Technical data
11 Safety information
11.1 Safety regulations for working on fuel supply
11.2 Safety measures when working on vehicles with start/stop system
11.4 Safety precautions when working on the cooling system
21.5 Safety precautions when working on ignition system
21.6 Safety precautions when working on exhaust system
32 Identification
42.1 Engine number/engine data
43 Repair notes
63.1 Rules for cleanliness
63.2 General information
63.3 General repair instructions
63.4 Foreign objects in engine
83.5 Contact corrosion
83.6 Routing and attachment of lines
83.7 Fitting radiator and condensers
83.8 Checking vacuum system
83.9 Identification labels
93.10 Using impact drivers
93.11 Nuts and bolts
103.12 Bleeding fuel system
103.13 Checking fuel system for leaks
10Removing and installing engine
111 Removing and installing engine
111.1 Removing engine
111.2 Separating engine and gearbox
251.3 Securing engine on engine and gearbox support
261.4 Installing engine
282 Assembly mountings
322.1 Assembly overview - assembly mountings
322.2 Removing and installing engine mounting
352.3 Removing and installing gearbox mounting
362.4 Removing and installing pendulum support
382.5 Supporting engine in installation position
382.6 Adjusting assembly mountings
432.7 Checking adjustment of assembly mountings
46Crankshaft group
481 Cylinder block (pulley end)
481.1 Assembly overview - poly V-belt drive
481.2 Assembly overview - sealing flange, belt pulley end
521.3 Removing and installing poly-V belt
551.4 Removing and installing tensioner for poly V-belt
591.5 Removing and installing vibration damper
601.6 Removing and installing engine support
621.7 Renewing crankshaft oil seal - belt pulley end
651.8 Removing and installing sealing flange on pulley end
682 Cylinder block, gearbox end
722.1 Assembly overview - flywheel
722.2 Assembly overview - drive plate
732.3 Removing and installing flywheel
752.4 Removing and installing drive plate
762.5 Removing and installing sealing flange on gearbox side
783 Crankshaft
913.1 Renewing needle bearing in crankshaft
913.2 Crankshaft dimensions
933.3 Measuring axial clearance of crankshaft
944 Pistons and conrods
964.1 Assembly overview - pistons and conrods
964.2 Removing and installing pistons
1004.3 Removing and installing oil spray jets
1014.4 Checking pistons and cylinder bores
1034.5 Checking radial clearance of conrods
1064.6 Separating new conrod
1064.7 Setting piston to TDC position
107Cylinder head, valve gear
1131 Cylinder head
1131.1 Assembly overview - cylinder head
1131.2 Assembly overview - camshaft housing
1151.3 Removing and installing cylinder head
1201.4 Removing and installing camshaft housing
1251.5 Checking compression
1302 Toothed belt drive
1322.1 Assembly overview - toothed belt cover
1322.2 Assembly overview - toothed belt
1322.3 Removing and installing toothed belt guard
1342.4 Removing and installing toothed belt
1352.5 Preassembling and installing valve timing tool
1402.6 Checking valve timing
1512.7 Adjusting valve timing
1532.8 Removing toothed belt from camshaft
1653 Valve gear
1703.1 Assembly overview - valve gear
1703.2 Measuring axial play of camshaft
1723.3 Removing and installing camshaft oil seal
1733.4 Removing and installing camshaft adjuster
1823.5 Removing and installing camshaft control valve 1 N205
1923.6 Removing and installing exhaust camshaft control valve 1 N318
1933.7 Removing and installing valve stem oil seals
1943.8 Removing and installing cam actuators
2044 Inlet and exhaust valves
2064.1 Checking valve guides
2064.2 Checking valves
2074.3 Valve dimensions
207Lubrication
2081 Sump, oil pump
2081.1 Assembly overview - sump/oil pump
2081.2 Engine oil:
2121.3 Removing and installing lower part of sump
2121.4 Removing and installing upper part of sump
2181.5 Removing and installing oil pump
2231.6 Removing and installing oil level and oil temperature sender G266
2252 Engine oil cooler
2262.1 Assembly overview - engine oil cooler
2262.2 Removing and installing engine oil cooler
2263 Crankcase ventilation
2283.1 Assembly overview - crankcase breather system
2283.2 Removing and installing oil separator
2294 Oil filter, oil pressure switch
2324.1 Assembly overview - oil filter/oil pressure switch
2324.2 Removing and installing oil pressure switch F1
2344.3 Removing and installing oil pressure switch for reduced oil pressure F378
2364.4 Removing and installing oil pressure regulating valve N428
2384.5 Checking oil pressure
239Cooling
2421 Cooling system/coolant
2421.1 Connection diagram - coolant hoses
2421.2 Assembly overview – coolant expansion tank
2431.3 Checking cooling system for leaks
2441.4 Draining and adding coolant
2481.5 Removing and installing coolant expansion tank
2562 Coolant pump, regulation of cooling system
2582.1 Assembly overview - coolant pump, thermostat
2582.2 Assembly overview - electric coolant pump
2612.3 Assembly overview - engine preheater
2622.4 Assembly overview - coolant temperature sender
2632.5 Removing and installing electric coolant pump
2642.6 Removing and installing coolant pump
2662.7 Removing and installing thermostat
2722.8 Removing and installing toothed belt pulley for coolant pump
2762.9 Removing and installing coolant temperature sender G62
2812.10 Removing and installing radiator outlet coolant temperature sender G83
2832.11 Removing and installing engine preheating element Z97
2843 Coolant pipes
2873.1 Assembly overview - coolant pipes
2873.2 Removing and installing coolant pipes
2884 Radiator, radiator fan
2954.1 Assembly overview - radiator/radiator fan
2954.2 Assembly overview – radiator cowl and radiator fan
2974.3 Removing and installing radiator
2994.4 Removing and installing water radiator for charge air cooling circuit
3034.5 Removing and installing radiator cowl with radiator fan
3044.6 Removing and installing radiator fan
306Turbocharging/supercharging
3081 Turbocharger
3081.1 Assembly overview - turbocharger
3081.2 Removing and installing turbocharger
3131.3 Removing and installing charge pressure positioner V465
3191.4 Removing and installing connection for turbocharger
3222 Charge air system
3252.1 Assembly overview - charge air system
3252.2 Removing and installing charge pressure sender GX26
3272.3 Removing and installing charge air cooler
3282.4 Checking charge air system for leaks
3312.5 Removing and installing air intake pipe
333Mixture preparation - injection
3351 Injection system
3351.1 Overview of fitting locations - injection system
3352 Injectors
3422.1 Assembly overview - fuel rail with injectors
3422.2 Removing and installing fuel rail
3442.3 Removing and installing injectors
3452.4 Cleaning injectors
3513 Air filter
3533.1 Assembly overview - air filter housing
3533.2 Removing and installing air filter housing
3553.3 Removing and installing air guide on lock carrier
3563.4 Removing and installing resonator for intake air
3574 Intake manifold
3594.1 Assembly overview – intake manifold
3594.2 Removing and installing intake manifold
3624.3 Removing and installing throttle valve module GX3
3684.4 Cleaning throttle valve module GX3
3694.5 Removing and installing activated charcoal filter solenoid valve 1 N80
3705 Senders and sensors
3725.1 Removing and installing intake manifold sender GX9
3725.2 Removing and installing fuel pressure sender G247
3725.3 Checking fuel pressure sender G247
3746 Engine control unit
3796.1 Assembly overview – engine/motor control unit
3796.2 Removing and installing engine control unit J623
3797 High-pressure pump
3877.1 Assembly overview - high-pressure pump
3877.2 Removing and installing high-pressure pump
3927.3 Removing and installing high-pressure pipe
3948 Lambda probe
3968.1 Assembly overview - Lambda probe
3968.2 Removing and installing Lambda probe
397Exhaust system
4011 Exhaust pipes and silencers
4011.1 Assembly overview – silencer
4011.2 Removing and installing silencer
4051.3 Separating exhaust pipes from silencers
4081.4 Aligning exhaust system free of stress
4101.5 Checking exhaust system for leaks
4111.6 Installation position of clamp
4112 Emission control
4142.1 Assembly overview – emission control
4142.2 Removing and installing catalytic converter
4182.3 Removing and installing particulate filter
4262.4 Removing and installing exhaust flap control unit J883
426Ignition system
4271 Ignition system
4271.1 Assembly overview - ignition system
4271.2 Removing and installing ignition coils with output stage
4291.3 Removing and installing knock sensor 1 G61
4321.4 Removing and installing Hall sender
4321.5 Removing and installing engine speed sender G28
433