6-cylinder injection engine (direct injection)

Chapter overview

• Technical data
  1
• 1 Identification
  1
• 1.1 Engine number/engine data
  1
• 2 General notes
  2
• 2.1 Numbering of cylinders
  2
• 3 Safety information
  3
• 3.1 Safety precautions during work on fuel system
  3
• 3.3 Safety precautions when working on cooling system
  4
• 3.4 Safety precautions when working on ignition system
  4
• 4 Repair notes
  6
• 4.1 Rules for cleanliness
  6
• 4.2 Foreign objects in engine
  6
• Removing and installing engine
  7
• 1 Removing and installing engine
  7
• 1.1 Removing engine
  7
• 1.2 Securing engine on engine and gearbox support
  19
• 1.3 Installing engine
  21
• Crankshaft group
  25
• 1 Cylinder block (pulley end)
  25
• 1.1 Assembly overview - cylinder block (pulley end)
  25
• 1.2 Removing and installing engine bracket
  28
• 1.3 Removing and installing poly-V belt
  30
• 1.4 Removing and installing sealing flange on pulley end
  31
• 2 Cylinder block, gearbox end
  35
• 2.1 Assembly overview - cylinder block, gearbox end
  35
• 2.2 Renewing crankshaft oil seal (gearbox end)
  36
• 2.3 Removing and installing sealing flange on gearbox side
  37
• 2.4 Removing and installing drive plate
  40
• 2.5 Removing and installing bracket for ancillaries
  42
• 3 Crankshaft
  44
• 3.1 Assembly overview - crankshaft
  44
• 3.2 Removing and installing sender wheel
  45
• 3.3 Allocation of main bearing shells
  46
• 4 Pistons and conrods
  51
• 4.1 Assembly overview - pistons and conrods
  51
• 4.2 Checking pistons and cylinder bores
  53
• 4.3 Removing and installing pistons
  54
• Cylinder head, valve gear
  60
• 1 Cylinder head
  60
• 1.1 Assembly overview - cylinder head
  60
• 1.2 Assembly overview - vacuum pump
  63
• 1.3 Removing and installing cylinder head
  63
• 1.4 Removing and installing cylinder head cover
  71
• 1.5 Removing and installing vacuum pump
  72
• 1.6 Checking compression
  75
• 2 Cover for timing chain
  79
• 2.1 Assembly overview - cover for timing chain
  79
• 2.2 Installing timing chain cover seals
  80
• 2.3 Assembly overview - valve timing housing, engine code CHNA
  81
• 2.4 Assembly overview - valve timing housing, engine codes CMVA, CPFA
  82
• 3 Chain drive
  83
• 3.1 Assembly overview - camshaft timing chains
  83
• 3.2 Removing and installing camshaft timing chain
  85
• 3.3 Removing and installing chain drive sprocket for high-pressure pump
  88
• 3.4 Removing and installing chain drive for oil pump
  89
• 3.5 Checking valve timing
  99
• 4 Valve gear
  102
• 4.1 Assembly overview - valve gear
  102
• 4.2 Measuring axial play of camshaft
  104
• 4.3 Removing and installing camshaft control valve
  105
• 4.4 Removing and installing camshaft
  108
• 4.5 Camshaft identification
  115
• 4.6 Removing and installing camshaft adjuster
  115
• 4.7 Removing and installing valve stem seal
  120
• 5 Inlet and exhaust valves
  123
• 5.1 Valve dimensions
  123
• 5.2 Checking valve guides
  123
• 5.3 Reworking valve seats
  124
• Lubrication
  126
• 1 Sump, oil pump
  126
• 1.1 Assembly overview - sump/oil pump
  126
• 1.2 Removing and installing oil sump
  131
• 1.3 Removing and installing oil pump
  133
• 1.4 Engine oil:
  143
• 2 Oil filter, oil pressure switch
  145
• 2.1 Assembly overview - oil filter housing, oil pressure switch
  145
• 2.2 Checking oil pressure and oil pressure switch
  147
• 3 Oil circuit
  150
• 3.1 Oil spray jets/nozzles
  150
• Cooling
  151
• 1 Cooling system/coolant
  151
• 1.1 Connection diagram - coolant hoses
  151
• 1.2 Draining and adding coolant
  154
• 1.3 Checking cooling system for leaks
  157
• 2 Coolant pump, regulation of cooling system
  158
• 2.1 Assembly overview - coolant pump, thermostat
  158
• 2.2 Removing and installing coolant pump
  159
• 2.3 Removing and installing thermostat
  160
• 2.4 Checking thermostat
  162
• 3 Coolant pipes
  163
• 3.1 Assembly overview - coolant pipes
  163
• 4 Radiator, radiator fan
  168
• 4.1 Assembly overview - radiator/radiator fan
  168
• 4.2 Assembly overview - radiator cowl and radiator fan
  169
• 4.3 Removing and installing radiator cowl with radiator fan
  169
• 4.4 Removing and installing radiator fan
  171
• 4.5 Removing and installing radiator
  172
• Mixture preparation - injection
  175
• 1 Vacuum system
  175
• 1.1 Checking vacuum system
  175
• 2 Injectors
  178
• 2.1 Assembly overview - fuel rail with injectors
  178
• 2.2 Assembly overview - injectors for cylinders 1, 3 and 5
  184
• 2.3 Assembly overview - injectors for cylinders 2, 4 and 6
  185
• 2.4 Removing and installing injectors
  185
• 2.5 Renewing seals on injectors
  188
• 3 High-pressure pump
  193
• 3.1 Assembly overview - high-pressure pump
  193
• 3.2 Removing and installing high-pressure pump
  194
• 4 Senders and sensors
  198
• 4.1 Checking fuel pressure sender G247
  198
• 5 Lambda probe
  201
• 5.1 Assembly overview - Lambda probe
  201
• 5.2 Removing and installing Lambda probe
  201
• 6 Intake manifold
  204
• 6.1 Assembly overview - intake manifold
  204
• 6.2 Removing and installing intake manifold upper part
  206
• 6.3 Removing and installing lower part of intake manifold with fuel rail
  209
• 7 Air filter
  214
• 7.1 Assembly overview - air filter housing
  214
• 8 Engine (motor) control unit
  216
• 8.1 Removing and installing engine control unit J623
  216
• Exhaust system
  217
• 1 Exhaust pipes, silencers
  217
• 1.1 Assembly overview - silencers
  217
• 1.2 Aligning exhaust system free of stress
  218
• 1.3 Separating exhaust pipes, silencers
  218
• 1.4 Installation position of clamp
  219
• 2 Exhaust gas cleaning
  220
• 2.1 Assembly overview - emission control
  220
• 2.2 Removing and installing starter catalytic converter
  221
• 3 Exhaust manifold
  223
• 3.1 Assembly overview - exhaust manifold
  223
• Ignition system
  224
• 1 Ignition system
  224
• 1.1 Assembly overview - ignition system
  224
• 1.2 Removing and installing ignition coils with output stage
  226
• 1.3 Removing and installing Hall sender
  228
• 1.4 Removing and installing engine speed sender G28
  229
• 1.5 Test data, spark plugs
  230