6-cylinder injection engine (4-valve), mechanics

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 Notes on removing
  4
• 1.2 Securing engine to assembly stand
  8
• 1.3 Notes on installing
  8
• 1.4 Specified torques
  10
• 1.5 Assembly mountings
  10
• 1.6 Additional information and assembly work for vehicles with air conditioner
  11
• Crankshaft group
  12
• 1 Dismantling and assembling engine
  12
• 1.1 Part I
  13
• 1.2 Part II
  16
• 1.3 Removing and installing poly-V belt
  18
• 2 Removing and installing sealing flanges and dual-mass flywheel
  20
• 2.1 Renewing crankshaft oil seal, vibration damper end
  22
• 2.2 Removing and installing drive plate
  24
• 3 Dismantling and assembling pistons and conrods
  26
• 3.1 Piston and cylinder dimensions
  30
• 4 Removing and installing crankshaft
  31
• Cylinder head, valve gear
  33
• 1 Assembly overview - cylinder head
  33
• 1.1 Removing and installing cylinder head cover
  38
• 1.2 Removing and installing cylinder head
  41
• 1.3 Checking valve timing
  47
• 1.4 Removing and installing camshaft adjuster
  50
• 1.5 Removing and installing camshaft timing chain and intermediate shaft drive chain
  57
• 1.6 Checking compression
  68
• 2 Repairing valve gear
  71
• 2.1 Reworking valve seats
  75
• 2.2 Removing and installing camshafts
  77
• 2.3 Checking variable valve timing
  83
• 2.4 Checking valve guides
  88
• 2.5 Renewing valve stem seals
  88
• Lubrication
  91
• 1 Removing and installing parts of lubrication system
  91
• 1.1 Engine oil:
  91
• 1.2 Assembly overview - sump
  91
• 1.3 Dismantling and assembling oil filter housing
  94
• 1.4 Dismantling and assembling oil pump
  96
• 1.5 Removing and installing sump
  97
• 1.6 Checking oil pressure and oil pressure switch
  98
• Cooling
  101
• 1 Removing and installing parts of cooling system
  101
• 1.1 Parts of cooling system, body side
  101
• 1.2 Parts of cooling system - engine side
  103
• 1.3 Coolant hose schematic diagram
  105
• 1.4 Dismantling and assembling thermostat housing
  105
• 1.5 Draining and adding coolant
  107
• 1.6 Removing and installing radiator and fan
  110
• 1.7 Checking radiator fan
  112
• 1.8 Checking continued coolant circulation pump
  113
• 1.9 Removing and installing coolant pump
  114
• Fuel supply system
  119
• 1 Removing and installing parts of fuel supply system
  119
• 1.1 Removing and installing fuel tank with attachments and fuel filter
  119
• 1.2 Safety measures when working on fuel supply
  123
• 1.3 Rules for cleanliness
  123
• 1.4 Removing and installing fuel delivery unit
  124
• 1.5 Removing and installing fuel gauge sender
  125
• 1.6 Crash fuel shut-off
  125
• 1.7 Checking fuel pump
  126
• 2 Activated charcoal filter system
  132
• 2.1 Function
  132
• 2.2 Repairing parts of activated charcoal filter system
  132
• 2.3 Checking activated charcoal filter system
  134
• 2.4 Checking fuel tank breather
  138
• 3 Electronic power control (EPC)
  140
• 3.1 Function of EPC system
  140
• 3.2 Repairing parts of electronic power control (EPC)
  140
• 3.3 Checking accelerator position sender
  142
• Exhaust system
  146
• 1 Removing and installing parts of exhaust system
  146
• 1.2 Silencer with mountings
  148
• 1.3 Checking catalytic converter
  148
• 2 Secondary air system
  155
• 2.1 Removing and installing parts of secondary air system
  155
• 2.2 Checking secondary air system
  158
• 2.3 Checking secondary air pump motor
  162
• 2.4 Checking combination valve
  163