Руководство Servicing 6-cylinder TDI engines DCPC, DEWA, DDVC, DDVB, DDVE, DDVF, DEWB, DHXA, DHXC, DCPE - Repair Manual

Repair Manual: Servicing 6-cylinder TDI engine, common rail (EA 897 Gen. II)
Engine: DCPC, DEWA, DDVC, DDVB, DDVE, DDVF, DEWB, DHXA, DHXC, DCPE
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
21 - Turbocharging/supercharging
23 - Mixture preparation - injection
26 - Exhaust system
28 - Glow plug system

Audi A4 2015 ->
Audi A5 2016 ->
Audi A6 2019 ->
Audi A7 Sportback 2018 ->
Audi A8 2018 ->
Audi Q5 2017 ->
Audi Q7 2016 ->
Audi Q8 2018 ->

00 - Technical data
1 Identification
1.1 Engine number/engine data
2 Safety precautions
2.1 Safety precautions when working on the fuel system
2.2 Safety precautions when working on vehicles with start/stop system
2.3 Safety precautions when using testers and measuring instruments during a road test
2.4 Safety precautions when working on the cooling system
2.5 Safety precautions when working on the exhaust system
2.6 Safety precautions when working on the SCR system
2.7 Safety precautions when working on the glow plug system
2.8 Safety precautions when working on the subframe
3 Repair instructions
3.1 Rules for cleanliness
3.2 General notes
3.3 General repair instructions
3.4 Foreign particles in engine
3.5 Contact corrosion
3.6 Routing and attachment of pipes, hoses and wiring
3.7 Installing radiators and condensers
3.8 Performing adaptions after renewing a component

10 - Removing and installing engine
1 Removing and installing engine
2 Assembly mountings
3 Engine cover panel
3.1 Removing and installing engine cover panel

13 - Crankshaft group
1 Cylinder block (pulley end)
1.1 Exploded view - cylinder block (pulley end)
1.2 Exploded view - sealing flange (pulley end)
1.3 Removing and installing poly V-belt
1.4 Removing and installing tensioner for poly V-belt
1.5 Removing and installing vibration damper
1.6 Removing and installing bracket for ancillaries
1.7 Removing and installing engine support
1.8 Renewing crankshaft oil seal (pulley end)
1.9 Removing and installing sealing flange (pulley end)
2 Cylinder block (gearbox end)
2.1 Exploded view - cylinder block (gearbox end)
2.2 Removing and installing drive plate
2.3 Renewing crankshaft oil seal (gearbox end)
3 Crankshaft
3.1 Exploded view - crankshaft
3.2 Crankshaft dimensions
3.3 Allocation of main bearing shells
3.4 Measuring axial clearance of crankshaft
3.5 Measuring radial clearance of crankshaft
3.6 Checking sender wheel
4 Balance shaft
4.1 Exploded view - balance shaft
4.2 Removing and installing balance shaft
4.3 Renewing roller bearings
5 Pistons and conrods
5.1 Exploded view - pistons and conrods
5.2 Removing and installing pistons
5.3 Measuring piston projection at TDC
5.4 Checking pistons and cylinder bores
5.5 Checking radial clearance of conrod bearings
15 - Cylinder head, valve gear
1 Timing chain cover
1.1 Exploded view - timing chain cover
1.2 Removing and installing timing chain cover
2 Chain drive
2.1 Exploded view - camshaft timing chains
2.2 Exploded view - drive chain for high-pressure pump
2.3 Exploded view - drive chain for oil pump
2.4 Exploded view - intermediate drive
2.5 Removing camshaft timing chain from camshafts
2.6 Removing and installing camshaft timing chain
2.7 Removing and installing drive chain for high-pressure pump
2.8 Installing intermediate drive
3 Cylinder head
3.1 Exploded view - cylinder head
3.2 Exploded view - cylinder head cover
3.3 Removing and installing cylinder head
3.4 Removing and installing cylinder head cover
3.5 Removing and installing seals for injectors
3.6 Checking compression
4 Valve gear
4.1 Exploded view - valve gear
4.2 Measuring axial clearance of camshaft
4.3 Measuring radial clearance of camshaft
4.4 Removing and installing camshaft
4.5 Removing and installing valve stem oil seals
5 Inlet and exhaust valves
5.1 Machining valve seats
5.2 Checking valve guides
5.3 Checking valves
5.4 Valve dimensions

17 - Lubrication
1 Sump/oil pump
1.1 Exploded view - sump/oil pump
1.2 Engine oil
1.3 Removing and installing sump (bottom section)
1.4 Removing and installing sump (top section)
1.5 Removing and installing oil pump
1.6 Removing and installing oil level and oil temperature sender G266
2 Engine oil cooler
2.1 Exploded view - engine oil cooler
2.2 Removing and installing engine oil cooler
2.3 Removing and installing temperature regulator for engine oil cooler
3 Crankcase breather
3.1 Exploded view - crankcase breather system
3.2 Removing and installing oil separator
4 Oil filter/oil pressure switches
4.1 Exploded view - oil filter
4.2 Removing and installing oil filter housing
4.3 Removing and installing oil pressure sender G10
4.4 Checking oil pressure
4.5 Removing and installing valve for oil pressure control N428
4.6 Removing and installing oil temperature sender 2 G664

19 - Cooling
1 Cooling system/coolant
1.1 Connection diagram - coolant hoses
1.2 Checking cooling system for leaks
1.3 Draining and filling cooling system
2 Coolant pump/thermostat assembly
2.1 Exploded view - coolant pump
2.2 Exploded view - electric coolant pump
2.3 Exploded view - thermostat
2.4 Exploded view - coolant temperature senders
2.5 Removing and installing electric coolant pump
2.6 Removing and installing coolant pump
2.7 Removing and installing thermostat
2.8 Removing and installing thermostat housing
2.9 Removing and installing coolant temperature sender G62
2.10 Removing and installing temperature sender for engine temperature regulation G694
2.11 Removing and installing coolant valves
3 Coolant pipes
4 Radiator/radiator fans

21 - Turbocharging/supercharging
1 Turbocharger
1.1 Exploded view - turbocharger
1.2 Removing and installing turbocharger
2 Charge air system
2.1 Exploded view - charge air system
2.2 Exploded view - hose connections for charge air system
2.3 Removing and installing charge air cooler
2.4 Removing and installing charge pressure sender G31
2.5 Removing and installing charge air temperature sender
2.6 Checking charge air system for leaks

23 - Mixture preparation - injection
1 Injection system
1.1 Overview - fuel system
1.2 Overview of fitting locations - injection system
1.3 Filling and bleeding fuel system
1.4 Checking fuel system for leaks
2 Vacuum system
2.1 Connection diagram - vacuum system
2.2 Checking vacuum system
3 Air cleaner
4 Intake manifold
4.1 Exploded view - intake manifold
4.2 Removing and installing intake manifold (top section)
4.3 Removing and installing intake manifold (bottom section)
4.4 Removing and installing intake manifold flap motor V157
4.5 Removing and installing throttle valve module J338
5 Injectors/high-pressure reservoir (rail)
5.1 Exploded view - injectors
5.2 Checking injectors
5.3 Performing adaption of correction values for injectors
5.4 Checking for injectors sticking open
5.5 Checking return flow rate of injectors with engine running
5.6 Checking return flow rate of injectors at starter cranking speed
5.7 Checking pressure retention valve in fuel return line
5.8 Removing and installing injectors
5.9 Installing high-pressure pipes
5.10 Removing and installing high-pressure reservoir (rail)
6 Senders and sensors
6.1 Removing and installing air mass meter G70
6.2 Removing and installing fuel temperature sender G81
6.3 Removing and installing fuel pressure sender G247
6.4 Removing and installing fuel pressure sender for low pressure G410
6.5 Checking fuel pressure regulating valve N276
6.6 Removing and installing fuel pressure regulating valve N276
6.7 Removing and installing pressure differential sender G505
7 High-pressure pump
7.1 Exploded view - high-pressure pump
7.2 Removing and installing high-pressure pump
8 Lambda probe
8.1 Exploded view - Lambda probe
8.2 Removing and installing Lambda probe
8.3 Removing and installing NOx senders
8.4 Removing and installing particulate sensor G784
9 Engine control unit

26 - Exhaust system
1 Exhaust pipes/silencers
1.1 Exploded view - silencers
1.2 Removing and installing front exhaust pipe
1.3 Separating exhaust pipes/silencers
1.4 Removing and installing silencers
1.5 Stress-free alignment of exhaust system
1.6 Checking exhaust system for leaks
2 Emission control system
2.1 Exploded view - emission control system
2.2 Removing and installing emission control module
2.3 Removing and installing trap catalytic converter
2.4 Removing and installing exhaust flap control unit J883
3 SCR (selective catalytic reduction) system
3.1 Exploded view - reducing agent tank
3.2 Exploded view - reducing agent supply line
3.3 Releasing pressure in SCR system
3.4 Draining reducing agent tank
3.5 Removing and installing reducing agent tank
3.6 Removing and installing injector for reducing agent N474
3.7 Removing and installing control unit for reducing agent metering system J880
4 Exhaust gas temperature control
4.1 Exploded view - exhaust gas temperature control
4.2 Removing and installing exhaust gas temperature sender 1 G235
4.3 Removing and installing exhaust gas temperature sender 2 G448
4.4 Removing and installing exhaust gas temperature sender 3 G495
4.5 Removing and installing exhaust gas temperature sender 4 G648
5 Exhaust gas recirculation
5.1 Exploded view - exhaust gas recirculation system
5.2 Removing and installing exhaust gas recirculation cooler
5.3 Removing and installing exhaust gas recirculation temperature sensor G98
5.4 Removing and installing pressure sender for exhaust gas recirculation G691
6 Exhaust manifold
6.1 Exploded view - exhaust manifold
6.2 Removing and installing exhaust manifold

28 - Glow plug system
1 Glow plug system
1.1 Exploded view - glow plug system
1.2 Removing and installing glow plug
1.3 Removing and installing automatic glow period control unit J179
1.4 Removing and installing Hall sender G40
1.5 Removing and installing engine speed sender G28