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

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
  6
• Removing and installing engine
  7
• 1 Removing and installing engine
  7
• 1.1 Removing engine
  7
• 1.2 Separating engine and gearbox
  19
• 1.3 Securing engine on engine support
  21
• 1.4 Installing engine
  22
• 1.5 Supporting engine in installation position
  24
• 2 Assembly mountings
  27
• 2.1 Assembly overview - assembly mountings
  27
• 2.2 Removing and installing engine mounting
  27
• Crankshaft group
  29
• 1 Dismantling and assembling engine
  29
• 1.1 Part I
  30
• 1.2 Part II
  32
• 1.3 Removing and installing poly-V belt
  34
• 1.4 Removing and installing vibration damper
  35
• 2 Sealing flanges and drive plate
  36
• 2.1 Assembly overview - sealing flanges and drive plate
  36
• 2.2 Assembly overview - timing chain covers
  37
• 2.3 Removing and installing seal on gearbox side
  38
• 2.4 Removing and installing sealing flange on gearbox side
  40
• 2.5 Renewing crankshaft sealing flange, vibration damper side
  43
• 2.6 Removing and installing drive plate
  45
• 2.7 Removing and installing bracket for ancillaries
  47
• 3 Crankshaft
  49
• 3.1 Assembly overview - crankshaft
  49
• 3.2 Fitting sender wheel to crankshaft
  50
• 3.3 Allocation of main bearing shells
  51
• 4 Pistons and conrods
  56
• 4.1 Assembly overview - pistons and conrods
  56
• 4.2 Checking piston and cylinder
  57
• 4.3 Piston and cylinder dimensions
  61
• Cylinder head, valve gear
  62
• 1 Chain drive
  62
• 1.1 Checking valve timing
  62
• 1.2 Removing and installing camshaft adjuster
  64
• 1.3 Removing and installing camshaft timing chain
  71
• 1.4 Removing and installing oil pump drive timing chain
  74
• 1.5 Removing and installing chain drive sprocket for high-pressure pump
  78
• 2 Cylinder head
  80
• 2.1 Assembly overview - cylinder head
  80
• 2.2 Removing and installing cylinder head
  82
• 2.3 Removing and installing cylinder head cover
  90
• 2.4 Assembly overview - mechanical vacuum pump
  92
• 2.5 Removing and installing mechanical vacuum pump
  93
• 2.6 Installing cover oil seals
  94
• 2.7 Checking compression
  95
• 3 Valve gear
  99
• 3.1 Assembly overview - valve gear
  99
• 3.2 Camshafts, checking axial clearance
  101
• 3.3 Assembly overview - timing housing
  102
• 3.4 Removing and installing camshaft control valves
  103
• 3.5 Removing and installing camshaft
  105
• 3.6 Camshaft identification
  110
• 4 Inlet and exhaust valves
  111
• 4.1 Renewing valve stem seals
  111
• 4.2 Valve dimensions
  113
• 4.3 Checking valve guides
  113
• 4.4 Reworking valve seats
  114
• Lubrication
  116
• 1 Sump, oil pump
  116
• 1.1 Assembly overview - sump/oil pump
  116
• 1.2 Engine oil:
  118
• 1.3 Removing and installing oil pan
  119
• 1.4 Removing and installing oil pump
  122
• 2 Oil filter, oil pressure switch
  128
• 2.1 Removing and installing oil spray jet
  128
• 2.2 Assembly overview - oil filter housing
  128
• 2.3 Removing and installing oil filter housing, engine support
  130
• 2.4 Removing and installing oil pressure switch F1
  131
• 2.5 Checking oil pressure and oil pressure switch
  131
• Cooling
  135
• 1 Cooling system (engine code CGRA)
  135
• 1.1 Coolant hose connection diagram
  135
• 1.2 Vacuum hose connection diagram
  137
• 1.3 Assembly overview - vacuum hoses
  138
• 1.4 Assembly overviews - cooling system
  138
• 2 Cooling system (engine code CMTA)
  142
• 2.1 Coolant hose connection diagram
  142
• 2.2 Assembly overview - cooling system, engine side, front and rear
  142
• 2.3 Assembly overview - cooling system, engine side, left
  143
• 3 Coolant pump and thermostat
  145
• 3.1 Assembly overview - coolant pump and thermostat
  146
• 3.2 Removing and installing coolant pump
  148
• 3.3 Removing and installing coolant circulation pump 2 V178
  149
• 3.4 Removing and installing, checking thermostat
  150
• 4 Coolant
  154
• 4.1 Draining coolant
  154
• 4.2 Draining cooling system (vehicles with one heat exchanger)
  155
• 4.3 Draining cooling system (vehicles with two heat exchangers)
  156
• 4.4 Filling with coolant
  158
• 4.5 Checking filling quality
  161
• 4.6 Checking cooling system for leaks
  162
• 5 Radiator and radiator fans
  164
• 5.1 Assembly overview - radiator and radiator fan
  164
• 5.2 Removing and installing radiator module
  165
• 5.3 Removing and installing radiator cowl
  170
• 5.4 Dismantling cooler module
  171
• Fuel supply system
  173
• 1 Safety precautions
  173
• 1.1 Safety regulations for working on fuel supply
  173
• 2 Parts of fuel supply system
  174
• 2.1 Rules for cleanliness
  175
• 2.2 Assembly overview - fuel tank with attachments
  175
• 2.3 Assembly overview - fuel delivery unit, fuel gauge sender and suction jet pumps
  177
• 2.4 Removing, installing and renewing fuel filter
  179
• 2.5 Emptying fuel tank
  181
• 2.6 Removing and installing fuel gauge sender 2 G169 and suction-jet pump
  184
• 2.7 Removing and installing fuel delivery unit and fuel gauge sender G
  188
• 2.8 Removing and installing fuel tank with attached components
  191
• 3 Checking fuel pump
  196
• 3.1 Checking fuel pressure
  196
• 3.2 Checking holding pressure
  200
• 4 Electronic power control (EPC)
  202
• 4.1 Assembly overview - accelerator
  202
• 5 Activated charcoal filter system
  203
• 5.1 Assembly overview - activated charcoal filter system
  203
• 5.2 Checking fuel system for leaks
  203
• 6 Activated charcoal filter system (vehicles for USA and Canada)
  206
• 6.1 Assembly overview - activated charcoal filter system
  207
• 6.2 Checking fuel system for leaks
  208
• Mixture preparation - injection
  215
• 1 Injection system
  215
• 1.1 General notes on the injection system
  215
• 1.2 Rules for cleanliness
  215
• 1.3 Technical data
  216
• 2 Injectors
  217
• 2.1 Assembly overview - fuel rail with high-pressure pump and injectors
  217
• 2.2 Removing and installing injectors
  221
• 2.3 Renewing seals on injectors
  225
• 3 Air filter
  229
• 3.1 Assembly overview - air filter
  229
• 3.2 Removing and installing air filter housing
  229
• 3.3 Removing and installing air filter element
  231
• 4 Intake manifold
  233
• 4.1 Assembly overview - intake manifold
  233
• 4.2 Checking vacuum unit for intake manifold flap
  234
• 4.3 Removing and installing intake manifold upper part
  236
• 4.4 Removing and installing lower part of intake manifold with fuel rail
  239
• 4.5 Removing and installing throttle valve module J338
  242
• 5 Senders and sensors
  243
• 5.1 Checking fuel pressure sender G247
  243
• 6 Engine control unit
  246
• 6.1 Removing and installing engine control unit J623
  246
• 7 High-pressure pump
  248
• 7.1 Assembly overview - high-pressure pump
  248
• 7.2 Removing and installing high-pressure pump
  249
• Exhaust system
  253
• 1 Exhaust manifold
  253
• 1.1 Assembly overview - exhaust manifold
  253
• 1.2 Removing and installing exhaust manifold
  253
• 2 Silencers and catalytic converters
  256
• 2.1 Assembly overview - catalytic converter
  256
• 2.2 Assembly overview - silencers
  258
• 2.3 Separating centre and rear silencers
  259
• 2.4 Replacing tail pipes
  260
• 2.5 Removing and installing catalytic converters
  260
• 2.6 Aligning exhaust system free of stress
  265
• 2.7 Checking exhaust system for leaks
  266
• Ignition system
  269
• 1 Ignition system
  269
• 1.1 General notes on ignition system
  269
• 1.2 Assembly overview - ignition system
  269
• 1.3 Safety precautions
  271
• 1.4 Test data, spark plugs
  272
• 1.5 Removing and installing ignition coils with output stage
  272
• 1.6 Removing and installing engine speed sender G28
  274