6-cylinder direct-injection engine (3.6 l engine, 4V)

Chapter overview

• Technical data
  1
• 1 Identification
  1
• 1.1 Engine number/engine data
  1
• 2 General information
  3
• 2.1 Numbering of cylinders
  3
• 3 Safety information
  4
• 3.1 Safety precautions during work on fuel system
  4
• 3.3 Safety precautions when working on the cooling system
  5
• 3.4 Safety precautions when working on ignition system
  5
• 4 Repair notes
  6
• 4.1 Rules for cleanliness
  6
• 4.2 Foreign objects in engine
  6
• Removing and installing engine
  7
• 1 Removing and installing engine
  7
• 1.1 Removing engine
  7
• 1.2 Separating engine and gearbox
  17
• 1.3 Securing engine on engine and gearbox support
  19
• 1.4 Installing engine
  21
• 2 Assembly mountings
  24
• 2.1 Assembly overview - assembly mountings
  24
• 2.2 Removing and installing engine mounting
  26
• 2.3 Adjusting assembly mountings
  28
• 2.4 Checking adjustment of assembly mountings (engine and gearbox mountings)
  33
• Crankshaft group
  34
• 1 Cylinder block (pulley end)
  34
• 1.1 Assembly overview - cylinder block (pulley end)
  34
• 1.2 Assembly overview - poly V-belt drive
  36
• 1.3 Removing and installing poly-V belt
  38
• 1.4 Removing and installing tensioner for poly V-belt
  39
• 1.5 Removing and installing vibration damper
  40
• 1.6 Removing and installing bracket for ancillaries
  41
• 1.7 Removing and installing sealing flange on pulley end
  42
• 2 Cylinder block, gearbox end
  45
• 2.1 Assembly overview - cylinder block, gearbox end
  45
• 2.2 Removing and installing flywheel
  45
• 2.3 Renewing crankshaft oil seal (gearbox end)
  47
• 3 Crankshaft
  50
• 3.1 Assembly overview - crankshaft
  50
• 3.2 Renewing needle bearing in crankshaft
  52
• 3.3 Crankshaft dimensions
  54
• 3.4 Measuring axial clearance of crankshaft
  54
• 3.5 Measuring radial clearance of crankshaft
  55
• 3.6 Allocation of main bearing shells
  56
• 3.7 Removing and installing sender wheel
  60
• 4 Pistons and conrods
  62
• 4.1 Assembly overview - pistons and conrods
  62
• 4.2 Removing and installing pistons
  64
• 4.3 Checking pistons and cylinder bores
  68
• 4.4 Separating new conrod
  70
• Cylinder head, valve gear
  71
• 1 Cylinder head
  71
• 1.1 Assembly overview - cylinder head
  71
• 1.2 Removing and installing cylinder head
  73
• 1.3 Removing and installing cylinder head cover
  84
• 1.4 Assembly overview - vacuum pump
  86
• 1.5 Removing and installing vacuum pump
  86
• 1.6 Checking compression
  88
• 2 Cover for timing chain
  92
• 2.1 Assembly overview - cover for timing chain
  92
• 2.2 Removing and installing timing chain cover
  93
• 2.3 Removing and installing the camshaft control valve seal
  98
• 2.4 Assembly overview - valve timing housing
  99
• 3 Chain drive
  101
• 3.1 Assembly overview - camshaft timing chains
  101
• 3.2 Removing and installing camshaft timing chain
  104
• 3.3 Removing and installing chain drive sprocket for high-pressure pump
  108
• 3.4 Removing and installing timing chain and chain drive for oil pump
  110
• 3.5 Checking valve timing
  115
• 3.6 Adjusting valve timing
  118
• 4 Valve gear
  124
• 4.1 Assembly overview - valve gear
  124
• 4.2 Measuring axial play of camshaft
  127
• 4.3 Removing and installing camshaft
  127
• 4.4 Removing and installing camshaft adjuster
  133
• 4.5 Removing and installing camshaft control valve
  142
• 4.6 Removing and installing valve stem seals
  147
• 5 Inlet and exhaust valves
  151
• 5.1 Checking valve guides
  151
• 5.2 Reworking valve seats
  151
• 5.3 Valve dimensions
  153
• Lubrication
  155
• 1 Sump, oil pump
  155
• 1.1 Assembly overview - sump/oil pump
  155
• 1.2 Removing and installing oil spray jet
  157
• 1.3 Removing and installing oil pan
  158
• 1.4 Removing and installing oil pump
  161
• 1.5 Engine oil:
  167
• 2 Oil filter, oil pressure switch
  169
• 2.1 Assembly overview - oil filter housing, oil pressure switch
  169
• 2.2 Checking oil pressure and oil pressure switch
  171
• Cooling
  175
• 1 Cooling system/coolant
  175
• 1.1 Connection diagram - coolant hoses
  175
• 1.2 Checking cooling system for leaks
  176
• 1.3 Draining and adding coolant
  180
• 2 Coolant pump, regulation of cooling system
  186
• 2.1 Assembly overview - coolant pump, thermostat
  186
• 2.2 Removing and installing coolant pump
  188
• 2.3 Removing and installing thermostat
  192
• 2.4 Checking thermostat
  193
• 2.5 Removing and installing continued coolant circulation pump V51
  193
• 3 Radiator, radiator fan
  195
• 3.1 Assembly overview - radiator/radiator fan
  195
• 3.2 Removing and installing radiator
  197
• 3.3 Removing and installing radiator cowl with radiator fan
  200
• 3.4 Removing and installing radiator fan
  201
• Mixture preparation - injection
  202
• 1 Injection system
  202
• 1.1 Overview of fitting locations - injection system
  202
• 2 Injectors
  205
• 2.1 Assembly overview - fuel rail with injectors
  205
• 2.2 Removing and installing injectors
  209
• 2.3 Renewing seals on injectors
  213
• 3 Air filter
  218
• 3.1 Assembly overview - air filter housing
  218
• 3.2 Removing and installing air filter housing
  219
• 3.3 Checking intake air preheating
  219
• 4 Intake manifold
  221
• 4.1 Assembly overview - intake manifold
  221
• 4.2 Removing and installing lower part of intake manifold with fuel rail
  223
• 4.3 Removing and installing intake manifold upper part
  226
• 4.4 Removing and installing throttle valve module J338
  230
• 5 Senders and sensors
  232
• 5.1 Checking fuel pressure sender G247
  232
• 6 Engine control unit
  236
• 6.1 Removing and installing engine control unit J623
  236
• 6.2 Removing and installing engine (motor) control unit J623 with protective housing
  237
• 7 High-pressure pump
  241
• 7.1 Assembly overview - high-pressure pump
  241
• 7.2 Removing and installing high-pressure pump
  242
• 8 Lambda probe
  248
• 8.1 Removing and installing lambda probe G39
  248
• 8.2 Removing and installing Lambda probe G108
  249
• Exhaust system
  253
• 1 Exhaust pipes and silencers
  253
• 1.1 Assembly overview - silencers
  253
• 1.2 Separating exhaust pipes from silencers
  255
• 1.3 Installation position of clamp
  257
• 2 Emission control
  259
• 2.1 Assembly overview - emission control
  259
• 2.2 Removing and installing catalytic converter
  261
• 3 Exhaust manifold
  265
• 3.1 Assembly overview - exhaust manifold
  265
• 3.2 Removing and installing exhaust manifold
  266
• Ignition system
  269
• 1 Ignition system
  269
• 1.1 Assembly overview - ignition system
  269
• 1.2 Removing and installing ignition coils with output stage
  271
• 1.3 Removing and installing engine speed sender G28
  273
• 1.4 Test data, spark plugs
  273