Technical data
11 Safety information
11.1 Safety regulations for working on fuel supply
11.2 Safety measures when working on vehicles with a start/stop system
21.4 Safety precautions when working on the cooling system
21.5 Safety precautions when working on the SCR system
31.6 Safety precautions when working on ignition system
31.7 Safety precautions when working on exhaust system
42 Identification
52.1 Engine number/engine data
53 Repair instructions
73.1 Rules for cleanliness
73.2 General notes
73.3 General repair instructions
83.4 Foreign objects in engine
83.5 Contact corrosion
83.6 Routing and attachment of lines
93.7 Fitting radiator and condensers
93.8 Checking vacuum system
9Removing and installing engine
161 Removing and installing engine
161.1 Removing engine
161.2 Separating engine and gearbox
261.3 Securing engine on engine and gearbox support
281.4 Installing engine
302 Assembly mountings
342.1 Assembly overview - assembly mountings
342.2 Removing and installing engine mounting
442.3 Removing and installing engine mounting
502.4 Removing and installing gearbox mounting
512.5 Removing and installing damper weight
532.6 Supporting engine in installation position
533 Engine cover panel
583.1 Assembly overview – engine compartment cover
583.2 Removing and installing engine compartment cover
58Crankshaft group
601 Cylinder block (pulley end)
601.1 Assembly overview - cylinder block (pulley end)
601.2 Assembly overview - sealing flange, belt pulley end
651.3 Removing and installing poly-V belt
661.4 Removing and installing tensioner for poly V-belt
701.5 Removing and installing vibration damper
711.6 Removing and installing bracket for ancillaries
751.7 Removing and installing engine support
791.8 Removing and installing sealing flange on pulley end
891.9 Renewing caps in cylinder block (pulley end)
912 Cylinder block, gearbox end
932.1 Assembly overview - cylinder block, gearbox end
932.2 Removing and installing flywheel
952.3 Removing and installing sealing flange on gearbox side
962.4 Renewing caps in cylinder block (gearbox end)
1163 Crankshaft
1183.1 Assembly overview - crankshaft
1183.2 Crankshaft dimensions
1203.3 Renewing needle bearing in crankshaft
1203.4 Measuring axial clearance of crankshaft
1223.5 Measuring radial clearance of crankshaft
1234 Pistons and conrods
1244.1 Assembly overview - pistons and conrods
1244.2 Removing and installing pistons
1274.3 Measuring piston projection at TDC
1284.4 Checking pistons and cylinder bores
1304.5 Separating new conrod
1334.6 Checking radial clearance of conrods
1334.7 Removing and installing oil spray jets
134Cylinder head, valve gear
1361 Cylinder head
1361.1 Assembly overview - cylinder head
1361.2 Assembly overview - camshaft housing
1391.3 Assembly overview - cylinder head cover
1411.4 Removing and installing cylinder head
1441.5 Removing and installing cylinder head cover
1521.6 Removing and installing injector seals
1541.7 Removing and installing camshaft housing
1551.8 Checking compression
1612 Toothed belt drive
1632.1 Assembly overview - toothed belt cover
1632.2 Assembly overview - toothed belt
1632.3 Removing and installing toothed belt guard
1652.4 Removing and installing toothed belt
1702.5 Removing toothed belt from camshaft
1853 Valve gear
1923.1 Assembly overview - valve gear
1923.2 Measuring axial play of camshaft
1943.3 Removing and installing camshaft oil seal
1953.4 Checking hydraulic compensation elements
1973.5 Removing and installing valve stem seals
1984 Inlet and exhaust valves
2154.1 Checking valve guides
2154.2 Checking valves
2164.3 Valve dimensions
216Lubrication
2181 Sump, oil pump
2181.1 Assembly overview - sump/oil pump
2181.2 Assembly overview - oil pump drive pulley
2231.3 Engine oil:
2241.4 Removing and installing oil sump
2241.5 Removing and installing oil pump
2291.6 Removing and installing oil level and oil temperature sender G266
2311.7 Removing and installing sump trim
2311.8 Removing and installing oil pump drive pulley
2322 Engine oil cooler
2373 Oil filter, oil pressure switch
2383.1 Assembly overview - oil filter housing, oil pressure switch
2383.2 Removing and installing oil pressure switch F1
2403.3 Removing and installing oil pressure switch for reduced oil pressure F378
2423.4 Checking oil pressure
2433.5 Removing and installing oil filter housing
2433.6 Removing and installing oil pressure regulating valve N428
2464 Oil circuit
2484.1 Assembly overview - oil circuit
2484.2 Removing and installing oil supply line
2514.3 Removing and installing oil return line for turbocharger
255Cooling
2591 Cooling system/coolant
2591.1 Connection diagram - coolant hoses
2591.2 Draining and adding coolant
2831.3 Checking coolant level and topping up
2921.4 Checking cooling system for leaks
2931.5 Removing and installing coolant expansion tank
2961.6 Assembly overview – coolant expansion tank
3002 Coolant pump, regulation of cooling system
3012.1 Assembly overview - coolant pump, thermostat
3012.2 Assembly overview - electric coolant pump
3032.3 Assembly overview - coolant temperature sender
3102.4 Assembly overview – coolant valves, 3/2-way valve
3132.5 Removing and installing electric coolant pump
3142.6 Removing and installing coolant pump
3202.7 Removing and installing thermostat
3212.8 Checking thermostat
3242.9 Removing and installing coolant valve for cylinder head N489
3242.10 Removing and installing coolant temperature sender G62
3252.11 Removing and installing radiator outlet coolant temperature sender G83
3272.12 Removing and installing coolant temperature sender 3 G812
3292.13 Removing and installing 3/2-way valve
3322.14 Removing and installing front shut-off flap
3363 Coolant pipes
3383.1 Assembly overview - coolant pipes
3383.2 Removing and installing coolant pipes
3454 Radiator, radiator fan
3474.1 Assembly overview - radiator/radiator fan
3474.2 Assembly overview – radiator cowl and radiator fan
3514.3 Removing and installing radiator
3514.4 Removing and installing radiator cowl with radiator fan
3664.5 Removing and installing radiator fan V7
367Turbocharging/supercharging
3691 Turbocharger
3691.1 Assembly overview - turbocharger
3691.2 Removing and installing turbocharger
3781.3 Checking vacuum unit for turbocharger, biturbo
3891.4 Removing and installing upper connecting pipes
4041.5 Removing and installing compressor housing and turbine housing, biturbo
4102 Charge air system
4122.1 Assembly overview - charge air system
4122.2 Removing and installing charge air cooler
4182.3 Removing and installing charge pressure sender G31
4272.4 Removing and installing charge pressure sender 2 G447
4282.5 Checking charge air system for leaks
4292.6 Detaching and securing charge air cooler
4312.7 Removing and installing bracket for charge air cooler
4382.8 Checking charge air cooler for leaks
442Mixture preparation - injection
4461 Injection system
4461.1 Overview of fitting locations - injection system
4461.2 Filling/bleeding fuel system
4611.3 Checking fuel system for leaks
4622 Vacuum system
4632.1 Connection diagram – vacuum system
4632.2 Assembly overview – vacuum system
4662.3 Assembly overview – valves for vacuum system
4712.4 Removing and installing solenoid valves N75/N274/N529
4753 Injectors/high-pressure accumulator (rail)
4773.1 Assembly overview - injectors
4773.2 Assembly overview - fuel rail
4793.3 Adapting correction values for injectors
4813.4 Testing injectors
4823.5 Testing jammed-open injectors
4823.6 Checking return flow rate of injectors with engine running
4843.7 Checking return flow rate of injectors at starter speed
4863.8 Removing and installing injectors
4893.9 Removing and installing high-pressure lines
4933.10 Removing and installing fuel rail
4984 Air filter
5004.1 Assembly overview - air filter housing
5004.2 Removing and installing air filter housing
5045 Intake manifold
5075.1 Assembly overview – intake manifold
5075.2 Removing and installing intake manifold
5115.3 Removing and installing throttle valve module GX3
5165.4 Removing and installing intake manifold flap valve N316
5185.5 Removing and installing vacuum unit for intake manifold
5206 Senders and sensors
5226.1 Removing and installing fuel pressure regulating valve N276
5226.2 Checking fuel pressure regulating valve N276
5256.3 Removing and installing fuel pressure sender G247
5266.4 Removing and installing air mass meter G70
5286.5 Removing and installing pressure differential sender G505
5306.8 Removing and installing fuel temperature sender G81
5346.10 Removing and installing intake manifold sender GX9
5406.12 Removing and installing control unit for NOx sender 2 J881/NOx sender 2 G687
5436.13 Removing and installing control unit for NOx sender J583/NOx sender G295
5476.14 Overview of fitting locations - exhaust gas sensors
5547 Engine control unit
5577.1 Removing and installing engine control unit J623
5578 High-pressure pump
5598.1 Assembly overview - high-pressure pump
5598.2 Removing and installing high-pressure pump
5628.3 Checking high-pressure pump
5669 Lambda probe
5699.1 Assembly overview - Lambda probe
5699.2 Removing and installing Lambda probe 1 before catalytic converter GX10
571Exhaust system
5761 Exhaust pipes and silencers
5761.1 Assembly overview – silencers
5761.2 Separating exhaust pipes from silencers
5781.3 Removing and installing front silencer
5801.4 Removing and installing rear silencer
5811.5 Aligning exhaust system free of stress
5831.6 Checking exhaust system for leaks
5841.7 Installation position of clamp
5852 Emission control
5862.1 Assembly overview – emission control
5862.2 Removing and installing catalytic converter
6072.3 Removing and installing particulate filter
6163 SCR system (selective catalytic reduction)
6243.1 Assembly overview – reducing agent tank
6243.2 Assembly overview - delivery module for reducing agent
6253.3 Assembly overview – filler tube for reducing agent tank
6263.4 Assembly overview - injector for reducing agent N474
6273.5 Removing and installing reducing agent tank VX85
6283.6 Removing and installing reducing agent supply line
6313.7 Removing and installing delivery unit for reducing agent metering system GX19
6343.8 Removing and installing injector for reduction agent N474
6373.9 Removing and installing control unit for reducing-agent heater J891
6403.10 Draining reducing agent tank VX85
6403.11 Removing and installing filler pipe for tank for reducing agent
6434 Exhaust gas temperature regulation
6454.1 Assembly overview – exhaust gas temperature regulation
6454.2 Removing and installing exhaust gas temperature sender 1 G235
6484.3 Removing and installing exhaust gas temperature sender 2 G448
6574.4 Removing and installing exhaust gas temperature sender 3 G495
6614.5 Removing and installing exhaust gas temperature sender 4 G648
6665 Exhaust gas recirculation
6715.1 Assembly overview – exhaust gas recirculation
6715.2 Removing and installing exhaust gas recirculation cooler
6735.3 Removing and installing exhaust gas recirculation pipes
6865.4 Removing and installing temperature sensor 2 for exhaust gas recirculation G690
6905.5 Checking exhaust gas recirculation cooler for leaks
6915.6 Removing and installing temperature sensor 3 for exhaust gas recirculation G949
695Glow plug system
7041 Glow plug system
7041.1 Assembly overview - glow plug system
7041.2 Removing and installing glow plug
7051.3 Checking glow plug
7101.4 Removing and installing automatic glow period control unit J179
7101.5 Removing and installing knock sensor 1 G61
7101.6 Removing and installing knock sensor 2 G66
7121.7 Removing and installing Hall sender G40
7131.8 Removing and installing engine speed sender G28
714