Technical data
11 Identification
11.1 Engine number, engine data
12 Safety instructions
22.1 Safety precautions when working on fuel supply system
22.2 Safety precautions when working on vehicles with a Start/Stop system
22.4 Safety precautions when working on cooling system
32.5 Safety precautions when working on ignition system
33 Repair instructions
43.1 Rules for cleanliness
43.2 Foreign objects in engine
43.3 Contact corrosion
43.4 Routing and securing lines
43.5 Installing coolers, condensers and radiators
5Removing and installing engine
61 Removing and installing engine
61.1 Removing engine
61.2 Separating engine and gearbox
161.3 Securing engine on engine and gearbox support
181.4 Installing engine
192 Assembly mountings
232.1 Assembly overview - assembly mountings
232.2 Supporting engine in installation position
252.3 Removing and installing engine mountings
272.4 Removing and installing gearbox mounting
282.5 Removing and installing pendulum support
302.6 Checking adjustment of assembly mountings (engine and gearbox mountings)
302.7 Adjusting assembly mountings
30Crankshaft group
331 Cylinder block (pulley end)
331.1 Assembly overview - poly V-belt drive
331.2 Assembly overview - sealing flange, belt pulley end
371.3 Removing and installing poly V-belt
381.4 Removing and installing tensioner for poly V-belt
421.5 Removing and installing vibration damper
421.6 Removing and installing engine support
431.7 Renewing crankshaft oil seal - belt pulley end
461.8 Removing and installing sealing flange on pulley end
482 Cylinder block, gearbox end
512.1 Assembly overview - cylinder block, gearbox end
512.2 Removing and installing flywheel
522.3 Removing and installing sealing flange on gearbox side
533 Crankshaft
633.1 Renewing needle bearing in crankshaft
633.2 Crankshaft dimensions
643.3 Measuring axial clearance of crankshaft
644 Pistons and conrods
664.1 Assembly overview - pistons and conrods
664.2 Removing and installing pistons
684.3 Removing and installing oil spray jets
694.4 Checking pistons and cylinder bores
704.5 Checking radial clearance of conrods
71Cylinder head, valve gear
731 Toothed belt drive
731.1 Assembly overview - toothed belt cover
731.2 Assembly overview - toothed belt
741.3 Checking valve timing
751.4 Removing toothed belt from camshaft
801.5 Removing and installing toothed belt
912 Cylinder head
1042.1 Assembly overview - cylinder head
1042.2 Assembly overview - camshaft housing
1062.3 Removing and installing cylinder head
1072.4 Removing and installing camshaft housing
1112.5 Checking compression
1153 Valve gear
1183.1 Assembly overview - valve gear
1183.2 Removing and installing inlet camshaft control valve 1 N205
1193.3 Removing and installing camshaft adjuster
1193.4 Measuring axial play of camshaft
1203.5 Removing and installing camshaft oil seal
1213.6 Removing and installing valve stem seal
1264 Inlet and exhaust valves
1344.1 Checking valve guides
1344.2 Checking valves
1344.3 Valve dimensions
135Lubrication
1361 Sump, oil pump
1361.1 Assembly overview - sump and oil pump
1361.2 Removing and installing oil level and oil temperature sender G266
1391.3 Removing and installing lower part of sump
1391.4 Removing and installing oil pump
1421.5 Removing and installing upper part of sump
1431.6 Engine oil
1462 Engine oil cooler
1472.1 Assembly overview - engine oil cooler
1472.2 Removing and installing engine oil cooler
1473 Crankcase breather
1493.1 Assembly overview - crankcase breather system
1493.2 Removing and installing oil separator
1504 Oil filter, oil pressure switch
1534.1 Assembly overview - oil filter/oil pressure switch
1534.2 Removing and installing oil pressure switch F1
1544.3 Removing and installing oil pressure switch for reduced oil pressure F378
1554.4 Removing and installing oil pressure regulating valve N428
1564.5 Checking oil pressure
157Cooling
1601 Cooling system, coolant
1601.1 Coolant hose schematic diagram
1601.2 Draining and filling coolant
1611.3 Checking cooling system for leaks
1662 Coolant pump, regulation of cooling system
1682.1 Assembly overview - coolant pump, thermostat
1682.2 Assembly overview - electric coolant pump
1702.3 Assembly overview - coolant temperature sender
1722.4 Removing and installing coolant pump
1732.5 Removing and installing toothed belt pulley for coolant pump
1762.6 Removing and installing thermostat
1772.7 Removing and installing electric coolant pump
1802.8 Removing and installing coolant temperature sender G62
1823 Coolant pipes
1853.1 Assembly overview - coolant pipes
1853.2 Removing and installing coolant pipes
1854 Radiator and radiator fan
1894.1 Assembly overview - radiator and radiator fan
1894.2 Assembly overview - radiator cowl and radiator fan
1914.3 Removing and installing radiator
1924.4 Removing and installing radiator cowling
1934.5 Removing and installing radiator fan V7 and radiator fan 2 V177
194Turbocharging/supercharging
1961 Turbocharger
1961.1 Assembly overview - turbocharger
1961.2 Removing and installing turbocharger
1981.3 Removing and installing charge pressure positioner V465
2022 Charge air system
2062.1 Assembly overview - charge air system
2062.2 Removing and installing charge pressure sender GX26
2082.3 Removing and installing charge air cooler
2082.4 Checking charge air system for leaks
211Mixture preparation - injection
2141 Injection system
2141.1 Overview of fitting locations - injection system
2141.2 Releasing high pressure in fuel system
2172 Air filter
2192.1 Assembly overview - air filter housing
2192.2 Removing and installing air filter housing
2203 Intake manifold
2213.1 Assembly overview - intake manifold
2213.2 Removing and installing intake manifold
2223.3 Removing and installing throttle valve module GX3
2253.4 Cleaning throttle valve module GX3
2264 Injectors
2284.1 Assembly overview - fuel rail with injectors
2284.2 Removing and installing fuel rail
2294.3 Removing and installing injectors
2304.4 Cleaning injectors
2345 Senders and sensors
2365.1 Removing and installing intake manifold sender GX9
2365.2 Removing and installing fuel pressure sender G247
2365.3 Checking fuel pressure sender G247
2376 High-pressure pump
2406.1 Assembly overview - high-pressure pump
2406.2 Removing and installing high-pressure pump
2416.3 Removing and installing high-pressure pipe
2427 Lambda probe
2447.1 Assembly overview - Lambda probe
2448 Engine control unit
2478.1 Removing and installing engine control unit J623
247Exhaust system
2511 Exhaust pipes, silencers
2511.1 Assembly overview - silencers
2511.2 Removing and installing silencer
2521.3 Separating exhaust pipes, silencers
2531.4 Aligning exhaust system free of tension
2531.5 Checking exhaust system for leaks
2542 Emission control
2552.1 Assembly overview - emission control
2552.2 Removing and installing catalytic converter
256Ignition system
2601 Ignition system
2601.1 Assembly overview - ignition system
2601.2 Test data, spark plugs
2611.3 Removing and installing ignition coils with output stage
2611.4 Removing and installing knock sensor 1 G61
2631.5 Removing and installing Hall sender G40
2641.6 Removing and installing engine speed sender G28
264