Technical data
11 Safety information
11.1 Safety precautions when working on the cooling system
11.2 Safety precautions when working on ignition system
11.3 Safety regulations for working on fuel supply
11.4 Safety measures when working on vehicles with a start/stop system
22 Identification
32.1 Engine number/engine data
33 Repair instructions
53.1 Rules for cleanliness
53.2 Foreign objects in engine
53.3 Contact corrosion
53.4 Routing and attachment of lines
53.5 Fitting radiator and condensers
63.6 Checking vacuum system
6Removing and installing engine
71 Removing and installing engine
71.1 Removing engine
71.2 Securing engine on engine and gearbox support
151.3 Installing engine
172 Assembly mountings
202.1 Assembly overview – assembly mountings
20Crankshaft group
221 Cylinder block (pulley end)
221.1 Assembly overview - poly V-belt drive
221.2 Assembly overview - sealing flange, belt pulley end
241.3 Removing and installing poly-V belt
251.4 Renewing crankshaft oil seal - belt pulley end
271.5 Removing and installing sealing flange on 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
362.3 Removing and installing flywheel
402.4 Removing and installing drive plate
423 Crankshaft
453.1 Assembly overview - crankshaft
453.2 Crankshaft dimensions
473.3 Allocation of main bearing shells
473.4 Removing and installing sender wheel
473.5 Pulling needle bearing out of and driving into crankshaft
484 Pistons and conrods
514.1 Assembly overview - pistons and conrods
514.2 Separating new conrod
534.3 Checking pistons and cylinder bores
54Cylinder head, valve gear
571 Cylinder head
571.1 Assembly overview - cylinder head
571.2 Removing and installing cylinder head
591.3 Removing and installing cylinder head cover
661.4 Checking compression
682 Toothed belt drive
702.1 Assembly overview - toothed belt
702.2 Removing and installing toothed belt
723 Valve gear
843.1 Assembly overview - valve gear
843.2 Removing and installing camshaft
863.3 Removing and installing camshaft oil seal
893.4 Removing and installing camshaft adjuster
933.5 Removing and installing camshaft control valve 1 N205
973.6 Removing and installing valve stem seals
994 Inlet and exhaust valves
1054.1 Valve dimensions
1054.2 Checking valve guides
105Lubrication
1071 Sump, oil pump
1071.1 Assembly overview - sump/oil pump
1071.2 Removing and installing oil sump
1091.3 Engine oil:
1122 Oil filter, oil pressure switch
1142.1 Assembly overview - oil filter housing, oil pressure switch
1142.2 Removing and installing oil pressure switch F1
1162.3 Removing and installing oil filter housing
1182.4 Checking oil pressure and oil pressure switch
1183 Oil circuit
1233.1 Assembly overview - oil circuit
1234 Balancer shaft module
1244.1 Assembly overview - balancer shaft module
1244.2 Removing and installing balance shaft module
126Cooling
1321 Cooling system/coolant
1321.1 Connection diagram - coolant hoses
1321.2 Draining and adding coolant
1341.3 Checking cooling system for leaks
1392 Coolant pump, regulation of cooling system
1422.1 Assembly overview - coolant pump, thermostat
1422.2 Assembly overview - electric coolant pump
1432.3 Removing and installing coolant pump
1432.4 Removing and installing thermostat
1452.5 Removing and installing coolant temperature sender G62
1462.6 Removing and installing radiator outlet coolant temperature sender G83
1473 Coolant pipes
1483.1 Assembly overview - coolant pipes
1483.2 Removing and installing coolant pipes
1504 Radiator, radiator fan
1534.1 Assembly overview - radiator/radiator fan
1534.2 Removing and installing radiator
1554.3 Removing and installing radiator fan V7
1554.4 Removing and installing auxiliary radiator
157Turbocharging/supercharging
1591 Turbocharger
1591.1 Assembly overview - turbocharger
1591.2 Removing and installing turbocharger
1621.3 Checking vacuum unit for turbocharger
1702 Charge air system
1732.1 Schematic overview - charge air system
1732.2 Assembly overview - charge air system
1732.3 Assembly overview - charge-air hose connections
1752.4 Removing and installing charge air cooler
1762.5 Checking charge air system for leaks
178Mixture preparation - injection
1811 Injection system
1811.1 Releasing high pressure in fuel system
1812 Injectors
1832.1 Assembly overview - fuel rail with injectors
1832.2 Removing and installing injectors
1852.3 Removing and installing fuel rail
1882.4 Renewing seals on injectors
1893 Air filter
1933.1 Assembly overview - air filter housing
1933.2 Removing and installing air filter housing
1944 Intake manifold
1974.1 Assembly overview – intake manifold
1974.2 Removing and installing intake manifold
1994.3 Removing and installing intake manifold flap motor V157
2014.4 Removing and installing throttle valve module J338
2045 Senders and sensors
2075.2 Removing and installing air mass meter G70
2085.3 Removing and installing fuel pressure sender G247
2085.4 Checking fuel pressure sender G247
2106 Engine control unit
2136.1 Removing and installing engine control unit J623
2137 High-pressure pump
2167.1 Assembly overview - high-pressure pump
2167.2 Removing and installing high-pressure pump
218Exhaust system
2211 Exhaust pipes and silencers
2211.1 Assembly overview – silencers
2211.2 Removing and installing front exhaust pipe
2231.3 Separating exhaust pipes from silencers
2261.4 Aligning exhaust system free of stress
2271.5 Installation position of clamp
2281.6 Checking exhaust system for leaks
2291.7 Checking exhaust flap
2292 Emission control
2312.1 Assembly overview – emission control
2312.2 Removing and installing catalytic converter
231Ignition system
2321 Ignition system
2321.1 Assembly overview - ignition system
2321.2 Removing and installing ignition coils with output stage
2321.3 Test data, spark plugs
234