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 to assembly stand
  11
• 1.3 Installing engine
  13
• Crankshaft group
  16
• 1 Dismantling and assembling engine
  16
• 1.1 Assembly overview - chain drive
  16
• 1.2 Assembly overview - cylinder block
  19
• 1.3 Removing and installing vibration damper
  21
• 1.5 Removing and installing poly V-belt
  24
• 2 Removing and installing sealing flanges and dual-mass flywheel
  26
• 2.1 Assembly overview - sealing flange
  26
• 2.2 Removing and installing drive plate
  27
• 2.3 Removing and installing seal, flywheel end
  28
• 2.4 Renewing crankshaft oil seal, vibration damper end
  29
• 2.5 Renewing crankshaft sealing flange -vibration damper side-
  31
• 3 Assembly overview - crankshaft
  34
• 3.1 Allocation of crankshaft bearing shells (classification)
  35
• 4 Dismantling and assembling pistons and conrods
  38
• 4.1 Assembly overview - pistons and conrods
  38
• 4.2 Checking pistons, piston rings and cylinder bores
  39
• Cylinder head, valve gear
  42
• 1 Cylinder head
  42
• 1.1 Assembly overview - cylinder head
  42
• 1.2 Removing and installing cylinder head
  46
• 1.3 Checking valve timing
  52
• 1.4 Installing timing chains for intermediate shaft drive and camshaft drive
  54
• 1.5 Installing camshaft adjuster with timing chain for camshaft drive
  60
• 1.6 Removing and installing cylinder head cover
  63
• 1.7 Assembly overview - removing and installing cover
  65
• 1.8 Checking compression
  68
• 2 Valve gear
  71
• 2.1 Assembly overview
  71
• 2.2 Removing and installing camshafts
  73
• 2.3 Removing and installing camshaft control valves
  80
• 2.4 Renewing valve stem seals
  84
• 2.5 Checking valve guides
  85
• 2.6 Reworking valve seats
  86
• Lubrication
  89
• 1 Removing and installing parts of lubrication system
  89
• 1.1 Assembly overview
  89
• 1.2 Dismantling and assembling oil filter housing
  92
• 1.3 Dismantling and assembling oil pump
  94
• 1.4 Removing and installing oil sump
  95
• 1.5 Checking oil pressure and oil pressure switch
  97
• Cooling
  100
• 1 Removing and installing parts of cooling system
  100
• 1.1 Assembly overview - radiator
  101
• 1.2 Assembly overview - radiator fan
  103
• 1.3 Assembly overview - parts of cooling system, body side
  103
• 1.4 Assembly overview - thermostat housing
  105
• 1.5 Removing and installing thermostat housing
  106
• 1.6 Removing and installing thermostat
  107
• 1.7 Assembly overview - parts of cooling system, engine side
  108
• 1.8 Coolant hose schematic diagram
  110
• 1.9 Draining and filling coolant
  111
• 1.10 Removing and installing radiator
  114
• 1.11 Removing and installing coolant pump
  115
• 1.12 Checking cooling system for leaks
  116
• Fuel supply system
  118
• 1 Parts of fuel supply system
  118
• 1.1 Assembly overview - fuel tank with attachments
  119
• 1.2 Assembly overview - fuel filter
  121
• 1.3 Schematic diagram of fuel lines and components in fuel tank
  121
• 1.4 Safety precautions when working on fuel supply system
  123
• 1.5 Rules for cleanliness
  123
• 1.6 Renewing fuel filter
  124
• 1.7 Bleeding fuel system
  125
• 1.8 Emptying fuel tank
  127
• 1.10 Removing and installing fuel tank with attached components
  132
• 1.11 Checking fuel pumps
  135
• 2 Electronic power control (EPC)
  146
• 3.1 Assembly overview - activated charcoal filter system
  149
• 4 Activated charcoal filter system (vehicles with engine code BAA or BMX)
  151
• 4.1 Assembly overview - activated charcoal filter system
  152
• 4.2 Checking fuel system for leaks
  153
• Mixture preparation - injection
  160
• 1 Repairing injection system
  160
• 1.1 Assembly overview - intake manifold
  160
• 1.2 Assembly overview - fuel rail
  162
• 1.3 Assembly overview - air filter
  162
• 1.4 Safety precautions
  165
• 1.5 Rules for cleanliness
  165
• 1.6 Technical data
  166
• 2 Checking components
  167
• 2.1 Checking injectors
  167
• 2.2 Checking fuel pressure regulator and holding pressure
  169
• 3 Engine control unit
  172
• 3.1 Removing and installing engine control unit
  172
• 3.2 Removing and installing anti-theft engine control unit
  172
• Exhaust system
  175
• 1 Removing and installing parts of exhaust system
  175
• 1.1 Assembly overview - exhaust manifold with starter catalytic converters and attachments
  176
• 1.2 Silencer with mountings
  178
• 2 Secondary air system
  181
• 2.1 Assembly overview - parts of secondary air system
  181
• 2.2 Checking combination valve
  183
• Ignition system
  185
• 1 Repairing ignition system
  185
• 1.1 Assembly overview - parts of ignition system
  185
• 1.2 Safety precautions
  187
• 1.3 Test data, spark plugs
  187
• 1.4 Removing and installing ignition coils with output stage
  188