Technical data
11 Engine number, engine data
12 Safety precautions
22.1 Safety precautions when working on fuel supply system
22.2 Safety precautions when working on ignition system
22.3 Releasing pressure in high-pressure area
33 General repair notes
53.1 Rules for cleanliness
53.2 Foreign objects in engine
5Removing and installing engine
61 Removing and installing engine
61.1 Removing engine
71.2 Securing engine to assembly stand
121.3 Installing engine
143 Engine cover
18Crankshaft group
191 Cylinder block (pulley end)
191.1 Assembly overview - cylinder block, belt pulley end
191.2 Assembly overview - poly V-belt drive
221.3 Removing and installing poly V-belt
231.4 Removing and installing tensioning element for poly V-belt
241.5 Removing and installing bracket for ancillaries
241.6 Renewing crankshaft oil seal - belt pulley end
261.7 Removing and installing sealing flange on pulley end
282 Cylinder block, gearbox end
322.1 Assembly overview - cylinder block, gearbox end
322.2 Removing and installing sealing flange on gearbox side
342.3 Removing and installing flywheel
352.4 Removing and installing drive plate
363 Crankshaft
383.1 Assembly overview - crankshaft
383.2 Renewing needle bearing in crankshaft
403.3 Crankshaft dimensions
413.4 Allocation of main bearings
414 Pistons and conrods
434.1 Assembly overview - pistons and conrods
434.2 Separating new conrod
444.3 Removing and installing pistons
454.4 Checking piston and cylinder bore
46Cylinder head, valve gear
491 Cylinder head
491.1 Assembly overview - cylinder head
491.2 Removing and installing cylinder head cover
511.3 Removing and installing cylinder head
531.4 Checking compression
582 Toothed belt drive
602.1 Removing and installing toothed belt
603 Valve gear
703.1 Assembly overview - valve gear
703.2 Removing and installing valve stem seals
723.3 Removing and installing camshaft adjuster
773.4 Removing and installing inlet camshaft control valve 1 N205
803.5 Removing and installing camshaft oil seal
823.6 Removing and installing camshafts
853.7 Inlet and exhaust valves
88Lubrication
901 Sump, oil pump
901.1 Engine oil
901.2 Assembly overview - sump
901.3 Removing and installing oil level and oil temperature sender G266
921.4 Removing and installing sump
922 Oil filter, oil pressure switch
962.1 Assembly overview - oil filter housing, oil pressure switch
962.2 Removing and installing oil filter housing
982.3 Checking oil pressure and oil pressure switch
992.4 Removing and installing oil pressure switch F1
1003 Balancer shaft module
1023.1 Assembly overview - balancer shaft module
1023.2 Removing and installing balance shaft module
103Cooling
1081 Cooling system, coolant
1081.1 Coolant hose schematic diagram
1081.2 Draining and filling coolant
1101.3 Checking cooling system for leaks
1142 Coolant pump, regulation of cooling system
1172.1 Assembly overview - coolant pump, thermostat
1172.2 Removing and installing coolant pump
1192.3 Removing and installing thermostat
1202.4 Removing and installing coolant temperature sender
1212.5 Electric coolant pump
1223 Coolant pipes
1253.1 Assembly overview - coolant pipes
1253.2 Removing and installing coolant pipes
1264 Coolers, radiator, radiator fan
1294.1 Assembly overview - radiator, radiator fan
1294.3 Removing and installing radiator
131Turbocharging/supercharging
1331 Turbocharger
1331.1 Assembly overview - turbocharger
1331.2 Removing and installing turbocharger
1381.3 Checking vacuum unit for turbocharger
1462 Charge air system
1482.1 Fitting hose connections with plug-in connectors
1482.2 Assembly overview - charge air system
1492.3 Schematic overview - charge air system
1512.4 Removing and installing charge air cooler
1512.5 Removing and installing charge pressure sender G31
1532.6 Checking charge air system for leaks
153Mixture preparation - injection
1561 Injection system
1561.1 Vacuum system
1561.2 Overview of fitting locations
1572 Injectors
1592.1 Removing and installing injectors
1592.2 Renewing seals on injectors
1612.3 Cleaning injectors
1633 High-pressure pump
1653.1 Assembly overview - high-pressure pump
1653.2 Removing and installing high-pressure pump
1663.3 Assembly overview - fuel pipes and fuel rail
1674 Senders and sensors
1704.1 Actuator for structure-borne sound R214 and control unit for structure-borne sound J869
1704.2 Removing and installing fuel pressure sender G247
1724.3 Checking fuel pressure sender G247
1734.4 Removing and installing air mass meter G70
1775 Intake manifold
1785.1 Assembly overview - intake manifold
1785.2 Removing and installing intake manifold with fuel rail
1795.4 Removing and installing throttle valve module J338
1855.5 Cleaning throttle valve module J338
1866 Air filter
1886.1 Assembly overview - air filter
1886.2 Removing and installing air filter, engine cover
1886.3 Removing and installing air filter element
1907 Engine control unit J623
1927.1 Removing and installing engine control unit
1927.2 Removing and installing engine control unit with protective housing
193Exhaust system
1971 Exhaust pipes, silencers
1971.1 Assembly overview - silencers
1971.2 Removing and installing front exhaust pipe
1991.3 Separating centre and rear silencers
2011.4 Aligning exhaust system free of stress
2021.5 Checking exhaust system for leaks
204Ignition system
2051 Ignition system
2051.1 Assembly overview - ignition system
2051.2 Removing and installing ignition coils with output stage
2061.3 Test data, spark plugs
208