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
21.5 Safety precautions when working on SCR system
21.6 Safety precautions when working on exhaust system
32 Identification
52.1 Engine number/engine 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
251.3 Securing engine on engine and gearbox support
281.4 Installing engine
292 Assembly mountings
342.1 Assembly overview - assembly mountings
342.2 Removing and installing engine mounting
362.3 Removing and installing gearbox mounting
382.4 Removing and installing pendulum support
392.5 Supporting engine in installation position
402.6 Adjusting assembly mountings
472.7 Checking adjustment of assembly mountings
483 Engine cover panel
503.1 Removing and installing engine cover
50Crankshaft group
511 Cylinder block (pulley end)
511.1 Assembly overview - cylinder block (pulley end)
511.2 Assembly overview - sealing flange, belt pulley end
541.3 Removing and installing poly-V belt
561.4 Removing and installing tensioner for poly V-belt
571.5 Removing and installing vibration damper
581.6 Removing and installing bracket for ancillaries
591.7 Removing and installing engine support
611.8 Removing and installing sealing flange on pulley end
632 Cylinder block, gearbox end
682.1 Assembly overview - cylinder block, gearbox end
682.2 Removing and installing flywheel
712.3 Removing and installing sealing flange on gearbox side
723 Crankshaft
833.1 Assembly overview - crankshaft
833.2 Crankshaft dimensions
833.3 Renewing needle bearing in crankshaft
833.4 Measuring axial clearance of crankshaft
864 Pistons and conrods
884.1 Assembly overview - pistons and conrods
884.2 Removing and installing pistons
914.3 Measuring piston projection at TDC
934.4 Checking pistons and cylinder bores
954.5 Separating new conrod
974.6 Checking radial clearance of conrods
98Cylinder head, valve gear
991 Cylinder head
991.1 Assembly overview - cylinder head
991.2 Assembly overview - cylinder head cover
1031.3 Removing and installing cylinder head
1061.4 Removing and installing cylinder head cover
1121.5 Removing and installing injector seals
1151.6 Removing and installing camshaft housing
1171.7 Checking compression
1212 Toothed belt drive
1242.1 Assembly overview - toothed belt cover
1242.2 Assembly overview - toothed belt
1242.3 Removing and installing toothed belt guard
1262.4 Removing and installing toothed belt
1322.5 Removing toothed belt from camshaft
1463 Valve gear
1523.1 Assembly overview - valve gear
1523.2 Measuring axial play of camshaft
1543.3 Removing and installing camshaft oil seal
1553.4 Checking hydraulic compensation elements
1573.5 Removing and installing valve stem seals
1584 Inlet and exhaust valves
1674.1 Checking valve guides
1674.2 Checking valves
1684.3 Valve dimensions
168Lubrication
1691 Sump, oil pump
1691.1 Assembly overview - sump/oil pump
1691.2 Engine oil:
1711.3 Removing and installing oil sump
1711.4 Removing and installing oil pump
1761.5 Removing and installing oil level and oil temperature sender G266
1772 Engine oil cooler
1793 Oil filter, oil pressure switch
1803.1 Assembly overview - oil filter housing, oil pressure switch
1803.2 Removing and installing oil pressure switch F1
1823.3 Removing and installing oil pressure switch for reduced oil pressure F378
1843.4 Checking oil pressure
1863.5 Removing and installing oil filter housing
1863.6 Removing and installing oil pressure regulating valve N428
190Cooling
1921 Cooling system/coolant
1921.1 Connection diagram - coolant hoses
1921.2 Checking cooling system for leaks
1941.3 Draining and adding coolant
1981.4 Checking filling quality of cooling system
2111.5 Checking electric vacuum pump VAS 6096/2
2141.6 Flushing cooling system
2151.7 Flushing cooling system, quick reference guide
2372 Coolant pump, regulation of cooling system
2392.1 Assembly overview - coolant pump, thermostat
2392.2 Assembly overview - electric coolant pump
2432.3 Assembly overview - coolant temperature sender
2452.4 Assembly overview - actuator for engine temperature regulation N493
2462.5 Removing and installing electric coolant pump
2472.6 Removing and installing coolant pump
2532.7 Removing and installing thermostat
2542.8 Checking thermostat
2582.9 Removing and installing coolant valve for cylinder head N489
2592.10 Removing and installing coolant temperature sender G62
2592.11 Removing and installing coolant temperature sender 2 G802
2612.12 Removing and installing actuator for engine temperature regulation N493
2633 Coolant pipes
2673.1 Assembly overview - coolant pipes
2673.2 Removing and installing coolant pipes
2714 Radiator, radiator fan
2984.1 Assembly overview - radiator, radiator fan
2984.2 Assembly overview - auxiliary radiator
3004.3 Assembly overview – radiator cowl and radiator fan
3014.4 Removing and installing radiator
3014.5 Removing and installing water radiator for charge air cooling circuit
3034.6 Removing and installing radiator cowl
3064.7 Removing and installing radiator fan
3084.8 Removing and installing auxiliary radiator
309Turbocharging/supercharging
3121 Turbocharger
3121.1 Assembly overview - turbocharger
3121.2 Removing and installing turbocharger
3251.3 Removing and installing vacuum unit for turbocharger
3361.4 Removing and installing turbocharger 1 control unit J724
3422 Charge air system
3462.1 Assembly overview - charge air system
3462.2 Removing and installing charge pressure sender G31
3482.3 Removing and installing charge pressure sender 2 G447
3482.4 Checking charge air system for leaks
3492.5 Removing and installing air intake pipe
3512.6 Checking charge air cooler for leaks
358Mixture preparation - injection
3631 Injection system
3631.1 Schematic overview - fuel system
3631.2 Overview of fitting locations - injection system
3641.3 Filling/bleeding fuel system
3771.4 Checking fuel system for leaks
3782 Vacuum system
3792.1 Connection diagram – vacuum system
3792.2 Checking vacuum system
3823 Injectors/high-pressure accumulator (rail)
3843.1 Assembly overview - injectors
3843.2 Assembly overview - fuel rail
3863.3 Adapting correction values for injectors
3883.4 Testing injectors
3893.5 Checking return flow rate of injectors with engine running
3893.6 Checking return flow rate of injectors at starter speed
3923.7 Removing and installing injectors
3953.8 Removing and installing high-pressure lines
3983.9 Removing and installing fuel rail
4044 Air filter
4084.1 Assembly overview - air filter housing
4084.2 Removing and installing air filter housing
4105 Intake manifold
4145.1 Assembly overview – intake manifold
4145.2 Removing and installing intake manifold
4175.3 Removing and installing throttle valve module J338
4236 Senders and sensors
4266.1 Removing and installing fuel pressure regulating valve N276
4266.2 Checking fuel pressure regulating valve N276
4286.3 Removing and installing fuel pressure sender G247
4306.4 Removing and installing air mass meter G70
4316.5 Removing and installing pressure differential sender G505
4336.6 Removing and installing exhaust gas pressure sensor 1 G450
4346.9 Removing and installing fuel temperature sender G81
4376.10 Assembly overview - NOx sender control unit GX30
4386.11 Removing and installing control unit for NOx sender GX30
4396.12 Removing and installing control unit 2 for NOx sender GX46
4416.13 Removing and installing particle sensor G784
4427 Engine control unit
4457.1 Removing and installing engine control unit J623
4458 High-pressure pump
4538.1 Assembly overview - high-pressure pump
4538.2 Removing and installing high-pressure pump
4559 Lambda probe
4599.1 Assembly overview - Lambda probe
4599.2 Removing and installing Lambda probe
459Exhaust system
4621 Exhaust pipes and silencers
4621.1 Assembly overview – silencers
4621.2 Removing and installing front exhaust pipe
4631.3 Removing and installing rear silencer
4651.4 Aligning exhaust system free of stress
4661.5 Checking exhaust system for leaks
4671.6 Assembly overview - front exhaust pipe
4671.7 Installation position of clamp
4711.8 Removing and installing bracket for front exhaust pipe
4712 Emission control
4732.1 Assembly overview – emission control
4732.2 Removing and installing emission control module
4792.3 Removing and installing exhaust flap control unit J883
4843 SCR system (selective catalytic reduction)
4863.1 Assembly overview – reducing agent tank
4863.2 Assembly overview - reducing agent supply line
4883.3 Assembly overview - delivery module for reducing agent
4893.4 Removing and installing reducing agent tank
4903.5 Removing and installing front section of reducing agent supply line
4933.6 Removing and installing delivery module for reducing agent
5003.7 Removing and installing injector for reduction agent N474
5033.8 Removing and installing control unit for reducing-agent heater J891
5053.9 Assembly overview - injector for reducing agent
5063.10 Draining reducing agent tank
5073.11 Removing and installing rear section of reducing agent supply line
5103.12 Removing and installing filler pipe for reducing agent tank
5113.13 Disconnecting reducing agent supply line
5143.14 SCR - resetting learnt values
5174 Exhaust gas temperature regulation
5184.1 Assembly overview – exhaust gas temperature regulation
5184.2 Removing and installing exhaust gas temperature sender 1 G235
5204.3 Removing and installing exhaust gas temperature sender 2 G448
5264.4 Removing and installing exhaust gas temperature sender 3 G495
5284.5 Removing and installing exhaust gas temperature sender 4 G648
5295 Exhaust gas recirculation
5325.1 Assembly overview – exhaust gas recirculation
5325.2 Assembly overview - exhaust gas recirculation valve 1 GX5
5345.3 Removing and installing exhaust gas recirculation cooler
5355.4 Removing and installing exhaust gas recirculation valve 1 GX5
5415.5 Removing and installing exhaust gas recirculation valve 2 GX6
5425.6 Checking exhaust gas recirculation cooler for leaks
5466 Exhaust manifold
5476.1 Assembly overview - exhaust manifold
5476.2 Removing and installing exhaust manifold
548Glow plug system
5501 Glow plug system
5501.1 Assembly overview – glow plug system
5501.2 Removing and installing glow plug
5511.3 Removing and installing automatic glow period control unit J179
5551.4 Removing and installing Hall sender G40
5551.5 Removing and installing engine speed sender G28
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