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 Installing engine
152 Assembly mountings
192.1 Assembly overview - assembly mountings
19Crankshaft group
211 Cylinder block (pulley end)
211.1 Assembly overview - poly V-belt drive
211.2 Assembly overview - cylinder block (pulley end)
231.3 Removing and installing poly V-belt
261.4 Removing and installing ancillary bracket
281.5 Removing and installing belt pulley
291.6 Renewing crankshaft oil seal - belt pulley end
312 Cylinder block, gearbox end
352.1 Assembly overview - cylinder block, gearbox end
352.2 Removing and installing sealing flange on gearbox side
363 Crankshaft
453.1 Assembly overview - crankshaft
453.2 Renewing needle bearing in crankshaft
463.3 Crankshaft dimensions
474 Pistons and conrods
484.1 Assembly overview - pistons and conrods
484.2 Removing and installing pistons
494.3 Removing and installing oil spray jets
504.4 Checking piston and cylinder bore
524.5 Separating new conrod
53Cylinder head, valve gear
541 Cylinder head
541.1 Assembly overview - cylinder head
541.2 Removing and installing cylinder head
571.3 Removing and installing camshaft housing
591.4 Checking compression
652 Cover for timing chain
682.1 Removing and installing valve timing housing
683 Chain drive
723.1 Removing and installing timing chain and chain drive for oil pump
723.2 Checking valve timing
803.3 Adjusting valve timing
833.4 Checking timing chain
904 Valve gear
984.1 Assembly overview - valve gear
984.2 Measuring axial play of camshaft
994.3 Removing and installing valve stem seals
1005 Inlet and exhaust valves
1035.1 Reworking valve seats
1035.2 Checking valve guides
104Lubrication
1051 Sump, oil pump
1051.1 Assembly overview - sump / oil pump
1051.2 Engine oil
1081.3 Removing and installing oil sump
1081.4 Removing and installing oil pump
1102 Oil filter, oil pressure switch
1142.1 Checking oil pressure and oil pressure switch
114Cooling
1161 Cooling system, coolant
1161.1 Coolant hose schematic diagram
1161.2 Checking cooling system for leaks
1181.3 Draining and filling coolant
1192 Coolant pump, regulation of cooling system
1252.1 Assembly overview - thermostat
1252.2 Removing and installing electric coolant pump
1262.3 Removing and installing coolant pump
1272.4 Removing and installing coolant pump pulley
1343 Radiator, radiator fan
1413.1 Assembly overview - radiator/radiator fan
1413.2 Removing and installing radiator
1423.3 Removing and installing radiator cowling
1443.4 Removing and installing radiator module
145Turbocharging/supercharging
1461 Turbocharger
1461.1 Assembly overview - turbocharger
1461.2 Removing and installing turbocharger
1501.3 Checking vacuum unit for turbocharger
1551.4 Adjusting vacuum unit for turbocharger
1571.5 Renewing vacuum unit for turbocharger
1622 Charge air system
1652.1 Assembly overview - charge air system
1652.2 Removing and installing charge air cooler
1682.3 Checking charge air system for leaks
1713 Supercharger
1753.1 Assembly overview - supercharger
1753.2 Removing and installing supercharger
1773.3 Removing and installing supercharger input shaft seal
184Mixture preparation - injection
1881 Injection system
1881.1 Releasing high pressure in fuel system
1882 Injectors
1892.1 Assembly overview - fuel rail with injectors
1892.2 Removing and installing injectors
1912.3 Renewing seals on injectors
1933 Air filter
1983.1 Assembly overview - air filter housing
1983.2 Removing and installing air filter housing
1994 Intake manifold
2004.1 Assembly overview - intake manifold
2004.2 Removing and installing throttle valve module J338
2054.3 Cleaning throttle valve module
2074.4 Removing and installing regulating flap control unit J808
2085 Senders and sensors
2115.1 Checking fuel pressure sender G247
2116 Engine control unit
2156.1 Removing and installing engine control unit J623
2156.2 Removing and installing engine control unit J623 with protective housing
2167 High-pressure pump
2197.1 Assembly overview - high-pressure pump
2197.2 Removing and installing high-pressure pump
220Exhaust system
2241 Exhaust pipes, silencers
2241.1 Assembly overview - silencers
2241.2 Removing and installing front exhaust pipe
2251.3 Separating exhaust pipes, silencers
2271.4 Aligning exhaust system free of stress
2281.5 Installation position of clamp
2292 Emission control
2312.1 Assembly overview - emission control
2312.2 Removing and installing catalytic converter
232Ignition system
2351 Ignition system
2351.1 Assembly overview - ignition system
2351.2 Test data, spark plugs
2361.3 Removing and installing ignition coils with output stage
2361.4 Removing and installing engine speed sender G28
238