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
11.4 Safety precautions when working on ignition system
21.5 Safety precautions when working on the cooling 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 Separating engine and gearbox
191.3 Securing engine on engine and gearbox support
201.4 Installing engine
222 Assembly mountings
252.1 Assembly overview - assembly mountings
252.2 Supporting engine in installation position
272.3 Removing and installing engine mounting
312.4 Removing and installing gearbox mounting
322.5 Removing and installing pendulum support
342.6 Checking adjustment of assembly mountings
352.7 Adjusting assembly mountings
353 Engine cover panel
383.1 Removing and installing engine cover
38Crankshaft group
391 Cylinder block (pulley end)
391.1 Assembly overview - cylinder block (pulley end)
391.2 Removing and installing poly-V belt
421.3 Removing and installing tensioner for poly V-belt
431.4 Removing and installing bracket for ancillaries
461.5 Removing and installing vibration damper
481.6 Removing and installing engine support
562 Cylinder block, gearbox end
582.1 Assembly overview - cylinder block, gearbox end
582.2 Removing and installing flywheel
592.3 Removing and installing sealing flange on gearbox side
613 Crankshaft
703.1 Assembly overview - crankshaft
703.2 Crankshaft dimensions
723.3 Allocation of main bearing shells
723.4 Renewing needle bearing in crankshaft
743.5 Measuring axial clearance of crankshaft
763.6 Measuring radial clearance of crankshaft
773.7 Removing and installing sender wheel
784 Balancer shaft
804.1 Assembly overview - balance shaft
804.2 Removing and installing balance shaft
835 Pistons and conrods
915.1 Assembly overview - pistons and conrods
915.2 Removing and installing pistons
955.3 Removing and installing oil spray jets
975.4 Checking pistons and cylinder bores
985.5 Separating new conrod
1015.6 Checking radial clearance of conrods
101Cylinder head, valve gear
1031 Cylinder head
1031.1 Assembly overview - cylinder head
1031.2 Renewing oil non-return valve in cylinder head
1071.3 Removing and installing cylinder head
1081.4 Checking compression
1251.5 Removing and installing vacuum pump
1272 Cover for timing chain
1292.1 Assembly overview - cover for timing chain
1292.2 Removing and installing upper timing chain cover
1312.3 Removing and installing timing chain cover (bottom)
1342.4 Renewing seal for vibration damper
1393 Chain drive
1433.1 Assembly overview - camshaft timing chains
1433.2 Removing and installing camshaft timing chain
1443.3 Removing and installing drive chain for balance shaft
1613.4 Checking valve timing
1624 Valve gear
1654.1 Assembly overview - valve gear
1654.2 Removing and installing camshaft
1684.3 Removing and installing camshaft control valve 1 N205
1874.4 Measuring axial play of camshaft
1874.5 Renewing valve stem seals
1885 Inlet and exhaust valves
2015.1 Checking valve guides
201Lubrication
2031 Sump, oil pump
2031.1 Assembly overview - sump/oil pump
2031.2 Removing and installing lower part of sump
2061.3 Removing and installing oil pump
2091.4 Removing and installing upper part of sump
2111.5 Engine oil:
2162 Engine oil cooler
2182.1 Removing and installing engine oil cooler
2183 Crankcase ventilation
2203.1 Removing and installing oil separator
2204 Oil filter, oil pressure switch
2214.1 Assembly overview - oil filter/oil pressure switch
2214.2 Removing and installing oil pressure regulating valve N428
2234.3 Removing and installing oil pressure switch F1
2234.4 Removing and installing oil pressure switch for reduced oil pressure F378
2254.5 Checking oil pressure
226Cooling
2301 Cooling system/coolant
2301.1 Connection diagram - coolant hoses
2301.2 Draining and adding coolant
2311.3 Checking cooling system for leaks
2372 Coolant pump, regulation of cooling system
2422.1 Assembly overview - coolant pump, thermostat
2422.2 Assembly overview - electric coolant pump
2452.3 Removing and installing electric coolant pump
2462.4 Removing and installing coolant pump with thermostat housing
2482.5 Removing and installing coolant pump on thermostat housing
2502.6 Removing and installing thermostat
2532.7 Removing and installing toothed belt for coolant pump
2562.8 Renewing oil seal for coolant pump drive
2592.9 Removing and installing coolant temperature sender G62
2613 Coolant pipes
2643.1 Assembly overview - coolant pipes
2643.2 Removing and installing lower coolant pipes
2643.3 Removing and installing upper coolant pipes
2664 Radiator, radiator fan
2704.1 Assembly overview - radiator/radiator fan
2704.2 Removing and installing radiator
2704.3 Removing and installing radiator cowl
2714.4 Removing and installing radiator fan V7 and radiator fan 2 V177
273Turbocharging/supercharging
2751 Turbocharger
2751.1 Assembly overview - turbocharger
2751.2 Removing and installing turbocharger
2801.3 Checking vacuum unit for turbocharger
2871.4 Renewing vacuum unit for turbocharger
2892 Charge air system
2902.1 Schematic overview - charge air system
2902.2 Assembly overview - charge air system
2912.3 Assembly overview - charge-air hose connections
2922.4 Removing and installing charge air cooler
2932.5 Checking charge air system for leaks
295Mixture preparation - injection
2991 Injection system
2991.1 Overview of fitting locations - injection system
2992 Injectors
3062.1 Assembly overview - fuel rail with injectors
3062.2 Removing and installing injectors
3082.3 Renewing seals on injectors
3122.4 Cleaning injectors
3143 Air filter
3173.1 Assembly overview - air filter housing
3173.2 Removing and installing air filter housing
3194 Intake manifold
3204.1 Assembly overview – intake manifold
3204.2 Removing and installing intake manifold with fuel rail
3224.3 Removing and installing fuel rail
3294.4 Removing and installing throttle valve module J338
3304.5 Cleaning throttle valve module
3324.6 Checking intake manifold change-over
3335 Senders and sensors
3365.2 Removing and installing air mass meter G70
3365.3 Removing and installing fuel pressure sender G247
3375.4 Checking fuel pressure sender G247
3396 Engine (motor) control unit
3446.1 Removing and installing engine control unit J623
3447 High-pressure pump
3507.1 Assembly overview - high-pressure pump
3507.2 Removing and installing high-pressure pump
352Exhaust system
3551 Exhaust pipes and silencers
3551.1 Assembly overview – silencers
3551.2 Separating exhaust pipes from silencers
3571.3 Aligning exhaust system free of stress
3591.4 Installation position of clamp
3601.5 Checking exhaust system for leaks
3612 Emission control
3622.1 Assembly overview – emission control
3622.2 Removing and installing catalytic converter
3643 Exhaust manifold
367Ignition system
3681 Ignition system
3681.1 Assembly overview - ignition system
3681.2 Removing and installing ignition coils with output stage
3691.3 Removing and installing knock sensor 1 G61
3701.4 Removing and installing engine speed sender G28
3711.5 Test data, spark plugs
372