Technical data
11 Safety information
11.1 Safety regulations for working on fuel supply
11.2 Safety measures when working on vehicles with start/stop system
21.4 Safety precautions when working on the cooling system
21.5 Safety precautions when working on ignition system
21.6 Safety precautions when working on exhaust system
32 Identification
42.1 Engine number/engine data
43 Repair instructions
73.1 Rules for cleanliness
73.2 General information
73.3 Foreign objects in engine
73.4 Contact corrosion
83.5 Routing and attachment of lines
83.6 Checking vacuum system
8Removing and installing engine
101 Removing and installing engine
101.1 Removing engine
101.2 Separating engine and gearbox
181.3 Securing engine on engine and gearbox support
221.4 Installing engine
232 Assembly mountings
272.1 Assembly overview – assembly mountings
272.2 Removing and installing engine mounting
292.3 Removing and installing gearbox mounting
302.4 Removing and installing pendulum support
312.5 Supporting engine in installation position
322.6 Adjusting assembly mountings
372.7 Checking adjustment of assembly mountings
393 Engine cover panel
403.1 Removing and installing engine cover
40Crankshaft group
411 Cylinder block (pulley end)
411.1 Assembly overview - cylinder block (pulley end)
411.2 Assembly overview - sealing flange, belt pulley end
431.3 Removing and installing poly-V belt
431.4 Removing and installing tensioner for poly V-belt
441.5 Removing and installing vibration damper
451.6 Removing and installing engine support
461.7 Renewing crankshaft oil seal - belt pulley end
481.8 Removing and installing sealing flange on pulley end
512 Cylinder block, gearbox end
522.1 Assembly overview - cylinder block, gearbox end
522.2 Removing and installing flywheel
542.3 Removing and installing sealing flange on gearbox side
562.4 Removing and installing adapter plate
672.5 Removing and installing intermediate plate
683 Crankshaft
693.1 Renewing needle bearing in crankshaft
693.2 Crankshaft dimensions
713.3 Measuring axial clearance of crankshaft
714 Pistons and conrods
744.1 Assembly overview - pistons and conrods
744.2 Removing and installing pistons
774.3 Checking pistons and cylinder bores
794.4 Separating new conrod
824.5 Checking radial clearance of conrods
824.6 Removing and installing oil spray jets
834.7 Setting piston to TDC position
84Cylinder head, valve gear
871 Cylinder head
871.1 Assembly overview - cylinder head
871.2 Assembly overview - camshaft housing
881.3 Removing and installing cylinder head
911.4 Removing and installing camshaft housing
951.5 Checking compression
982 Toothed belt drive
1012.1 Assembly overview - toothed belt cover
1012.2 Assembly overview - toothed belt
1012.3 Removing and installing toothed belt guard
1032.4 Removing and installing toothed belt
1052.5 Checking valve timing
1082.6 Preassembling and installing valve timing tool
1112.7 Adjusting valve timing
1202.8 Removing toothed belt from camshaft
1303 Valve gear
1333.1 Assembly overview - valve gear
1333.2 Removing and installing camshaft oil seal
1353.3 Removing and installing camshaft adjuster
1423.4 Removing and installing cam actuator N583/N587/N591/N595
1503.5 Removing and installing exhaust camshaft control valve 1 N318
1523.6 Removing and installing valve stem seals
1533.7 Removing and installing holder for oil seal
1593.8 Checking control valve
1623.9 Removing and installing oil seal on holder
1623.10 Removing and installing inlet camshaft control valve 1 N727
1644 Inlet and exhaust valves
1664.1 Checking valve guides
1664.2 Checking valves
1674.3 Valve dimensions
167Lubrication
1681 Sump, oil pump
1681.1 Assembly overview - sump/oil pump
1681.2 Engine oil:
1711.3 Removing and installing oil sump
1711.4 Removing and installing oil pump
1731.5 Removing and installing oil level and oil temperature sender G266
1752 Engine oil cooler
1772.1 Assembly overview - engine oil cooler
1772.2 Removing and installing engine oil cooler
1773 Crankcase ventilation
1793.1 Assembly overview - crankcase breather system
1793.2 Removing and installing oil separator
1804 Oil filter, oil pressure switch
1844.1 Assembly overview - oil pressure switches/oil pressure control
1844.2 Removing and installing oil pressure sender G10
1844.3 Checking oil pressure and oil pressure switch
1864.4 Removing and installing oil pressure regulating valve N428
1865 Oil circuit
1885.1 Assembly overview - oil circuit
1885.2 Removing and installing oil supply line
1905.3 Removing and installing oil return line for turbocharger
191Cooling
1931 Cooling system/coolant
1931.1 Connection diagram - coolant hoses
1931.2 Checking cooling system for leaks
1951.3 Draining and adding coolant
1972 Coolant pump, regulation of cooling system
2052.1 Assembly overview - coolant pump, thermostat
2052.2 Assembly overview - electric coolant pump
2062.3 Assembly overview - coolant temperature sender
2072.4 Removing and installing charge air cooling pump V188
2082.5 Checking coolant pump
2102.6 Removing and installing coolant pump
2122.7 Removing and installing toothed belt for coolant pump
2162.8 Removing and installing toothed belt pulley for coolant pump
2162.9 Removing and installing coolant temperature sender G62
2192.10 Removing and installing engine outlet coolant temperature sender G82
2202.11 Removing and installing radiator outlet coolant temperature sender G83
2212.12 Removing and installing engine temperature regulation module GX33
2233 Coolant pipes
2263.1 Assembly overview - coolant pipes
2263.2 Removing and installing coolant pipes
2274 Radiator, radiator fan
2384.1 Assembly overview - radiator, radiator fan
2384.2 Assembly overview – radiator cowl and radiator fan
2404.3 Removing and installing radiator
2404.4 Removing and installing cooler for charge air cooling circuit
2424.5 Removing and installing radiator cowl
2444.6 Removing and installing radiator fan VX57
2454.7 Removing and installing radiator fan 2 V177
246Turbocharging/supercharging
2481 Turbocharger
2481.1 Assembly overview - turbocharger
2481.2 Removing and installing turbocharger
2501.3 Removing and installing connection for turbocharger
2541.4 Removing and installing charge pressure control module GX34
2552 Charge air system
2572.1 Assembly overview - charge air system
2572.2 Checking charge air cooler for leaks
2592.3 Removing and installing charge air cooler
2642.4 Removing and installing charge pressure sender GX26
2662.5 Checking charge air system for leaks
2672.6 Removing and installing air intake pipe
270Mixture preparation - injection
2711 Injectors
2711.1 Assembly overview - fuel rail with injectors
2711.2 Removing and installing fuel rail
2721.3 Removing and installing injectors
2741.4 Cleaning injectors
2782 Air filter
2812.1 Assembly overview - air filter housing
2812.2 Removing and installing air filter housing
2832.3 Removing and installing air guide on lock carrier
2833 Intake manifold
2853.1 Assembly overview – intake manifold
2853.2 Removing and installing intake manifold
2873.3 Cleaning throttle valve module GX3
2903.4 Removing and installing throttle valve module GX3
2903.5 Removing and installing intake connecting pipe
2924 Senders and sensors
2944.1 Removing and installing fuel pressure sender G247
2944.2 Checking fuel pressure sender G247
2954.3 Removing and installing intake manifold sender GX9
2964.4 Removing and installing exhaust gas pressure sensor 1 G450
2974.5 Removing and installing air mass measurement module GX35
2995 Engine control unit
3005.1 Removing and installing engine control unit J623
3006 High-pressure pump
3016.1 Assembly overview - high-pressure pump
3016.2 Removing and installing high-pressure pump
3026.3 Removing and installing high-pressure pipe
3037 Lambda probe
3057.1 Assembly overview - Lambda probe
3057.2 Removing and installing Lambda probe 1 before catalytic converter GX10
3057.3 Removing and installing Lambda probe 1 after catalytic converter GX7
307Exhaust system
3101 Exhaust pipes and silencers
3101.1 Assembly overview – silencers
3101.2 Separating exhaust pipes from silencers
3121.3 Removing and installing front silencer
3131.4 Removing and installing centre silencer
3141.5 Removing and installing rear silencer
3151.6 Aligning exhaust system free of stress
3161.7 Checking exhaust system for leaks
3171.8 Installation position of clamp
3182 Emission control
3192.1 Assembly overview – emission control
3192.2 Removing and installing catalytic converter
3212.3 Removing and installing particulate filter
324Ignition system
3251 Ignition system
3251.1 Assembly overview - ignition system
3251.2 Removing and installing ignition coils
3271.3 Removing and installing knock sensor 1 G61
3291.4 Removing and installing engine speed sender G28
3301.5 Removing and installing inlet camshaft position sender G1002
3311.6 Removing and installing exhaust camshaft position sender G1003
332