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
71.3 Notes on installing
71.4 Assembly mountings
10Crankshaft group
121 Dismantling and assembling engine
121.1 Assembly overview - poly V-belt drive
121.2 Removing and installing poly V-belt
131.3 Assembly overview - toothed belt drive
151.4 Assembly overview - crankcase
192 Sealing flange, seals and flywheel
202.1 Assembly overview - sealing flanges and flywheel
202.2 Renewing crankshaft oil seal - pulley end
212.3 Removing and installing sealing flange - pulley end
232.4 Renewing crankshaft sealing flange - flywheel end
253 Crankshaft
333.1 Assembly overview - crankshaft
333.2 Crankshaft dimensions
384 Dismantling and assembling pistons and conrods
394.1 Assembly overview - pistons and conrods
394.2 Separating new conrod
404.3 Checking piston projection at TDC
414.4 Piston and cylinder dimensions
424.5 Piston rings, cylinder bore and piston installation position
42Cylinder head, valve gear
451 Cylinder head
451.1 Assembly overview - cylinder head
461.2 Removing and installing cylinder head cover
491.3 Removing, installing and tensioning toothed belts
511.4 Removing and installing cylinder head
661.5 Checking compression
712 Valve gear
732.1 Assembly overview - valve gear
732.2 Checking valve guides
752.3 Renewing valve stem seals
772.4 Removing and installing camshaft
792.5 Removing and installing camshaft oil seal
83Lubrication
851 Engine oil
851.1 Oil capacities
851.2 Checking engine oil level
852 Parts of lubrication system
862.1 Assembly overview - oil pump, sump
862.2 Removing and installing sump
873 Oil filter bracket, oil pressure, engine oil cooler and oil supply line
913.1 Assembly overview - oil filter bracket and engine oil cooler
913.2 Checking oil pressure and oil pressure switch
923.3 Assembly overview - oil supply line to turbocharger
933.4 Removing and installing oil supply line to turbocharger
94Cooling
971 Removing and installing parts of cooling system
971.1 Assembly overview - parts of cooling system, body side (radiator with two radiator fans)
981.3 Parts of cooling system, engine side
1001.4 Coolant hose schematic diagram
1021.5 Draining and filling with coolant
1031.6 Removing and installing radiator
1061.7 Removing and installing coolant pump
1071.8 Removing and installing thermostat
1091.9 Checking cooling system for leaks
1111.10 Checking oil cooler for leaks
113Fuel supply system
1151 Parts of fuel supply system
1151.1 Safety precautions when working on fuel supply system
1151.2 Rules for cleanliness
1161.3 Fuel tank with attachments
1171.4 Assembly overview - fuel filter (AVQ, BKC, BRU)
1191.5 Assembly overview - fuel filter (BLS, BXE, BXF, BXJ)
1201.6 Removing and installing fuel cooler
1211.7 Emptying fuel tank
1221.8 Removing and installing fuel tank
1261.9 Removing and installing fuel delivery unit
1271.10 Removing and installing fuel gauge sender
1291.11 Checking fuel pump
1301.12 Checking voltage supply and current draw of fuel pump
1321.13 Assembly overview - accelerator mechanism
1341.14 Checking tandem pump
1361.15 Removing and installing tandem pump
140Turbocharging/supercharging
1441 Charge air system with turbocharger
1441.1 Safety precautions
1441.2 Rules for cleanliness
1441.3 Hose connections
1451.4 Assembly overview - turbocharger
1461.5 Removing and installing turbocharger
1501.6 Assembly overview - parts of charge air cooling
1521.7 Vacuum hose schematic diagram
1551.8 Checking charge air system for leaks
156Mixture preparation - injection
1591 Diesel direct injection system
1591.1 Safety precautions
1591.2 Rules for cleanliness
1601.3 Assembly overview - unit injector
1601.4 Removing and installing unit injector
1621.5 Adjusting non-contact gap of unit injectors
1641.6 Removing and installing O-rings for unit injector
1651.7 Assembly overview - intake manifold
1671.8 Assembly overview - air filter
1692 Engine control unit
1702.1 Reading and erasing engine control unit fault memory
1702.2 Adapting functions and components
1712.3 Removing and installing engine control unit
1712.4 Removing and installing anti-theft engine control unit
172Exhaust system
1761 Exhaust system
1761.1 Assembly overview - front exhaust pipe with catalytic converter
1761.2 Assembly overview - front exhaust pipe with particulate filter
1771.3 Assembly overview - silencers with mountings
1791.4 Aligning exhaust system free of stress
1812 Exhaust gas recirculation system
1822.1 Assembly overview - parts of exhaust gas recirculation
182Glow plug system
1851 Checking glow plug system
1851.1 Checking glow plug system
185