Technical data
11 \--- Change history ---
12 Identification
22.1 Engine number/engine characteristics
23 Safety indications
43.1 Safety measures for working on fuel supply system
43.2 Safety measures for work in vehicles with Start-Stop system
43.3 Safety measures for test drives with testing and measuring equipment
43.4 Safety measures when working on the cooling system
53.5 Safety measures when working on the ignition system
54 Repair instructions
64.1 Cleanliness rules
64.2 Foreign bodies on the engine
64.3 Contact corrosion
64.4 Cable routing and fastening
64.5 Radiators and condensers - assembly
7Removing and installing engine
81 Engine - remove and install
81.1 Engine - removal
81.2 Engine and gearbox - separate
211.3 Engine in the gearbox and engine support - secure
251.4 Engine - install
262 Assembly mountings
302.1 Assembly mountings - assembly overview
302.2 Hold the engine in assembly position
352.3 Engine bracket - remove and install
402.4 Gearbox bracket - remove and install
422.5 Pendulum support (torque limiter) - remove and install
442.6 Assembly mountings adjustment - check
452.7 Assembly mountings - adjust
46Crankshaft group
491 Cylinder block - belt pulley side
491.1 Poly-V belt drive - assembly overview
491.2 Pulley side sealing flange - assembly overview
511.3 Poly-V belt - remove and install
531.4 Poly-V belt tensioner - remove and install
551.5 Pulley (vibration damper) - remove and install
561.6 Engine console - remove and install
571.7 Crankshaft seal on the pulley side - replace
621.8 Sealing flange on the belt pulley side - remove and install
642 Cylinder block, gearbox side
682.1 Cylinder block (gearbox side) - assembly overview
682.2 Clutch Disk - removal and installation
702.3 Sealing flange on the gearbox side - remove and install
733 Crankshaft
863.1 Crankshaft - dimensions
863.2 Crankshaft axial clearance - measure
864 Piston and connecting rod
884.1 Piston and connecting rod - assembly overview
884.2 Pistons - remove and install
924.3 Oil injectors - remove and install
934.4 Piston and cylinder - test
944.5 Conrod radial clearance - check
96Cylinder head, valve gear
981 Toothed belt drive
981.1 Toothed belt cover - assembly overview
981.2 Toothed belt - assembly overview
991.3 Toothed belt guard - remove and install
1011.4 Valve timing - check
1021.5 Remove the camshaft toothed belt
1081.6 Valve timing - adjust
1151.7 Toothed belt - remove and install
1232 Engine cylinder head
1302.1 Engine cylinder head - assembly overview
1302.2 Cylinder head cover with camshafts - assembly overview
1322.3 Engine cylinder head - remove and install
1352.4 Cylinder head cover with camshafts - remove and install
1402.5 Compression pressure - check
1453 Valve gear
1473.1 Valve gear - assembly overview
1473.2 Camshaft adjustment valve 1 N205 - remove and install
1493.3 Exhaust camshaft adjustment valve 1 N318 - remove and install
1493.4 Camshaft control shaft adjuster - remove and install
1503.5 Camshaft axial clearance - measure
1513.6 Camshaft seal - remove and install
1523.7 Valve stem sealant - remove and install
1584 Inlet and exhaust valves
1694.1 Valve guides - check
1694.2 Valves - check
1704.3 Valve dimensions
170Lubrication
1711 Crankcase/oil pump
1711.1 Crankcase/oil pump - assembly overview
1711.2 Sump (bottom section) - remove and install
1751.3 Oil pump - remove and install
1801.4 Sump (top section) - remove and install
1821.5 Engine oil
1882 Engine oil cooler
1892.1 Engine oil cooler - assembly overview
1892.2 Engine oil cooler - remove and install
1893 Crankcase breather
1913.1 Crankcase breather - assembly overview
1913.2 Oil separator - remove and install
1924 Oil filter/Oil pressure switch
1954.1 Oil filter/Oil pressure switch - assembly overview
1954.2 Oil pressure switch F1 - remove and install
1964.3 Oil pressure switch F378 – remove and install
1974.4 Oil pressure control valve N428 - remove and install
1984.5 Oil pressure - check
199Cooling
2021 Cooling system/coolant
2021.1 Coolant lines - connection diagram
2021.2 Coolant - drain and fill
2041.3 Cooling system - check tightness
2112 Coolant pump/coolant thermostat
2142.1 Coolant pump/coolant thermostat - assembly overview
2142.2 Air intake cooling pump - assembly overview
2172.3 Coolant temperature sensor - assembly overview
2182.4 Coolant pump - remove and install
2192.5 Coolant pump toothed belt roller - remove and install
2252.6 Coolant thermostat - remove and install
2262.7 Air intake cooling pump - remove and install
2302.8 Coolant temperature sensor G62 - remove and install
2322.9 radiator outlet coolant temperature sender G83 remove and install
2333 Coolant lines
2353.1 Coolant lines - assembly overview
2353.2 Coolant lines - remove and install
2354 Radiator/Radiator fan
2404.1 Radiator - assembly overview
2404.2 Fan cowl and radiator fan - assembly overview
2424.3 Radiator - remove and install
2434.4 Fan housing - remove and install
2454.5 Radiator fan V7 - remove and install
2464.6 Charge air cooling system radiator - remove and install
247Fuel supply system
2511 Fuel tank
2511.1 Fuel tank - assembly overview
2511.2 Fuel tank - remove and install
2531.3 Fuel tank - drain
2602 Fuel supply unit/Fuel level sensor
2712.1 Fuel pump (pre-supply pump) G6/Fuel gauge sensor G - assembly overview
2712.2 Fuel pump (pre-supply pump) G6/Fuel gauge sensor G - remove and install
2732.3 Fuel gauge sensor G - remove and install
2782.4 Installation opening cover - remove and install
2793 Plug-in connectors
2813.1 Plug-in connectors - disconnect
2814 Fuel filter
2874.1 Fuel filter - remove and install
2875 Activated charcoal system
2895.1 Activated charcoal filter system - assembly overview
2895.2 Activated charcoal filter - remove and install
2905.3 Fuel tank ventilation - check
2916 Accelerator activation
2986.1 Accelerator pedal module - assembly overview
2986.2 Accelerator pedal module GX2 - remove and install
2987 Fuel system pressurisation pump G6
3007.1 Fuel system pressurisation pump G6 - check
3007.2 Fuel pump control unit J538 - remove and install
3198 Fuel lines
3218.1 Fuel lines - remove and install
321Turbocharging/supercharging
3261 Turbocharger
3261.1 Turbocharger - assembly overview
3261.2 Turbocharger - remove and install
3301.3 Load pressure control V465 - remove and install
3341.4 Turbocharger inlet nozzle - remove and install
3362 Supercharging air system
3382.1 Supercharging air system - assembly overview
3382.2 Load pressure sensor GX26 - remove and install
3412.3 Intercooler - remove and install
3422.4 Charge air system - check air-tightness
3452.5 Air duct - remove and install
347Mixture preparation - injection
3501 Injection system
3501.1 Injection system - assembly overview
3501.2 High fuel pressure - relieve
3542 Air cleaner
3562.1 Air filter - assembly overview
3562.2 Air filter - remove and install
3582.3 Air duct - remove and install
3593 Intake manifold
3613.1 Intake manifold - assembly overview
3613.2 Intake manifold - remove and install
3643.3 Throttle butterfly valve control unit GX3 - remove and install
3663.4 Throttle valve control unit GX3 - clean
3674 Injection valves
3694.1 Fuel rail with injection valves - assembly overview
3694.2 Fuel distributor - removal and installation
3714.3 Injection valves - remove and install
3724.4 Injectors - clean
3785 Transmitters and sensors
3805.1 Intake manifold sensor GX9 - remove and install
3805.2 Fuel pressure sensor G247 - remove and install
3815.3 Fuel pressure sensor G247 - check
3825.4 Ethanol concentration sensor G708
3845.5 Control unit and actuator for structure-borne sound – assembly overview
3886 High pressure pump
3906.1 High pressure pump - assembly overview
3906.2 High pressure pump - remove and install
3916.3 Rigid high pressure line - remove and install
3927 Lambda probe
3957.1 Lambda probe - assembly overview
3957.2 Lambda probe - remove and install
3968 Engine control unit
4008.1 Engine control unit J623 - remove and install
400Exhaust system
4021 Silencer/exhaust pipes
4021.1 Silencer - assembly overview
4021.2 Silencer/exhaust pipes - detach
4041.3 Centre silencer with rear silencer - remove and install
4061.4 Centre silencer - remove and install
4101.5 Rear silencer - remove and install
4121.6 Exhaust system - tension free alignment
4131.7 Exhaust tail pipe - align
4131.8 Exhaust system - check tightness
4141.9 Pipe clamp installation position
4142 Emission control
4162.1 Emission control - assembly overview
4162.2 Catalytic converter - remove and install
419Ignition system
4241 Ignition system
4241.1 Ignition system - assembly overview
4241.2 Test data, spark plugs
4261.3 Ignition coil with final power stage - remove and install
4261.4 Knock sensor 1 G61 - remove and install
4291.5 Hall Sensor - remove and install
4301.6 Engine speed sensor G28 - remove and install
431