6-cylinder direct-injection engine (3.0 l engine, 4V, hybrid)

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety regulations for working on fuel supply
  1
• 1.2 Safety measures when working on vehicles with a start/stop system
  1
• 1.4 Safety precautions when working on ignition system
  2
• 1.5 Safety precautions when working on the cooling system
  2
• 2 Identification
  3
• 2.1 Engine number/engine data
  3
• 2.2 Numbering of cylinders
  4
• 3 Repair instructions
  5
• 3.1 Rules for cleanliness
  5
• 3.2 Foreign objects in engine
  5
• 3.3 Contact corrosion
  5
• 3.4 Routing and attachment of lines
  5
• 3.5 Fitting radiator and condensers
  5
• Removing and installing engine
  7
• 1 Removing and installing engine
  7
• 1.1 Removing engine
  7
• 1.2 Securing engine on engine and gearbox support VAS 6095
  21
• 1.3 Installing engine
  24
• 1.4 Dismantling and assembling engine and electric drive motor with gearbox
  27
• 1.5 Detaching electric drive motor and gearbox
  31
• 2 Assembly mountings
  34
• 2.1 Assembly overview - assembly mountings
  34
• 2.2 Removing and installing left engine mounting
  34
• 2.3 Removing and installing right engine mounting
  37
• 3 Engine cover panel
  41
• 3.1 Removing and installing engine compartment cover
  41
• Crankshaft group
  42
• 1 Cylinder block (pulley end)
  42
• 1.1 Assembly overview - poly V-belt drive for supercharger
  42
• 1.2 Removing and installing supercharger poly V-belt
  43
• 1.3 Removing and installing tensioner for supercharger poly V-belt
  44
• 1.4 Assembly overview - poly V-belt drive
  44
• 1.5 Removing and installing poly-V belt
  45
• 1.6 Removing and installing tensioner for poly V-belt
  46
• 1.7 Removing and installing vibration damper
  47
• 1.8 Removing and installing sealing flange on pulley end
  48
• 2 Cylinder block, gearbox end
  52
• 2.1 Assembly overview - drive plate
  52
• 2.2 Removing and installing drive plate
  53
• 2.3 Removing and installing sender wheel
  53
• 2.4 Checking sender wheel
  54
• 2.5 Renewing crankshaft oil seal (gearbox end)
  55
• 3 Crankshaft
  57
• 3.1 Assembly overview - crankshaft
  57
• 3.2 Crankshaft dimensions
  60
• 3.3 Measuring axial clearance of crankshaft
  60
• 3.4 Measuring radial clearance of crankshaft
  61
• 3.5 Removing needle bearing from and installing to crankshaft
  61
• 4 Balancer shaft
  63
• 4.1 Assembly overview - balance shaft
  63
• 4.2 Removing and installing balance shaft
  63
• 5 Pistons and conrods
  66
• 5.1 Assembly overview - pistons and conrods
  66
• 5.2 Checking pistons and cylinder bores
  68
• 5.3 Checking radial clearance of conrods
  69
• Cylinder head, valve gear
  70
• 1 Cylinder head
  70
• 1.1 Assembly overview - cylinder head
  70
• 1.2 Removing and installing left cylinder head cover
  73
• 1.3 Removing and installing right cylinder head cover
  74
• 1.4 Removing and installing cylinder head
  76
• 1.5 Checking compression
  82
• 2 Cover for timing chain
  84
• 2.1 Assembly overview - cover for timing chain
  84
• 2.2 Removing and installing left and right timing chain cover
  86
• 2.3 Removing and installing lower timing chain cover
  89
• 3 Chain drive
  94
• 3.1 Assembly overview - camshaft timing chains
  94
• 3.2 Assembly overview - drive chain for valve gear
  96
• 3.3 Assembly overview - drive chain for balance shaft and oil pump
  97
• 3.4 Removing and installing camshaft timing chain
  98
• 3.5 Removing and installing drive chain for valve gear
  100
• 3.6 Removing and installing drive chain for balance shaft and oil pump
  102
• 3.7 Checking valve timing
  105
• 4 Valve gear
  108
• 4.1 Assembly overview - valve gear
  108
• 4.2 Checking axial clearance of camshaft
  110
• 4.3 Measuring radial play of camshaft
  111
• 4.4 Removing and installing camshaft
  111
• 4.5 Removing and installing camshaft adjuster
  118
• 4.6 Checking hydraulic compensation elements
  128
• 4.7 Removing and installing valve stem seals with cylinder head installed
  130
• 4.8 Removing and installing valve stem seals with cylinder head removed
  134
• 5 Inlet and exhaust valves
  139
• 5.1 Checking valve guides
  139
• 5.2 Checking valves
  140
• 5.3 Valve dimensions
  140
• Lubrication
  141
• 1 Sump, oil pump
  141
• 1.1 Assembly overview - sump/oil pump
  141
• 1.2 Engine oil:
  143
• 1.3 Removing and installing lower part of sump
  145
• 1.4 Removing and installing upper part of sump
  147
• 1.5 Removing and installing oil pump
  150
• 1.6 Removing and installing oil level and oil temperature sender G266
  150
• 2 Engine oil cooler
  152
• 2.1 Removing and installing engine oil cooler
  152
• 3 Crankcase ventilation
  154
• 3.1 Assembly overview - crankcase breather system
  154
• 3.2 Removing and installing pipes for crankcase breather system
  155
• 3.3 Removing and installing oil separator
  155
• 4 Oil filter, oil pressure switch
  157
• 4.1 Assembly overview - oil filter housing, oil pressure switch
  157
• 4.2 Removing and installing oil pressure switch F22
  158
• 4.3 Removing and installing oil pressure switch for reduced oil pressure F378
  159
• 4.4 Checking oil pressure
  161
• 4.6 Removing and installing oil filter housing
  162
• 4.7 Removing and installing oil pressure regulating valve N428
  164
• Cooling
  165
• 1 Cooling system/coolant
  165
• 1.1 Connection diagram - coolant hoses
  165
• 1.2 Fitting location overview - cooling system
  167
• 1.3 Fitting location overview - cooling system
  170
• 1.4 Checking cooling system for leaks
  173
• 1.5 Draining and adding coolant
  177
• 1.6 Draining cooling system, high-temperature circuit
  187
• 1.7 Checking coolant quality, high-temperature circuit
  188
• 2 Coolant pump, regulation of cooling system
  190
• 2.1 Assembly overview - coolant pump, thermostat
  190
• 2.2 Removing and installing electric coolant pump
  191
• 2.3 Removing and installing coolant pump
  193
• 2.4 Removing and installing thermostat
  194
• 2.5 Checking thermostat
  195
• 2.6 Removing and installing coolant temperature sender G62
  195
• 3 Coolant pipes
  197
• 3.1 Assembly overview - coolant pipes
  197
• 3.2 Removing and installing coolant pipes for engine cooler
  198
• 3.3 Removing and installing coolant pipe for low-temperature cooling circuit
  200
• 3.4 Removing and installing front coolant pipe
  202
• 3.5 Removing and installing upper coolant pipe
  204
• 3.6 Removing and installing coolant pipe on supercharger
  205
• 4 Radiator, radiator fan
  208
• 4.1 Assembly overview - radiator/radiator fan
  208
• 4.2 Removing and installing radiator module
  209
• 4.3 Dismantling cooler module
  214
• 4.4 Removing and installing centre radiator for charge air cooling circuit
  215
• 4.5 Removing and installing right radiator for charge air cooling circuit
  216
• 4.6 Removing and installing radiator cowl
  217
• Fuel supply system
  219
• 1 Fuel
  219
• 1.1 Assembly overview - fuel tank
  219
• 1.2 Emptying fuel tank
  221
• 1.3 Removing and installing fuel tank
  223
• 2 Fuel delivery unit, fuel gauge sender
  228
• 2.1 Assembly overview - fuel delivery unit/fuel gauge sender
  228
• 2.2 Removing and installing fuel delivery unit, fuel gauge sender
  229
• 2.3 Removing and installing fuel gauge sender 2 G169 and suction-jet pump
  232
• 3 Fuel filter
  237
• 3.1 Removing and installing fuel filter
  237
• 4 Activated charcoal filter system
  240
• 4.1 Assembly overview - activated charcoal filter system
  240
• 4.2 Checking fuel system for leaks
  240
• 5 Activated charcoal filter system, engine code CGFA
  243
• 5.1 Connection diagram - activated charcoal filter system
  243
• 5.2 Assembly overview – activated charcoal filter system
  243
• 5.3 Checking fuel system for leaks
  244
• 6 Accelerator pedal
  249
• 6.1 Assembly overview - accelerator module
  249
• 7 Fuel pump
  250
• 7.1 Checking fuel pump
  250
• Turbocharging/supercharging
  259
• 1 Charge air system
  259
• 1.1 Assembly overview - charge air cooler
  259
• 1.2 Removing and installing charge pressure sender G31 and G447
  260
• 1.3 Removing and installing charge air cooler
  261
• 2 Compressor
  265
• 2.1 Assembly overview - supercharger
  265
• 2.2 Assembly overview - drive unit
  267
• 2.3 Removing and installing supercharger
  267
• 2.4 Checking supercharger for leaks
  272
• 2.5 Removing and installing ancillary drive unit and decoupling spring
  274
• 2.6 For assembly work, secure supercharger on engine and gearbox support
  276
• 2.7 For leak test, secure supercharger on engine and gearbox support
  278
• Mixture preparation - injection
  280
• 1 Vacuum system
  280
• 1.1 Assembly overview - vacuum pump
  280
• 1.2 Removing and installing vacuum pump
  280
• 1.3 Checking vacuum system
  281
• 1.4 Assembly overview - vacuum system
  282
• 2 Injectors
  284
• 2.1 Removing and installing injectors
  284
• 3 Air filter
  287
• 3.1 Assembly overview - air filter housing
  287
• 3.2 Removing and installing air filter element
  287
• 3.3 Removing and installing air filter housing
  290
• 4 Intake manifold
  291
• 4.1 Assembly overview - lower part of intake manifold with fuel rail
  291
• 4.2 Removing and installing lower part of intake manifold with fuel rail
  293
• 4.3 Removing and installing throttle valve module J338
  296
• 4.4 Removing and installing regulating flap control unit J808
  297
• 4.5 Removing and installing vacuum servo element for actuating intake manifold flaps
  299
• 5 Senders and sensors
  301
• 6 Engine control unit
  302
• 6.1 Removing and installing engine (motor) control unit J623
  302
• 7 High-pressure pump
  304
• 7.1 Assembly overview - high-pressure pump
  304
• 7.2 Removing and installing high-pressure pump
  305
• 7.3 Removing and installing high-pressure pipe
  308
• 8 Lambda probes
  311
• 8.1 Assembly overview - Lambda probe
  311
• 8.2 Removing and installing Lambda probe G39
  312
• 8.3 Removing and installing Lambda probe after catalytic converter G130
  313
• 8.4 Removing and installing Lambda probe 2 G108
  315
• 8.5 Removing and installing Lambda probe 2 after catalytic converter G131
  316
• Exhaust system
  319
• 1 Exhaust pipes and silencers
  319
• 1.1 Assembly overview - silencers
  319
• 1.2 Separating exhaust pipes from silencers
  320
• 1.3 Replacing tail pipes
  321
• 1.4 Aligning exhaust system free of stress
  321
• 1.5 Checking exhaust system for leaks
  322
• 2 Emission control
  323
• 2.1 Assembly overview - emission control
  323
• 2.2 Removing and installing left catalytic converter, bank 2
  324
• 2.3 Removing and installing right catalytic converter, bank 1
  326
• 3 Secondary air system
  328
• 3.1 Assembly overview - secondary air system
  328
• 3.2 Removing and installing secondary air pump motor V101
  329
• 3.3 Checking combination valves for secondary air system for proper operation and leakage
  330
• 3.4 Removing and installing left combination valve for secondary air system
  331
• 3.5 Removing and installing right combination valve for secondary air system
  332
• 3.6 Removing and installing sender 1 for secondary air pressure G609
  333
• 4 Exhaust manifold
  335
• 4.1 Assembly overview - exhaust manifold
  335
• 4.2 Removing and installing left exhaust manifold, bank 2
  336
• 4.3 Removing and installing right exhaust manifold, bank 1
  338
• Ignition system
  340
• 1 Ignition system
  340
• 1.1 Assembly overview - ignition system
  340
• 1.2 Test data, spark plugs
  341
• 1.3 Removing and installing ignition coils with output stage
  342
• 1.4 Removing and installing knock sensors G61 and G66
  345
• 1.5 Removing and installing Hall senders G40 and G163
  346
• 1.6 Removing and installing engine speed sender G28
  346