
  67
• 3.1 Removing and installing engine cover
  67
• Crankshaft group
  69
• 1 Cylinder block (pulley end)
  69
• 1.1 Assembly overview - cylinder block (pulley end)
  69
• 1.2 Assembly overview - sealing flange, belt pulley end
  73
• 1.3 Removing and installing poly-V belt
  74
• 1.4 Removing and installing tensioner for poly V-belt
  75
• 1.5 Removing and installing bracket for ancillaries
  76
• 1.6 Removing and installing engine support
  78
• 1.7 Removing and installing pulley
  79
• 1.8 Renewing crankshaft oil seal - belt pulley end
  81
• 1.9 Removing and installing sealing flange on pulley end
  83
• 2 Cylinder block, gearbox end
  85
• 2.1 Assembly overview - cylinder block, gearbox end
  85
• 2.2 Removing and installing drive plate
  85
• 2.3 Renewing crankshaft oil seal (gearbox end)
  87
• 3 Crankshaft
  90
• 3.1 Assembly overview - crankshaft
  90
• 3.2 Crankshaft dimensions
  92
• 3.3 Allocation of main bearing shells
  92
• 3.4 Measuring axial clearance of crankshaft
  94
• 3.5 Measuring radial clearance of crankshaft
  95
• 3.6 Checking sender wheel
  95
• 4 Balancer shaft
  97
• 4.1 Assembly overview - balance shaft
  97
• 4.2 Removing and installing balance shaft
  97
• 5 Pistons and conrods
  99
• 5.1 Assembly overview - pistons and conrods
  99
• 5.2 Removing and installing pistons
  101
• 5.3 Measuring piston projection at TDC
  105
• 5.4 Checking pistons and cylinder bores
  107
• 5.5 Checking radial clearance of conrods
  109
• 5.6 Removing and installing oil spray jets
  109
• Cylinder head, valve gear
  111
• 1 Cylinder head
  111
• 1.1 Assembly overview - cylinder head
  111
• 1.2 Assembly overview - cylinder head cover
  113
• 1.3 Removing and installing cylinder head
  116
• 1.4 Removing and installing cylinder head cover
  129
• 1.5 Removing and installing injector seals
  138
• 1.6 Checking compression
  140
• 2 Cover for timing chain
  143
• 2.1 Assembly overview - cover for timing chain
  143
• 2.2 Removing and installing timing chain cover
  147
• 3 Chain drive
  157
• 3.1 Assembly overview - camshaft timing chains
  157
• 3.2 Assembly overview - drive chain for high pressure pump
  159
• 3.3 Assembly overview - drive chain for oil pump
  159
• 3.4 Removing and installing camshaft timing chain
  160
• 3.5 Removing camshaft timing chain from camshafts
  171
• 3.6 Removing and installing drive chain for high-pressure pump
  183
• 3.7 Installing intermediate drive
  185
• 4 Valve gear
  192
• 4.1 Assembly overview - valve gear
  192
• 4.2 Measuring axial play of camshaft
  200
• 4.3 Measuring radial play of camshaft
  202
• 4.4 Removing and installing camshaft
  202
• 4.5 Removing and installing cam actuators
  218
• 4.6 Removing and installing valve stem seals
  227
• 5 Inlet and exhaust valves
  237
• 5.1 Reworking valve seats
  237
• 5.2 Checking valve guides
  237
• 5.3 Checking valves
  238
• 5.4 Valve dimensions
  239
• Lubrication
  240
• 1 Sump, oil pump
  240
• 1.1 Assembly overview - sump/oil pump
  240
• 1.2 Engine oil:
  246
• 1.3 Removing and installing lower part of sump
  247
• 1.4 Removing and installing upper part of sump
  249
• 1.5 Removing and installing oil pump
  254
• 1.6 Removing and installing oil level and oil temperature sender G266
  256
• 2 Engine oil cooler
  258
• 2.1 Assembly overview - engine oil cooler
  258
• 2.2 Removing and installing engine oil cooler
  259
• 3 Crankcase ventilation
  262
• 3.1 Assembly overview - crankcase breather system
  262
• 3.2 Removing and installing crankcase breather module
  263
• 4 Oil filter, oil pressure switch
  265
• 4.1 Assembly overview - oil filter
  265
• 4.2 Removing and installingoil temperature sender G8
  265
• 4.3 Removing and installing oil pressure sender G10
  267
• 4.4 Checking oil pressure
  267
• 4.5 Removing and installing oil filter housing
  268
• 4.6 Removing and installing oil pressure regulating valve N428
  269
• Cooling
  270
• 1 Cooling system/coolant
  270
• 1.1 Connection diagram - coolant hoses
  270
• 1.2 Checking cooling system for leaks
  274
• 1.3 Draining and adding coolant
  277
• 2 Coolant pump, regulation of cooling system
  288
• 2.1 Assembly overview - coolant pump
  288
• 2.2 Assembly overview - electric coolant pump
  289
• 2.3 Assembly overview - thermostat
  290
• 2.4 Assembly overview – coolant valves
  292
• 2.5 Assembly overview - coolant temperature sender
  293
• 2.6 Removing and installing auxiliary pump for heating V488
  294
• 2.7 Removing and installing coolant pump
  296
• 2.8 Removing and installing map-controlled engine cooling thermostat F265
  296
• 2.9 Removing and installing coolant temperature sender G62/G83
  302
• 2.10 Removing and installing coolant temperature sender 3 G812
  303
• 2.11 Removing and installing coolant valves
  304
• 3 Coolant pipes
  308
• 3.1 Assembly overview - coolant pipes
  308
• 3.2 Removing and installing coolant pipes
  313
• 3.3 Removing and installing coolant pipes for gearbox
  328
• 4 Radiator, radiator fan
  330
• 4.1 Assembly overview - radiator/radiator fan
  330
• 4.2 Removing and installing radiator
  332
• 4.3 Removing and installing radiator fan V7 and radiator fan 2 V177
  337
• Turbocharging/supercharging
  338
• 1 Turbocharger
  338
• 1.1 Assembly overview - turbocharger
  338
• 1.2 Assembly overview - recirculation valve
  347
• 1.3 Removing and installing turbocharger
  348
• 1.4 Removing and installing recirculation valve
  356
• 1.5 Removing and installing sender 1 for turbocharger speed G688
  358
• 1.6 Removing and installing sender 2 for turbocharger speed G689
  359
• 1.7 Removing and installing temperature sender for engine cover panel G765
  360
• 2 Charge air system
  363
• 2.1 Assembly overview - charge air system
  363
• 2.2 Assembly overview - charge-air hose connections
  368
• 2.3 Removing and installing charge air cooler
  368
• 2.4 Checking charge air system for leaks
  371
• Mixture preparation - injection
  376
• 1 Injection system
  376
• 1.1 Schematic overview - fuel system
  376
• 1.2 Overview of fitting locations - injection system
  376
• 1.3 Filling/bleeding fuel system
  388
• 1.4 Checking fuel system for leaks
  389
• 2 Vacuum system
  390
• 2.1 Connection diagram - vacuum system
  390
• 2.2 Checking vacuum system
  391
• 3 Injectors/high-pressure accumulator (rail)
  393
• 3.1 Assembly overview - injectors
  393
• 3.2 Testing injectors
  397
• 3.3 Adapting correction values for injectors
  398
• 3.4 Checking return flow rate of injectors with engine running
  399
• 3.5 Checking return flow rate of injectors at starter speed
  403
• 3.6 Testing jammed-open injectors
  406
• 3.7 Checking restrictor in fuel return line
  410
• 3.8 Removing and installing injectors
  411
• 3.9 Removing and installing high-pressure lines
  419
• 3.10 Removing and installing fuel rail
  421
• 4 Air filter
  427
• 4.1 Assembly overview - air filter housing
  427
• 4.2 Removing and installing air filter housing
  429
• 5 Intake manifold
  432
• 5.1 Assembly overview – intake manifold
  432
• 5.2 Removing and installing intake manifold
  433
• 5.4 Removing and installing throttle valve module GX3/throttle valve module 2 GX4
  437
• 6 Senders and sensors
  439
• 6.2 Removing and installing actuator for structure-borne sound R214
  440
• 6.3 Removing and installing control unit for structure-borne sound J869
  441
• 6.4 Removing and installing fuel pressure regulating valve N276
  442
• 6.5 Checking fuel pressure regulating valve N276
  444
• 6.6 Removing and installing fuel pressure sender G247
  446
• 6.7 Removing and installing fuel pressure sender for low-pressure G410
  449
• 6.8 Removing and installing air mass meter G70/air mass meter 2 G246
  450
• 6.9 Removing and installing pressure differential sender G505
  451
• 6.10 Removing and installing intake manifold pressure sender G71
  452
• 2 G299
  452
• 6.12 Removing and installing fuel temperature sender G81
  453
• 7 Engine control unit
  455
• 7.1 Assembly overview – motor control unit
  455
• 7.2 Removing and installing engine control unit J623
  456
• 8 High-pressure pump
  457
• 8.1 Assembly overview - high-pressure pump
  457
• 8.2 Removing and installing high-pressure pump
  460
• 9 Lambda probe
  465
• 9.1 Assembly overview - Lambda probe
  465
• 9.2 Removing and installing Lambda probe
  467
• 9.3 Removing and installing NOx sender
  470
• 9.4 Removing and installing particle sensor G784
  474
• Exhaust system
  477
• 1 Exhaust pipes and silencers
  477
• 1.1 Assembly overview – silencers
  477
• 1.2 Removing and installing front exhaust pipe
  480
• 1.3 Removing and installing silencer
  482
• 1.4 Aligning exhaust system free of stress
  483
• 1.5 Checking exhaust system for leaks
  485
• 2 Emission control
  486
• 2.1 Assembly overview – emission control
  486
• 2.2 Removing and installing emission control module
  488
• 3 SCR system (selective catalytic reduction)
  494
• 3.1 Assembly overview - tank for reducing agent
  494
• 3.2 Assembly overview - reducing agent supply line
  496
• 3.3 Assembly overview - injector for reducing agent
  497
• 3.4 Assembly overview - control unit for reducing agent metering system
  498
• 3.5 Removing and installing reducing agent tank
  499
• 3.6 Removing and installing injector for reduction agent N474
  502
• 3.7 Draining reducing agent tank
  504
• 3.8 Removing and installing control unit for reducing agent metering system J880
  505
• 3.9 Removing and installing reducing agent quality sensor G849
  506
• 4 Exhaust gas temperature regulation
  507
• 4.1 Assembly overview – exhaust gas temperature regulation
  507
• 4.2 Removing and installing parts of exhaust gas temperature regulation
  509
• 5 Exhaust gas recirculation
  520
• 5.1 Assembly overview – exhaust gas recirculation
  520
• 5.2 Removing and installing exhaust gas recirculation cooler
  522
• 5.3 Removing and installing exhaust gas recirculation temperature sensor G98
  524
• 5.4 Removing and installing pressure sender for exhaust gas recirculation G691
  525
• 6 Exhaust manifold
  527
• 6.1 Assembly overview - exhaust manifold
  527
• 6.2 Removing and installing exhaust manifold
  531
• Glow plug system
  537
• 1 Glow plug system
  537
• 1.1 Assembly overview - glow plug system
  537
• 1.2 Removing and installing glow plug
  539
• 1.4 Removing and installing Hall sender G40
  545
• 1.5 Removing and installing engine speed sender G28
  545