6-cylinder injection engine Volkswagen R GmbH

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
  14
• 1 Dismantling and assembling engine
  14
• 1.1 Part I: Assembly overview - chain drive
  16
• 1.2 Part II: Assembly overview - crankshaft drive
  18
• 1.3 Removing and installing vibration damper
  19
• 1.4 Assembly overview - poly V-belt drive
  21
• 1.5 Removing and installing poly-V belt
  23
• 1.6 Removing and installing tensioner for poly V-belt
  24
• 2 Sealing flanges and flywheel
  26
• 2.1 Assembly overview - sealing flange
  26
• 2.2 Removing and installing crankshaft seal on gearbox side
  27
• 2.3 Renewing crankshaft sealing flange, vibration damper side
  28
• 2.4 Removing and installing flywheel
  30
• 2.5 Removing and installing drive plate
  31
• 3 Crankshaft
  34
• 3.1 Assembly overview - crankshaft
  34
• 3.2 Allocation of crankshaft bearing shells (classification)
  35
• 3.3 Fitting sender wheel to crankshaft
  37
• 3.4 Pulling needle bearing out of and driving into crankshaft
  37
• 4 Pistons and conrods
  41
• 4.1 Assembly overview - pistons and conrods
  41
• 4.2 Checking pistons, piston rings and cylinder bores
  43
• 4.3 Installing piston
  44
• 4.4 Piston and cylinder dimensions
  45
• Cylinder head, valve gear
  46
• 1 Cylinder head
  46
• 1.1 Assembly overview - cylinder head
  46
• 1.2 Removing and installing cylinder head
  49
• 1.3 Assembly overview - cover
  57
• 1.4 Checking valve timing
  59
• 1.5 Installing camshaft adjuster with timing chain for camshaft drive
  62
• 1.6 Installing timing chains for intermediate shaft drive and camshaft drive
  67
• 1.7 Removing and installing cylinder head cover
  74
• 1.8 Checking compression
  75
• 2 Valve gear
  78
• 2.1 Assembly overview
  78
• 2.2 Removing and installing camshafts
  80
• 2.3 Removing and installing camshaft control valves
  86
• 2.4 Valve stem seals
  90
• 2.5 Checking valve guides
  94
• 2.6 Reworking valve seats
  95
• Lubrication
  97
• 1 Parts of lubrication system
  97
• 1.1 Engine oil:
  97
• 1.2 Assembly overview - sump
  97
• 1.3 Removing and installing sump
  100
• 1.4 Assembly overview - oil filter bracket
  102
• 1.5 Removing and installing oil filter bracket
  104
• 1.6 Assembly overview - oil pump
  105
• 1.7 Checking oil pressure and oil pressure switch
  107
• Cooling
  111
• 1 Removing and installing parts of cooling system
  111
• 1.1 Assembly overview - parts of cooling system, body side
  112
• 1.2 Assembly overview - cooling system, engine side
  114
• 1.3 Assembly overview - thermostat housing
  115
• 1.4 Coolant hose connection diagram
  117
• 1.5 Draining and adding coolant
  118
• 1.6 Removing and installing fan mounting with fans
  121
• 1.7 Removing and installing radiator
  122
• 1.8 Checking continued coolant circulation pump
  124
• 1.9 Removing and installing coolant pump
  125
• 1.10 Removing and installing thermostat housing
  128
• 1.11 Removing and installing thermostat
  131
• 1.12 Removing and installing coolant pipe
  132
• 1.13 Checking cooling system for leaks
  134
• Fuel supply system
  136
• 1 Safety regulations for working on fuel supply
  136
• 2 Rules for cleanliness
  137
• 3 Fuel
  138
• 3.1 Assembly overview - fuel tank
  138
• 3.2 Emptying fuel tank
  140
• 3.3 Removing and installing fuel tank
  145
• 4 Repairing fuel supply
  149
• 4.1 Removing and installing fuel delivery unit
  149
• 4.2 Removing and installing fuel gauge sender 2 G169
  152
• 4.3 Removing and installing suction-jet pump
  154
• 4.4 Removing and installing fuel gauge sender G
  154
• 4.5 Assembly overview - fuel filter with attachments
  156
• 4.6 Removing and installing fuel filter
  157
• 4.7 Checking fuel pump
  157
• 4.8 Bleeding fuel system
  165
• 5 Electronic power control (EPC)
  168
• 5.1 Assembly overview - accelerator module
  168
• 5.2 Removing and installing accelerator pedal module
  168
• 6 Activated charcoal filter system
  171
• 6.1 Assembly overview - activated charcoal filter system
  171
• 6.2 Checking fuel tank breather
  172
• Mixture preparation - injection
  174
• 1 Repairing injection system
  174
• 1.1 General notes on the injection system
  174
• 1.2 Technical data
  174
• 1.3 Assembly overview - intake manifold
  175
• 1.4 Removing and installing throttle valve module J338
  178
• 1.5 Removing and installing intake manifold
  178
• 1.6 Assembly overview - fuel rail
  180
• 1.7 Assembly overview - air filter
  182
• 1.8 Assembly overview - damping chamber with resonance air pipe
  183
• 1.9 Checking intake air preheating
  183
• 2 Checking components
  185
• 2.1 Checking vacuum unit for intake manifold flaps
  185
• 2.2 Checking injectors for leaks and quantity injected
  186
• 2.3 Checking fuel pressure regulator and holding pressure
  189
• 3 Engine (motor) control unit
  193
• 3.1 Removing and installing engine control unit
  193
• 3.2 Removing and installing anti-theft engine control unit
  193
• Exhaust system
  197
• 1 Exhaust manifold, front exhaust pipe with catalytic converters and Lambda probes
  197
• 1.2 Removing and installing Lambda probe G39 and Lambda probe 2 G108
  200
• 1.3 Removing and installing exhaust manifold
  202
• 1.4 Removing and installing front exhaust pipe with catalytic converters
  203
• 2 Silencer with mountings
  206
• 2.1 Assembly overview - silencers with mountings
  206
• 2.2 Checking exhaust flap
  207
• 2.3 Aligning exhaust system free of stress
  208
• 3 Secondary air system
  210
• 3.1 Function
  210
• 3.2 Assembly overview - secondary air system
  210
• 3.3 Removing and installing secondary air pump motor V101
  212
• 3.4 Checking combination valve for secondary air system
  213
• 3.5 Removing and installing combination valve for secondary air system
  213
• Ignition system
  214
• 1 Ignition system
  214
• 1.1 General notes on ignition system
  214
• 1.2 Safety precautions
  214
• 1.3 Assembly overview - parts of ignition system
  215
• 1.4 Removing and installing ignition coils with output stage
  216
• 1.5 Test data, spark plugs
  218