6-cyl. direct injection (3.0 l, 4V, EA 839, turbocharger)

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety precautions when working on high-voltage system
  1
• 1.2 Safety precautions when working in the vicinity of high-voltage components
  2
• 1.3 Safety regulations for working on fuel supply
  2
• 1.4 Safety measures when working on vehicles with a start/stop system
  3
• 1.6 Safety precautions when working on subframe
  3
• 1.7 Safety precautions when working on ignition system
  3
• 1.8 Safety precautions when working on the cooling system
  4
• 1.9 Safety precautions when working on exhaust system
  4
• 2 Identification
  5
• 2.1 Engine number/engine data
  5
• 2.2 Numbering of cylinders
  6
• 3 Repair instructions
  7
• 3.1 Rules for cleanliness
  7
• 3.2 Foreign objects in engine
  7
• 3.3 Contact corrosion
  7
• 3.4 Routing and attachment of lines
  8
• 3.5 Fitting radiator and condensers
  8
• 3.6 Checking fuel system for leaks
  8
• 4 Hazard classification of high-voltage system
  9
• Removing and installing engine
  16
• 1 Removing and installing engine
  16
• 1.1 Removing engine
  16
• 1.2 Separating engine and gearbox
  49
• 1.3 Removing engine from scissor-type assembly platform
  57
• 1.4 Securing engine on engine and gearbox support
  58
• 1.5 Installing engine
  61
• 2 Assembly mountings
  68
• 2.1 Assembly overview – assembly mountings
  68
• 2.2 Supporting engine in installation position
  74
• 2.3 Removing and installing engine mounting
  75
• 2.4 Removing and installing gearbox mounting
  79
• 2.5 Removing and installing power unit mounting senders
  84
• 2.6 Calibrating electrohydraulic engine mounting
  84
• 3 Engine cover panel
  86
• 3.1 Removing and installing engine cover
  86
• Crankshaft group
  87
• 1 Cylinder block (pulley end)
  87
• 1.1 Assembly overview - cylinder block (pulley end)
  87
• 1.2 Assembly overview - sealing flange, belt pulley end
  93
• 1.3 Removing and installing poly-V belt
  95
• 1.4 Removing and installing tensioner for poly V-belt
  99
• 1.5 Removing and installing vibration damper
  101
• 1.6 Removing and installing bracket for ancillaries
  106
• 1.7 Removing and installing engine support
  107
• 1.8 Renewing crankshaft oil seal - belt pulley end
  108
• 1.9 Removing and installing sealing flange on pulley end
  110
• 2 Cylinder block, gearbox end
  115
• 2.1 Assembly overview - cylinder block, gearbox end
  115
• 2.2 Removing and installing drive plate
  115
• 2.3 Renewing crankshaft oil seal (gearbox end)
  117
• 3 Crankshaft
  120
• 3.1 Assembly overview - crankshaft
  120
• 3.2 Crankshaft dimensions
  123
• 3.3 Allocation of main bearing shells
  123
• 3.4 Measuring axial clearance of crankshaft
  125
• 3.5 Measuring radial clearance of crankshaft
  126
• 3.6 Removing and installing sender wheel
  126
• 3.7 Checking sender wheel
  127
• 3.8 Removing and installing crankshaft
  128
• 4 Balancer shaft
  132
• 4.1 Assembly overview - balance shaft
  132
• 4.2 Removing and installing balance shaft
  132
• 5 Pistons and conrods
  138
• 5.1 Assembly overview - pistons and conrods
  138
• 5.2 Removing and installing pistons
  143
• 5.3 Removing and installing oil spray jets
  147
• 5.4 Checking pistons and cylinder bores
  148
• 5.5 Checking radial clearance of conrods
  150
• Cylinder head, valve gear
  152
• 1 Cylinder head
  152
• 1.1 Assembly overview - cylinder head
  152
• 1.2 Assembly overview - camshaft housing
  156
• 1.3 Removing and installing cylinder head
  159
• 1.4 Removing and installing camshaft housing
  168
• 1.5 Checking compression
  181
• 2 Cover for timing chain
  183
• 2.1 Assembly overview - cover for timing chain
  183
• 2.2 Removing and installing timing chain cover
  186
• 3 Chain drive
  197
• 3.1 Assembly overview - camshaft timing chains
  197
• 3.2 Assembly overview - drive chain for oil pump
  201
• 3.3 Removing camshaft timing chain from camshafts
  202
• 3.4 Removing and installing camshaft timing chain
  228
• 3.5 Removing and installing chain tensioner
  229
• 4 Valve gear
  233
• 4.1 Assembly overview - valve gear
  233
• 4.2 Measuring axial play of camshaft
  236
• 4.3 Measuring radial play of camshaft
  237
• 4.4 Removing and installing camshaft
  238
• 4.5 Removing and installing cam actuators
  240
• 4.6 Removing and installing camshaft control valve 1 N205
  243
• 4.7 Removing and installing valve stem seals
  243
• 5 Inlet and exhaust valves
  258
• 5.1 Checking valve guides
  258
• 5.2 Checking valves
  259
• 5.3 Valve dimensions
  259
• Lubrication
  260
• 1 Sump, oil pump
  260
• 1.1 Assembly overview - sump/oil pump
  260
• 1.2 Engine oil:
  265
• 1.3 Removing and installing lower part of sump
  266
• 1.4 Removing and installing upper part of sump
  269
• 1.5 Removing and installing oil baffle plate
  276
• 1.6 Removing and installing oil pump
  278
• 1.7 Removing and installing oil level and oil temperature sender G266
  280
• 2 Engine oil cooler
  281
• 2.1 Assembly overview - engine oil cooler
  281
• 2.2 Removing and installing engine oil cooler
  281
• 2.3 Removing and installing spray nozzle valve
  284
• 3 Crankcase ventilation
  286
• 3.1 Assembly overview - crankcase breather system
  286
• 3.2 Removing and installing crankcase breather module
  287
• 4 Oil filter, oil pressure switch
  289
• 4.1 Assembly overview - oil filter
  289
• 4.2 Assembly overview - oil pressure switches/oil pressure control
  291
• 4.3 Removing and installing oil pressure switch F22
  292
• 4.4 Removing and installingoil temperature sender G8
  293
• 4.5 Checking oil pressure
  294
• 4.6 Removing and installing oil filter housing
  295
• 4.7 Removing and installing oil pressure regulating valve N428
  297
• 4.8 Removing and installing oil pressure sender G10
  298
• Cooling
  300
• 1 Cooling system/coolant
  300
• 1.1 Connection diagram - coolant hoses
  300
• 1.2 Overview of fitting locations – cooling system
  308
• 1.3 Assembly overview – coolant expansion tank
  311
• 1.4 Checking cooling system for leaks
  313
• 1.5 Draining and adding coolant
  323
• 1.6 Removing and installing coolant expansion tank
  349
• 2 Coolant pump, regulation of cooling system
  355
• 2.1 Assembly overview - coolant pump, thermostat
  355
• 2.2 Assembly overview - electric coolant pump
  357
• 2.3 Assembly overview - coolant temperature sender
  359
• 2.4 Assembly overview – coolant valves
  363
• 2.5 Removing and installing electric coolant pump
  365
• 2.6 Removing and installing coolant pump
  371
• 2.7 Removing and installing map-controlled engine cooling thermostat F265
  372
• 2.8 Removing and installing coolant temperature sender G62
  374
• 2.9 Removing and installing engine outlet coolant temperature sender G82
  375
• 2.10 Removing and installing radiator outlet coolant temperature sender G83
  377
• 2.12 Removing and installing coolant valves
  381
• 2.13 Removing and installing coolant temperature sender for high-voltage system
  387
• 3 Coolant pipes
  397
• 3.1 Assembly overview - coolant pipes
  397
• 3.2 Removing and installing coolant pipes
  399
• 4 Radiator, radiator fan
  407
• 4.1 Assembly overview – radiator, radiator fan
  407
• 4.2 Removing and installing radiator
  412
• 4.3 Removing and installing radiator cowl
  417
• 4.4 Removing and installing radiator fan V7
  422
• 4.5 Removing and installing radiator for high-voltage system coolant circuit
  422
• 4.6 Removing and installing air ducts
  425
• Turbocharging/supercharging
  430
• 1 Turbocharger
  430
• 1.1 Assembly overview - turbocharger
  430
• 1.2 Removing and installing turbocharger
  435
• 1.3 Renewing vacuum unit for turbocharger
  441
• 1.4 Removing and installing temperature sender for engine cover panel G765
  447
• 2 Charge air system
  448
• 2.1 Assembly overview - charge air system
  448
• 2.2 Assembly overview - charge-air hose connections
  453
• 2.3 Removing and installing air pipe
  454
• 2.4 Removing and installing pressure pipe
  457
• 2.5 Removing and installing charge air cooler
  461
• 2.6 Removing and installing charge pressure sender G31
  464
• 2.7 Removing and installing overrun air recirculation valve
  465
• 2.8 Checking charge air system for leaks
  465
• Mixture preparation - injection
  468
• 1 Injection system
  468
• 1.1 Overview of fitting locations - injection system
  468
• 1.2 Checking fuel system for leaks
  478
• 2 Vacuum system
  479
• 2.1 Connection diagram – vacuum system
  479
• 2.2 Checking vacuum system
  479
• 3 Injectors
  481
• 3.1 Assembly overview - fuel rail with injectors
  481
• 3.2 Removing and installing fuel rail
  483
• 3.3 Removing and installing injectors
  485
• 3.4 Cleaning injectors
  491
• 4 Air filter
  494
• 4.1 Assembly overview - air filter housing
  494
• 4.2 Removing and installing air filter housing
  495
• 5 Intake manifold
  497
• 5.1 Assembly overview – intake manifold
  497
• 5.2 Removing and installing intake manifold
  498
• 5.3 Removing and installing throttle valve module J338
  501
• 5.4 Cleaning throttle valve module
  503
• 6 Senders and sensors
  505
• 6.2 Assembly overview - pressure differential sender, models with particulate filter
  506
• 6.3 Removing and installing actuator for structure-borne sound R214
  507
• 6.4 Removing and installing control unit for structure-borne sound J869
  508
• 6.5 Removing and installing intake manifold sender GX9
  508
• 6.6 Removing and installing fuel pressure sender G247
  509
• 6.7 Removing and installing fuel pressure sender for low-pressure G410
  510
• 7 Engine control unit
  514
• 7.1 Assembly overview – engine/motor control unit
  514
• 7.2 Removing and installing engine control unit J623
  514
• 8 High-pressure pump
  516
• 8.1 Assembly overview - high-pressure pump
  516
• 8.2 Removing and installing high-pressure pump
  520
• 8.3 Removing and installing high-pressure pipe
  523
• 9 Lambda probe
  527
• 9.1 Assembly overview - Lambda probe
  527
• 9.2 Removing and installing Lambda probe
  528
• Exhaust system
  533
• 1 Exhaust pipes and silencers
  533
• 1.1 Assembly overview – silencers
  533
• 1.2 Removing and installing front silencer
  540
• 1.3 Separating exhaust pipes from silencers
  543
• 1.4 Removing and installing silencer
  544
• 1.5 Aligning exhaust system free of stress
  545
• 1.6 Checking exhaust system for leaks
  546
• 2 Emission control
  547
• 2.1 Assembly overview – emission control
  547
• 2.2 Removing and installing catalytic converter
  550
• 2.3 Removing and installing particulate filter
  551
• 3 Exhaust gas temperature regulation
  554
• 3.1 Removing and installing exhaust gas temperature sender 3 G495
  554
• Ignition system
  556
• 1 Ignition system
  556
• 1.1 Assembly overview - ignition system
  556
• 1.2 Removing and installing ignition coils with output stage
  558
• 1.3 Removing and installing knock sensor 1 G61
  562
• 1.4 Removing and installing Hall sender
  563
• 1.5 Removing and installing engine speed sender G28
  564
• Electric drive systems
  566
• 1 High-voltage components
  566
• 1.1 Overview of fitting locations - high-voltage components
  566
• 2 Warning stickers
  569
• 2.1 Checking warning stickers
  569
• 3 High-voltage battery unit
  573
• 3.1 Assembly overview – high-voltage battery
  573
• 3.2 Visual inspection of high-voltage battery 1 AX2
  575
• 3.3 Diagnosing high-voltage battery 1 AX2
  576
• 3.4 Searching for leaks from high-voltage battery
  577
• 3.5 Removing and installing high-voltage battery 1 AX2
  584
• 3.6 Removing and installing battery regulation control unit J840
  593
• 3.7 Removing and installing switching unit for high-voltage battery SX6
  594
• 4 High-voltage battery components
  597
• 4.1 Assembly overview – high-voltage battery
  597
• 4.2 Overview of fitting locations - battery modules
  602
• 4.3 Overview of fitting locations – battery connectors
  603
• 4.4 Marking battery modules
  604
• 4.5 Removing battery module
  605
• 4.6 Installing battery module
  619
• 5 Power and control electronics for electric drive
  635
• 5.1 Overview of fitting locations - power and control electronics for electric drive
  635
• 5.2 Removing and installing power and control electronics for electric drive
  638
• 6 Electric drive motor
  644
• 6.1 Assembly overview – electric drive motor
  644
• 6.2 Removing and installing three-phase current drive VX54
  648
• 6.3 Removing and installing centring sleeve
  648
• 6.4 Removing and installing drive motor temperature sender G712
  650
• 6.5 Removing and installing drive motor rotor position sender 1 G713
  651
• 6.6 Removing and installing torsion damper
  652
• 6.7 Removing and installing actuator for disengagement clutch V606
  654
• 6.8 Removing and installing coolant connection
  657
• 6.9 Transporting three-phase current drive
  658
• 6.10 Checking ease of movement of disengagement clutch
  659
• 7 High-voltage cables
  661
• 7.1 Overview of fitting locations - high-voltage cables
  661
• 7.2 Removing and installing high-voltage wiring harness for high-voltage battery
  668
• 7.3 Removing and installing high-voltage wiring harness for drive motor
  673
• 7.5 Removing and installing high-voltage cable for high-voltage heater (PTC)
  681
• 8 De-energising high-voltage system
  689
• 9 Re-energising high-voltage system
  691
• 10 Potential equalisation lines
  692
• 10.1 General notes - potential equalisation lines
  692
• 10.2 Overview of fitting locations - potential equalisation lines
  692
• 10.3 Removing and installing potential equalisation line
  694
• 11 Charging socket
  698
• 11.1 Assembly overview – charging socket
  698
• 11.2 Removing and installing high-voltage battery charging socket 1 UX4
  699
• 11.3 Removing and installing module for battery charge selector buttons EX32
  704
• 12 Charging unit for high-voltage battery
  705
• 12.1 Assembly overview – charging unit for high-voltage battery
  705
• 12.2 Removing and installing charging unit 1 for high-voltage battery AX4
  705
• 12.3 Removing and installing bracket for charging unit 1 for high-voltage battery AX4
  710