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
61.2 Separating engine and gearbox
151.3 Securing engine on engine and gearbox support
161.4 Installing engine
182 Assembly mountings
212.1 Assembly overview - assembly mountings
212.2 Removing and installing engine mounting
222.3 Removing and installing gearbox mounting
232.4 Removing and installing pendulum support
262.5 Supporting engine in installation position
263 Engine cover panel
293.1 Removing and installing engine cover panel
29Crankshaft group
301 Cylinder block (pulley end)
301.1 Assembly overview - poly V-belt drive
301.2 Assembly overview – sealing flange, pulley end
311.3 Removing and installing poly V-belt
321.4 Removing and installing tensioner for poly V-belt
341.5 Removing and installing bracket for ancillaries
341.6 Removing and installing vibration damper
351.7 Renewing crankshaft oil seal - belt pulley end
361.8 Removing and installing sealing flange on pulley end
382 Cylinder block, gearbox end
422.1 Assembly overview - cylinder block, gearbox end
422.2 Removing and installing flywheel
432.3 Removing and installing sealing flange on gearbox side
443 Crankshaft
473.1 Assembly overview - crankshaft
473.2 Crankshaft dimensions
493.3 Measuring axial clearance of crankshaft
493.4 Measuring radial clearance of crankshaft
503.5 Removing and installing drive chain sprocket
514 Pistons and conrods
544.1 Assembly overview - pistons and conrods
544.2 Removing and installing pistons
554.3 Checking piston and cylinder bore
574.4 Checking radial clearance of conrods
58Cylinder head, valve gear
601 Cylinder head
601.1 Assembly overview - cylinder head
601.2 Removing and installing cylinder head
621.3 Removing and installing cylinder head cover
681.4 Checking compression
701.5 Removing and installing vacuum pump
712 Toothed belt drive
732.1 Assembly overview - toothed belt
732.2 Removing and installing toothed belt
743 Valve gear
793.1 Assembly overview - valve gear
793.2 Measuring axial play of camshaft
813.3 Measuring radial play of camshaft
823.4 Removing and installing camshaft oil seal
833.5 Removing and installing camshaft adjuster
853.6 Removing and installing inlet camshaft control valve 1 N205
893.7 Removing and installing camshaft
903.8 Removing and installing valve stem seals
944 Inlet and exhaust valves
1034.1 Checking valve guides
1034.2 Checking valves
1044.3 Valve dimensions
104Lubrication
1051 Sump, oil pump
1051.1 Assembly overview - sump, oil pump
1051.2 Engine oil
1061.3 Removing and installing sump
1061.4 Removing and installing oil level and oil temperature sender G266
1102 Engine oil cooler
1112.1 Removing and installing engine oil cooler
1113 Oil filter, oil pressure switch
1133.1 Assembly overview - oil filter housing, oil pressure switch
1133.2 Draining oil filter housing
1143.3 Removing and installing oil filter housing
1163.4 Removing and installing oil pressure switch F1
1163.5 Checking oil pressure and oil pressure switch
1184 Balancer shaft module
1204.1 Assembly overview - balancer shaft module
1204.2 Removing and installing balance shaft module
121Cooling
1271 Cooling system, coolant
1271.1 Coolant hose schematic diagram
1271.2 Draining and filling coolant
1281.3 Checking cooling system for leaks
1332 Coolant pump, regulation of cooling system
1352.1 Assembly overview - coolant pump, thermostat
1352.2 Assembly overview - electric coolant pump
1362.3 Removing and installing continued coolant circulation pump V51
1362.4 Removing and installing coolant pump
1372.5 Removing and installing thermostat
1382.6 Removing and installing coolant temperature sender G62
1393 Coolant pipes
1423.1 Assembly overview - coolant pipes
1423.2 Removing and installing coolant pipes
1433.3 Removing and installing front right coolant pipe
1454 Radiator, radiator fan
1474.1 Assembly overview - radiator, radiator fan
1474.2 Removing and installing radiator
1484.3 Removing and installing radiator cowling with radiator fan
1504.4 Removing and installing radiator fan
152Turbocharging/supercharging
1531 Turbocharger
1531.1 Assembly overview - turbocharger
1531.2 Removing and installing turbocharger
1561.3 Checking vacuum unit for turbocharger
1611.4 Renewing vacuum unit for turbocharger
1631.5 Adjusting vacuum unit for turbocharger
1632 Charge air system
1682.1 Schematic overview - charge air system
1682.2 Assembly overview - charge air system
1692.3 Assembly overview - charge-air hose connections
1712.4 Removing and installing charge air cooler
1722.5 Removing and installing charge pressure sender G31
1732.6 Checking charge air system for leaks
173Mixture preparation - injection
1761 Injection system
1761.1 Overview of fitting locations - injection system
1762 Air filter
1852.1 Assembly overview - air filter housing
1852.2 Removing and installing air filter housing
1863 Intake manifold
1883.1 Assembly overview - intake manifold
1883.2 Assembly overview - intake manifold with fuel rail
1903.3 Removing and installing intake manifold with fuel rail
1913.4 Removing and installing throttle valve module J338
1943.5 Cleaning throttle valve module
1963.6 Removing and installing intake manifold flap motor V157
1973.7 Checking intake manifold change-over
1983.8 Checking double non-return valve
2004 High-pressure pump
2024.1 Assembly overview - high-pressure pump
2024.2 Removing and installing high-pressure pump
2035 Injectors
2055.1 Removing and installing fuel rail
2055.2 Removing and installing injectors
2065.3 Renewing seals on injectors
2095.4 Cleaning injectors
2116 Senders and sensors
2136.2 Removing and installing air mass meter G70
2146.3 Removing and installing fuel pressure sender G247
2146.4 Checking fuel pressure sender G247
2167 Lambda probe
2197.1 Assembly overview - Lambda probe
2197.2 Removing and installing Lambda probe G39
2197.3 Removing and installing Lambda probe after catalytic converter G130
2218 Engine control unit
2238.1 Removing and installing engine control unit J623
223Exhaust system
2251 Exhaust pipes, silencers
2251.1 Assembly overview - silencers
2251.2 Separating exhaust pipes, silencers
2261.3 Aligning exhaust system free of stress
2271.4 Checking exhaust system for leaks
2282 Emission control
2292.1 Assembly overview - emission control
2292.2 Removing and installing catalytic converter
2303 Exhaust manifold
233Ignition system
2341 Ignition system
2341.1 Assembly overview - ignition system
2341.2 Test data, spark plugs
2351.3 Removing and installing ignition coils with output stage
2361.4 Removing and installing knock sensor 1 G61
2371.5 Removing and installing knock sensor 2 G66
2381.6 Removing and installing Hall sender G40
2391.7 Removing and installing engine speed sender G28
239