Technical data
11 Technical data
11.1 Engine number
11.2 Engine data
1Removing and installing engine
21 Removing and installing engine
21.1 Removing engine
21.2 Securing engine to assembly stand
61.3 Notes on installing
71.4 Assembly mountings
81.5 Additional notes and assembly work for vehicles with air conditioner
9Crankshaft group
101 Dismantling and assembling engine
101.1 Assembly overview - toothed belt drive
101.2 Assembly overview - poly V-belt drive
111.3 Removing and installing poly V-belt
131.4 Assembly overview - crankcase
152 Sealing flange and flywheel
172.2 Assembly overview - sealing flange and flywheel, engine code BMT
192.3 Renewing crankshaft oil seal - belt pulley end
202.4 Removing and installing sealing flange - belt pulley end
212.5 Renewing crankshaft sealing flange - flywheel end, engine code BMT
232.6 Removing and installing engine speed sender G28 , engine code BMT
303 Crankshaft
323.1 Assembly overview - crankshaft
323.2 Crankshaft dimensions
334 Pistons and conrods
354.1 Assembly overview - pistons and conrods
354.2 Separating new conrods
364.3 Checking pistons, piston rings and cylinder bores
374.4 Checking piston projection at TDC
384.5 Piston and cylinder dimensions
40Cylinder head, valve gear
411 Cylinder head
411.1 Assembly overview - cylinder head
411.2 Removing and installing cylinder head cover
441.3 Removing, installing and tensioning toothed belt
451.4 Removing and installing cylinder head
541.5 Checking compression
582 Valve gear
612.1 Assembly overview - valve gear
612.2 Checking valve guides
642.3 Renewing valve stem oil seals
652.4 Removing and installing camshaft
662.5 Removing and installing camshaft oil seal
70Lubrication
731 Engine oil
731.1 Oil capacities
731.2 Checking engine oil level
732 Parts of lubrication system
742.1 Assembly overview - parts of lubrication system
742.2 Removing and installing sump
752.3 Assembly overview - oil filter bracket
772.4 Checking oil pressure and oil pressure switch
782.5 Assembly overview - oil supply line
792.6 Removing and installing oil supply line
80Cooling
831 Parts of cooling system
831.1 Assembly overview - parts of cooling system, body side
841.2 Assembly overview - parts of cooling system, engine side
871.3 Coolant hose schematic diagram
881.4 Draining and filling coolant
921.5 Removing and installing radiator
941.6 Removing and installing coolant pump
961.7 Removing and installing thermostat
971.8 Checking cooling system for leaks
991.9 Checking oil cooler for leaks
101Fuel supply system
1041 Removing and installing parts of fuel supply system
1041.1 Safety precautions when working on fuel supply system
1041.2 Rules for cleanliness
1051.3 Assembly overview - fuel tank with attachments
1051.4 Assembly overview - fuel filter
1081.5 Removing and installing fuel cooler
1091.6 Removing and installing fuel tank
1101.7 Removing and installing fuel delivery unit
1111.8 Removing and installing fuel gauge sender G
1131.9 Checking fuel pump
1141.10 Assembly overview - accelerator mechanism
1151.11 Checking tandem pump
1161.12 Removing and installing tandem pump
119Turbocharging/supercharging
1231 Charge air system with turbocharger
1231.1 Safety precautions
1231.2 Rules for cleanliness
1241.4 Hose connections with spring band ring
1251.5 Assembly overview - turbocharger with attachments
1251.6 Removing and installing turbocharger, engine code BMT
1301.7 Assembly overview - parts of charge air cooling
1321.8 Checking charge air system for leaks
134Mixture preparation - injection
1371 Repairing diesel direct injection system
1371.1 Safety precautions
1371.2 Rules for cleanliness
1381.3 Assembly overview - intake manifold with intake manifold flap
1381.4 Assembly overview - air filter
1421.5 Assembly overview - unit injector
1421.6 Removing and installing unit injector O-rings
1431.7 Removing and installing unit injector
1452 Engine control unit
1492.1 Reading and clearing engine control unit fault memory
1492.2 Adapting functions and components
1492.3 Removing and installing engine control unit
150Exhaust system
1551 Exhaust system
1551.1 Assembly overview - front exhaust pipe with catalytic converter and silencers
1571.2 Assembly overview - front exhaust pipe with particulate filter
1581.3 Assembly overview - silencer (vehicle with particulate filter)
1601.4 Removing and installing front exhaust pipe with particulate filter
1601.5 Aligning exhaust system stress free
1632 Exhaust gas recirculation system
1652.1 Assembly overview - parts of exhaust gas recirculation
1652.2 Assembly overview - exhaust gas recirculation cooler, engine code BMT
1692.3 Removing and installing exhaust gas recirculation cooler, engine code BMT
1702.4 Schematic diagram for vacuum hoses
171Ignition system
1721 Checking glow plug system
1721.1 Removing, installing and checking glow plugs
1721.2 Characteristics of ceramic glow plugs
1731.3 Removing, installing and checking ceramic glow plugs
173