Technical data
11 Technical data
11.1 Engine number
11.2 Engine data
1Removing and installing engine
31 Removing and installing engine
31.1 Removing engine
31.2 Notes on installing
151.3 Specified torques
161.4 Front engine mounting
16Crankshaft group
181 Dismantling and assembling engine
181.1 Assembly overview - poly V-belt drive
201.2 Removing and installing poly V-belt
231.3 Renewing crankshaft oil seal - belt pulley end
241.4 Removing and installing front sealing flange
261.5 Assembly overview - drive plate/dual-mass flywheel
291.6 Removing and installing dual-mass flywheel
301.7 Extracting and driving in needle roller bearing for dual-mass flywheel
311.8 Removing and installing drive plate
321.9 Renewing crankshaft oil seal on timing chain end
331.10 Assembly overview - timing chain covers
351.11 Removing and installing timing chain covers
361.12 Assembly overview - balancer shaft
431.13 Removing and installing balancer shaft
442 Chain drive (engine code BMK)
472.1 Assembly overview - drive chain for valve gear
472.2 Removing and installing drive chain for valve gear
482.3 Assembly overview - chain for balancer shaft and oil pump
492.4 Removing and installing chain for balancer shaft and oil pump
513 Chain drive (engine codes CARA, CEXA, CEXB)
553.1 Assembly overview - drive chain for valve gear
553.2 Removing and installing drive chain for valve gear
563.3 Assembly overview - chain for balancer shaft and oil pump
573.4 Removing and installing chain for balancer shaft and oil pump
594 Removing and installing crankshaft
634.1 Assembly overview - crankshaft
634.2 Crankshaft dimensions
654.3 Measuring axial clearance
654.4 Measuring radial clearance
665 Pistons and conrods
675.1 Assembly overview - pistons and conrods
675.2 Checking piston projection at TDC
705.3 Piston and cylinder dimensions
715.4 Checking radial clearance of conrods
71Cylinder head, valve gear
721 Cylinder head
721.1 Assembly overview - cylinder head
721.2 Assembly overview - cylinder head cover
751.3 Removing and installing cylinder head cover
781.4 Removing and installing cylinder head
841.5 Checking compression
911.6 Assembly overview - vacuum pump
932 Valve gear
952.1 Assembly overview - valve gear
952.2 Checking axial clearance of camshafts
962.3 Renewing camshaft oil seal
972.4 Removing and installing camshafts
1002.5 Renewing valve stem seals
1042.6 Checking hydraulic valve compensation elements
1082.7 Valve dimensions
1102.8 Checking valve guides
1103 Chain drive for camshafts
1123.1 Camshaft timing chains (engine code BMK)
1123.2 Camshaft timing chains (engine codes CARA, CEXA, CEXB)
131Lubrication
1511 Engine oil
1511.1 Oil capacities
1511.2 Checking engine oil level
1512 Parts of lubrication system
1522.1 Assembly overview - oil pump, lower part of sump
1522.2 Removing and installing lower part of sump
1532.3 Removing and installing oil pump
1552.4 Assembly overview - upper part of sump
1562.5 Removing and installing upper part of sump
1573 Oil cooler, pressure control valve and oil filter housing
1613.1 Assembly overview - oil cooler, pressure control valve, and oil filter housing
1613.2 Removing and installing oil cooler
1623.3 Removing and installing oil filter housing
1633.7 Checking oil pressure and oil pressure switch
167Cooling
1701 Parts of cooling system
1701.1 Assembly overview - radiator
1701.2 Removing and installing fan support
1711.3 Assembly overview - fans
1721.4 Checking cooling system for leaks
1731.5 Draining and filling coolant
1731.6 Assembly overview - coolant pump and thermostat
1771.7 Removing and installing coolant pump
1771.8 Removing and installing continued coolant circulation pump V51
1781.9 Removing and installing hose connection with thermostat
1791.10 Assembly overview - pump for exhaust gas recirculation cooler V400
1801.11 Removing and installing pump for exhaust gas recirculation cooler V400
1811.12 Assembly overview - coolant pipes
1821.13 Removing and installing coolant pipes
1851.14 Removing and installing coolant temperature sender G62
192Turbocharging/supercharging
1941 Charge air system with turbocharger
1941.1 Rules for cleanliness
1941.2 Assembly overview - turbocharger (engine code BMK)
1941.3 Removing and installing turbocharger (engine code BMK)
1961.4 Assembly overview - turbocharger (engine codes CARA, CEXA und CEXB)
1981.5 Removing and installing turbocharger (engine codes CARA, CEXA und CEXB)
2001.6 Removing and installing turbocharger 1 control unit J724
2041.7 Assembly overview - parts of charge air cooling
2131.8 Removing and installing charge air cooler
214Mixture preparation - injection
2161 Diesel direct injection system
2171.1 Safety precautions
2181.2 Rules for cleanliness and instructions for working on fuel system
2181.3 Schematic overview of fuel system (engine code BMK)
2191.4 Schematic overview of fuel system (engine codes CARA, CEXA und CEXB)
2211.5 Assembly overview - fuel system (engine code BMK)
2231.6 Assembly overview - fuel system (engine codes CARA, CEXA und CEXB)
2251.7 Assembly overview - intake manifold
2281.8 Removing and installing intake manifold upper part
2321.9 Removing and installing intake manifold flap motor V157 or intake manifold flap 2 motor V275
2361.10 Removing and installing lower parts of intake manifold (engine code BMK)
2431.12 Removing and installing injectors (piezo injectors)
2531.13 Checking fuel pressure regulating valve N276
2591.14 Removing and installing fuel pressure regulating valve N276
2591.15 Removing and installing fuel pressure sender G247
2611.16 Checking return flow rate of injectors (piezo injectors) with engine running
2621.17 Checking return flow rate of injectors (piezo injectors) at starting speed
2651.18 Checking for injectors sticking open (piezo injectors)
2661.19 Installing high-pressure lines
2671.20 Checking pressure retention valve in fuel return
2701.21 Assembly overview - toothed belt for high-pressure pump (engine code BMK)
2711.23 Assembly overview - high-pressure pump (engine code BMK)
2771.24 Removing and installing high-pressure pump (engine code BMK)
2801.29 Bleeding fuel system
2941.30 Assembly overview - air filter
2952 Engine control unit
2982.1 Reading and clearing engine control unit fault memory
2982.2 Adapting functions and components
2992.3 Removing and installing engine control unit
3002.4 Fitting locations
300Exhaust system
3031 Parts of the exhaust system
3031.1 Assembly overview - exhaust system
3031.2 Assembly overview - front exhaust pipe and catalytic converter
3061.3 Assembly overview - exhaust manifold and intermediate pipes
3072 Exhaust gas recirculation system, engine code BMK
3082.1 Assembly overview - exhaust gas recirculation system
3082.2 Checking mechanical exhaust gas recirculation valve
3092.3 Removing and installing mechanical exhaust gas recirculation valve
3102.4 Removing and installing exhaust gas recirculation cooler
3103 Exhaust gas recirculation, engine codes CARA, CEXA, CEXB
3123.1 Assembly overview - exhaust gas recirculation system
3123.2 Removing and installing exhaust gas recirculation control motor V338
3133.3 Removing and installing exhaust gas recirculation cooler
3143.4 Removing and installing exhaust gas recirculation temperature sensor G98
316Glow plug system
3181 Glow plug system
3181.1 Glow plug characteristics
3181.2 Removing, installing and checking ceramic glow pin plugs
3181.3 Removing and installing metal glow plugs
3201.4 Checking metal glow plugs
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