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
181.3 Installing engine
201.4 Checking and adjusting assembly mounting
221.5 Assembly mounting - Torque settings
25Crankshaft group
271 Dismantling and assembling engine
271.1 Assembly overview - poly-V-belt drive
271.2 Assembly overview - toothed belt drive
281.3 Cylinder block - Assembly overview
291.4 Removing and installing poly-V-belt
302 Removing and installing sealing flange and flywheel
332.1 Assembly overview
332.2 Renewing crankshaft oil seal - belt pulley end
342.3 Removing and installing sealing flange - pulley end
362.4 Renewing crankshaft sealing flange - flywheel end
382.5 Removing and installing two-part flywheel
452.6 Removing and installing engine speed sender G28
473 Crankshaft
493.1 Assembly overview - crankshaft
493.2 Crankshaft dimensions
503.3 Marking on crankshaft bearing top
503.4 Pulling needle bearing out of and driving into crankshaft
504 Pistons and conrods
534.1 Assembly overview - pistons and conrods
534.2 Checking piston projection at TDC
544.3 Piston and cylinder dimensions
554.4 Piston rings, cylinder bore and piston installation position
56Cylinder head, valve gear
581 Cylinder head
581.1 Assembly overview - cylinder head
581.2 Removing and installing cylinder head cover
601.3 Removing, installing and tensioning toothed belt
611.4 Removing and installing cylinder head
701.5 Checking compression
782 Valve gear
792.1 Assembly overview - valve gear
792.2 Checking camshaft axial clearance
822.3 Removing and installing roller rocker fingers
822.4 Valves
832.5 Renewing valve stem seals
842.6 Removing and installing camshafts
862.7 Removing and installing camshaft oil seal
902.8 Checking hydraulic tappets
92Lubrication
941 Engine oil
941.1 Oil capacities
941.2 Checking engine oil level
942 Parts of lubrication system
952.1 Assembly overview - oil pump, sump
952.2 Removing and installing sump
972.3 Removing and installing oil pump
993 Oil filter bracket, oil pressure, oil cooler and oil supply pipe
1003.1 Assembly overview - oil filter bracket and oil cooler
1003.2 Removing and installing oil filter bracket with oil cooler
1013.3 Checking oil pressure and oil pressure switch
1053.4 Oil supply pipe to turbocharger - Assembly overview
1073.5 Removing and installing oil supply line to turbocharger
108Cooling
1111 Parts of cooling system
1111.1 Assembly overview - parts of cooling system, body side
1121.2 Assembly overview - parts of cooling system, engine side
1131.3 Coolant hose schematic diagram
1141.4 Draining and filling coolant
1171.5 Removing and installing radiator fan V7 and radiator fan 2 V177
1201.6 Removing and installing radiator
1211.7 Removing and installing coolant pump
1231.8 Removing and installing thermostat
1251.9 Checking cooling system for leaks
1281.10 Checking oil cooler for leaks
129Fuel supply system
1321 Parts of fuel system
1321.1 Safety precautions when working on fuel supply system
1321.2 Rules for cleanliness
1331.3 Assembly overview - fuel tank
1331.4 Emptying fuel tank
1351.5 Removing and installing fuel tank
1371.6 Assembly overview - fuel filter
1401.7 Removing and installing fuel cooler
1421.8 Removing and installing fuel delivery unit
1431.9 Removing and installing fuel gauge sender G
1451.10 Removing and installing tandem pump
1461.11 Checking tandem pump
1481.12 Checking fuel pump
1532 Electronic power control (EPC)
1562.1 Function of EPC system
1562.2 Accelerator pedal module - Assembly overview
1562.3 Removing and installing accelerator pedal module
157Turbocharging/supercharging
1591 Charge air system with turbocharger: Engine codes AZV, BKD
1591.1 General notes
1591.2 Safety precautions
1601.3 Rules for cleanliness
1601.4 Charge pressure control schematic diagram
1601.5 Solenoid valve block schematic diagram
1611.6 Assembly overview - turbocharger with attachments
1621.7 Removing and installing turbocharger
1631.8 Assembly overview - parts of charge air cooling
1681.9 Removing and installing charge air cooler
1691.10 Installing hose connections with connector couplings
1701.11 Checking charge air system for leaks
1712 Charge air system with turbocharger: Engine code BMN
1742.1 General notes
1742.2 Safety precautions
1742.3 Rules for cleanliness
1752.4 Charge pressure control schematic diagram
1752.5 Assembly overview - turbocharger with attachments
1762.6 Removing and installing turbocharger
1782.7 Assembly overview - parts of charge air cooling
1792.8 Removing and installing charge air cooler
1802.9 Installing hose connections with connector couplings
1812.10 Checking charge air system for leaks
182Mixture preparation - injection
1851 Diesel direct injection system
1851.1 Safety precautions
1861.2 Rules for cleanliness
1861.3 Removing and installing intake manifold flap motor V157
1871.5 Assembly overview - intake manifold with attachments: engine code BMN
1911.6 Removing and installing intake manifold
1911.7 Pre-wiring for unit injector - Assembly overview
1951.8 Removing and installing pre-wired wiring harness for unit injectors and glow plugs
1951.9 Assembly overview - unit injector
1981.10 Removing and installing unit injector
2001.11 Removing and installing O-rings for unit injector
2031.12 Assembly overview - air filter
2041.13 Removing and installing automatic glow period control unit J179
2042 Engine control unit
2082.1 Reading and clearing engine control unit fault memory
2082.2 Removing and installing engine control unit
209Exhaust system
2131 Exhaust system
2131.1 Assembly overview - front exhaust pipe with catalytic converter
2151.2 Assembly overview - front exhaust pipe with particulate filter
2161.3 Assembly overview - silencer with mountings
2181.4 Removing and installing front exhaust pipe with catalytic converter
2191.5 Removing and installing front exhaust pipe with particulate filter
2201.6 Connecting and disconnecting front and rear silencers
2221.7 Aligning exhaust system free of stress
2232 Exhaust gas recirculation system
2252.2 Parts of exhaust gas recirculation - assembly overview: engine code BMN
2272.3 Checking mechanical exhaust gas recirculation valve: engine codes AZV, BKD
2272.5 Removing and installing exhaust gas recirculation radiator, engine code BMN
231Glow plug system
2341 Checking glow plug system
2341.1 Removing and installing glow plugs
2341.2 Characteristics of ceramic glow plugs
2351.3 Removing, installing and checking ceramic glow plugs
235