8-cylinder direct-injection engine (4.2 l engine, 4V)

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety regulations for working on fuel supply
  1
• 1.2 Safety measures when working on vehicles with start/stop system
  1
• 1.4 Safety precautions when working on ignition system
  2
• 1.5 Safety precautions when working on the cooling system
  2
• 2 Identification
  3
• 2.1 Engine number/engine data
  3
• 2.2 Numbering of cylinders
  4
• 3 Repair instructions
  5
• 3.1 Rules for cleanliness
  5
• 3.2 Foreign objects in engine
  5
• 3.3 Contact corrosion
  5
• 3.4 Routing and attachment of lines
  5
• 3.5 Fitting radiator and condensers
  6
• Removing and installing engine
  7
• 1 Removing and installing engine
  7
• 1.1 Removing engine
  7
• 1.2 Installing engine
  20
• 1.3 Separating engine and gearbox
  23
• 1.4 Securing engine on engine and gearbox support VAS 6095
  29
• 1.5 Supporting engine in installation position
  31
• 2 Assembly mountings
  35
• 2.1 Assembly overview - assembly mountings
  35
• 2.2 Removing engine mounting (left-side)
  36
• 2.3 Remove engine mounting (right-side)
  39
• Crankshaft group
  43
• 1 Cylinder block - belt pulley end
  43
• 1.1 Assembly overview - poly V-belt drive
  43
• 1.2 Removing and installing poly-V belt
  45
• 1.3 Removing and installing tensioning element for poly V-belt
  45
• 1.4 Removing and installing bracket for alternator
  46
• 1.5 Removing and installing vibration damper
  46
• 1.6 Renewing crankshaft oil seal - belt pulley end
  47
• 2 Cylinder block, gearbox end
  49
• 2.1 Assembly overview - drive plate
  49
• 2.2 Removing and installing drive plate
  50
• 2.3 Removing and installing sender wheel
  51
• 2.4 Checking sender wheel
  52
• 2.5 Renewing oil seal for crankshaft at gearbox end
  52
• 3 Crankshaft
  55
• 3.1 Assembly overview - crankshaft
  55
• 3.2 Allocation of main bearing shells for new crankshaft
  59
• 3.3 Allocation of main bearing shells for worn and re-machined crankshaft
  60
• 3.4 Crankshaft dimensions
  60
• 3.5 Measuring axial clearance of crankshaft
  60
• 3.6 Measuring radial clearance of crankshaft
  61
• 4 Pistons and conrods
  63
• 4.1 Assembly overview - pistons and conrods
  63
• 4.2 Piston and cylinder dimensions
  66
• 4.3 Measuring radial clearance of conrods
  66
• Cylinder head, valve gear
  67
• 1 Chain drive
  67
• 1.1 Assembly overview - timing chain covers
  67
• 1.2 Removing and installing timing chain cover (left)
  69
• 1.3 Removing and installing timing chain cover (right)
  71
• 1.4 Removing and installing timing chain cover (bottom)
  74
• 1.5 Assembly overview - camshaft timing chains
  78
• 1.6 Removing camshaft timing chains from camshafts
  82
• 1.7 Removing and installing camshaft timing chains
  89
• 1.8 Assembly overview - drive chain for valve gear
  91
• 1.9 Removing and installing drive chain for valve gear
  93
• 1.10 Assembly overview - drive chain for auxiliary drives
  94
• 1.11 Removing and installing drive chain for auxiliary drives
  95
• 1.12 Assembly overview - auxiliary drives
  95
• 1.13 Renewing oil seal for vane pump drive
  97
• 1.14 Renewing oil seal for air conditioning compressor drive
  98
• 1.15 Removing and installing spur gear drive
  100
• 2 Cylinder head
  104
• 2.1 Assembly overview - cylinder head
  104
• 2.2 Removing and installing cylinder head cover
  107
• 2.3 Removing left cylinder head
  109
• 2.4 Removing right cylinder head
  110
• 2.5 Installing cylinder head
  112
• 2.6 Checking compression
  115
• 3 Valve gear
  119
• 3.1 Assembly overview - valve gear
  119
• 3.2 Measuring axial clearance of camshaft
  122
• 3.3 Measuring radial clearance of camshafts
  123
• 3.4 Removing and installing camshafts
  123
• 3.5 Checking hydraulic compensation elements
  132
• 3.6 Renewing valve stem seals with cylinder head installed
  134
• 3.7 Renewing valve stem seals with cylinder head removed
  137
• 3.8 Valve dimensions
  141
• 3.9 Checking valve guides
  141
• 3.10 Checking valves
  142
• Lubrication
  143
• 1 Engine oil:
  143
• 1.1 Check engine oil level with oil gauge tester T40178
  143
• 2 Oil pump and lower part of sump
  145
• 2.1 Assembly overview - oil pump and lower part of sump
  145
• 2.2 Removing and installing oil level and oil temperature sender G266
  148
• 2.3 Removing and installing lower part of sump
  148
• 2.4 Removing and installing oil pump
  151
• 3 Upper part of sump
  153
• 3.1 Assembly overview - upper part of sump
  153
• 3.2 Removing and installing oil pressure regulating valve N428
  154
• 3.3 Removing and installing upper part of sump
  154
• 4 Spray nozzle valve, oil pressure switch, oil filter housing, engine oil cooler
  159
• 4.1 Assembly overview - spray nozzle valve and oil pressure switch F22
  159
• 4.2 Removing and installing oil pressure switch F22
  160
• 4.3 Removing and installing spray nozzle valve
  161
• 4.4 Removing and installing hose for crankcase breather system
  162
• 4.5 Assembly overview - oil filter housing and oil pressure switch for reduced oil pressure F378
  163
• 4.6 Removing and installing oil filter housing
  164
• 4.7 Removing and installing engine oil cooler
  165
• 4.9 Removing and installing oil pressure switch for reduced oil pressure F378
  166
• 4.10 Checking oil pressure
  168
• Cooling
  170
• 1 Cooling system
  170
• 1.1 Connection diagrams for coolant hoses
  170
• 1.2 Draining coolant
  171
• 1.3 Draining cooling system (vehicles with one heat exchanger)
  173
• 1.4 Draining cooling system (vehicles with two heat exchangers)
  175
• 1.5 Filling with coolant
  176
• 1.6 Checking filling quality
  180
• 1.7 Checking cooling system for leaks
  181
• 2 Coolant pump and thermostat
  184
• 2.1 Assembly overview - coolant pump and thermostat
  184
• 2.2 Removing and installing coolant pump
  185
• 2.3 Removing and installing map-controlled engine cooling thermostat F265
  186
• 2.4 Thermostat opening data
  187
• 3 Coolant pipes
  188
• 3.1 Assembly overview - coolant pipes
  188
• 3.2 Removing and installing coolant temperature sender G62
  189
• 3.4 Removing and installing front coolant pipe
  191
• 3.5 Removing and installing right coolant pipe
  192
• 3.6 Removing and installing left coolant pipe
  193
• 3.7 Removing and installing coolant shut-off valve
  196
• 3.8 Removing and installing coolant union
  196
• 3.9 Removing and installing rear coolant pipe
  197
• 4 Radiator and radiator fans
  200
• 4.1 Assembly overview - radiator and radiator fan
  200
• 4.2 Removing and installing radiator module
  201
• 4.3 Removing and installing radiator cowl
  205
• 4.4 Dismantling cooler module
  206
• Fuel supply system
  208
• 1 Safety precautions
  208
• 1.1 Safety regulations for working on fuel supply
  208
• 2 Parts of fuel supply system
  209
• 2.1 Rules for cleanliness
  210
• 2.2 Assembly overview - fuel tank with attachments
  210
• 2.3 Assembly overview - fuel delivery unit, fuel gauge sender and suction jet pumps
  212
• 2.4 Removing, installing and renewing fuel filter
  214
• 2.5 Emptying fuel tank
  216
• 2.6 Removing and installing fuel gauge sender 2 G169 and suction-jet pump
  219
• 2.7 Removing and installing fuel delivery unit and fuel gauge sender G
  223
• 2.8 Removing and installing fuel tank with attached components
  226
• 3 Checking fuel pump
  231
• 3.1 Checking fuel pressure
  231
• 3.2 Checking holding pressure
  235
• 3.3 Checking fuel delivery rate
  236
• 4 Electronic power control (EPC)
  241
• 4.1 Assembly overview - accelerator
  241
• 5 Activated charcoal filter system
  242
• 5.1 Assembly overview - activated charcoal filter system
  242
• 5.2 Checking fuel system for leaks
  242
• Mixture preparation - injection
  245
• 1 Injection system
  245
• 1.1 Rules for cleanliness
  245
• 1.2 Technical data
  245
• 1.3 Assembly overview - connectors and senders at front of engine
  246
• 2 Vacuum system
  247
• 2.1 Assembly overview - vacuum hoses at front of engine
  247
• 2.2 Assembly overview - vacuum hoses at rear of engine
  248
• 2.3 Checking vacuum system
  248
• 3 Injectors
  250
• 3.1 Removing and installing injectors
  250
• 4 Intake manifold
  256
• 4.1 Assembly overview - intake manifold
  256
• 4.2 Removing and installing intake manifold
  257
• 4.3 Assembly overview - lower part of intake manifold with fuel rail
  260
• 4.4 Removing and installing lower part of intake manifold with fuel rail
  263
• 4.5 Removing and installing throttle valve module J338
  266
• 5 Air filter
  268
• 5.1 Assembly overview - air filter
  268
• 5.2 Removing and installing air filter element
  268
• 5.3 Removing and installing lower part of air filter
  270
• 6 Senders and sensors
  272
• 6.2 Removing and installing fuel pressure sender G247
  273
• 7 Engine control unit
  275
• 7.1 Removing and installing engine (motor) control unit J623
  275
• 8 High-pressure pump
  277
• 8.1 Assembly overview - high-pressure pump
  277
• 8.2 Removing and installing high-pressure pump
  278
• 9 Lambda probes
  281
• 9.1 Overview - Lambda probes
  281
• 9.2 Removing and installing Lambda probe G39
  282
• 9.3 Removing and installing Lambda probe 2 G108
  283
• 9.4 Removing and installing Lambda probe after catalytic converter G130
  285
• 9.5 Removing and installing Lambda probe 2 after catalytic converter G131
  285
• Exhaust system
  287
• 1 Exhaust manifold
  287
• 1.1 Assembly overview - exhaust manifold
  287
• 1.2 Removing and installing left exhaust manifold
  288
• 1.3 Removing and installing right exhaust manifold
  289
• 2 Silencers and catalytic converters
  291
• 2.1 Assembly overview - catalytic converters and front silencers
  291
• 2.2 Assembly overview - catalytic converter mountings
  292
• 2.3 Assembly overview - centre and rear silencers
  293
• 2.4 Removing and installing left catalytic converter (bank 2)
  294
• 2.5 Removing and installing right catalytic converter (bank 1)
  296
• 2.6 Separating centre and rear silencers
  298
• 2.7 Aligning exhaust system free of stress
  299
• 2.8 Renewing and aligning exhaust pipes
  300
• 2.9 Checking exhaust system for leaks
  300
• 3 Secondary air system
  301
• 3.1 Assembly overview - secondary air system
  301
• 3.2 Checking combination valves for secondary air system for proper operation and leakage
  303
• 3.3 Removing and installing combination valve for secondary air system
  304
• 3.4 Removing and installing secondary air pump
  304
• 3.5 Removing and installing sender 1 for secondary air pressure G609
  305
• Ignition system
  306
• 1 Ignition system
  306
• 1.1 Safety precautions
  306
• 1.2 Assembly overview - ignition system
  306
• 1.3 Removing and installing ignition coils with output stage
  308
• 1.4 Removing and installing knock sensors G61 , G66 , G198 , G199
  310
• 1.5 Removing and installing Hall sender
  311
• 1.6 Removing and installing engine speed sender G28
  312
• 1.7 Test data, spark plugs
  312