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
  11
• 1.3 Installing engine
  13
• 2 Assembly mountings
  16
• 2.1 Assembly overview - assembly mountings
  16
• 2.2 Removing and installing engine mountings
  16
• Crankshaft group
  21
• 1 Dismantling and assembling engine
  21
• 1.1 Part I
  22
• 1.2 Part II
  25
• 1.3 Removing and installing poly V-belt
  27
• 2 Sealing flange and dual-mass flywheel/drive plate
  29
• 2.1 Assembly overview - sealing flanges and dual-mass flywheel/drive plate
  29
• 2.2 Assembly overview - timing chain covers
  30
• 2.3 Removing and installing seal, flywheel end
  31
• 2.4 Removing and installing sealing flange on gearbox side
  32
• 2.5 Removing and installing flywheel
  35
• 2.6 Removing and installing drive plate
  36
• 2.7 Renewing crankshaft sealing flange -vibration damper side-
  37
• 3 Crankshaft
  40
• 3.1 Assembly overview - crankshaft
  40
• 3.2 Fitting sender wheel to crankshaft
  41
• 3.3 Allocation of main bearing shells
  42
• 4 Pistons and conrods
  47
• 4.1 Assembly overview - pistons and conrods
  47
• 4.2 Checking piston and cylinder
  48
• 4.3 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
  63
• 1.4 Removing and installing camshaft adjuster
  69
• 1.5 Removing and installing chain drive for oil pump
  82
• 1.6 Removing and installing camshaft drive timing chain, vehicles with vacuum pump
  91
• 1.8 Removing and installing cylinder head cover
  99
• 1.9 Assembly overview - mechanical vacuum pump
  101
• 1.10 Removing and installing mechanical vacuum pump
  102
• 1.11 Installing cover oil seals
  104
• 1.12 Checking compression
  105
• 2 Valve gear
  108
• 2.1 Assembly overview - valve gear
  108
• 2.2 Camshafts, checking axial clearance
  110
• 2.3 Assembly overview - timing housing
  111
• 2.4 Removing and installing camshaft control valves
  112
• 2.5 Removing and installing camshafts
  114
• 2.6 Camshaft identification
  121
• 2.7 Renewing valve stem seals
  121
• 2.8 Valve dimensions
  124
• 2.9 Checking valve guides
  124
• 2.10 Reworking valve seats
  125
• Lubrication
  127
• 1 Parts of lubrication system
  127
• 1.1 Engine oil
  127
• 1.2 Assembly overview - sump, oil pump and oil filter bracket
  128
• 1.3 Removing and installing oil sump
  130
• 1.4 Removing and installing oil pump
  135
• 1.5 Assembly overview - oil filter housing
  138
• 1.6 Removing and installing left engine support with oil filter housing
  140
• 1.7 Removing and installing engine oil cooler
  143
• 1.8 Checking oil pressure and oil pressure switch
  145
• Cooling
  149
• 1 Parts of cooling system
  149
• 1.1 Assembly overview - radiator
  150
• 1.2 Assembly overview - radiator fan
  152
• 1.3 Assembly overview - cooling system, engine side, front and rear
  152
• 1.4 Assembly overview - cooling system, engine side, left
  153
• 1.5 Assembly overview - coolant pump and thermostat
  154
• 1.6 Assembly overview - parts of cooling system, body side
  156
• 1.7 Coolant hose schematic diagram
  157
• 1.8 Draining and filling coolant
  158
• 1.9 Removing and installing fan support with fans
  161
• 1.10 Removing and installing radiator
  161
• 1.11 Removing and installing, checking thermostat
  163
• 1.12 Removing and installing coolant pump
  164
• 1.13 Checking cooling system for leaks
  166
• Fuel supply system
  169
• 1 Safety precautions
  169
• 1.1 Safety precautions when working on fuel supply system
  169
• 1.2 Releasing pressure in high-pressure area
  170
• 2 Parts of fuel supply system
  172
• 2.1 Rules for cleanliness
  173
• 2.2 Assembly overview - fuel tank with attachments
  174
• 2.3 Assembly overview - fuel filter
  176
• 2.4 Renewing fuel filter
  176
• 2.5 Emptying fuel tank
  178
• 2.6 Removing and installing fuel gauge sender and suction-jet pumps
  181
• 2.7 Removing and installing fuel delivery unit and fuel gauge sender
  183
• 2.8 Removing and installing fuel tank with attached components
  186
• 2.9 Checking fuel pump (vehicles with one-piece intake manifold)
  190
• 2.10 Checking fuel pumps (vehicles with two-piece intake manifold)
  199
• 3 Electronic power control (EPC)
  207
• 3.1 Function of EPC system
  207
• 3.2 Assembly overview - accelerator
  207
• 4 Activated charcoal filter system
  209
• 4.1 Function
  209
• 4.2 Assembly overview - activated charcoal filter system (vehicles up to 08.2006)
  210
• 4.3 Assembly overview - activated charcoal filter system (vehicles from 08.2006)
  211
• 5.1 Assembly overview - activated charcoal filter system
  213
• 5.2 Checking fuel system for leaks
  215
• 6 Activated charcoal filter system (vehicles for USA and Canada from 08.2006)
  222
• 6.1 Assembly overview - activated charcoal filter system
  223
• 6.2 Checking fuel system for leaks
  224
• Mixture preparation - injection
  232
• 1 Injection system (vehicles with one-piece manifold)
  232
• 1.1 General notes on the injection system
  233
• 1.2 Rules for cleanliness
  233
• 1.3 Technical data
  233
• 1.4 Assembly overview - intake manifold
  234
• 1.5 Checking vacuum reservoir in intake manifold for leaks
  235
• 1.6 Checking vacuum unit for intake manifold flaps
  236
• 1.7 Assembly overview - fuel rail with high-pressure pump and injectors
  237
• 1.8 Assembly overview - air filter
  240
• 1.9 Assembly overview - suction-jet pump
  241
• 1.10 Removing and installing intake manifold
  242
• 1.11 Removing and installing high-pressure pump
  248
• 1.12 Checking fuel pressure sender G247
  250
• 1.13 Removing and installing injectors
  253
• 2 Injection system (vehicles with two-piece manifold)
  261
• 2.1 General notes on the injection system
  262
• 2.2 Rules for cleanliness
  262
• 2.3 Technical data
  262
• 2.4 Assembly overview - intake manifold
  263
• 2.5 Checking vacuum reservoir in intake manifold for leaks
  264
• 2.6 Checking vacuum unit for intake manifold flap
  265
• 2.7 Assembly overview - fuel rail with high-pressure pump and injectors
  266
• 2.8 Assembly overview - air filter
  269
• 2.9 Removing and installing intake manifold upper part
  270
• 2.10 Removing and installing intake manifold lower part with fuel rail
  273
• 2.11 Removing and installing high-pressure pump
  276
• 2.12 Checking fuel pressure sender G247
  278
• 2.13 Removing and installing injectors
  281
• 3 Engine control unit
  288
• 3.1 Removing and installing engine control unit
  288
• 3.2 Removing and installing anti-theft engine control unit
  288
• Exhaust system
  292
• 1 Parts of the exhaust system
  292
• 1.1 Assembly overview - exhaust manifold with starter catalytic converters and attachments
  293
• 1.2 Silencer with mountings
  295
• 1.4 Removing and installing catalytic converters
  297
• Ignition system
  299
• 1 Ignition system
  299
• 1.1 General notes on ignition system
  299
• 1.2 Assembly overview - ignition system
  299
• 1.3 Safety precautions
  301
• 1.4 Test data, spark plugs
  302
• 1.5 Removing and installing ignition coils with output stage
  302