Technical data
11 Safety information
11.1 Safety measures for working on vehicles with high-voltage system
11.2 Safety regulations for working on fuel supply
21.4 Safety precautions when working on the cooling system
31.5 Safety precautions when working on ignition system
32 Identification
42.1 Engine number/engine data
43 Repair instructions
53.1 Rules for cleanliness
53.2 Foreign objects in engine
53.3 Contact corrosion
53.4 Routing and attachment of lines
63.5 Fitting radiator and condensers
63.6 Checking vacuum system
6Removing and installing engine
71 Removing and installing engine
71.1 Removing engine
71.2 Separating engine and gearbox
191.3 Separating electric drive motor V141 and engine
231.4 Securing engine on engine and gearbox support
311.5 Connecting electric drive motor V141 and engine
321.6 Installing engine
502 Assembly mountings
562.1 Assembly overview - assembly mountings
562.2 Removing and installing motor mounting
582.3 Removing and installing gearbox mounting
622.4 Removing and installing pendulum support
682.5 Adjusting assembly mountings
692.6 Checking adjustment of assembly mountings (engine and gearbox mountings)
793 Motor cover
813.1 Removing and installing engine cover
81Crankshaft group
821 Cylinder block (pulley end)
821.1 Assembly overview - sealing flange, belt pulley end
821.2 Removing and installing vibration damper
831.3 Removing and installing engine bracket
841.4 Renewing crankshaft oil seal - belt pulley end
851.5 Removing and installing sealing flange on pulley end
872 Cylinder block, gearbox end
902.1 Assembly overview - cylinder block, gearbox end
902.2 Removing and installing sealing flange on gearbox side
923 Crankshaft
1013.1 Crankshaft dimensions
1013.2 Measuring axial clearance of crankshaft
1014 Pistons and conrods
1034.1 Assembly overview - pistons and conrods
1034.2 Removing and installing pistons
1054.3 Checking pistons and cylinder bores
1064.4 Checking radial clearance of conrods
1074.5 Removing and installing oil spray jets
108Cylinder head, valve gear
1101 Cylinder head
1101.1 Assembly overview - cylinder head
1101.2 Assembly overview - camshaft housing
1111.3 Removing and installing cylinder head
1131.4 Removing and installing camshaft housing
1171.5 Checking compression
1212 Toothed belt drive
1242.1 Assembly overview - toothed belt cover
1242.2 Assembly overview - toothed belt
1252.3 Removing and installing toothed belt guard
1262.4 Removing and installing toothed belt
1272.5 Checking valve timing
1332.6 Adjusting valve timing
1392.7 Removing toothed belt from camshaft
1463 Valve gear
1503.1 Assembly overview - valve gear
1503.2 Measuring axial play of camshaft
1513.3 Removing and installing camshaft oil seal
1523.4 Removing and installing camshaft adjuster
1583.5 Removing and installing camshaft control valve 1 N205
1663.6 Removing and installing exhaust camshaft control valve 1 N318
1673.7 Removing and installing valve stem seals
1674 Inlet and exhaust valves
1744.1 Checking valve guides
1744.2 Checking valves
1744.3 Valve dimensions
175Lubrication
1761 Sump, oil pump
1761.1 Assembly overview - sump/oil pump
1761.2 Engine oil:
1791.3 Removing and installing lower part of sump
1801.4 Removing and installing upper part of sump
1841.5 Removing and installing oil pump
1891.6 Removing and installing oil level and oil temperature sender G266
1902 Engine oil cooler
1922.1 Assembly overview - engine oil cooler
1922.2 Removing and installing engine oil cooler
1923 Crankcase ventilation
1943.1 Assembly overview - crankcase breather system
1943.2 Removing and installing oil separator
1954 Oil filter, oil pressure switch
1974.1 Assembly overview - oil filter/oil pressure switch
1974.2 Removing and installing oil pressure switch F22
1984.3 Removing and installing oil pressure switch for reduced oil pressure F378
1994.4 Checking oil pressure
2004.5 Removing and installing oil pressure regulating valve N428
202Cooling
2031 Cooling system/coolant
2031.1 Connection diagram - coolant hoses
2031.2 Checking cooling system for leaks
2041.3 Draining and adding coolant
2062 Coolant pump, regulation of cooling system
2132.1 Assembly overview - coolant pump, thermostat
2132.2 Assembly overview - electric coolant pump
2182.3 Assembly overview - coolant temperature sender
2192.4 Removing and installing electric coolant pump
2192.5 Removing and installing coolant pump
2232.6 Removing and installing thermostat
2292.7 Removing and installing toothed belt pulley for coolant pump
2312.8 Removing and installing coolant temperature sender G62
2352.9 Removing and installing radiator outlet coolant temperature sender G83
2363 Coolant pipes
2383.1 Assembly overview - coolant pipes
2383.2 Removing and installing coolant pipes
2384 Radiator, radiator fan
2414.1 Assembly overview - radiator/radiator fan
2414.2 Removing and installing radiator
2424.3 Removing and installing radiator cowl
2444.4 Removing and installing radiator fan
245Turbocharging/supercharging
2471 Exhaust turbocharger
2471.1 Assembly overview - turbocharger
2471.2 Removing and installing turbocharger
2501.3 Removing and installing charge pressure positioner V465
2571.4 Removing and installing connection for turbocharger
2602 Charge air system
2642.1 Assembly overview - charge air system
2642.2 Removing and installing charge air cooler
2662.3 Removing and installing charge pressure sender GX26
2692.4 Checking charge air system for leaks
2692.5 Removing and installing air pipe
271Mixture preparation - injection
2731 Injectors
2731.1 Assembly overview - fuel rail with injectors
2731.2 Removing and installing fuel rail
2741.3 Removing and installing injectors
2741.4 Cleaning injectors
2782 Air filter
2802.1 Assembly overview - air filter housing
2802.2 Removing and installing air filter housing
2812.3 Removing and installing resonator for intake air
2823 Intake manifold
2833.1 Assembly overview - intake manifold
2833.2 Removing and installing intake manifold
2843.3 Removing and installing throttle valve module GX3
2873.4 Cleaning throttle valve module GX3
2884 Senders and sensors
2904.1 Removing and installing fuel pressure sender G247
2904.2 Checking fuel pressure sender G247
2914.3 Removing and installing intake manifold sender GX9
2945 Engine (motor) control unit
2965.1 Removing and installing engine (motor) control unit J623
2966 High-pressure pump
3006.1 Assembly overview - high-pressure pump
3006.2 Removing and installing high-pressure pump
3016.3 Removing and installing high-pressure pipe
3037 Lambda probe
3067.1 Assembly overview - Lambda probe
3067.2 Removing and installing Lambda probe
307Exhaust system
3121 Exhaust pipes and silencers
3121.1 Assembly overview - silencers
3121.2 Removing and installing rear silencer
3131.3 Aligning exhaust system free of stress
3141.4 Check exhaust system for leaks
3151.5 Installation position of clamp
3152 Exhaust gas cleaning
3182.1 Assembly overview - emission control
3182.2 Removing and installing catalytic converter
3193 Secondary air system
3243.1 Assembly overview - secondary air system
3243.2 Removing and installing secondary air pump motor V101
3253.3 Removing and installing secondary air inlet valve N112
325Ignition system
3261 Ignition system
3261.1 Assembly overview - ignition system
3261.2 Test data, spark plugs
3271.3 Removing and installing ignition coils with output stage
3271.4 Removing and installing knock sensor 1 G61
3301.5 Removing and installing Hall sender
3301.6 Removing and installing engine speed sender G28
332