6-cylinder injection engine

Chapter overview

• Technical data
  1
• 1 Engine number
  1
• 2 Engine data
  2
• Removing and installing engine
  3
• 1 Removing and installing engine
  3
• 1.1 Removing engine
  4
• 1.2 Securing engine on engine and gearbox support VAS 6095
  10
• 1.3 Installing engine
  11
• 1.4 Specified torques for assembly mounting
  13
• Crankshaft group
  15
• 1 Dismantling and assembling engine
  15
• 1.1 Assembly overview - parts l and ll
  15
• 1.2 Assembly overview - part I: chain drive
  17
• 1.3 Part II: Assembly overview - crankshaft drive
  19
• 1.4 Removing and installing poly-V belt
  20
• 1.5 Removing and installing vibration damper
  22
• 2 Sealing flanges and flywheel
  24
• 2.1 Assembly overview - sealing flange
  24
• 2.2 Removing and installing crankshaft seal on gearbox side
  25
• 2.3 Renewing crankshaft sealing flange, vibration damper side
  26
• 2.4 Removing and installing flywheel
  28
• 2.5 Removing and installing drive plate
  29
• 3 Crankshaft
  32
• 3.1 Assembly overview - crankshaft
  32
• 3.2 Allocation of main bearing shells
  33
• 3.3 Fitting sender wheel to crankshaft
  37
• 3.4 Pulling needle bearing out of and driving into crankshaft
  38
• 4 Pistons and conrods
  40
• 4.1 Assembly overview - pistons and conrods
  40
• 4.2 Checking pistons, piston rings and cylinder bores
  42
• 4.3 Installing piston
  43
• 4.4 Piston and cylinder dimensions
  44
• Cylinder head, valve gear
  45
• 1 Cylinder head
  45
• 1.1 Assembly overview - cylinder head
  45
• 1.2 Removing and installing cylinder head
  48
• 1.3 Assembly overview - cover
  56
• 1.4 Checking valve timing
  58
• 1.5 Removing and installing camshaft adjuster
  64
• 1.6 Removing and installing camshaft timing chain and intermediate shaft drive chain
  78
• 1.7 Removing and installing cylinder head cover
  100
• 1.8 Checking compression
  101
• 2 Valve gear
  104
• 2.1 Assembly overview
  104
• 2.2 Removing and installing camshafts
  106
• 2.3 Removing and installing camshaft control valves
  112
• 2.4 Valve stem seals
  116
• 2.5 Checking valve guides
  120
• 2.6 Reworking valve seats
  120
• Lubrication
  123
• 1 Parts of lubrication system
  123
• 1.1 Engine oil:
  123
• 1.2 Assembly overview - sump
  123
• 1.3 Removing and installing sump
  126
• 1.4 Assembly overview - oil filter bracket
  128
• 1.5 Removing and installing oil filter bracket
  130
• 1.6 Assembly overview - oil pump
  131
• 1.7 Checking oil pressure and oil pressure switch
  133
• Cooling
  137
• 1 Removing and installing parts of cooling system
  137
• 1.1 Assembly overview - parts of cooling system, body side
  138
• 1.2 Assembly overview - cooling system, engine side (vehicles with manual gearbox)
  140
• 1.3 Assembly overview - cooling system, engine side (vehicles with DSG®)
  141
• 1.4 Assembly overview - thermostat housing
  143
• 1.5 Coolant hose connection diagram
  145
• 1.6 Draining and adding coolant
  146
• 1.7 Removing and installing fan mounting with fans
  149
• 1.8 Removing and installing radiator
  150
• 1.9 Checking continued coolant circulation pump
  152
• 1.10 Removing and installing coolant pump
  153
• 1.11 Removing and installing thermostat housing
  156
• 1.12 Removing and installing thermostat
  159
• 1.13 Removing and installing coolant pipe
  160
• 1.14 Checking cooling system for leaks
  162
• Fuel supply system
  164
• 1 Safety measures when working on fuel supply
  164
• 2 Rules for cleanliness
  165
• 3 Fuel
  166
• 3.1 Assembly overview - fuel tank
  166
• 3.2 Assembly overview - fuel tank (vehicles for USA and Canada)
  168
• 3.3 Emptying fuel tank
  170
• 3.4 Removing and installing fuel tank
  174
• 4 Repairing fuel supply
  178
• 4.1 Removing and installing fuel delivery unit
  178
• 4.2 Removing and installing fuel gauge sender G
  181
• 4.3 Assembly overview - fuel filter with attachments
  183
• 4.4 Removing and installing fuel filter
  184
• 4.5 Checking fuel pump
  185
• 4.6 Bleeding fuel system
  193
• 5 Electronic power control (EPC)
  196
• 5.1 Assembly overview - accelerator module
  196
• 5.2 Removing and installing accelerator pedal module
  196
• 6 Activated charcoal filter system
  199
• 6.1 Assembly overview - activated charcoal filter system
  199
• 6.2 Checking fuel tank breather
  199
• 7 Activated charcoal filter system (vehicles for USA and Canada)
  202
• 7.1 Overview of activated charcoal filter system
  202
• 7.2 Assembly overview - activated charcoal filter system
  203
• 7.3 Removing and installing activated charcoal filter
  204
• 7.4 Removing and installing fuel system diagnostic pump V144
  206
• 7.5 Checking fuel system for leaks
  206
• Mixture preparation - injection
  214
• 1 Repairing injection system
  214
• 1.1 General notes on the injection system
  214
• 1.2 Technical data
  214
• 1.3 Assembly overview - intake manifold
  215
• 1.4 Removing and installing throttle valve module J338
  219
• 1.5 Removing and installing intake manifold
  219
• 1.6 Assembly overview - fuel rail
  222
• 1.7 Assembly overview - air filter
  223
• 1.8 Checking intake air preheating
  223
• 2 Checking components
  225
• 2.1 Checking vacuum unit for intake manifold flaps
  225
• 2.2 Checking injectors for leaks and quantity injected
  226
• 2.3 Checking fuel pressure regulator and holding pressure
  231
• 3 Engine control unit
  235
• 3.1 Removing and installing engine control unit
  235
• 3.2 Removing and installing anti-theft engine control unit
  235
• Exhaust system
  239
• 1 Exhaust manifold, front exhaust pipe with catalytic converters and Lambda probes
  239
• 1.2 Removing and installing Lambda probe G39 and Lambda probe 2 G108
  242
• 1.3 Removing and installing exhaust manifold
  243
• 1.4 Removing and installing front exhaust pipe with catalytic converters
  245
• 2 Silencer with mountings
  248
• 2.1 Assembly overview - silencers with mountings
  248
• 2.2 Clamps
  249
• 2.3 Separating centre and rear silencers
  249
• 2.4 Aligning exhaust system free of stress
  250
• 3 Secondary air system (engine code BUB)
  252
• 3.1 Function
  252
• 3.2 Assembly overview - secondary air system
  252
• 3.3 Removing and installing secondary air pump motor V101
  253
• 3.4 Checking combination valve for secondary air system
  254
• 3.5 Removing and installing combination valve for secondary air system
  254
• 4 Secondary air system (engine code CBRA)
  256
• 4.1 Function
  256
• 4.2 Assembly overview - secondary air system
  256
• 4.3 Checking secondary air combination valves
  258
• 4.4 Removing and installing left combination valve for secondary air system
  259
• 4.5 Removing and installing right combination valve for secondary air system
  259
• Ignition system
  261
• 1 Ignition system
  261
• 1.1 General notes on ignition system
  261
• 1.2 Safety precautions
  261
• 1.3 Assembly overview - parts of ignition system
  262
• 1.4 Removing and installing ignition coils with output stage
  263
• 1.5 Test data, spark plugs
  265