Lesson 1 -- General

2.4L DuraTorq turbocharged diesel engine - overview

1 2

11

10
4

7773/01/ESG

1 Intake manifold 6 Oil cooler/oil filter

2 Cylinder head cover 7 Stiffening frame
3 Camshaft carrier 8 oil pan
4 Cylinder head 9 Fully electronic fuel injection pump
5 Water-cooled EGR cooler (not on 10 EGR connector
75 PS variant) 11 EGR valve

8 Service Training
 Lesson 1 -- General

Engine views

Longitudinal view

1
12 2

11 3
10

9 4

7773/03/ESG

1 Fuel injector 7 Piston

2 Rocker arm (intake) 8 Exhaust valve
3 Intake camshaft 9 Exhaust port
4 Intake port 10 Glow plug
5 Intake valve 11 Exhaust camshaft
6 Piston bowl 12 Rocker arm (exhaust)

10 Service Training
Lesson 1 -- General

Engine views (continued)

Cross-section

7773/85/ESG

Service Training 11
 Lesson 2 -- Cylinder head

Cylinder head and valve gear - overview

1 5

3
7

7773/09/ESG

1 Cylinder head cover 5 Exhaust camshaft

2 Rocker shaft with rocker arms (exhaust) 6 Intake camshaft
3 Rocker shaft with rocker arms (intake) 7 Cylinder head
4 Camshaft carrier 8 Cylinder head gasket

20 Service Training
 Lesson 2 -- Cylinder head

Rocker shafts and rocker arms

1
4 5 6
2

4
8

7773/11/ESG

1 Rocker shaft for exhaust valves 6 Helical spring

2 Rocker arms for exhaust valves 7 Driving chain connecting links
3 Oil bore 8 Timing marks
4 Rocker shaft for intake valves 9 Rocker shaft identification
5 Rocker arms for intake valves

22 Service Training
 Lesson 2 -- Cylinder head

Cylinder head gasket

1 2

7773/16/ESG

1 Cylinder head gasket

2 Thickness of cylinder head gasket
3 Locating bushings

30 Service Training
Lesson 3 -- Cylinder block and crank gear

Cylinder block and crank gear -- overview

1 5

7773/23/ESG

1 Oil pan 5 Bearing cap

2 Stiffening frame 6 Crankshaft
3 Cylinder block 7 Upper bearing shell
4 Lower bearing shell 8 Upper bearing shell No. three with flange

Service Training 41
Lesson 3 -- Cylinder block and crank gear

Connecting rods

D The connecting rods are available in three different
lengths. For identification, the large end and
bearing cap are marked with the corresponding
length code (H to J):
D An engine may only be fitted with connecting rods
of the same length.
D The connecting rod bearing shells have no retaining
lugs.

-- H = 149.74 mm D The projection on the connecting rod bearing cap

indicates the position in which it should be
-- I = 149.80 mm installed (facing the timing case).

D New bearing cap retaining bolts must be used for

-- J = 149.86 mm installation.

9
8

4
7
5

6
7773/26/ESG

1 Circlip 4 Large end 7 Retaining bolts

2 Piston pin 5 Projection 8 Length identification
3 Connecting rod 6 Bearing cap 9 Bearing shell

Service Training 45
 Lesson 3 -- Cylinder block and crank gear

Pistons

6
7

A B
2

D 4 E

7773/27/ESG

A Groove for upper compression ring 3 Oil control ring

B Groove for lower compression ring 4 Molybdenum-coated surfaces
C Groove for oil control ring 5 Piston skirt marking
D Piston without oil cooling bores (75/90 PS) 6 Engine cooling code
E Piston with oil cooling bores (120 PS) 7 Skirt diameter code
1 Upper compression ring
2 Lower compression ring

46 Service Training