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
31.7 Safety precautions when working on exhaust system
32 Identification
52.1 Engine number/engine data
52.2 Engine type
63 Repair instructions
93.1 Rules for cleanliness
93.2 General information
93.3 General repair instructions
93.4 Foreign objects in engine
113.5 Contact corrosion
113.6 Routing and attachment of lines
113.7 Fitting radiator and condensers
113.8 Checking vacuum system
113.9 Identification labels
123.10 Using impact drivers
123.11 Nuts and bolts
133.12 Bleeding fuel system
133.13 Checking fuel system for leaks
13Removing and installing engine
141 Removing and installing engine
141.1 Removing engine
141.2 Separating engine and gearbox
301.3 Securing engine on engine and gearbox support
351.4 Installing engine
382 Assembly mountings
422.1 Assembly overview – assembly mountings
422.2 Supporting engine in installation position
442.3 Removing and installing engine mounting
482.4 Removing and installing gearbox mounting
492.5 Removing and installing pendulum support
512.6 Checking adjustment of assembly mountings
522.7 Adjusting assembly mountings
523 Engine cover panel
553.1 Removing and installing engine cover
55Crankshaft group
561 Cylinder block (pulley end)
561.1 Assembly overview - cylinder block (pulley end)
561.2 Removing and installing poly-V belt
591.3 Removing and installing tensioner for poly V-belt
611.4 Removing and installing vibration damper
611.5 Removing and installing bracket for ancillaries
681.6 Removing and installing engine support
711.7 Renewing seal for vibration damper
722 Cylinder block, gearbox end
762.1 Assembly overview - flywheel
762.2 Assembly overview - drive plate
782.3 Removing and installing flywheel
792.4 Removing and installing drive plate
802.5 Removing and installing sealing flange on gearbox side
823 Crankshaft
883.1 Assembly overview - crankshaft
883.2 Crankshaft dimensions
913.3 Allocation of main bearing shells
913.4 Renewing needle bearing in crankshaft
933.5 Measuring axial clearance of crankshaft
953.6 Measuring radial clearance of crankshaft
963.7 Removing and installing sender wheel
974 Balancer shaft
994.1 Assembly overview - balance shaft
994.2 Removing and installing balance shaft
1014.3 Renewing oil seal for balance shaft (inlet side)
1065 Pistons and conrods
1095.1 Assembly overview - pistons and conrods
1095.2 Removing and installing pistons
1145.3 Removing and installing oil spray jets
1165.4 Checking pistons and cylinder bores
1185.5 Separating new conrod
1205.6 Checking radial clearance of conrods
1215.7 Removing and installing oil spray jets
121Cylinder head, valve gear
1231 Cylinder head
1231.1 Assembly overview - cylinder head
1231.2 Removing and installing cylinder head
1261.3 Removing and installing vacuum pump
1331.4 Checking compression
1352 Cover for timing chain
1382.1 Assembly overview - cover for timing chain
1382.2 Removing and installing timing chain cover
1442.3 Renewing seal for vibration damper
1523 Chain drive
1553.1 Assembly overview - camshaft timing chains
1553.2 Removing and installing camshaft timing chain
1603.3 Assembly overview - drive chain for balance shaft
1943.4 Removing and installing drive chain for balance shaft
1973.5 Removing and installing bearing saddle
1993.6 Checking timing chain
2123.7 Checking valve timing
2134 Valve gear
2174.1 Assembly overview - valve gear
2174.2 Removing and installing camshaft
2264.3 Removing and installing camshaft control valve 1 N205
2634.4 Removing and installing exhaust camshaft control valve 1 N318
2634.5 Installing ball for sliding piece
2644.6 Removing and installing actuators for camshaft adjustment
2654.7 Removing and installing valve stem oil seals
2655 Inlet and exhaust valves
2785.1 Checking valve guides
2785.2 Checking valves
2795.3 Valve dimensions
279Lubrication
2801 Sump, oil pump
2801.1 Assembly overview - sump/oil pump
2801.2 Removing and installing oil level and oil temperature sender G266
2841.3 Removing and installing lower part of sump
2851.4 Removing and installing oil pump
2911.5 Removing and installing upper part of sump
2941.6 Engine oil:
2992 Engine oil cooler
3002.1 Assembly overview - engine oil cooler
3002.2 Removing and installing engine oil cooler
3002.3 Removing and installing mechanical switching valve
3013 Crankcase ventilation
3023.1 Assembly overview - crankcase breather system
3023.2 Removing and installing oil separator
3034 Oil filter, oil pressure switch
3054.1 Assembly overview - oil filter
3054.2 Assembly overview - oil pressure switches/oil pressure control
3054.3 Removing and installing piston cooling jet control valve N522
3074.4 Removing and installing oil pressure regulating valve N428
3074.5 Removing and installing oil pressure switch F1
3084.6 Removing and installing oil pressure switch for reduced oil pressure F378
3094.7 Removing and installing stage 3 oil pressure switch F447
3104.8 Checking oil pressure
311Cooling
3151 Cooling system/coolant
3151.1 Connection diagram - coolant hoses
3151.2 Assembly overview – coolant expansion tank
3211.3 Draining and adding coolant
3211.4 Checking cooling system for leaks
3281.5 Flushing cooling system
3331.6 Removing and installing coolant expansion tank
3542 Coolant pump, regulation of cooling system
3572.1 Assembly overview - coolant pump, thermostat
3572.2 Assembly overview - electric coolant pump
3592.3 Assembly overview – coolant valves
3602.4 Assembly overview - coolant temperature sender
3632.5 Removing and installing toothed belt for coolant pump
3642.6 Removing and installing coolant pump
3662.7 Removing and installing auxiliary pump for heating V488
3692.8 Removing and installing coolant valves
3712.9 Removing and installing actuator for engine temperature regulation N493
3772.10 Removing and installing coolant temperature sender G62
3792.11 Removing and installing radiator outlet coolant temperature sender G83
3803 Coolant pipes
3823.1 Assembly overview - coolant pipes
3823.2 Removing and installing coolant pipes
3824 Radiator, radiator fan
3864.1 Assembly overview – radiator
3864.2 Assembly overview - auxiliary radiator
3874.3 Assembly overview – radiator cowl and radiator fan
3894.4 Removing and installing radiator
3904.5 Removing and installing radiator cowl with radiator fan
3924.6 Removing and installing radiator fan
3944.7 Removing and installing auxiliary radiator
395Turbocharging/supercharging
4001 Turbocharger
4001.1 Assembly overview - turbocharger
4001.2 Removing and installing turbocharger
4031.3 Removing and installing charge pressure positioner V465
4101.4 Adjusting charge pressure positioner V465
4111.5 Removing and installing turbocharger air recirculation valve
4132 Charge air system
4152.1 Assembly overview - charge air system
4152.2 Assembly overview - charge-air hose connections
4172.3 Removing and installing charge air cooler
4172.4 Removing and installing charge pressure sender G31
4222.5 Checking charge air system for leaks
422Mixture preparation - injection
4271 Injection system
4271.1 Overview of fitting locations - injection system
4272 Injectors
4462.1 Assembly overview - fuel rail with injectors
4462.2 Removing and installing fuel rail
4482.3 Removing and installing injectors
4492.4 Renewing seals on injectors
4572.5 Cleaning injectors
4603 Air filter
4633.1 Assembly overview - air filter housing
4633.2 Removing and installing air filter housing
4653.3 Removing and installing air guide on lock carrier
4664 Intake manifold
4684.1 Assembly overview – intake manifold
4684.2 Removing and installing intake manifold
4704.3 Removing and installing throttle valve module GX3
4764.4 Cleaning throttle valve module
4784.5 Checking intake manifold change-over
4795 Senders and sensors
4825.2 Removing and installing fuel pressure sender G247
4845.3 Checking fuel pressure sender G247
4875.4 Removing and installing fuel pressure sender for low-pressure G410
4925.5 Removing and installing intake manifold sender GX9
4935.6 Removing and installing pressure differential sender for particulate filter G1037
4946 Engine control unit
4966.1 Assembly overview – engine/motor control unit
4966.2 Removing and installing engine control unit J623
4967 High-pressure pump
5027.1 Assembly overview - high-pressure pump
5027.2 Removing and installing high-pressure pump
5047.3 Removing and installing high-pressure pipe
5088 Lambda probe
5118.1 Assembly overview - Lambda probe
5118.2 Removing and installing Lambda probe
512Exhaust system
5161 Exhaust pipes and silencers
5161.1 Assembly overview – silencers
5161.2 Removing and installing silencer
5171.3 Aligning exhaust system free of stress
5191.4 Checking exhaust system for leaks
5201.5 Installation position of clamp
5202 Emission control
5222.1 Assembly overview – emission control
5222.3 Removing and installing bracket for catalytic converter
5302.4 Removing and installing catalytic converter
5333 Exhaust gas temperature regulation
5503.1 Assembly overview – exhaust gas temperature regulation
5503.2 Removing and installing parts of exhaust gas temperature regulation
5514 Secondary air system
5564.1 Assembly overview - secondary air system
5564.2 Removing and installing secondary air pump motor V101
5574.3 Renewing stop buffer for secondary air pump
5574.4 Removing and installing secondary air inlet valve N112
558Ignition system
5601 Ignition system
5601.1 Assembly overview - ignition system
5601.2 Removing and installing ignition coils with output stage
5621.3 Removing and installing knock sensor I G61
5651.4 Removing and installing Hall sender
5671.5 Removing and installing engine speed sender G28
568