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 Removing engine
  4
• 1.2 Securing engine on engine and gearbox support VAS 6095
  14
• 1.3 Installing engine
  15
• Crankshaft group
  19
• 1 Dismantling and assembling engine
  19
• 1.1 Part I: assembly overview - chain drive
  20
• 1.2 Part II: assembly overview - cylinder block
  23
• 1.3 Removing and installing vibration damper
  25
• 1.5 Removing and installing poly V-belt
  28
• 2 Sealing flange and dual-mass flywheel
  30
• 2.1 Assembly overview
  30
• 2.2 Removing and installing seal, flywheel end
  31
• 2.3 Removing and installing flywheel
  33
• 2.4 Removing and installing drive plate
  34
• 2.5 Renewing crankshaft oil seal, vibration damper end
  35
• 2.6 Renewing crankshaft sealing flange -vibration damper side-
  37
• 3 Pistons and conrods
  40
• 3.1 Assembly overview
  40
• 3.2 Separating new conrod
  41
• 3.3 Checking piston and cylinder
  41
• 3.4 Piston and cylinder dimensions
  43
• 4 Crankshaft
  44
• 4.1 Assembly overview
  44
• 4.2 Fitting sender wheel to crankshaft
  45
• 4.3 Allocation of crankshaft bearing shells (classification)
  46
• Cylinder head, valve gear
  48
• 1 Cylinder head
  48
• 1.1 Assembly overview
  48
• 1.2 Removing and installing cylinder head
  52
• 1.3 Checking valve timing
  56
• 1.4 Installing timing chain for intermediate shaft drive and camshaft drive
  58
• 1.5 Installing camshaft adjuster with timing chain for camshaft drive
  64
• 1.6 Removing and installing cylinder head cover
  68
• 1.7 Assembly overview - cover part
  71
• 1.8 Checking compression
  74
• 2 Valve gear
  76
• 2.1 Assembly overview - valve gear
  76
• 2.2 Removing and installing camshaft control valves
  79
• 2.3 Removing and installing camshafts
  82
• 2.4 Renewing valve stem seals
  87
• 2.5 Checking valve guides
  91
• 2.6 Reworking valve seats
  91
• Lubrication
  95
• 1 Parts of lubrication system
  95
• 1.1 Engine oil
  95
• 1.2 Assembly overview
  95
• 1.3 Assembly overview - dismantling and assembling oil filter housing
  98
• 1.4 Assembly overview - dismantling and assembling oil pump
  100
• 1.5 Removing and installing sump
  101
• 1.6 Checking oil pressure and oil pressure switch
  104
• Cooling
  108
• 1 Parts of cooling system
  108
• 1.1 Assembly overview - radiator
  109
• 1.2 Assembly overview - removing and installing fan
  110
• 1.3 Assembly overview - parts of cooling system, body side
  111
• 1.4 Assembly overview - thermostat housing
  112
• 1.5 Assembly overview - parts of cooling system, engine side
  113
• 1.6 Coolant hose schematic diagram
  114
• 1.7 Draining and filling coolant
  115
• 1.8 Removing and installing radiator
  118
• 1.9 Removing and installing coolant pump
  119
• Fuel supply system
  120
• 1 Parts of fuel supply system
  120
• 1.1 Assembly overview - fuel tank with attachments and fuel filter
  120
• 1.3 Assembly overview - fuel delivery unit, fuel gauge sender and suction jet pump on left side
  124
• 1.4 Schematic diagram of fuel lines and components in fuel tank
  126
• 1.5 Safety precautions when working on fuel supply system
  128
• 1.6 Rules for cleanliness
  128
• 1.7 Emptying fuel tank
  128
• 1.8 Removing and installing fuel delivery unit, fuel gauge sender and suction-jet pump, right side
  131
• 1.9 Removing and installing fuel delivery unit, fuel gauge sender and suction-jet pump, left side
  134
• 1.10 Removing and installing fuel tank with attachments and fuel filter
  137
• 1.11 Checking fuel pumps
  139
• 2 Activated charcoal filter system
  148
• 2.1 Assembly overview - parts of activated charcoal filter system
  148
• 2.2 Checking activated charcoal filter system for leaks
  150
• 3 Checking electronic power control (EPC)
  153
• Mixture preparation - injection
  155
• 1 Injection system
  155
• 1.1 General notes on injection
  155
• 1.2 Assembly overview - intake manifold
  155
• 1.3 Assembly overview - fuel rail
  157
• 1.4 Assembly overview - air filter
  158
• 1.5 Safety precautions
  158
• 1.6 Rules for cleanliness
  159
• 1.7 Technical data
  159
• 2 Checking components
  161
• 2.1 Checking injectors
  161
• 2.2 Checking fuel pressure regulator and holding pressure
  163
• 3 Engine control unit
  167
• 3.1 Removing and installing engine control unit
  167
• 3.2 Reading and erasing engine control unit fault memory
  167
• Exhaust system
  169
• 1 Parts of exhaust system
  169
• 1.1 Assembly overview - exhaust manifold with starter catalytic converters and attachments
  170
• 1.2 Exhaust pipes with main catalytic converters and silencers with mountings
  172
• 2 Secondary air system
  176
• 2.1 Assembly overview - parts of secondary air system
  176
• 2.2 Checking combination valve
  178
• Ignition system
  180
• 1 Ignition system
  180
• 1.1 Assembly overview - parts of ignition system
  180
• 1.2 Safety precautions
  182
• 1.3 Removing and installing ignition coils with output stage
  182
• 1.4 Test data, spark plugs
  184