Technical data
11 Safety information
11.1 Safety regulations for working on fuel supply
11.2 Safety measures when working on vehicles with a start/stop system
11.4 Safety precautions when working on ignition system
21.5 Safety precautions when working on the cooling system
21.6 Safety precautions when working on exhaust system
32 Identification
42.1 Engine number/engine data
43 Repair instructions
63.1 Rules for cleanliness
63.2 Foreign objects in engine
63.3 Contact corrosion
63.4 Routing and attachment of lines
63.5 Fitting radiator and condensers
73.6 Checking vacuum system
7Removing and installing engine
81 Removing and installing engine
81.1 Removing engine
81.2 Separating engine and gearbox
251.3 Securing engine on engine and gearbox support
301.4 Installing engine
332 Assembly mountings
362.1 Assembly overview - assembly mountings
362.2 Removing and installing engine mounting
382.3 Removing and installing gearbox mounting
402.4 Removing and installing pendulum support
432.5 Supporting engine in installation position
463 Engine cover panel
513.1 Removing and installing engine cover
51Crankshaft group
521 Cylinder block (pulley end)
521.1 Assembly overview - cylinder block (pulley end)
521.2 Removing and installing poly-V belt
551.3 Removing and installing tensioner for poly V-belt
561.4 Removing and installing vibration damper
571.5 Removing and installing bracket for ancillaries
641.6 Renewing seal for vibration damper
671.7 Removing and installing engine support
702 Cylinder block, gearbox end
722.1 Assembly overview - cylinder block, gearbox end
722.2 Removing and installing flywheel
732.3 Removing and installing sealing flange on gearbox side
753 Crankshaft
803.1 Assembly overview - crankshaft
803.2 Crankshaft dimensions
823.3 Allocation of main bearing shells
823.4 Renewing needle bearing in crankshaft
843.5 Measuring axial clearance of crankshaft
863.6 Measuring radial clearance of crankshaft
873.7 Removing and installing sender wheel
884 Balancer shaft
904.1 Assembly overview - balance shaft
904.2 Removing and installing balance shaft
914.3 Renewing oil seal for balance shaft (inlet side)
965 Pistons and conrods
985.1 Assembly overview - pistons and conrods
985.2 Removing and installing pistons
1025.3 Removing and installing oil spray jets
1045.4 Checking pistons and cylinder bores
1055.5 Separating new conrod
1085.6 Checking radial clearance of conrods
108Cylinder head, valve gear
1101 Cylinder head
1101.1 Assembly overview - cylinder head
1101.2 Removing and installing cylinder head
1131.3 Removing and installing vacuum pump
1201.4 Checking compression
1222 Cover for timing chain
1252.1 Assembly overview - cover for timing chain
1252.3 Removing and installing timing chain cover
1273 Chain drive
1343.1 Assembly overview - camshaft timing chains
1343.2 Removing and installing camshaft timing chain
1373.3 Assembly overview - drive chain for balance shaft
1533.4 Removing and installing drive chain for balance shaft
1563.5 Checking timing chain
1563.6 Checking valve timing
1574 Valve gear
1604.1 Assembly overview - valve gear
1604.2 Removing and installing camshaft
1654.3 Installing ball for sliding piece
1824.4 Removing and installing valve stem seals
1835 Inlet and exhaust valves
1945.1 Checking valve guides
1945.2 Checking valves
1955.3 Valve dimensions
195Lubrication
1961 Sump, oil pump
1961.1 Assembly overview - sump/oil pump
1961.2 Removing and installing oil level and oil temperature sender G266
1991.3 Removing and installing lower part of sump
2001.4 Removing and installing oil pump
2061.5 Removing and installing upper part of sump
2091.6 Engine oil:
2152 Engine oil cooler
2162.1 Assembly overview - engine oil cooler
2162.2 Removing and installing engine oil cooler
2162.3 Removing and installing mechanical switching valve
2183 Crankcase ventilation
2193.1 Assembly overview - crankcase breather system
2193.2 Removing and installing oil separator
2204 Oil filter, oil pressure switch
2214.1 Assembly overview - oil filter
2214.2 Assembly overview - oil pressure switches/oil pressure control
2214.3 Removing and installing piston cooling jet control valve N522
2234.4 Removing and installing oil pressure regulating valve N428
2234.5 Removing and installing oil pressure switch
2254.6 Checking oil pressure
229Cooling
2341 Cooling system/coolant
2341.1 Connection diagram - coolant hoses
2341.2 Draining and adding coolant
2371.3 Checking cooling system for leaks
2451.4 Flushing cooling system
2482 Coolant pump, regulation of cooling system
2722.1 Assembly overview - coolant pump, thermostat
2722.2 Assembly overview - electric coolant pump
2742.3 Assembly overview - coolant temperature sender
2762.4 Removing and installing toothed belt for coolant pump
2772.5 Removing and installing coolant pump
2802.6 Removing and installing auxiliary pump for heating V488
2842.7 Removing and installing coolant shut-off valve N82
2882.8 Removing and installing coolant valve for gearbox N488, vehicles with dual clutch gearbox
2902.9 Removing and installing actuator for engine temperature regulation N493
2922.10 Removing and installing coolant temperature sender G62
2942.11 Removing and installing radiator outlet coolant temperature sender G83
2963 Coolant pipes
2983.1 Assembly overview - coolant pipes
2983.2 Removing and installing front coolant pipe
2983.3 Removing and installing upper coolant pipes
3004 Radiator, radiator fan
3034.1 Assembly overview - radiator/radiator fan
3034.2 Removing and installing radiator
3044.3 Removing and installing radiator cowl with radiator fan
3084.4 Removing and installing radiator fan
312Turbocharging/supercharging
3131 Turbocharger
3131.1 Assembly overview - turbocharger
3131.2 Removing and installing turbocharger
3171.3 Removing and installing charge pressure positioner V465
3211.4 Adjusting charge pressure positioner V465
3222 Charge air system
3252.1 Assembly overview - charge air system
3252.2 Assembly overview - charge-air hose connections
3272.3 Removing and installing charge air cooler
3292.4 Removing and installing charge pressure sender G31
3302.5 Checking charge air system for leaks
331Mixture preparation - injection
3341 Injection system
3341.1 Overview of fitting locations - injection system
3342 Injectors
3432.1 Assembly overview - fuel rail with injectors
3432.2 Removing and installing fuel rail
3452.3 Removing and installing injectors
3462.4 Renewing seals on injectors
3522.5 Cleaning injectors
3553 Air filter
3573.1 Assembly overview - air filter housing
3573.2 Removing and installing air filter housing
3584 Intake manifold
3594.1 Assembly overview – intake manifold
3594.2 Removing and installing intake manifold
3614.3 Removing and installing throttle valve module GX3
3674.4 Cleaning throttle valve module
3695 Senders and sensors
3715.2 Removing and installing fuel pressure sender G247
3735.3 Checking fuel pressure sender G247
3765.4 Removing and installing fuel pressure sender for low-pressure G410
3795.5 Removing and installing intake manifold sender GX9
3806 Engine control unit
3816.1 Removing and installing engine control unit J623
3817 High-pressure pump
3837.1 Assembly overview - high-pressure pump
3837.2 Removing and installing high-pressure pump
3857.3 Removing and installing high-pressure pipe
3898 Lambda probe
3938.1 Assembly overview - Lambda probe
3938.2 Removing and installing Lambda probe
394Exhaust system
3971 Exhaust pipes and silencers
3971.1 Assembly overview – silencers
3971.2 Separating exhaust pipes from silencers
3981.3 Aligning exhaust system free of stress
3991.4 Checking exhaust system for leaks
4002 Emission control
4012.1 Assembly overview – emission control
4012.2 Removing and installing catalytic converter
403Ignition system
4081 Ignition system
4081.1 Assembly overview - ignition system
4081.2 Test data, spark plugs
4101.3 Removing and installing ignition coils with output stage
4101.4 Removing and installing knock sensor 1 G61
4131.5 Removing and installing Hall sender
4141.6 Removing and installing engine speed sender G28
415