6-cylinder injection engine

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  1
• Removing and installing engine
  3
• 1 Removing and installing engine
  3
• 1.1 Notes on removing
  4
• 1.2 Securing engine on engine and gearbox support VAS 6095
  8
• 1.3 Notes on installing
  9
• 1.4 Tightening torque
  11
• 1.5 Aligning engine and gearbox mountings
  11
• 1.6 Assembly mountings
  12
• 1.7 Additional information and assembly work for vehicles with air conditioner
  13
• Crankshaft group
  14
• 1 Dismantling and assembling engine
  14
• 1.1 Parts I and II - assembly overview - engine codes AQP and AUE
  14
• 1.2 Parts I and II - assembly overview - engine codes BDE, BFH, BJS and BML
  15
• 1.3 Part I: chain drive - assembly overview - engine codes AQP and AUE
  17
• 1.5 Part II: Assembly overview - crankshaft drive
  21
• 1.6 Removing and installing poly-V belt
  23
• 2 Removing and installing sealing flanges and dual-mass flywheel
  24
• 2.1 Assembly overview
  24
• 2.2 Removing and installing seal, flywheel end
  25
• 2.3 Removing and installing drive plate
  26
• 2.4 Renewing crankshaft oil seal, vibration damper end
  28
• 2.5 Renewing crankshaft sealing flange -vibration damper side-
  30
• 3 Removing and installing crankshaft
  33
• 3.1 Assembly overview
  33
• 3.2 Fitting sender wheel to crankshaft
  34
• 3.3 Pulling needle bearing out of and driving into crankshaft
  35
• 4 Dismantling and assembling pistons and conrods
  38
• 4.1 Assembly overview
  38
• 4.2 Piston and cylinder dimensions
  41
• Cylinder head, valve gear
  42
• 1 Cylinder head (engine codes AQP, AUE)
  42
• 1.1 Assembly overview - cylinder head
  42
• 1.2 Removing and installing cylinder head
  45
• 1.3 Checking valve timing
  51
• 1.4 Adjusting valve timing
  52
• 1.5 Removing and installing cylinder head cover
  58
• 1.6 Checking compression
  60
• 2 Cylinder head (engine codes BDE, BFH, BJS, BML)
  62
• 2.1 Assembly overview - cylinder head
  62
• 2.2 Removing and installing cylinder head
  66
• 2.3 Assembly overview - cover section
  70
• 2.4 Checking valve timing
  72
• 2.5 Renewing timing chains
  73
• 2.6 Removing and installing cylinder head cover
  83
• 2.7 Checking compression
  85
• 3 Repairing valve gear (engine codes AQP, AUE)
  88
• 3.1 Assembly overview
  88
• 3.2 Removing and installing camshafts for engine codes AQP and AUE
  90
• 3.3 Renewing valve stem seals
  96
• 3.4 Checking valve guides
  99
• 3.5 Reworking valve seats
  99
• 4 Repairing valve gear (engine codes BDE, BFH, BJS, BML)
  102
• 4.1 Assembly overview - valve gear
  102
• 4.2 Removing and installing camshaft adjuster
  104
• 4.3 Removing and installing camshafts
  112
• 4.4 Renewing valve stem seals
  116
• 4.5 Checking valve guides
  118
• 4.6 Reworking valve seats (engine codes BFH, BJS, BML)
  119
• 4.7 Reworking valve seats (engine code BDE)
  121
• Lubrication
  124
• 1 Removing and installing parts of lubrication system
  124
• 1.1 Engine oil:
  124
• 1.2 Assembly overview
  124
• 1.3 Assembly overview - oil filter housing
  127
• 1.4 Assembly overview - oil pump
  129
• 1.5 Removing and installing oil pan
  130
• 1.6 Checking oil pressure and oil pressure switch
  132
• Cooling
  135
• 1 Removing and installing parts of cooling system
  135
• 1.1 Assembly overview - parts of cooling system, body side
  135
• 1.2 Assembly overview - parts of cooling system, engine side
  137
• 1.3 Coolant hose schematic diagram
  139
• 1.4 Assembly overview - thermostat housing
  140
• 1.5 Removing and installing thermostat housing
  140
• 1.6 Draining and adding coolant
  142
• 1.7 Removing and installing radiator
  145
• 1.8 Checking continued coolant circulation pump
  147
• 1.9 Checking radiator fan
  148
• 1.10 Removing and installing coolant pump
  149
• Fuel supply system
  153
• 1 Removing and installing parts of fuel supply system
  153
• 1.1 Assembly overview - fuel tank with attachments and fuel filter
  153
• 1.2 Safety regulations for working on fuel supply
  156
• 1.3 Rules for cleanliness
  156
• 1.4 Removing and installing suction-jet pump
  156
• 1.5 Removing and installing fuel delivery unit
  158
• 1.6 Removing and installing fuel gauge sender
  161
• 1.7 Removing and installing fuel tank
  162
• 1.8 Crash fuel shut-off
  164
• 1.9 Checking fuel pump
  164
• 2 Active charcoal filter system (vehicles with engine codes AQP, AUE, BDE, BFH and BML)
  171
• 2.1 Functional check
  171
• 2.2 Assembly overview
  171
• 2.3 Checking fuel tank breather
  172
• 3 Activated charcoal filter system (vehicles with engine code BJS)
  174
• 3.1 Functional check
  174
• 3.2 Assembly overview - parts of activated charcoal filter system
  175
• 3.3 Assembly overview - parts of fuel system diagnostic pump
  176
• 3.4 Removing and installing fuel system diagnostic pump and activated charcoal filter
  177
• 4 Electronic power control (EPC)
  178
• 4.1 Function of EPC system
  178
• 4.2 Assembly overview
  178
• Mixture preparation - injection
  180
• 1 Repairing injection system
  180
• 1.1 Overview of fitting locations
  180
• 1.2 General notes on injection
  182
• 1.3 Assembly overview - parts of injection system
  183
• 1.4 Assembly overview - intake manifold
  186
• 1.5 Removing and installing intake manifold
  187
• 1.6 Assembly overview - fuel rail for engine codes AQP, AUE and BDE
  190
• 1.7 Assembly overview - fuel rail for engine codes BFH, BJS and BML
  191
• 1.8 Assembly overview - air filter
  192
• 1.9 Safety precautions
  193
• 1.10 Rules for cleanliness
  194
• 1.11 Technical data
  194
• 2 Checking components
  195
• 2.1 Checking injectors
  195
• 2.2 Checking fuel pressure regulator and holding pressure
  197
• 3 Engine (motor) control unit
  201
• 3.1 Removing and installing engine control unit
  201
• 3.2 Adapting functions and components
  201
• 3.3 Reading and erasing engine control unit fault memory
  202
• Exhaust system
  204
• 1.2 Assembly overview - silencers with mountings
  206
• 2.2 Assembly overview - silencers with mountings
  209
• 3 Secondary air system
  211
• 3.1 Functional check
  211
• 3.2 Assembly overview - parts of secondary air system
  211
• 3.3 Checking combination valve
  213
• Ignition system
  215
• 1 Repairing ignition system
  215
• 1.1 Assembly overview - parts of ignition system for engine codes AQP and AUE
  215
• 1.2 Assembly overview - parts of ignition system for engine codes BDE, BFH, BJS and BML
  218
• 1.3 Removing and installing ignition coils with output stage
  219
• 1.4 Safety precautions
  220
• 1.5 Test data, spark plugs
  221