6-cylinder injection engine (direct injection)

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 on engine and gearbox support VAS 6095
  10
• 1.3 Installing engine
  11
• 1.4 Specified torques for assembly mounting
  13
• Crankshaft group
  15
• 1 Dismantling and assembling engine
  15
• 1.1 Part I
  16
• 1.2 Part II
  19
• 1.3 Removing and installing vibration damper
  20
• 1.4 Removing and installing ancillary bracket
  22
• 1.5 Assembly overview - poly V-belt drive
  22
• 1.6 Removing and installing poly V-belt
  24
• 1.7 Removing and installing tensioner for poly V-belt
  25
• 2 Sealing flange and flywheel or drive plate
  26
• 2.1 Assembly overview - sealing flanges and flywheel
  26
• 2.2 Assembly overview - sealing flanges and drive plate
  27
• 2.3 Assembly overview - timing chain covers
  28
• 2.4 Removing and installing crankshaft seal on gearbox side
  29
• 2.5 Removing and installing sealing flange on gearbox side
  30
• 2.6 Removing and installing flywheel
  33
• 2.7 Removing and installing drive plate
  34
• 2.8 Renewing crankshaft sealing flange -vibration damper side-
  35
• 3 Assembly overview - crankshaft
  38
• 3.1 Fitting sender wheel to crankshaft
  39
• 3.2 Pulling needle bearing out of and driving into crankshaft
  40
• 3.3 Allocation of main bearing shells
  42
• 4 Pistons and conrods
  47
• 4.1 Checking piston and cylinder
  48
• 4.2 Piston and cylinder dimensions
  52
• Cylinder head, valve gear
  53
• 1 Cylinder head
  53
• 1.1 Assembly overview - cylinder head
  53
• 1.2 Removing and installing cylinder head
  56
• 1.3 Checking valve timing
  64
• 1.4 Removing and installing camshaft adjuster
  70
• 1.5 Removing and installing chain drive for oil pump
  83
• 1.6 Removing and installing camshaft drive timing chain, vehicles with vacuum pump
  92
• 1.8 Removing and installing cylinder head cover
  100
• 1.9 Assembly overview - mechanical vacuum pump
  102
• 1.10 Removing and installing mechanical vacuum pump
  103
• 1.11 Installing cover oil seals
  105
• 1.12 Checking compression
  106
• 2 Valve gear
  110
• 2.1 Assembly overview - valve gear
  110
• 2.2 Camshafts, checking axial clearance
  112
• 2.3 Assembly overview - control housing
  113
• 2.4 Removing and installing camshaft control valves
  114
• 2.5 Removing and installing camshafts
  118
• 2.6 Camshaft identification
  125
• 2.7 Renewing valve stem seals
  125
• 2.8 Valve dimensions
  128
• 2.9 Checking valve guides
  128
• 2.10 Reworking valve seats
  129
• Lubrication
  131
• 1 Parts of lubrication system
  131
• 1.1 Engine oil
  131
• 1.2 Assembly overview - sump, oil pump and oil filter bracket
  132
• 1.3 Removing and installing oil sump
  134
• 1.4 Removing and installing oil pump
  137
• 1.5 Assembly overview - oil filter housing
  145
• 1.6 Checking oil pressure and oil pressure switch
  147
• Cooling
  150
• 1 Parts of cooling system
  150
• 1.1 Assembly overview - parts of cooling system, body side
  151
• 1.2 Assembly overview - additional cooler
  153
• 1.3 Assembly overview - cooling system, engine side
  153
• 1.4 Coolant hose schematic diagram
  156
• 1.5 Draining and filling coolant
  157
• 1.6 Removing and installing fan support with fans
  160
• 1.7 Removing and installing radiator
  162
• 1.8 Removing and installing coolant pump
  164
• 1.9 Removing and installing thermostat
  167
• 1.10 Checking cooling system for leaks
  168
• Fuel supply system
  171
• 1 Safety precautions and rules for cleanliness
  171
• 1.1 Safety precautions when working on fuel supply system
  171
• 1.2 Releasing pressure in high-pressure area
  172
• 1.3 Rules for cleanliness
  173
• 2 Fuel tank, vehicles with front-wheel drive
  174
• 2.1 Assembly overview - fuel tank
  174
• 2.2 Emptying fuel tank
  176
• 2.3 Removing and installing fuel tank
  180
• 2.4 Removing and installing fuel gauge sender G
  183
• 3 Fuel tank, vehicles with four-wheel drive
  185
• 3.1 Rules for cleanliness
  185
• 3.2 Assembly overview - fuel tank (engine code AXZ)
  185
• 3.3 Assembly overview - fuel tank (engine code BLV)
  188
• 3.4 Emptying fuel tank
  189
• 3.5 Removing and installing fuel tank (vehicles to 06/2007)
  195
• 3.6 Removing and installing fuel tank (vehicles from 06/2007)
  201
• 3.7 Removing and installing fuel gauge sender 2 G169
  206
• 3.8 Removing and installing suction-jet pump
  209
• 4 Repairing fuel supply
  211
• 4.1 Rules for cleanliness
  211
• 4.2 Removing and installing fuel delivery unit
  211
• 4.3 Removing and installing fuel gauge sender G
  216
• 4.4 Checking fuel pump
  217
• 5 Electronic power control (EPC)
  234
• 5.1 Assembly overview - accelerator module
  234
• 5.2 Removing and installing accelerator module
  234
• 6 Assembly overview - activated charcoal filter system (engine code BLV)
  237
• 6.1 Function
  237
• 6.2 Assembly overview - activated charcoal filter system
  237
• 6.3 Checking fuel system for leaks
  238
• 7 Activated charcoal filter system (engine code AXZ)
  246
• 7.1 Function
  246
• 7.2 Assembly overview - activated charcoal filter system
  246
• 7.3 Checking fuel tank breather
  247
• Mixture preparation - injection
  249
• 1 Injection system (vehicles with one-piece manifold)
  249
• 1.1 General notes on the injection system
  250
• 1.2 Rules for cleanliness
  250
• 1.3 Technical data
  251
• 1.4 Assembly overview - intake manifold
  251
• 1.5 Checking vacuum reservoir in intake manifold for leaks
  252
• 1.6 Checking vacuum unit for intake manifold flaps
  253
• 1.7 Assembly overview - fuel rail with high-pressure pump (vehicles up to 07.2007)
  255
• 1.8 Assembly overview - fuel rail with high-pressure pump (vehicles from 07.2007)
  257
• 1.9 Assembly overview - air filter
  260
• 1.10 Checking intake air preheating
  261
• 1.11 Assembly overview - suction-jet pump
  261
• 1.12 Removing and installing intake manifold
  262
• 1.13 Removing and installing high-pressure pump
  268
• 1.14 Checking fuel pressure sender G247
  271
• 1.15 Removing and installing injectors
  274
• 2 Injection system (vehicles with two-piece manifold)
  282
• 2.1 General notes on the injection system
  283
• 2.2 Rules for cleanliness
  283
• 2.3 Technical data
  284
• 2.4 Assembly overview - intake manifold
  284
• 2.5 Assembly overview - fuel rail with high-pressure pump and injectors
  285
• 2.6 Assembly overview - air filter
  288
• 2.7 Checking intake air preheating
  289
• 2.8 Removing and installing intake manifold upper part
  289
• 2.9 Removing and installing intake manifold lower part with fuel rail
  292
• 2.10 Removing and installing high-pressure pump
  295
• 2.11 Checking fuel pressure sender G247
  297
• 2.12 Removing and installing injectors
  300
• 3 Engine control unit J623
  308
• 3.1 Removing and installing engine control unit J623
  308
• 3.3 Removing and installing anti-theft engine control unit J623 (with locking clip)
  313
• Exhaust system
  315
• 1 Exhaust system (engine code AXZ)
  315
• 1.2 Removing and installing exhaust manifold
  318
• 1.3 Removing and installing Lambda probe G39 and Lambda probe 2 G108
  319
• 1.4 Removing and installing front exhaust pipes with catalytic converters and front silencers
  321
• 1.5 Assembly overview - silencers with mountings
  323
• 2 Exhaust system (engine code BLV)
  327
• 2.2 Removing and installing exhaust manifold
  331
• 2.3 Removing and installing Lambda probe G39 and Lambda probe 2 G108
  332
• 2.6 Assembly overview - silencer with mountings (front-wheel drive)
  338
• 2.7 Assembly overview - silencer with mountings (four-wheel drive)
  340
• Ignition system
  345
• 1 Ignition system
  345
• 1.1 General notes on ignition system
  345
• 1.2 Assembly overview - ignition system
  345
• 1.3 Test data, spark plugs
  347
• 1.4 Removing and installing ignition coils with output stage
  347