Technical data
11 Safety information
11.1 Safety precautions when working on exhaust system
11.2 Safety regulations for working on fuel supply
11.3 Safety measures when working on vehicles with a start/stop system
21.5 Safety precautions when working on ignition system
21.6 Safety precautions when working on the cooling system
32 Identification
42.1 Engine number/engine data
43 Repair instructions
63.1 Rules for cleanliness
63.2 General information
63.3 General repair instructions
73.4 Foreign objects in engine
83.5 Contact corrosion
83.6 Routing and attachment of lines
83.7 Fitting radiator and condensers
83.8 Checking vacuum system
93.9 Nuts and bolts
93.10 Identification labels
93.11 Using impact drivers
103.12 Checking fuel system for leaks
10Removing and installing engine
111 Removing and installing engine
111.1 Removing engine
111.2 Separating engine and gearbox
291.3 Securing engine on engine and gearbox support
371.4 Installing engine
392 Assembly mountings
432.1 Assembly overview – assembly mountings
432.2 Removing and installing engine mounting
452.3 Removing and installing gearbox mounting
462.4 Removing and installing pendulum support
482.5 Supporting engine in installation position
492.6 Checking adjustment of assembly mountings
532.7 Adjusting assembly mountings
543 Engine cover panel
563.1 Removing and installing engine cover
56Crankshaft group
571 Cylinder block (pulley end)
571.1 Assembly overview - cylinder block (pulley end)
571.2 Removing and installing poly-V belt
601.3 Removing and installing tensioner for poly V-belt
611.4 Removing and installing vibration damper
621.5 Renewing seal for vibration damper
691.6 Removing and installing bracket for ancillaries
721.7 Removing and installing engine support
742 Cylinder block, gearbox end
772.1 Assembly overview - cylinder block, gearbox end, flywheel
772.2 Assembly overview - cylinder block, gearbox end, 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
833 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
963.6 Measuring radial clearance of crankshaft
973.7 Removing and installing sender wheel
984 Balancer shaft
1004.1 Assembly overview - balance shaft
1004.2 Removing and installing balance shaft
1024.3 Renewing oil seal for balance shaft (inlet side)
1075 Pistons and conrods
1095.1 Assembly overview - pistons and conrods
1095.2 Removing and installing pistons
1145.3 Checking pistons and cylinder bores
1165.4 Separating new conrod
1175.5 Checking radial clearance of conrods
1185.6 Removing and installing oil spray jets
118Cylinder head, valve gear
1201 Cylinder head
1201.1 Assembly overview - cylinder head
1201.2 Removing and installing cylinder head
1231.3 Assembly overview - vacuum pump
1301.4 Removing and installing vacuum pump
1311.5 Checking compression
1332 Cover for timing chain
1372.1 Assembly overview - cover for timing chain
1372.2 Removing and installing upper timing chain cover
1402.3 Removing and installing timing chain cover (bottom)
1423 Chain drive
1473.1 Assembly overview - camshaft timing chains
1473.2 Assembly overview - drive chain for balance shaft
1503.3 Removing and installing camshaft timing chain
1523.4 Removing and installing drive chain for balance shaft
1653.5 Removing and installing bearing saddle
1683.6 Checking valve timing
1743.7 Checking timing chain
1764 Valve gear
1784.1 Assembly overview - valve gear
1784.2 Removing and installing camshaft
1824.3 Installing ball for sliding piece
1924.4 Removing and installing actuators for camshaft adjustment
1934.5 Removing and installing camshaft control valve 1 N205
1944.6 Removing and installing exhaust camshaft control valve 1 N318
1954.7 Removing and installing valve stem oil seals
1955 Inlet and exhaust valves
2075.1 Checking valve guides
2075.2 Checking valves
2085.3 Valve dimensions
208Lubrication
2091 Sump, oil pump
2091.1 Assembly overview - sump/oil pump
2091.2 Engine oil:
2131.3 Removing and installing lower part of sump
2131.4 Removing and installing upper part of sump
2191.5 Removing and installing oil pump
2241.6 Removing and installing oil level and oil temperature sender G266
2272 Engine oil cooler
2292.1 Assembly overview - engine oil cooler
2292.2 Removing and installing engine oil cooler
2292.3 Removing and installing mechanical switching valve
2313 Crankcase ventilation
2323.1 Assembly overview - crankcase breather system
2323.2 Removing and installing oil separator
2334 Oil filter, oil pressure switch
2354.1 Assembly overview - oil filter
2354.2 Assembly overview - oil pressure switches/oil pressure control
2354.3 Removing and installing piston cooling jet control valve N522
2374.4 Removing and installing oil pressure switch F1
2384.5 Removing and installing oil pressure switch for reduced oil pressure F378
2394.6 Removing and installing stage 3 oil pressure switch F447
2404.7 Checking oil pressure
2414.8 Removing and installing oil pressure regulating valve N428
246Cooling
2481 Cooling system/coolant
2481.1 Connection diagram - coolant hoses
2481.2 Assembly overview – coolant expansion tank
2511.3 Checking cooling system for leaks
2521.4 Draining and adding coolant
2561.5 Flushing cooling system
2631.6 Flushing cooling system, quick reference guide
2861.7 Removing and installing coolant expansion tank
2872 Coolant pump, regulation of cooling system
2902.1 Assembly overview - coolant pump, thermostat
2902.2 Assembly overview - electric coolant pump
2922.3 Assembly overview - coolant temperature sender
2942.4 Removing and installing electric coolant pump
2952.5 Removing and installing coolant pump
2982.6 Removing and installing toothed belt for coolant pump
3022.7 Removing and installing coolant valves
3052.8 Removing and installing actuator for engine temperature regulation
3082.9 Removing and installing coolant temperature sender G62
3112.10 Removing and installing radiator outlet coolant temperature sender G83
3123 Coolant pipes
3143.1 Assembly overview - coolant pipes
3143.2 Removing and installing coolant pipes
3153.3 Removing and installing upper coolant pipes
3194 Radiator, radiator fan
3214.1 Assembly overview – radiator
3214.2 Assembly overview – radiator cowl and radiator fan
3224.3 Removing and installing radiator
3234.4 Removing and installing radiator cowl
3244.5 Removing and installing radiator fan
326Turbocharging/supercharging
3281 Turbocharger
3281.1 Assembly overview - turbocharger
3281.2 Removing and installing turbocharger
3331.3 Removing and installing turbocharger air recirculation valve
3452 Charge air system
3472.1 Assembly overview - charge air system
3472.2 Assembly overview - charge-air hose connections
3492.3 Removing and installing charge air cooler
3492.4 Removing and installing charge pressure sender G31
3532.5 Checking charge air system for leaks
353Mixture preparation - injection
3581 Injection system
3581.1 Overview of fitting locations - injection system
3582 Injectors
3702.1 Assembly overview - fuel rail with injectors
3702.2 Removing and installing fuel rail
3722.3 Removing and installing injectors
3732.4 Renewing seals on injectors
3802.5 Cleaning injectors
3833 Air filter
3853.1 Assembly overview - air filter housing
3853.2 Removing and installing air filter housing
3873.3 Removing and installing air guide on lock carrier
3884 Intake manifold
3904.1 Assembly overview – intake manifold
3904.2 Removing and installing intake manifold
3924.3 Removing and installing throttle valve module GX3
4004.4 Cleaning throttle valve module
4024.5 Checking intake manifold change-over
4035 Senders and sensors
4065.2 Removing and installing fuel pressure sender G247
4085.3 Checking fuel pressure sender G247
4105.4 Removing and installing fuel pressure sender for low-pressure
4145.5 Removing and installing intake manifold sender GX9
4155.6 Removing and installing air mass meter G70
4165.7 Removing and installing exhaust gas pressure sensor 1 G450
4176 Engine control unit
4196.1 Assembly overview – engine/motor control unit
4196.2 Removing and installing engine control unit J623
4196.3 Removing and installing engine (motor) control unit J623 with protective housing
4217 High-pressure pump
4257.1 Assembly overview - high-pressure pump
4257.2 Removing and installing high-pressure pump
4277.3 Removing and installing high-pressure pipe
4328 Lambda probe
4368.1 Assembly overview - Lambda probe
4368.2 Removing and installing Lambda probe
437Exhaust system
4411 Exhaust pipes and silencers
4411.1 Assembly overview – silencers
4411.2 Removing and installing silencer
4421.3 Aligning exhaust system free of stress
4441.4 Checking exhaust system for leaks
4451.5 Installation position of clamp
4452 Emission control
4472.1 Assembly overview – emission control
4472.2 Removing and installing bracket for catalytic converter
4512.3 Removing and installing catalytic converter
4522.4 Removing and installing particulate filter
4583 Exhaust gas temperature regulation
4653.1 Assembly overview – exhaust gas temperature regulation
4653.2 Removing and installing parts of exhaust gas temperature regulation
4694 Secondary air system
4744.1 Assembly overview - secondary air system
4744.2 Removing and installing secondary air pump motor V101
4754.3 Renewing stop buffer for secondary air pump
4764.4 Removing and installing secondary air inlet valve N112
477Ignition system
4791 Ignition system
4791.1 Assembly overview - ignition system
4791.2 Removing and installing ignition coils with output stage
4811.3 Removing and installing knock sensor 1 G61
4831.4 Removing and installing Hall sender
4851.5 Removing and installing engine speed sender G28
486