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

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
  3
• 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
  19
• 1.3 Installing engine
  22
• 1.4 Separating engine and gearbox
  24
• 2 Assembly mountings
  30
• 2.1 Assembly overview - assembly mountings
  30
• 2.2 Removing engine mounting (left-side)
  30
• 2.3 Remove engine mounting (right-side)
  33
• Crankshaft group
  37
• 1 Cylinder block (pulley end)
  37
• 1.1 Assembly overview - supercharger poly V-belt drive
  37
• 1.2 Removing and installing supercharger poly V-belt
  38
• 1.3 Removing and installing tensioning element for supercharger poly V-belt
  39
• 1.4 Assembly overview - poly-V-belt drive for ancillary units
  40
• 1.5 Removing and installing poly-V belt
  42
• 1.6 Removing and installing tensioning element for poly V-belt
  43
• 1.7 Removing and installing vibration damper
  45
• 1.8 Renewing sealing flange with oil seal for crankshaft
  45
• 2 Cylinder block, gearbox end
  50
• 2.1 Assembly overview - drive plate
  50
• 2.2 Removing and installing drive plate
  50
• 2.3 Removing and installing sender wheel
  51
• 2.4 Checking sender wheel
  52
• 2.5 Renewing oil seal for crankshaft at gearbox end
  52
• 3 Crankshaft
  55
• 3.1 Assembly overview - crankshaft
  55
• 3.2 Crankshaft dimensions
  58
• 3.3 Measuring axial clearance of crankshaft
  58
• 3.4 Measuring radial clearance of crankshaft
  59
• 4 Pistons and conrods
  60
• 4.1 Assembly overview - pistons and conrods
  60
• 4.2 Piston and cylinder dimensions
  63
• 4.3 Measuring radial clearance of conrods
  63
• Cylinder head, valve gear
  64
• 1 Cylinder head
  64
• 1.1 Assembly overview - cylinder head
  64
• 1.2 Removing and installing left cylinder head cover
  67
• 1.3 Removing and installing cylinder head cover (right side)
  67
• 1.4 Removing and installing cylinder heads
  69
• 1.5 Checking compression
  75
• 2 Chain drive
  77
• 2.1 Assembly overview - timing chain covers
  77
• 2.2 Removing and installing timing chain cover (left and right)
  80
• 2.3 Removing and installing timing chain cover (bottom)
  83
• 2.4 Assembly overview - camshaft timing chains
  87
• 2.5 Checking valve timing
  89
• 2.6 Removing and installing camshaft adjuster
  90
• 2.7 Removing and installing camshaft timing chains
  100
• 2.8 Assembly overview - drive chain for valve gear
  102
• 2.9 Removing and installing drive chain for valve gear
  104
• 2.10 Assembly overview - drive chain for auxiliary drives
  105
• 2.11 Removing and installing drive chain for auxiliary drives
  106
• 2.12 Assembly overview - balance shaft
  110
• 2.13 Removing and installing balance shaft
  110
• 3 Valve gear
  113
• 3.1 Assembly overview - valve gear
  113
• 3.2 Checking axial clearance of camshafts
  116
• 3.3 Measuring radial clearance of camshafts
  116
• 3.4 Removing and installing camshafts
  117
• 3.5 Checking hydraulic compensation elements
  123
• 3.6 Renewing valve stem seals with cylinder head installed
  125
• 3.7 Renewing valve stem seals with cylinder head removed
  128
• 3.8 Valve dimensions
  132
• 3.9 Checking valve guides
  132
• 3.10 Checking valves
  133
• Lubrication
  134
• 1 Engine oil:
  134
• 1.1 Check engine oil level with oil gauge tester T40178
  134
• 2 Lower part of sump, upper part of sump, oil pump, engine oil cooler
  136
• 2.1 Assembly overview - lower part of sump, upper part of sump, oil pump, engine oil cooler
  136
• 2.2 Removing and installing engine oil cooler
  139
• 2.3 Removing and installing oil level and oil temperature sender G266
  140
• 2.4 Removing and installing lower part of sump
  141
• 2.5 Removing and installing oil pump
  143
• 2.6 Removing and installing upper part of sump
  144
• 3 Oil filter housing, oil pressure switch
  147
• 3.1 Assembly overview – oil filter housing
  147
• 3.2 Assembly overview - oil pressure switch for reduced oil pressure F378
  148
• 3.3 Removing and installing oil filter housing
  148
• 3.5 Removing and installing oil pressure switch F22
  150
• 3.6 Removing and installing oil pressure switch for reduced oil pressure F378
  151
• 3.7 Removing and installing oil pressure regulating valve N428
  153
• 3.8 Checking oil pressure
  153
• 4 Renewing oil non-return valve, oil separator
  155
• 4.1 Assembly overview - oil non-return valve, oil separator
  155
• 4.2 Removing and installing pipes for crankcase breather system
  156
• 4.3 Removing and installing cover with oil separator
  156
• Cooling
  158
• 1 Cooling system
  158
• 1.1 Coolant hose connection diagram
  158
• 1.2 Cooling system - fitting locations
  160
• 1.3 Assembly overviews - cooling system
  161
• 2 Coolant for high-temperature cooling circuit
  164
• 2.1 Drain coolant (high-temperature cooling circuit)
  164
• 2.2 Drain cooling system (high-temperature cooling circuit)
  165
• 2.3 Filling with coolant
  166
• 2.4 Checking coolant for air bubbles (high-temperature cooling circuit)
  170
• 2.5 Checking cooling system for leaks
  171
• 3 Coolant for low-temperature cooling circuit
  174
• 3.1 Draining and adding coolant
  174
• 3.2 Checking cooling system for leaks
  179
• 4 Coolant pump, thermostat
  182
• 4.1 Assembly overview - coolant pump, thermostat, connections
  182
• 4.2 Removing and installing coolant pump
  183
• 4.3 Removing and installing thermostat
  183
• 4.4 Checking thermostat
  184
• 5 Coolant pipes, coolant temperature sender G62 and electric coolant pump
  185
• 5.1 Assembly overview - coolant pipes
  185
• 5.2 Removing and installing coolant temperature sender G62
  188
• 5.3 Removing and installing front coolant pipe
  189
• 5.4 Removing and installing front left coolant pipes
  191
• 5.5 Removing and installing pipes for engine cooling system
  193
• 5.6 Removing and installing rear left coolant pipe on gearbox
  195
• 5.7 Removing and installing upper coolant pipe
  196
• 5.8 Removing and installing coolant pipe on supercharger
  197
• 5.9 Removing and installing electric coolant pump
  199
• 6 Radiator and radiator fans
  200
• 6.1 Assembly overview - radiator and radiator fan
  200
• 6.2 Removing and installing radiator module
  201
• 6.3 Removing and installing cooler for charge air cooling circuit
  205
• 6.4 Removing and installing radiator cowl
  207
• 6.5 Dismantling cooler module
  208
• Fuel supply system
  210
• 1 Parts of fuel supply system
  210
• 1.1 Rules for cleanliness
  211
• 1.2 Assembly overview - fuel tank with attachments
  211
• 1.3 Assembly overview - fuel delivery unit, fuel gauge sender and suction jet pumps
  213
• 1.4 Removing, installing and renewing fuel filter
  215
• 1.5 Emptying fuel tank
  217
• 1.6 Removing and installing fuel gauge sender 2 G169 and suction-jet pump
  219
• 1.7 Removing and installing fuel delivery unit and fuel gauge sender G
  223
• 1.8 Removing and installing fuel tank with attached components
  226
• 2 Checking fuel pump
  231
• 2.1 Checking fuel pressure
  231
• 2.2 Checking holding pressure
  234
• 2.3 Checking fuel delivery rate
  235
• 3 Electronic power control (EPC)
  240
• 3.1 Assembly overview - accelerator
  240
• 4 Activated charcoal filter system
  241
• 4.1 Assembly overview - activated charcoal filter system
  241
• 4.2 Checking fuel system for leaks
  241
• Turbocharging/supercharging
  244
• 1 Compressor
  244
• 1.1 Assembly overview - supercharger
  244
• 1.2 Removing and installing charge pressure sender G31 and G447
  246
• 1.3 Removing and installing supercharger
  248
• 1.4 Assembly overview - charge air cooler
  252
• 1.5 For assembly work, secure supercharger on engine and gearbox support
  253
• 1.6 For leak test, secure supercharger on engine and gearbox support
  255
• 1.7 Removing and installing charge air cooler
  256
• 1.8 Assembly overview - drive unit
  260
• 1.9 Removing and installing ancillary drive unit and decoupling spring
  260
• 1.10 Checking supercharger for leaks
  262
• Mixture preparation - injection
  265
• 1 Injection system
  265
• 1.1 Rules for cleanliness
  265
• 1.2 Technical data
  265
• 2 Vacuum system
  266
• 2.1 Assembly overview – vacuum pump
  266
• 2.2 Removing and installing vacuum pump
  266
• 2.3 Checking vacuum system
  267
• 2.4 Assembly overview - vacuum system
  268
• 3 Injectors
  270
• 3.1 Removing and installing injectors
  270
• 4 Air filter
  274
• 4.1 Assembly overview - air filter
  274
• 4.2 Removing and installing air filter element
  274
• 4.3 Removing and installing air filter housing
  277
• 5 Intake manifold
  278
• 5.1 Assembly overview - intake manifold lower part, fuel rail
  278
• 5.2 Removing and installing lower part of intake manifold with fuel rail
  280
• 5.3 Removing and installing vacuum servo element for actuating intake manifold flaps
  283
• 5.4 Removing and installing throttle valve module J338
  284
• 5.5 Removing and installing regulating flap control unit J808
  286
• 6 Senders and sensors
  288
• 7 Engine control unit
  289
• 7.1 Removing and installing engine (motor) control unit J623
  289
• 8 High-pressure pump
  291
• 8.1 Assembly overview - high-pressure pump
  291
• 8.2 Removing and installing high-pressure pipe
  292
• 8.3 Removing and installing high-pressure pump
  295
• 9 Lambda probes
  298
• 9.1 Assembly overview – lambda probes
  298
• 9.2 Removing and installing Lambda probe G39
  299
• 9.3 Removing and installing Lambda probe after catalytic converter G130
  300
• 9.4 Removing and installing Lambda probe 2 G108
  302
• 9.5 Removing and installing Lambda probe 2 after catalytic converter G131
  303
• Exhaust system
  306
• 1 Exhaust manifold
  306
• 1.1 Assembly overview - exhaust manifold
  306
• 1.2 Removing and installing left exhaust manifold (bank 2)
  307
• 1.3 Removing and installing right exhaust manifold (bank 1)
  309
• 2 Silencers and catalytic converters
  311
• 2.1 Assembly overview - catalytic converters and front silencers
  311
• 2.2 Assembly overview - catalytic converter mountings
  312
• 2.3 Assembly overview - centre and rear silencers
  313
• 2.4 Removing and installing left catalytic converter (bank 2)
  314
• 2.5 Removing and installing right catalytic converter (bank 1)
  315
• 2.6 Separating centre and rear silencers
  316
• 2.7 Aligning exhaust system free of stress
  317
• 2.8 Renew and align exhaust pipes
  318
• 2.9 Checking exhaust system for leaks
  319
• 3 Secondary air system
  320
• 3.1 Assembly overview - secondary air system
  320
• 3.2 Removing and installing secondary air pump motor V101
  322
• 3.3 Checking combination valves for secondary air system for proper operation and leakage
  322
• 3.4 Removing and installing left combination valve for secondary air system
  324
• 3.5 Removing and installing right combination valve for secondary air system
  325
• Ignition system
  326
• 1 General notes and safety precautions
  326
• 1.1 General notes on ignition system
  326
• 1.2 Safety precautions
  326
• 2 Repairing ignition system
  327
• 2.1 Assembly overview - ignition system
  327
• 2.2 Removing and installing ignition coils with output stage
  328
• 2.3 Removing and installing knock sensors G61 and G66
  331
• 2.4 Removing and installing Hall senders G40 and G163
  331
• 2.5 Removing and installing engine speed sender G28
  332
• 2.6 Test data, spark plugs
  333