Part 1

WM 100137 Disassembling and assembling V6 DFI engine

Tools





Technical values









Preliminary work

Information

- Dispose of fluid in accordance with legal requirements.

1. Remove engine. -> 100119 Removing and installing 3.6-litre DFI engine - section on "Removing" 100119 Removing and Installing 3.6-Litre DFI Engine
2. Remove engine from transmission. -> 100127 Removing engine from transmission and mounting engine on transmission 100127 Removing engine from transmission and mounting engine on transmission
3. Secure engine on mounting bracket. -> 1001IN Supporting V6 3.6-litre DFI engine on mounting bracket 1001IN Supporting V6 3.6 l DFI engine on the mounting bracket
4. Remove engine carrier eyebolt at the front and rear. -> 1001IN Lifting V6 3.6-litre DFI engine with a workshop crane 1001IN Lifting V6 3.6 l DFI engine with a workshop crane

Disassembling V6 DFI engine

1. Remove the engine wire harness. -> 97522100 Removing wire harness for engine (V6) 975219 Removing and installing wire harness for engine
2. Remove bar ignition modules. -> 282020 Removing and installing DFI bar ignition modules Service and Repair
3. Remove the intake-air distributor. -> 244619 Removing and installing DFI intake-air distributor - section on "Removing" Removal and Replacement
4. Remove drive belt. -> 137819 Removing and installing drive belt on V6 DFI engines - section on "Removing" Service and Repair
5. Remove belt tensioner. -> 137319 Removing and installing belt tensioner on DFI engines - section on "Removing" Service and Repair





Belt tensioner





6. Remove unit carrier.





Removing and installing unit carrier





7. Remove generator. -> 272219 Removing and installing generator - section on "Removing" Service and Repair
8. Remove coolant pump. -> 195019 Removing and installing coolant pump on DFI engines - section on "Removing" Service and Repair





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





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 sheetmetal holder -1-.
10. Remove oil/water heat exchanger and engine support arm. -> 174019 Removing and installing oil/water heat exchanger (oil cooler) on V6 DFI engines
11. Remove exhaust manifold if necessary. -> 261019 Removing and installing exhaust manifold on V6 DFI engines - section on "Removing" Service and Repair





Exhaust manifold





12. Remove fuel distribution pipe (fuel rail). -> 243019 Removing and installing fuel distribution pipe (fuel rail) on DFI engines - section on "Removing" Service and Repair





Fuel distribution pipe





13. Remove coolant regulator. -> 195819 Removing and installing coolant regulator (thermostat) on DFI engines - section on "Removing" Service and Repair





Coolant regulator





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.-> 158219 Removing and installing cylinder head cover on V6 DFI engines Removal and Replacement
15. Remove flywheel/drive plate.
15.1. Remove dual-mass flywheel on vehicles with manual transmission. -> 136219 Removing and installing dual-mass flywheel - section on "Removing"
15.2. Remove drive plate on vehicles with automatic transmission. -> 136319 Removing and installing drive plate for torque converter
16. Remove oil pan. -> 175019 Removing and installing oil pan on V6 DFI engines - section on "Removing" Service and Repair
17. Remove upper and lower timing-case cover. -> 153319 Removing and installing timing-case cover on V6 DFI engines - section on "Removing" Service and Repair
18. Position crankshaft to the compression TDC for cylinder 1. -> 150502 Checking the timing on V6 DFI engines Testing and Inspection
19. Remove chain tensioner. -> 153619 Removing and installing chain tensioner on V6 DFI engines - section on "Removing" Service and Repair

Information

- 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.-> 153519 Removing and installing timing chains on V6 DFI engines - section on "Removing" Service and Repair
20.1. Remove camshaft controllers. -> 158419 Removing and installing camshaft controller on V6 DFI engines Service and Repair
21. Remove the camshafts. -> 150520 Removing and installing camshafts on V6 DFI engines Removal and Replacement





Overview of cylinder head on V6 DFI engine





21.1. Remove timing chain housing.





Removing 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.-> 155919 Removing and installing hydraulic tappets on DFI engines Service and Repair
23. Remove cylinder head. -> 157019 Removing and installing cylinder head on V6 DFI engines - section on "Removing" Removal and Replacement
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. -> 172019 Removing and installing oil pump on V6 DFI engines Service and Repair

Information

- 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. -> 131019 Removing and installing pistons on V6 DFI engines - section on "Removing" Removal and Replacement
26. Remove vibration balancer. -> 137619 Removing and installing vibration balancer (crankshaft pulley) on V6 DFI engines Removal and Replacement





Brace

27. Remove joint flange behind the vibration balancer.





Crankshaft joint flange





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 colour coding.

28. Remove crankshaft. -> 134819 Removing and installing crankshaft on V6 DFI engines Removal and Replacement





Crank drive on V6 DFI engine





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.