VW 6-cylinder Injection Engine Individual Workshop Manual

VW 6-cylinder Injection Engine Individual Workshop Manual PDF free online

List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups

Repair Group
00 – Technical data
10 – Removing and installing engine
13 – Crankshaft group
15 – Cylinder head, valve gear
17 – Lubrication
19 – Cooling
20 – Fuel supply system
24 – Mixture preparation – injection
26 – Exhaust system
28 – Ignition system

CONTENTS

  • 00 – Technical data
    • Engine number
    • Engine data
  • 10 – Removing and installing engine
    • Removing and installing engine
    • Removing engine
    • Securing engine on engine and gearbox support VAS 6095
    • Installing engine
    • Specified torques for assembly mounting
  • 13 – Crankshaft group
    • Dismantling and assembling engine
    • Part I: assembly overview – chain drive
    • Part II: assembly overview – crankshaft group
    • Removing and installing poly V-belt
    • Sealing flanges and flywheel
    • Assembly overview – sealing flange
    • Removing and installing crankshaft seal on gearbox side
    • Renewing crankshaft sealing flange -vibration damper side
    • Removing and installing flywheel
    • Removing and installing drive plate
    • Crankshaft
    • Assembly overview – crankshaft
    • Allocation of crankshaft bearing shells (classification)
    • Fitting sender wheel to crankshaft
    • Pulling needle bearing out of and driving into crankshaft
    • Pistons and conrods
    • Assembly overview – pistons and conrods
    • Checking pistons, piston rings and cylinder bores
    • Installing piston
    • Piston and cylinder dimensions
  • 15 – Cylinder head, valve gear
    • Cylinder head
    • Assembly overview – cylinder head
    • Removing and installing cylinder head
    • Assembly overview – cover
    • Checking valve timing
    • Installing camshaft adjuster with timing chain for camshaft drive
    • Installing timing chain for intermediate shaft drive and camshaft drive
    • Removing and installing cylinder head cover
    • Checking compression
    • Valve gear
    • Assembly overview
    • Removing and installing camshafts
    • Removing and installing camshaft control valves
    • Valve stem oil seals
    • Checking valve guides
    • Reworking valve seats
  • 17 – Lubrication
    • Parts of lubrication system
    • Engine oil
    • Assembly overview – sump
    • Removing and installing oil sump
    • Assembly overview – oil filter bracket
    • Removing and installing oil filter bracket
    • Assembly overview – oil pump
    • Checking oil pressure and oil pressure switch
  • 19 – Cooling
    • Removing and installing parts of cooling system
    • Assembly overview – parts of cooling system, body side
    • Assembly overview – cooling system, engine side
    • Assembly overview – thermostat housing
    • Coolant hose schematic diagram
    • Draining and filling coolant
    • Removing and installing fan support with fans
    • Removing and installing radiator
    • Checking continued coolant circulation pump
    • Removing and installing coolant pump
    • Removing and installing thermostat housing
    • Removing and installing thermostat
    • Removing and installing coolant pipe
    • Checking cooling system for leaks
  • 20 – Fuel supply system
    • Safety precautions when working on fuel supply system
    • Rules for cleanliness
    • Fuel tank
    • Assembly overview – fuel tank
    • Emptying fuel tank
    • Removing and installing fuel tank
    • Repairing fuel supply
    • Removing and installing fuel delivery unit
    • Removing and installing fuel gauge sender 2 G169
    • Removing and installing suction-jet pump
    • Removing and installing fuel gauge sender G
    • Assembly overview – fuel filter with attachments
    • Removing and installing fuel filter
    • Checking fuel pump
    • Bleeding fuel system
    • Electronic power control (EPC)
    • Assembly overview – accelerator module
    • Removing and installing accelerator module
    • Activated charcoal filter system
    • Assembly overview – activated charcoal filter system
    • Checking fuel tank breather
  • 24 – Mixture preparation – injection
    • Repairing injection system
    • General notes on the injection system
    • Technical data
    • Assembly overview – intake manifold
    • Removing and installing throttle valve module J338
    • Removing and installing intake manifold
    • Assembly overview – fuel rail
    • Assembly overview – air filter
    • Assembly overview – resonator with resonance air pipe
    • Checking intake air preheating
    • Checking components
    • Checking vacuum unit for intake manifold flaps
    • Checking injectors for leaks and quantity injected
    • Checking fuel pressure regulator and holding pressure
    • Engine control unit
    • Removing and installing engine control unit
    • Removing and installing anti-theft engine control unit
  • 26 – Exhaust system
    • Exhaust manifold, front exhaust pipe with catalytic converters and Lambda probes
    • Assembly overview – exhaust manifold, front exhaust pipe with catalytic converters
    • Removing and installing Lambda probe G39 and Lambda probe 2 G108
    • Removing and installing exhaust manifold
    • Removing and installing front exhaust pipe with catalytic converters
    • Silencer with mountings
    • Assembly overview – silencers with mountings
    • Checking exhaust flap
    • Aligning exhaust system free of stress
    • Secondary air system
    • Function
    • Assembly overview – secondary air system
    • Removing and installing secondary air pump motor V101
    • Checking combination valve for secondary air system
    • Removing and installing combination valve for secondary air system
  • 28 – Ignition system
    • Ignition system
    • General notes on ignition system
    • Safety precautions
    • Assembly overview – parts of ignition system
    • Removing and installing ignition coils with output stage
    • Test data, spark plugs

Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.

Edition: 10.2009 (K0058995820)
Language: English
Format: PDF
Pages: 217

VW 6-cylinder Injection Engine Individual Workshop Manual PDF free online

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