6-cylinder injection engine

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine data
  1
• Removing and installing engine
  3
• 1 Removing and installing engine
  3
• 1.1 Notes on removing
  5
• 1.2 Securing engine to assembly stand
  9
• 1.3 Notes on installing
  10
• 1.4 Specified torques
  13
• 1.5 Additional information for vehicles with air conditioner
  13
• 1.6 Assembly overview - front engine mounting
  14
• Crankshaft group
  15
• 1 Dismantling and assembling engine
  15
• 1.1 Assembly overview - engine, belt pulley end
  15
• 1.2 Assembly overview - toothed belt drive
  17
• 1.3 Assembly overview - poly V-belt drive
  18
• 1.4 Removing and installing belt pulley or vibration damper
  19
• 1.5 Removing and installing poly V-belt
  20
• 1.6 Assembly overview - crankcase breather
  22
• 2 Removing and installing sealing flanges and flywheel or drive plate
  23
• 2.1 Assembly overview - sealing flange
  23
• 2.2 Renewing crankshaft oil seal - pulley end
  25
• 2.3 Removing and installing sealing flange - pulley end
  26
• 2.4 Removing and installing crankshaft sealing flange - flywheel end
  32
• 2.5 Removing and installing dual-mass flywheel
  33
• 2.6 Pulling needle bearing out of and driving into crankshaft
  35
• 2.7 Removing and installing drive plate
  35
• 3 Crankshaft
  38
• 3.1 Assembly overview - crankshaft
  38
• 3.2 Crankshaft dimensions
  40
• 3.3 Measuring axial clearance of crankshaft
  40
• 3.4 Measuring radial clearance of crankshaft
  41
• 3.5 Removing and installing drive chain sprocket for oil pump
  42
• 4 Dismantling and assembling pistons and conrods
  44
• 4.1 Checking pistons, piston rings and cylinder bores
  44
• 4.2 Assembly overview - pistons and conrods
  46
• 4.3 Piston and cylinder dimensions
  48
• Cylinder head, valve gear
  49
• 1 Cylinder head
  49
• 1.1 Assembly overview - cylinder head
  49
• 1.2 Removing, installing and tensioning toothed belt
  51
• 1.3 Removing and installing cylinder head
  55
• 1.4 Compression test
  61
• 2 Valve gear
  64
• 2.1 Assembly overview
  64
• 2.2 Reworking valve seats
  69
• 2.3 Renewing camshaft oil seals
  70
• 2.4 Checking hydraulic bucket tappets
  73
• 2.5 Removing and installing camshafts and variable camshaft timing adjusters
  74
• 2.6 Driving sealing cap (core plug) into replacement cylinder head
  81
• 2.7 Checking valve guides
  81
• 2.8 Renewing valve stem seals
  82
• Lubrication
  84
• 1 Parts of lubrication system
  84
• 1.1 Engine oil
  84
• 1.2 Assembly overview - oil pump with chain drive
  85
• 1.3 Removing and installing lower part of sump
  87
• 1.4 Checking chain tensioner for oil pump and removing and installing oil pump
  91
• 1.5 Removing and installing chain and chain tensioner for oil pump
  93
• 1.6 Removing and installing upper part of sump
  93
• 1.7 Renewing oil retention valves
  99
• 1.8 Checking oil pressure and oil pressure switch
  100
• Cooling
  103
• 1 Parts of cooling system
  103
• 1.1 Assembly overview - parts of cooling system, body side
  103
• 1.2 Assembly overview - parts of cooling system, engine side
  105
• 1.3 Checking continued coolant circulation pump
  107
• 1.4 Coolant hose schematic diagram
  108
• 1.5 Draining and filling coolant
  110
• 1.6 Removing and installing radiator
  114
• 1.7 Removing and installing coolant pump
  116
• 1.8 Removing and installing thermostat
  118
• 1.9 Removing and installing viscous fan coupling
  120
• Fuel supply system
  122
• 1 Parts of fuel supply system - vehicles with front-wheel drive
  122
• 1.1 Safety precautions when working on fuel supply system
  122
• 1.2 Rules for cleanliness
  123
• 1.11 Assembly overview - fuel tank with attachments: engine codes AHA, ATQ
  139
• 1.12 Removing and installing fuel tank
  142
• 1.13 Crash fuel shut-off
  144
• 1.14 Checking fuel pump
  144
• 2 Parts of fuel supply system - vehicles with four-wheel drive
  150
• 2.2 Assembly overview - fuel tank with attachments: engine codes AHA, ATQ
  153
• 2.3 Assembly overview - fuel filter
  158
• 2.4 Emptying fuel tank
  159
• 2.5 Removing and installing fuel delivery unit
  161
• 2.6 Removing and installing fuel gauge sender G
  166
• 2.7 Removing and installing fuel gauge sender 2 G169
  167
• 2.8 Removing and installing fuel gauge sender 3 G237
  169
• 2.9 Removing, installing and checking suction-jet pumps
  172
• 2.10 Removing and installing fuel tank
  173
• 2.11 Checking fuel pump
  176
• 3 Accelerator mechanism: engine codes ACK, AGE, AHA, ALG
  182
• 3.1 Assembly overview
  182
• 3.2 Adjusting accelerator cable
  183
• 4.1 Function of the electronic throttle
  185
• 4.2 Assembly overview
  185
• 5.1 Activated charcoal filter system function description
  187
• 5.2 Assembly overview
  187
• 5.3 Checking fuel tank breather
  189
• 6 Activated charcoal filter system: engine codes AHA, ATQ
  193
• 6.1 Activated charcoal filter system function description
  193
• 6.2 Assembly overview
  194
• 6.3 Overview of activated charcoal filter system
  195
• Mixture preparation - injection
  196
• 1 Repairing injection system
  196
• 1.1 Safety precautions
  196
• 1.2 Rules for cleanliness
  197
• 1.3 Assembly overview - air filter
  197
• 1.4 Assembly overview - fuel rail with injectors
  199
• 1.7 Technical data
  204
• 2 Checking components
  205
• 2.1 Checking injectors for leaks and injection rate
  205
• 2.2 Checking fuel pressure regulator and holding pressure
  207
• 3 Engine control unit
  211
• 3.1 Renewing engine control unit
  211
• 3.2 Adapting functions and components
  212
• 3.3 Reading and erasing engine control unit fault memory
  214
• Exhaust system
  216
• 1 Removing and installing parts of exhaust system
  216
• 1.3 Assembly overview - silencer with mountings: vehicles with front-wheel drive
  221
• 1.4 Assembly overview - silencer with mountings: vehicles with four-wheel drive
  222
• 1.5 Removing and installing front exhaust pipe with catalytic converter
  223
• 2.1 Assembly overview
  229
• 2.2 Checking combination valve
  232
• 2.3 Removing and installing combination valve
  233
• Ignition system
  235
• 1 Ignition system
  235
• 1.1 Safety precautions
  235
• 1.2 Assembly overview
  235
• 1.3 Test data, spark plugs
  237