奥迪Q7发动机（6缸3.0）机械部分维修手册.pdf

《奥迪Q7发动机（6缸3.0）机械部分维修手册.pdf》由会员分享，可在线阅读，更多相关《奥迪Q7发动机（6缸3.0）机械部分维修手册.pdf（228页珍藏版）》请在淘文阁 - 分享文档赚钱的网站上搜索。

1、Service6Service Department.Technical InformationWorkshop ManualAudi Q7 2007!6-cylinder TDI engine(3.0 ltr.4-valve common rail),mechanicsEdition 01.2006Engine codeBUNBUGService6All rights reserved.No reproduction without prior agreement from publisher.Printed in GermanyA00.5Q70.11.20Copyright 2006 Au

2、di AG,IngolstadtRepair Group overview for workshop manualAudi Q7 2007!When filing a Technical Bulletin,enter the bulletin number in the column adjacent to the RepairGroup.When using the Maintenance Manual you can then see at a glance whether TechnicalBulletins have been published which refer to the

3、Repair Group you are looking for.Technical information should always be available to the foremen and mechanics,because theircareful and constant adherence to the instructions is essential to ensure vehicle road-worthinessand safety.In addition,the normal basic safety precautions for working on motor

4、 vehicles must,as a matter of course,be observed.6-cylinder TDI engine(3.0 ltr.4-valve common rail),mechanicsEdition 01.2006Repair GroupTechnical Bulletins00 Technical data10 Removing and installing engine13 Crankshaft group15 Cylinder head,valve gear17 Lubrication19 Cooling21 Turbocharging/supercha

5、rging26 Exhaust systemAudi Q7 2007!6-cylinder TDI engine(3.0 ltr.4-valve common rail),mechanics 01.2006Contentsiii6Contents00 Technical data.1Technical data.1.1Engine number.1.2Engine data.2General repair instructions.2.1Rules for cleanliness when working on the injection system.2.2Checking for leak

6、s in the fuel system.10 Removing and installing engine.1Removing and installing engine.1.1Removing engine.1.2Separating engine and gearbox.1.3Securing engine to assembly stand.1.4Installing engine.13 Crankshaft group.1Servicing work on pulley end.1.1Poly V-belt drive-exploded view of components.1.2R

7、emoving and installing poly V-belt.1.3Removing and installing tensioner for poly V-belt.1.4Removing and installing vibration damper.1.5Renewing crankshaft oil seal(pulley end).1.6Removing and installing sealing flange(front).1.7Toothed belt for high-pressure pump-exploded view of components.1.8Remov

8、ing and installing toothed belt for high-pressure pump.1.9Exhauster pump-exploded view of components.1.10 Removing and installing exhauster pump.2Servicing work on timing chain end.2.1Drive plate-exploded view of components.2.2Removing and installing drive plate.2.3Renewing crankshaft oil seal(timin

9、g chain end).2.4Timing chain covers-exploded view of components.2.5Removing and installing timing chain covers.2.6Camshaft timing chains-exploded view of components.2.7Removing and installing camshaft timing chains.2.8Detaching camshaft timing chains from camshafts.2.9Drive chain for valve gear-expl

10、oded view of components.2.10 Removing and installing drive chain for valve gear.2.11 Drive chain for oil pump and balance shaft-exploded view of components.2.12 Removing and installing drive chain for oil pump and balance shaft.2.13 Balance shaft-exploded view of components.2.14 Removing and install

11、ing balance shaft.3Removing and installing crankshaft.3.1Crankshaft-exploded view of components.3.2Crankshaft dimensions.3.3Measuring axial clearance.111222344421293237373739404041434648525254545455585963657382838485888992929494Audi Q7 2007!6-cylinder TDI engine(3.0 ltr.4-valve common rail),mechanic

12、s 01.2006Contents6iv3.4Measuring radial clearance.4Dismantling and assembling pistons and conrods.4.1Pistons and conrods-exploded view of components.4.2Checking piston projection at“TDC”.4.3Piston and cylinder dimensions.4.4Checking radial clearance of conrod bearings.15 Cylinder head,valve gear.1Re

13、moving and installing cylinder head.1.1Cylinder head-exploded view of components.1.2Cylinder head cover-exploded view of components.1.3Removing and installing cylinder head cover.1.4Removing and installing cylinder head.1.5Checking compression.2Servicing valve gear.2.1Valve gear-exploded view of com

14、ponents.2.2Checking axial clearance of camshafts.2.3Renewing camshaft oil seal.2.4Removing and installing camshafts.2.5Checking hydraulic valve compensation elements.2.6Renewing valve stem oil seals.2.7Valve dimensions.2.8Machining valve seats.2.9Checking valve guides.2.10 Checking valves.17 Lubrica

15、tion.1Removing and installing parts of lubrication system.1.1Oil pump,sump(bottom section)-exploded view of components.1.2Removing and installing sump(bottom section).1.3Removing and installing oil pump.1.4Sump(top section)-exploded view of components.1.5Removing and installing sump(top section).1.6

16、Oil cooler,pressure control valve,and oil filter housing-exploded view of components1.7Removing and installing oil cooler.1.8Removing and installing oil filter housing.1.9Removing and installing pressure control valve for crankcase breather system.1.10 Removing and installing mounting plate for oil

17、cooler,pressure control valve and oil filter housing.1.11 Removing and installing oil pressure switch-F1-.1.12 Checking oil pressure.1.13 Engine oil.1.14 Checking oil level.19 Cooling.1Removing and installing parts of cooling system.1.1Diagram of coolant hose connections.1.2Draining and filling cool

18、ing system.1.3Coolant pump and thermostat-exploded view of components.1.4Removing and installing coolant pump.95969699100100102102102105107112117117118119120123128129132133133134135135136138142144145148149150152153154156157157159159160161167167Audi Q7 2007!6-cylinder TDI engine(3.0 ltr.4-valve commo

19、n rail),mechanics 01.2006Contentsv61.5Removing and installing continued coolant circulation pump-V51-.1.6Removing and installing hose connection with thermostat.1.7Removing and installing coolant temperature sender-G62-.1.8Removing and installing coolant pipe(front).1.9Removing and installing coolan

20、t pipe(left-side).1.10 Removing and installing coolant pipes(rear left).1.11 Removing and installing coolant pipe(right-side).1.12 Removing and installing coolant pipe(rear right).1.13 Removing and installing radiator.1.14 Removing and installing fuel cooler.1.15 Checking cooling system for leaks.1.

21、16 Removing and installing radiator cowl.1.17 Removing and installing radiator fans-V7-and-V177-.21 Turbocharging/supercharging.1Servicing charge air system with turbocharger.1.1Rules for cleanliness.1.2Turbocharger-exploded view of components.1.3Removing and installing turbocharger.1.4Removing and

22、installing intermediate flange.1.5Charge air cooler-exploded view of components.1.6Removing and installing charge air cooler.1.7Removing and installing charge air pressure sender-G31-.26 Exhaust system.1Removing and installing parts of exhaust system.1.1Exhaust system-exploded view of components.1.2

23、Renewing tailpipes.1.3Removing and installing starter catalytic converter.1.4Removing and installing particulate filter.1.5Exhaust manifold-exploded view of components.1.6Removing and installing exhaust manifold(left-side).1.7Removing and installing exhaust manifold(right-side).1.8Removing and insta

24、lling intermediate pipe(left-side).1.9Removing and installing intermediate pipe(right-side).1.10 Stress-free alignment of exhaust system.1.11 Checking exhaust system for leaks.2Removing and installing parts of exhaust gas temperature control.2.1Removing and installing exhaust gas temperature sender

25、1-G235-.2.2Removing and installing temperature sender before particulate filter-G506-.3Exhaust gas recirculation system.3.1Exhaust gas recirculation system-exploded view of components.3.2Removing and installing mechanical exhaust gas recirculation valve.3.3Removing and installing exhaust gas recircu

26、lation cooler.169171172173174176177181184187188189192193193193194195197198199200202202202204204207209210211213215217217218218219220220221221Audi Q7 2007!6-cylinder TDI engine(3.0 ltr.4-valve common rail),mechanics 01.2006Contents6viAudi Q7 2007!6-cylinder TDI engine(3.0 ltr.4-valve common rail),mech

27、anics 01.20061 Technical data161Technical data1.1Engine numberThe engine code is also included on the vehicle data sticker.The following steps are required to make the stamped engine number visible.Carefully pull engine cover panel off four retaining pins one after the other-arrows-.Before removing,

28、mark direction of rotation of poly V-belt with chalk or felt-tipped pen.If the belt runs in the opposite direc-tion when it is refitted,this can cause breakage.Slacken poly V-belt by swivelling tensioner in direction of-arrow-,using a lever with TORX 60 bit.Remove poly V-belt from tensioning roller.

29、Unscrew bolts-arrows-and detach idler roller from front sealing flange.00Technical dataNoteNoteAudi Q7 2007!6-cylinder TDI engine(3.0 ltr.4-valve common rail),mechanics 01.2006Repair Group 00 Technical data62The engine number(“engine code”and“serial number”)can be found at the front below the toothe

30、d belt for the high-pressure pump(left-side)-arrow-.There is also a sticker on the toothed belt cover showing the“engine code”and“serial number”.1.2Engine dataAudi Q7 models with a 3.0 ltr.TDI engine are always equipped with steel glow plugs.2General repair instructions2.1Rules for cleanliness when

31、working on the injection systemEven small amounts of dirt can cause faults in the injection system.When working on the fuel supply/injection system,pay careful attention to the following basic rules:Code lettersBUGBUNCapacityltr.2.9672.967Power outputkW at rpm171/40001551/4000TorqueNm at rpm500/1500

32、 2750500/1400 2750Bore in mm83.083.0Strokemm91.491.4Compression ratio1717CNat least5151Firing order1-4-3-6-2-51-4-3-6-2-5Exhaust gas recirculationyesyesTurbocharging/superchargingyesyesSelf-diagnosisyesyesGlow plugsSteel glow plugsSteel glow plugsCatalytic converteryesyesCharge air coolingyesyesLamb

33、da controlyesyesNoteAudi Q7 2007!6-cylinder TDI engine(3.0 ltr.4-valve common rail),mechanics 01.20062 General repair instructions36Carefully clean connection points and the surrounding area with engine cleaner or brake cleaner and allow to dry thor-oughly before opening.Plug open lines and connecti

34、ons with suitable protective caps immediately.Place parts that have been removed on a clean surface and cover them over.Use only lint-free cloths.Only install clean components;replacement parts should only be unpacked immediately prior to installation.Do not use parts that have been previously unpac

35、ked and stored away loose(e.g.in toolboxes,etc.).When the system is open:Do not work with compressed air.Do not move the vehicle unless absolutely necessary.2.2Checking for leaks in the fuel systemStart the engine and let it run at medium speed for a few minutes.Switch off ignition.Check the entire

36、fuel system for leaks.If leaks are found although the connections have been tightened to the correct torque,the relevant component must be renewed.Then carry out a test drive with at least one full-power ac-celeration.Then check high-pressure part of fuel system again for leakage.Audi Q7 2007!6-cyli

37、nder TDI engine(3.0 ltr.4-valve common rail),mechanics 01.2006Repair Group 10 Removing and installing engine641Removing and installing engineThe engine is removed from underneath together with the gearbox and subframe(with lock carrier installed).All cable ties which are released or cut open when re

38、mov-ing must be fitted in the same position when installing.Collect drained coolant in a clean container for re-use or disposal.1.1Removing engineSpecial tools and workshop equipment requiredSpring tensioner-VW 552-Removal lever-80-200-Hose clamps for hoses up to 25 mm -3094-Used oil collection and

39、extraction unit-V.A.G 1782-Hose clip pliers-V.A.G 1921-Stepladder-VAS 5085-10 Removing and installing engineNoteAudi Q7 2007!6-cylinder TDI engine(3.0 ltr.4-valve common rail),mechanics 01.20061 Removing and installing engine56Scissor-type assembly platform-VAS 6131-with support set for Audi-VAS 613

40、1/10-and support set-VAS 6131/11-,-VAS 6131/13-and 3x-VAS 6131/10-2-Drip tray for workshop hoist-VAS 6208-ProcedureActivate jacking-up mode on vehicles with air suspension Rep.Gr.43.Move drivers seat as far back as possible and to highest position,using range of full seat adjustment.Switch off ignit

41、ion.Reach under drivers seat and release retaining clips on rear side of cover-1-in direction of-arrow A-.Then detach cover from drivers seat console in direction of-arrow B-.Use removal lever-80-200-to pry out cover-1-from floor covering.Lift floor covering-2-slightly around earth wire.Unscrew nut-

42、3-and detach earth wire-4-from earth point.Discharge the refrigerant system Air conditioner system-with refrigerant R134a.Extract hydraulic fluid for power steering from reservoir us-ing used oil collection and extraction unit-V.A.G 1782-.Open filler cap on coolant expansion tank.WARNING!Hot steam o

43、r hot coolant can escape when expansion tank is opened;cover filler cap with cloth and open carefully.Audi Q7 2007!6-cylinder TDI engine(3.0 ltr.4-valve common rail),mechanics 01.2006Repair Group 10 Removing and installing engine66Remove both front wheels.Unscrew bolts and take off front noise insul

44、ation-1-and rear noise insulation-2-.Remove front wheel housing liners(right and left)Rep.Gr.66.Disconnect air intake hoses-1-and-4-.Unscrew bolts-2-and-3-and remove air pipe(bottom).Place drip tray for workshop hoist-VAS 6208-under en-gine.Disconnect coolant hose-arrow-from coolant pipe(left-side)a

45、nd drain off coolant.Unplug electrical connector-2-at radiator outlet coolant temperature sender-G83-.Disconnect coolant hose(bottom right)-1-at radiator and drain off coolant.Audi Q7 2007!6-cylinder TDI engine(3.0 ltr.4-valve common rail),mechanics 01.20061 Removing and installing engine76Disconnec

46、t coolant hoses from coolant pipes-arrows-and drain off coolant.Disconnect coolant hose from coolant pipe(right-side)-ar-row-and drain off remaining coolant.Carefully pull engine cover panel off four retaining pins one after the other-arrows-.Detach cover above radiator-arrows-.Audi Q7 2007!6-cylind

47、er TDI engine(3.0 ltr.4-valve common rail),mechanics 01.2006Repair Group 10 Removing and installing engine68Detach coolant hose-1-.Disconnect vacuum hose going to vacuum reservoir-2-.Lay a clean cloth under the separating points to catch es-caping fuel.Detach fuel supply hose-6-from fuel filter.Deta

48、ch fuel hose going to fuel cooler at the connections marked-3-and-5-.Remove bolts-1-and-2-and nut-4-.Move fuel lines at bulkhead clear and lay aside fuel filter with fuel hoses connected.Remove bolts-1.4-.The fuel filter bracket remains installed.Open cover above terminal B+-arrow-.Unscrew positive

49、cable-1-going to starter and alternator and move electrical wiring clear.Caution!Observe rules for cleanliness when working on the injection system page 2.NoteAudi Q7 2007!6-cylinder TDI engine(3.0 ltr.4-valve common rail),mechanics 01.20061 Removing and installing engine96Remove air intake hose-arr

50、ows-.Unplug electrical connector-3-.Remove bolts-1-and-2-and detach throttle valve module-J338-from intake connecting pipe.Lay a cloth under the separating point to catch escaping hy-draulic fluid.Clamp off hydraulic hose for power steering pump using a hose clamp-3094-.Disconnect hydraulic hose-1-f