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
  15
• 1 Dismantling and assembling engine
  15
• 1.1 Part I
  16
• 1.2 Part II
  19
• 1.3 Removing and installing vibration damper (engine code BWS)
  20
• 1.4 Removing and installing bracket for ancillaries
  21
• 1.5 Removing and installing poly-V belt
  22
• 2 Sealing flange and flywheel or drive plate
  24
• 2.1 Assembly overview - sealing flanges and flywheel
  24
• 2.2 Assembly overview - sealing flanges and drive plate
  25
• 2.3 Assembly overview - timing chain covers
  26
• 2.4 Removing and installing crankshaft seal on gearbox side
  27
• 2.5 Removing and installing sealing flange on gearbox side
  28
• 2.6 Removing and installing flywheel
  31
• 2.7 Removing and installing drive plate
  32
• 2.8 Renewing crankshaft sealing flange, vibration damper side
  33
• 3 Assembly overview - crankshaft
  36
• 3.1 Fitting sender wheel to crankshaft
  37
• 3.2 Pulling needle bearing out of and driving into crankshaft
  38
• 3.3 Allocation of crankshaft bearing shells (classification)
  40
• 4 Pistons and conrods
  42
• 4.1 Checking piston and cylinder
  43
• 4.2 Piston and cylinder dimensions
  47
• Cylinder head, valve gear
  48
• 1 Cylinder head
  48
• 1.1 Assembly overview - cylinder head
  48
• 1.2 Removing and installing cylinder head
  51
• 1.3 Checking valve timing
  58
• 1.4 Installing camshaft adjuster with timing chain for camshaft drive
  64
• 1.5 Installing timing chain for oil pump drive and camshaft drive
  71
• 1.6 Removing and installing cylinder head cover
  76
• 1.7 Assembly overview - mechanical vacuum pump
  79
• 1.8 Removing and installing mechanical vacuum pump
  79
• 1.9 Installing cover oil seals
  81
• 1.10 Checking compression
  82
• 2 Valve gear
  86
• 2.1 Assembly overview - valve gear
  86
• 2.2 Camshafts, checking axial clearance
  88
• 2.3 Assembly overview - timing housing
  89
• 2.4 Removing and installing camshaft control valves
  90
• 2.5 Removing and installing camshafts
  94
• 2.6 Camshaft identification
  101
• 2.7 Renewing valve stem seals
  101
• 2.8 Valve dimensions
  104
• 2.9 Checking valve guides
  104
• 2.10 Reworking valve seats
  105
• Lubrication
  107
• 1 Parts of lubrication system
  107
• 1.1 Engine oil:
  107
• 1.2 Assembly overview - sump, oil pump and oil filter bracket
  108
• 1.3 Removing and installing sump
  110
• 1.4 Removing and installing oil pump
  113
• 1.5 Assembly overview – oil filter housing
  117
• 1.6 Checking oil pressure and oil pressure switch
  118
• Cooling
  121
• 1 Parts of cooling system
  121
• 1.1 Assembly overview - parts of cooling system, body side
  122
• 1.2 Assembly overview - additional cooler
  123
• 1.3 Assembly overview - cooling system, engine side
  124
• 1.4 Coolant hose connection diagram
  126
• 1.5 Draining and adding coolant
  127
• 1.6 Removing and installing fan mounting with fans
  130
• 1.7 Removing and installing radiator
  132
• 1.8 Removing and installing coolant pump
  134
• 1.9 Removing and installing thermostat
  136
• 1.10 Checking cooling system for leaks
  138
• Fuel supply system
  141
• 1 Safety precautions and rules for cleanliness
  141
• 1.1 Safety measures when working on fuel supply
  141
• 1.2 Releasing pressure in high-pressure area
  142
• 1.3 Rules for cleanliness
  143
• 2 Fuel tank, vehicles with four-wheel drive
  144
• 2.1 Rules for cleanliness
  144
• 2.2 Assembly overview - fuel tank
  144
• 2.3 Emptying fuel tank
  146
• 2.4 Removing and installing fuel tank
  152
• 2.5 Removing and installing fuel gauge sender 2 G169
  156
• 2.6 Removing and installing suction-jet pump
  159
• 3 Repairing fuel supply
  161
• 3.1 Rules for cleanliness
  161
• 3.2 Removing and installing fuel delivery unit
  161
• 3.3 Removing and installing fuel gauge sender G
  165
• 3.4 Checking fuel pump
  166
• 4 Electronic power control (EPC)
  176
• 4.1 Assembly overview - accelerator module
  176
• 4.2 Removing and installing accelerator pedal module
  176
• 5 Activated charcoal filter system
  179
• 5.1 Function
  179
• 5.2 Assembly overview - activated charcoal filter system
  179
• 5.3 Checking fuel system for leaks
  180
• Mixture preparation - injection
  188
• 1 Injection system
  188
• 1.1 General notes on the injection system
  189
• 1.2 Rules for cleanliness
  189
• 1.3 Technical data
  190
• 1.4 Assembly overview - intake manifold
  190
• 1.5 Assembly overview - fuel rail with high-pressure pump and injectors
  191
• 1.6 Assembly overview - air filter
  194
• 1.7 Assembly overview - sound generator with resonance air pipe
  195
• 1.8 Checking intake air preheating
  195
• 1.9 Removing and installing intake manifold upper part
  196
• 1.10 Removing and installing lower part of intake manifold with fuel rail
  199
• 1.11 Removing and installing high-pressure pump
  202
• 1.12 Checking fuel pressure sender G247
  204
• 1.13 Removing and installing injectors
  206
• 1.14 Renewing Teflon seal and support washer on injector
  209
• 2 Engine control unit J623
  214
• 2.1 Removing and installing engine (motor) control unit J623
  214
• 2.3 Removing and installing anti-theft engine control unit J623 (with locking clip)
  219
• Exhaust system
  222
• 1 Parts of the exhaust system
  222
• 1.2 Removing and installing exhaust manifold
  226
• 1.3 Removing and installing Lambda probe G39 and Lambda probe 2 G108
  227
• 1.4 Removing and installing front exhaust pipes with catalytic converters and front silencers
  228
• 1.5 Assembly overview - silencers with mountings
  231
• Ignition system
  235
• 1 Ignition system
  235
• 1.1 General notes on ignition system
  235
• 1.2 Assembly overview - ignition system
  235
• 1.3 Test data, spark plugs
  237
• 1.4 Removing and installing ignition coils with output stage
  237