Technical data
11 \--- Change history ---
12 Safety instructions
22.1 Safety measures regarding work on the fuel supply
22.2 Safety measures in test drives using testing and measurement devices
32.3 Safety measures when working on the cooling system
42.4 Safety measures when working on the ignition system
53 Identification
63.1 Engine number/engine characteristics
64 Repair instructions
84.1 Cleaning rules
84.2 General instructions
84.3 General repair instructions
84.4 Foreign bodies on the engine
94.5 Contact corrosion
94.6 Connection installation and fastening
94.7 Radiator and capacitor installation
9Removing and installing engine
101 Engine - remove and install
101.1 Engine - removal
101.2 Engine - separate gearbox
181.3 Secure the engine to the engine and gearbox swivelling stand
201.4 Engine - installation
222 Power-drive unit supports
242.1 Power unit brackets - assembly overview
242.2 Power unit bracket (engine side) - remove and install
262.3 Power-drive unit supports (gearbox side) - remove and install
272.4 Pendulum support (torque limiter) - remove and install
302.5 Support the engine in assembly position
302.6 Power-drive group support (engine side) - adjust
332.7 Additional notes and installation works in vehicles with air conditioning
33Crankshaft group
351 Cylinder block (pulley side)
351.1 Poly-V belt mechanism - assembly overview
351.2 Poly-V belt mechanism - assembly overview
361.3 Cylinder block (pulley side) - assembly overview
371.4 Poly-V belt - remove and install
391.5 Poly-V belt - remove and install
411.6 Poly-V belt tensioner - remove and install
431.7 Engine console - remove and install
441.8 Crankshaft pulley (vibration damper) - remove and install
451.9 Crankshaft seal (pulley side) - replace
462 Cylinder block (gearbox side)
502.1 Cylinder block (gearbox side) - assembly overview
502.2 Flywheel - remove and install
512.3 Crankshaft flange (flywheel side) - replace
523 Crankshaft
613.1 Crankshaft - dimensions
614 Pistons and conrods
624.1 Pistons and conrods - assembly overview
624.2 Pistons - remove and install
644.3 Pistons, rings, and cylinders - check
654.4 Conrod and cap (new part) - separate
674.5 Conrod radial clearance - check
684.6 Oil spray jet and valve - remove and install
68Cylinder head, valve gear
701 Cylinder head - assembly and disassembly
701.1 Cylinder head - assembly overview
701.2 Engine cylinder head - remove and install
721.3 Cylinder head cover with exhaust and inlet camshafts - remove and install
781.4 Compression - check
872 Toothed belt drive
912.1 Toothed belt - remove and install
912.2 Valve timing - check
1022.3 Valve timing - adjust
1063 Camshaft mechanism
1193.1 Camshaft mechanism - assembly overview
1193.2 Crankshaft - check axial clearance
1213.3 Crankshaft seal - replace
1223.4 Inlet camshaft regulator - remove and install
1383.5 Exhaust camshaft sprocket - remove and install
1443.6 Camshaft adjustment valve 1 N205 - remove and install
1493.7 Valve stem sealant - replace
1494 Inlet and exhaust valves
1564.1 Valve guides - check
1564.2 Valves - check
1564.3 Valve dimensions
157Lubrication
1581 Crankcase/oil pump
1581.1 Crankcase/oil pump - assembly overview
1581.2 Engine oil
1611.3 Lower sump - remove and install
1621.4 Upper crankcase - remove and install
1631.5 Oil pump - remove and install
1672 Engine crankcase ventilation
1702.1 Engine crankcase ventilation - assembly overview
1702.2 Crankcase ventilation device - remove and install
1713 Oil filter/ Oil pressure switch F1
1733.1 Oil pressure switch F1 - remove and install
1733.2 Oil pressure and Oil pressure switch F1 - check
1743.3 Oil filter - remove and install
176Cooling
1781 Cooling system/coolant
1781.1 Hose connection diagram for cooling system
1781.2 Cooling system - check air-tightness
1781.3 Coolant tank flap - check safety valve
1801.4 Cooling system - drainage and replenishment
1812 Water pump/coolant adjustment
1902.1 Water pump - assembly overview
1902.2 Water pump - remove and install
1922.3 Thermostat valve - assembly overview
1962.4 Thermostat valve - removal and installation
1982.5 Water pump toothed belt - remove and install
2032.6 Water pump sprocket - remove and install
2062.7 Coolant temperature sensor G62 - remove and install
2073 Radiator/ Radiator fan V7
2103.1 Radiator/ Radiator fan V7 - assembly overview
2103.2 Radiator - remove and install
2123.3 Radiator fan V7 air deflector - remove and install
2153.4 Radiator fan V7 - remove and install
218Fuel supply system
2211 Fuel reservoir
2211.1 Fuel tank - assembly overview
2211.2 Cold start system components - remove and install
2251.3 Fuel reservoir - remove and install
2261.4 Fuel tank - drain
2302 Fuel pump (pre-supply pump) G6 / Fuel gauge sensor G
2372.2 Fuel pump (pre-supply pump) G6 / Fuel gauge sensor G - remove and install
2392.3 Fuel gauge sensor G - remove and install
2433 Quick-release fastener with button
2453.1 Quick-release fastener with button - disconnect
2454 Fuel filter
2494.1 Fuel filter - remove and install
2495 Activated charcoal filter system
2505.1 Activated charcoal filter system - operation
2505.2 Activated charcoal filter system - assembly overview
2515.3 Fuel tank ventilation system - check
2525.4 Activated charcoal filter - remove and install
2586 Engine power electronic adjustment (electronic accelerator)
2636.1 Accelerator pedal module (electric throttle) - assembly overview
2636.2 Accelerator pedal module (electric throttle) - remove and install
2647 Fuel pump (pre-supply pump) G6
2667.1 Fuel pump (pre-supply pump) G6 - check
266Mixture preparation - injection
2871 Injection system
2871.1 Injection system - assembly overview
2871.2 Combustion system - assembly overview
2902 Injection valves
2922.1 Fuel rail with injection valves - assembly overview
2922.2 Injection valves - remove and install
2952.3 Injection valves - check
2993 Air cleaner
3053.1 Air filter - assembly overview
3053.2 Air filter - remove and install
3064 Intake manifold
3074.1 Intake manifold - assembly overview
3074.2 Intake manifold - remove and install
3084.3 Throttle butterfly valve control unit J338 - remove and install
3104.4 Throttle valve control unit J338 - clean
3125 Transmitters and sensors
3136 Engine control unit J623
3156.1 Engine control unit J623 - assembly overview
3156.2 Engine control unit J623 - remove and install
3166.3 Engine control unit J623 support - remove and install
3197 Lambda probe
3207.1 Lambda probe - remove and install
320Exhaust system
3241 Silencer/exhaust pipes
3241.1 Silencer - assembly overview
3241.2 Silencer/exhaust pipes - separation
3251.3 Silencer - remove and install
3261.4 Exhaust system - check air-tightness
3281.5 Double clamp - installation position
3292 Exhaust system
3302.1 Front exhaust pipe - assembly overview
3302.2 Catalytic converter - remove and install
331Ignition system
3341 Ignition system
3341.1 Ignition system - assembly overview
3341.2 Ignition coils with final power stage - assembly overview
3351.3 Spark plugs Q - technical data
3361.4 Ignition coil with final power stage - remove and install
3361.5 Knock sensor 1 G61 - remove and install
3391.6 Hall Sensor G40 - remove and install
3401.7 Engine speed sensor G28 - remove and install
341