8-cylinder diesel engine (4.2 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 motor
  3
• 1.3 Separating engine and gearbox
  20
• 1.4 Removing and installing engine supports
  27
• 1.5 Securing engine on engine and gearbox support
  31
• 1.6 Installing engine
  35
• 1.7 Supporting engine in installation position
  40
• 1.8 Removing and installing engine mounting
  42
• 2 Assembly mountings
  44
• 2.1 Assembly overview - assembly mountings
  44
• 2.2 Removing and installing left engine mounting
  45
• 2.3 Removing and installing right engine mounting
  47
• Crankshaft group
  49
• 1 Cylinder block (pulley end)
  49
• 1.1 Assembly overview - poly V-belt drive
  49
• 1.2 Removing and installing poly-V belt
  51
• 1.3 Removing and installing tensioning element for poly V-belt
  53
• 1.4 Removing and installing vibration damper
  53
• 1.5 Assembly overview - oil seal and sealing flange on pulley end
  55
• 1.6 Replacing oil seal for crankshaft at belt pulley end
  56
• 1.7 Removing and installing sealing flange on pulley end
  58
• 2 Cylinder block, gearbox end
  64
• 2.1 Assembly overview - drive plate
  64
• 2.2 Removing and installing drive plate
  64
• 2.3 Renewing oil seal for crankshaft at gearbox end
  65
• 2.4 Removing and installing engine speed sender G28
  68
• 3 Crankshaft
  69
• 3.1 Assembly overview - crankshaft
  69
• 3.2 Allocation of main bearing shells for new crankshaft
  71
• 3.4 Crankshaft dimensions
  75
• 3.5 Measuring axial clearance
  75
• 3.6 Measuring radial clearance
  76
• 4 Pistons and conrods
  77
• 4.1 Assembly overview - pistons and conrods
  77
• 4.2 Measuring piston projection at “TDC”
  82
• 4.3 Piston and cylinder dimensions
  85
• 4.4 Measuring radial clearance of conrods
  85
• 4.5 Allocation of conrod bearing shells
  85
• Cylinder head, valve gear
  86
• 1 Timing chain covers
  86
• 1.1 Assembly overview - timing chain covers
  86
• 1.2 Renewing oil seal for toothed belt pulley
  89
• 1.3 Removing and installing timing chain cover (left)
  91
• 1.4 Removing and installing timing chain cover (right)
  94
• 1.5 Removing and installing timing chain cover (bottom)
  97
• 2 Chain drive
  103
• 2.1 Assembly overview - camshaft timing chains
  103
• 2.2 Removing camshaft timing chains from camshafts
  105
• 2.3 Removing and installing camshaft timing chains
  117
• 2.4 Assembly overview - drive chain for valve gear
  129
• 2.5 Removing and installing drive chain for valve gear
  131
• 2.6 Assembly overview - drive chain for auxiliary drives
  132
• 2.7 Removing and installing drive chain for auxiliary drives
  132
• 2.8 Assembly overview - auxiliary drives
  134
• 2.9 Renewing oil seal for vane pump drive
  136
• 2.10 Removing and installing spur gear drive
  137
• 3 Cylinder head
  142
• 3.1 Assembly overview - cylinder head cover
  142
• 3.2 Removing and installing cylinder head cover
  144
• 3.3 Assembly overview - cylinder head
  146
• 3.4 Removing cylinder head
  149
• 3.5 Installing cylinder head
  152
• 3.6 Checking compression
  157
• 4 Valve gear
  159
• 4.1 Assembly overview - valve gear
  159
• 4.2 Measuring axial clearance of camshaft
  161
• 4.3 Measuring radial clearance of camshafts
  162
• 4.4 Removing and installing camshafts
  163
• 4.5 Checking hydraulic compensation elements
  170
• 4.6 Renewing valve stem seals with cylinder head installed
  172
• 4.7 Renewing valve stem seals with cylinder head removed
  177
• 4.8 Valve dimensions
  182
• 4.9 Reworking valve seats
  182
• 4.10 Checking valve guides
  182
• 4.11 Checking valves
  184
• Lubrication
  185
• 1 Engine oil:
  185
• 1.1 Oil capacities
  185
• 1.2 Using tester to check engine oil level
  185
• 2 Oil pump, lower part of sump, upper part of sump
  187
• 2.1 Assembly overview - oil pump, lower part of sump, upper part of sump
  187
• 2.2 Removing and installing oil level and oil temperature sender G266
  191
• 2.3 Removing and installing lower part of sump
  191
• 2.4 Removing and installing oil pump
  195
• 2.5 Removing and installing upper part of sump
  196
• 3.2 Removing and installing engine oil cooler
  203
• 3.3 Removing and installing oil filter housing
  205
• 3.4 Removing and installing pressure control valve for crankcase breather system
  207
• 3.6 Removing and installing oil pressure switch F22
  209
• 3.7 Removing and installing oil pressure switch for reduced oil pressure F378
  209
• 3.8 Removing and installingoil temperature sender G8
  210
• 3.9 Removing and installing oil pressure regulating valve N428
  210
• 3.10 Checking oil pressure
  212
• Cooling
  214
• 1 Cooling system
  214
• 1.1 Coolant hose connection diagram
  214
• 1.2 Locations
  215
• 1.3 Assembly overviews
  218
• 1.4 Assembly overview - pump for exhaust gas recirculation cooler V400
  221
• 1.5 Removing and installing pump for exhaust gas recirculation cooler V400
  222
• 2 Coolant
  224
• 2.1 Draining coolant
  224
• 2.2 Draining cooling system
  225
• 2.3 Filling with coolant
  227
• 2.4 Checking filling quality
  230
• 2.5 Checking cooling system for leaks
  231
• 3 Radiator module and radiator fan
  234
• 3.1 Assembly overview - radiator module and radiator fan
  234
• 3.2 Removing and installing radiator cowl and radiator fan
  234
• 3.3 Removing, installing and dismantling radiator module
  236
• 4 Coolant pump and thermostat
  242
• 4.1 Assembly overview - coolant pump and thermostat
  242
• 4.2 Removing and installing coolant pump
  243
• 4.3 Removing and installing thermostat
  247
• Turbocharging/supercharging
  250
• 1 Rules for cleanliness
  250
• 2 Turbocharger
  251
• 2.1 Assembly overview - turbocharger
  251
• 2.2 Removing and installing turbocharger on left
  254
• 2.3 Removing and installing turbocharger on right
  258
• 2.4 Removing and installing sender 1 for turbocharger speed G688
  261
• 2.5 Removing and installing sender 2 for turbocharger speed G689
  263
• 3 Charge air cooling
  266
• 3.1 Assembly overview - air ducts
  266
• 3.2 Assembly overview - charge air cooling
  267
• 3.3 Removing and installing charge air cooler
  268
• 3.5 Checking charge air system for leaks
  271
• 4 Vacuum system
  274
• 4.1 Overview - vacuum system
  274
• 4.2 Checking vacuum system
  274
• Mixture preparation - injection
  276
• 1 Safety precautions and rules for cleanliness
  276
• 1.1 Safety precautions
  276
• 1.2 Rules for cleanliness and instructions for working on fuel system
  277
• 2 Diesel direct injection system
  280
• 2.1 Schematic overview of the fuel system
  281
• 2.2 Assembly overview - fuel system
  283
• 2.3 Assembly overview - injectors and high-pressure lines
  287
• 2.4 Removing and installing injectors
  291
• 2.5 Testing injectors
  296
• 2.6 Checking and setting injector correction values
  296
• 2.7 Measuring return rate of injectors with engine running
  297
• 2.8 Measuring return rate of injection units at starter speed
  301
• 2.9 Testing jammed-open injectors
  303
• 2.10 Checking throttle in fuel return line
  305
• 2.11 Installing high-pressure lines
  306
• 2.12 Installing fuel return lines
  308
• 2.13 Assembly overview - toothed belt for high-pressure pump
  308
• 2.14 Removing and installing toothed belt for high-pressure pump
  309
• 2.15 Assembly overview - high-pressure pump
  317
• 2.16 Removing and installing high-pressure pump
  319
• 2.17 Checking fuel pressure regulating valve N276
  321
• 2.18 Removing and installing fuel pressure regulating valve N276
  322
• 2.19 Removing and installing fuel pressure sender G247
  324
• 2.20 Bleeding fuel system/filling tank with fuel for first time
  325
• 2.21 Checking fuel system for leaks
  326
• 3 Intake manifolds
  327
• 3.1 Assembly overview - intake manifolds
  327
• 3.2 Removing and installing intake manifold upper part
  329
• 3.3 Removing and installing lower part of intake manifold on right (cylinder bank 1)
  330
• 3.4 Removing and installing lower part of intake manifold on left (cylinder bank 2)
  331
• 4 Air filter
  333
• 4.1 Assembly overview - air filter
  333
• 4.2 Removing and installing lower part of air filter
  335
• 5 Engine control units
  337
• 5.1 Removing and installing engine control unit J623 and engine control unit 2 J624
  337
• Exhaust system
  340
• 1 Particulate filters and catalytic converters
  340
• 1.1 Assembly overview - particulate filters and catalytic converters
  340
• 1.2 Removing and installing particulate filter
  342
• 1.3 Removing and installing catalytic converters
  345
• 2 Silencers and exhaust manifolds
  348
• 2.1 Silencer
  348
• 2.2 Exhaust manifold
  354
• 3 Lambda probes, exhaust temperature and pressure senders
  359
• 3.1 Assembly overview - Lambda probes, exhaust temperature and pressure senders
  359
• 3.2 Removing and installing exhaust gas temperature sender 1 G235
  361
• 3.4 Removing and installing Lambda probe G39 with Lambda probe heater Z19
  363
• 3.5 Removing and installing Lambda probe 2 G108
  365
• 4 Exhaust gas recirculation
  375
• 4.1 Assembly overview - exhaust gas recirculation
  375
• 4.2 Removing and installing exhaust gas recirculation control motor V338/V339
  377
• 4.3 Assembly overview - exhaust gas recirculation cooler
  378
• 4.4 Removing and installing exhaust gas recirculation cooler
  380
• 4.5 Removing and installing exhaust gas recirculation temperature sensor G98
  382
• Glow plug system
  383
• 1 Removing and installing glow plugs
  383