Part 1
Disassembling and assembling V6 DFI engine
Preliminary work
Information:
^ Dispose of fluid in accordance with legal requirements.
1. Remove engine.
2. Remove engine from transmission.
3. Secure engine on mounting bracket.
4. Remove engine carrier eyebolt at the front and rear.
Disassembling V6 DFI engine
1. Remove the engine wire harness.
2. Remove bar ignition modules.
3. Remove the intake-air distributor.
4. Remove drive belt.
5. Remove belt tensioner.
Pfeile - Belt tensioner
Belt tensioner
6. Remove unit carrier.
Removing and installing unit carrier
1 - Belt tensioner
2 - Cheese head bolt on belt tensioner
3 - Unit carrier
4 - Fit bolt for unit carrier
5 - Cheese head bolt for unit carrier
6 - Dowel sleeve for unit carrier
7 - Deflection roller with fastening screw
8 - Drive belt (poly-rib belt)
9 - Generator
10 - Coolant pump pulley
11 - Drive wheel for air conditioning compressor
12 - Power-steering pump pulley
13 - Crankshaft vibration damper
7. Remove generator.
8. Remove coolant pump.
Pfeile - Oval-head screws for pulley (coolant pump)
Coolant pump
8.1. Remove coolant pump pulley if necessary.
9. Remove all coolant hoses and additional coolant pump with holder.
Removing and installing additional coolant pump
1 - sheet metal holder
2 - Fastening screws for coolant pump holder
3 - Coolant hose
4 - Coolant hose
5 - Coolant hose
9.1. Unscrew fastening screws -2-.
9.2. Pull off cable plugs and remove coolant hoses -3, 4, 5-.
9.3. Remove additional coolant pump with sheet metal holder -1-.
10. Remove oil/water heat exchanger and engine support arm.
11. Remove exhaust manifold if necessary.
Pfeile - Fastening nuts for exhaust manifold
Exhaust manifold
12. Remove fuel distribution pipe (fuel rail).
Fuel distribution pipe
1 - Fuel line (low-pressure)
2 - Cheese head bolts for fuel distribution pipe
3 - Fuel injectors
13. Remove coolant regulator.
Coolant regulator
1 - Thermostat housing
2 - Spring band clamp
3 - Coolant hose
13.1. Loosen the spring band clamp -2-.
13.2. Pull thermostat housing -1- completely out of the cylinder block.
14. Remove cylinder head cover.
15. Remove flywheel/drive plate.
15.1. Remove dual-mass flywheel on vehicles with manual transmission.
15.2. Remove drive plate on vehicles with automatic transmission.
16. Remove oil pan.
17. Remove upper and lower timing-case cover.
18. Position crankshaft to the compression TDC for cylinder 1.
19. Remove chain tensioner.
Information:
^ Removal of chain tensioner
^ Press the bottom chain tensioner together during removal because otherwise it will push out due to spring tensioning. Secure chain tensioner with a tie-wrap in tensioned state.
20. Remove timing chains.
20.1. Remove camshaft controllers.
21. Remove the camshafts.
Overview of cylinder head on V6 DFI engine
1 - Intake camshaft
2 - Camshaft bearing cover
3 - Outlet camshaft
4 - Hexagon nut on camshaft bearing cover
5 - Sealing rings (40 x 1.5)
6 - Timing chain housing
7 - Oval-head screw on timing chain housing
8 - Outlet camshaft controller (marking 32 A)
9 - Intake camshaft controller (marking 24 E)
10 - Hexagon-head bolts on camshaft controllers
11 - Cylinder head height (min. height a=1 39.9 mm)
12 - Drive gearwheel for high-pressure pump
13 - Bearing shaft
14 - Valves
15 - Dowel sleeve
16 - Cylinder head
17 - Pump tappet
18 - Support element
19 - Valve stem seal
20 - Timing chain
21 - Safety clip
22 - Rocker arm
23 - Valve spring
24 - Valve-spring plate
25 - Valve collets
21.1. Remove timing chain housing.
Removing timing chain housing
1 - Cheese head bolt -> Tightening torque: 8 Nm (6 ftlb.)
2 - Timing chain housing
21.2. Remove intake camshaft. Loosen the hexagon nuts on the bearing covers alternately and crosswise. Note the sequence in which the bearing covers are removed.
21.2.1. Remove bearing covers 1 and 13.
21.2.2. Remove bearing covers 3 and 11.
21.2.3. Remove bearing cover 7.
21.2.4. Remove bearing covers 5 and 9.
21.3. Remove outlet camshaft. Loosen the hexagon nuts on the bearing covers alternately and crosswise. Note the sequence in which the bearing covers are removed.
21.3.1. Remove bearing covers 2 and 14.
21.3.2. Remove bearing covers 4 and 12.
21.3.3. Remove bearing cover 8.
21.3.4. Remove bearing covers 6 and 10.
22. Remove hydraulic tappets.
23. Remove cylinder head.
23.1. Remove and dispose of cylinder head gasket.
23.2. Pull oil retaining valve -arrow- out using an M8 screw if necessary.
Oil retaining valve
24. Remove oil pump.
Information:
^ Removal of connecting-rod bearing cap:
^ Connecting-rod bearing caps must be marked and numbered during removal. Retaining lugs of bearing shells are pressed together. The cast lugs of connecting-rod bearings and connecting-rod big end are identical!
25. Remove piston.
26. Remove vibration balancer.
Brace
27. Remove joint flange behind the vibration balancer.
Crankshaft joint flange
1 - Cylinder block
2 - Vibration balancer joint flange
3 - Hexagon-head bolt on vibration balancer joint flange
4 - Straight pin
5 - Lower timing-case cover
6 - Fastening screw on lower timing-case cover
27.1. Unscrew hexagon-head bolts -3-.
27.2. Carefully lever off the joint flange -2- with a screwdriver.
Information
Removal of crankshaft
Before removing the crankshaft, have a suitable tray ready so that the pulse-generating wheel is not damaged as a result of excessive contact.
The engine is secured on the engine support to facilitate assembly work.
When replacing bearing shells, only use bearing shells with the same color coding.
28. Remove crankshaft.
Crank drive on V6 DFI engine
1 - Crankshaft bearing covers
2 - Internal serration screws on crankshaft bearing covers
3 - Crankshaft bearing shells must always be replaced
4 - Thrust washer for bearing cover 5 must always be replaced
5 - Crankshaft
6 - Drive plate for inductive pickup (speed sender)
7 - Fastening screw on drive plate for inductive pickup (speed sender)
8 - Oil spray jet
28.1. Prepare a clean surface for laying down the crankshaft. Make sure not to damage the drive plate for the inductive pickup (speed sender) when laying down the crankshaft.
28.2. Remove crankshaft bearing covers -1- and lay them down arranged according to cylinder.
28.3. Dispose of thrust washers -4- and crankshaft bearing shells -3-.
28.4. Remove the crankshaft and lay it down on the prepared surface.
28.5. Remove oil spray jets -8- if necessary.