6-cylinder injection engine

Kapitelübersicht

• Technical data
  1
• 1 Engine number
  1
• 2 Engine data
  2
• Removing and installing engine
  3
• 1 Removing and installing engine
  3
• 1.1 Removing engine
  4
• 1.2 Securing engine on engine and gearbox support VAS 6095
  10
• 1.3 Installing engine
  11
• 1.4 Specified torques for assembly mounting
  13
• Crankshaft group
  15
• 1 Dismantling and assembling engine
  15
• 1.1 Part I: Assembly overview - chain drive
  17
• 1.2 Part II: Assembly overview - crankshaft drive
  19
• 1.3 Removing and installing vibration damper
  20
• 1.4 Removing and installing poly V-belt
  22
• 2 Sealing flanges and flywheel
  24
• 2.1 Assembly overview - sealing flange
  24
• 2.2 Removing and installing crankshaft seal on gearbox side
  25
• 2.3 Renewing crankshaft sealing flange -vibration damper side-
  26
• 2.4 Removing and installing flywheel
  28
• 2.5 Removing and installing drive plate
  29
• 3 Crankshaft
  31
• 3.1 Assembly overview - crankshaft
  31
• 3.2 Allocation of main bearing shells
  32
• 3.3 Fitting sender wheel to crankshaft
  36
• 3.4 Pulling needle bearing out of and driving into crankshaft
  37
• 4 Pistons and conrods
  40
• 4.1 Assembly overview - pistons and conrods
  40
• 4.2 Checking pistons, piston rings and cylinder bores
  42
• 4.3 Installing piston
  43
• 4.4 Piston and cylinder dimensions
  44
• Cylinder head, valve gear
  45
• 1 Cylinder head
  45
• 1.1 Assembly overview - cylinder head
  45
• 1.2 Removing and installing cylinder head
  48
• 1.3 Assembly overview - cover
  56
• 1.4 Checking valve timing
  58
• 1.5 Removing and installing camshaft adjuster
  61
• 1.6 Removing and installing camshaft timing chain and intermediate shaft drive chain
  68
• 1.7 Removing and installing cylinder head cover
  79
• 1.8 Checking compression
  80
• 2 Valve gear
  83
• 2.1 Assembly overview
  83
• 2.2 Removing and installing camshafts
  85
• 2.3 Removing and installing camshaft control valves
  91
• 2.4 Valve stem seals
  95
• 2.5 Checking valve guides
  98
• 2.6 Reworking valve seats
  99
• Lubrication
  101
• 1 Parts of lubrication system
  101
• 1.1 Engine oil
  101
• 1.2 Assembly overview - sump
  101
• 1.3 Removing and installing oil sump
  104
• 1.4 Assembly overview - oil filter bracket
  106
• 1.5 Removing and installing oil filter bracket
  108
• 1.6 Assembly overview - oil pump
  109
• 1.7 Checking oil pressure and oil pressure switch
  111
• Cooling
  115
• 1 Removing and installing parts of cooling system
  115
• 1.1 Assembly overview - parts of cooling system, body side
  116
• 1.2 Assembly overview - cooling system, engine side (vehicles with manual gearbox)
  118
• 1.3 Assembly overview - cooling system, engine side (vehicles with DSG®)
  119
• 1.4 Assembly overview - thermostat housing
  121
• 1.5 Coolant hose schematic diagram
  123
• 1.6 Draining and filling coolant
  124
• 1.7 Removing and installing fan support with fans
  127
• 1.8 Removing and installing radiator
  128
• 1.9 Checking continued coolant circulation pump
  130
• 1.10 Removing and installing coolant pump
  131
• 1.11 Removing and installing thermostat housing
  134
• 1.12 Removing and installing thermostat
  137
• 1.13 Removing and installing coolant pipe
  138
• 1.14 Checking cooling system for leaks
  140
• Fuel supply system
  142
• 1 Safety precautions when working on fuel supply system
  142
• 2 Rules for cleanliness
  143
• 3 Fuel tank
  144
• 3.1 Assembly overview - fuel tank
  144
• 3.2 Emptying fuel tank
  146
• 3.3 Removing and installing fuel tank
  151
• 4 Repairing fuel supply
  155
• 4.1 Removing and installing fuel delivery unit
  155
• 4.2 Removing and installing fuel gauge sender 2 G169
  158
• 4.3 Removing and installing suction-jet pump
  160
• 4.4 Removing and installing fuel gauge sender G
  160
• 4.5 Assembly overview - fuel filter with attachments
  162
• 4.6 Removing and installing fuel filter
  163
• 4.7 Checking fuel pump
  164
• 4.8 Bleeding fuel system
  171
• 5 Electronic power control (EPC)
  174
• 5.1 Assembly overview - accelerator module
  174
• 5.2 Removing and installing accelerator module
  174
• 6 Activated charcoal filter system
  177
• 6.1 Assembly overview - activated charcoal filter system
  177
• 6.2 Checking fuel tank breather
  177
• Mixture preparation - injection
  180
• 1 Repairing injection system
  180
• 1.1 General notes on the injection system
  180
• 1.2 Technical data
  180
• 1.3 Assembly overview - intake manifold
  181
• 1.4 Removing and installing throttle valve module J338
  183
• 1.5 Removing and installing intake manifold
  184
• 1.6 Assembly overview - fuel rail
  186
• 1.7 Assembly overview - air filter
  188
• 1.8 Assembly overview - resonator with resonance air pipe
  189
• 1.9 Checking intake air preheating
  189
• 2 Checking components
  191
• 2.1 Checking vacuum unit for intake manifold flaps
  191
• 2.2 Checking injectors for leaks and quantity injected
  192
• 2.3 Checking fuel pressure regulator and holding pressure
  195
• 3 Engine control unit
  199
• 3.1 Removing and installing engine control unit
  199
• 3.2 Removing and installing anti-theft engine control unit
  199
• Exhaust system
  203
• 1 Exhaust manifold, front exhaust pipe with catalytic converters and Lambda probes
  203
• 1.2 Removing and installing Lambda probe G39 and Lambda probe 2 G108
  206
• 1.3 Removing and installing exhaust manifold
  208
• 1.4 Removing and installing front exhaust pipe with catalytic converters
  209
• 2 Silencer with mountings
  212
• 2.1 Assembly overview - silencers with mountings
  212
• 2.2 Checking exhaust flap
  213
• 2.3 Aligning exhaust system free of stress
  214
• 3 Secondary air system
  216
• 3.1 Function
  216
• 3.2 Assembly overview - secondary air system
  216
• 3.3 Removing and installing secondary air pump motor V101
  217
• 3.4 Checking combi-valve for secondary air system
  218
• 3.5 Removing and installing left combi-valve for secondary air
  218
• Ignition system
  219
• 1 Ignition system
  219
• 1.1 General notes on ignition system
  219
• 1.2 Safety precautions
  219
• 1.3 Assembly overview - parts of ignition system
  220
• 1.4 Removing and installing ignition coils with output stage
  221
• 1.5 Test data, spark plugs
  223