Technical data
11 Safety information
11.1 Safety regulations for working on fuel supply
11.2 Safety measures when working on vehicles with start/stop system
21.4 Safety precautions when working on the cooling system
31.5 Safety precautions when working on exhaust system
32 Identification
52.1 Motor number/motor data
53 Repair instructions
73.1 Rules for cleanliness
73.2 Foreign objects in engine
73.3 Contact corrosion
73.4 Routing and attachment of lines
83.5 Fitting radiator and condensers
84 Technical data
104.1 Coolant
11Removing and installing engine
131 Removing and installing engine
131.1 Removing engine
131.2 Separating engine and gearbox
211.3 Securing engine on engine and gearbox support
261.4 Installing engine
282 Assembly mountings
322.1 Assembly overview - assembly mountings
322.2 Supporting engine in installation position
342.3 Removing and installing engine mounting
362.4 Removing and installing gearbox mounting
372.5 Removing and installing pendulum support
383 Engine cover panel
403.1 Removing and installing engine cover
40Crankshaft group
411 Cylinder block (pulley end)
411.1 Assembly overview - poly V-belt drive
411.2 Assembly overview - sealing flange, belt pulley end
431.3 Removing and installing poly-V belt
441.4 Removing and installing tensioner for poly V-belt
451.5 Removing and installing vibration damper
461.6 Removing and installing bracket for ancillaries
471.7 Removing and installing engine support
491.8 Removing and installing sealing flange on pulley end
512 Cylinder block, gearbox end
542.1 Assembly overview - cylinder block, gearbox end
542.2 Removing and installing flywheel
552.3 Removing and installing sealing flange on gearbox side
583 Crankshaft
713.1 Assembly overview - crankshaft
713.2 Crankshaft dimensions
733.3 Measuring axial clearance of crankshaft
733.4 Renewing needle bearing in crankshaft
744 Pistons and conrods
774.1 Assembly overview - pistons and conrods
774.2 Removing and installing pistons
814.3 Measuring piston projection at TDC
824.4 Checking pistons and cylinder bores
854.5 Checking radial clearance of conrods
87Cylinder head, valve gear
881 Cylinder head
881.1 Assembly overview - cylinder head
881.2 Assembly overview - cylinder head cover
921.3 Removing and installing cylinder head cover
931.4 Removing and installing cylinder head
951.5 Removing and installing injector seals
1031.6 Checking compression
1041.7 Removing and installing camshaft housing
1062 Toothed belt drive
1112.1 Assembly overview - toothed belt cover
1112.2 Assembly overview - toothed belt
1112.3 Removing and installing toothed belt guard
1132.4 Removing toothed belt from camshaft
1152.5 Removing and installing toothed belt
1193 Valve gear
1343.1 Assembly overview - valve gear
1343.2 Measuring axial play of camshaft
1363.3 Removing and installing camshaft oil seal
1373.4 Checking hydraulic compensation elements
1393.5 Removing and installing valve stem seals
1404 Inlet and exhaust valves
1494.1 Checking valve guides
1494.2 Checking valves
1504.3 Valve dimensions
150Lubrication
1511 Sump, oil pump
1511.1 Assembly overview - sump/oil pump
1511.2 Engine oil:
1531.3 Removing and installing oil sump
1531.4 Removing and installing oil pump
1601.5 Removing and installing oil level and oil temperature sender G266
1642 Engine oil cooler
1663 Oil filter, oil pressure switch
1673.1 Assembly overview - oil filter housing, oil pressure switch
1673.2 Removing and installing oil pressure switch F1
1683.3 Checking oil pressure
1693.4 Removing and installing oil filter housing
1703.5 Removing and installing oil pressure regulating valve N428
174Cooling
1761 Cooling system/coolant
1761.1 Connection diagram - coolant hoses
1761.2 Checking cooling system for leaks
1771.3 Draining coolant
1811.4 Filling with coolant
1821.5 Checking filling quality of cooling system
1951.6 Checking electric vacuum pump VAS 6096/2
1971.7 Flushing cooling system
1982 Coolant pump, regulation of cooling system
2232.1 Assembly overview - coolant pump, thermostat
2232.2 Assembly overview - coolant temperature sender
2252.3 Assembly overview - electric coolant pump
2262.4 Removing and installing coolant pump
2272.5 Removing and installing thermostat
2292.6 Removing and installing coolant valve for cylinder head N489
2302.7 Checking thermostat
2312.8 Removing and installing coolant temperature sender G62
2312.9 Removing and installing electric coolant pump
2333 Coolant pipes
2383.1 Assembly overview - coolant pipes
2384 Radiator, radiator fan
2394.1 Assembly overview - radiator/radiator fan
2394.2 Assembly overview – radiator cowl and radiator fan
2414.3 Removing and installing radiator
2424.4 Removing and installing radiator cowl
2484.5 Removing and installing radiator fan
249Turbocharging/supercharging
2521 Turbocharger
2521.1 Assembly overview - turbocharger
2521.2 Removing and installing turbocharger
2571.3 Renewing vacuum unit for turbocharger
2652 Charge air system
2762.1 Assembly overview - charge air system
2762.2 Removing and installing charge air cooler
2782.3 Removing and installing bracket for charge air cooler
2792.4 Removing and installing charge air temperature sender
2802.5 Removing and installing charge pressure sender G31
2812.6 Checking charge air system for leaks
2822.7 Checking charge air cooler for leaks
285Mixture preparation - injection
2911 Injection system
2911.1 Overview of fitting locations - injection system
2911.2 Schematic overview - fuel system
2951.3 Filling/bleeding fuel system
2961.4 Checking fuel system for leaks
2972 Vacuum system
2982.1 Connection diagram – vacuum system
2982.2 Checking vacuum system
2983 Injectors/high-pressure accumulator (rail)
3003.1 Assembly overview - injectors
3003.2 Assembly overview - fuel rail
3023.3 Removing and installing injectors
3033.4 Removing and installing high-pressure lines
3083.5 Testing jammed-open injectors
3113.6 Checking return flow rate of injectors with engine running
3133.7 Removing and installing fuel rail
3154 Air filter
3194.1 Assembly overview - air filter housing
3194.2 Removing and installing air filter housing
3215 Intake manifold
3235.1 Assembly overview – intake manifold
3235.2 Removing and installing throttle valve module J338
3235.3 Removing and installing intake manifold
3256 Senders and sensors
3316.1 Removing and installing fuel temperature sender G81
3316.2 Removing and installing air mass meter G70
3316.3 Removing and installing fuel pressure regulating valve N276
3336.4 Removing and installing fuel pressure sender G247
3346.5 Removing and installing pressure differential sender G505
3366.6 Removing and installing exhaust gas pressure sensor 1 G450
3377 Engine control unit
3397.1 Assembly overview – engine/motor control unit
3397.2 Removing and installing engine control unit J623
3407.3 Removing and installing engine (motor) control unit J623 with protective housing
3418 High-pressure pump
3438.1 Assembly overview - high-pressure pump
3438.2 Removing and installing high-pressure pump
3459 Lambda probe
3519.1 Assembly overview - Lambda probe
3519.2 Removing and installing Lambda probe
352Exhaust system
3571 Exhaust pipes and silencers
3571.1 Assembly overview – silencers
3571.2 Separating exhaust pipes from silencers
3581.3 Removing and installing silencer
3601.4 Removing and installing front exhaust pipe
3611.5 Aligning exhaust system free of stress
3631.6 Installation position of clamp
3641.7 Align end exhaust pipes
3651.8 Checking exhaust system for leaks
3652 Emission control
3662.1 Assembly overview – emission control
3662.2 Removing and installing emission control module
3692.3 Removing and installing particulate filter
3752.4 Removing and installing exhaust flap control unit J883
3783 Exhaust gas temperature regulation
3803.1 Assembly overview – exhaust gas temperature regulation
3803.2 Removing and installing exhaust gas temperature sender
3824 Exhaust gas recirculation
3874.1 Assembly overview – exhaust gas recirculation
3874.2 Removing and installing exhaust gas recirculation cooler
3934.3 Removing and installing exhaust gas recirculation control motor V338
3994.4 Removing and installing exhaust gas recirculation control motor 2 V339
4014.5 Checking exhaust gas recirculation cooler for leaks
403Glow plug system
4041 Glow plug system
4041.1 Assembly overview – glow plug system
4041.2 Removing and installing glow plug
4051.3 Removing and installing automatic glow period control unit J179
4091.4 Removing and installing knock sensor 1 G61
4091.5 Removing and installing Hall sender G40
4101.6 Removing and installing engine speed sender G28
411