Technical data
11 Identification
11.1 Engine number, engine data
12 Safety instructions
32.1 Safety precautions when working on fuel supply system
32.2 Safety precautions when working on vehicles with a Start/Stop system
32.4 Safety precautions when working on cooling system
42.5 Safety precautions when working on ignition system
43 Repair instructions
53.1 Rules for cleanliness
5Removing and installing engine
61 Removing and installing engine
61.1 Removing engine
61.2 Securing engine on engine and gearbox support
141.3 Installing engine
142 Assembly mountings
172.1 Assembly overview - assembly mountings
17Crankshaft group
181 Cylinder block (pulley end)
181.1 Assembly overview - poly V-belt drive
181.2 Assembly overview - cylinder block (pulley end)
191.3 Removing and installing poly V-belt
211.4 Removing and installing ancillary bracket
221.5 Removing and installing belt pulley
231.6 Renewing crankshaft oil seal - belt pulley end
272 Cylinder block, gearbox end
302.1 Assembly overview - cylinder block, gearbox end
302.2 Renewing crankshaft oil seal - gearbox end
313 Crankshaft
393.1 Assembly overview - crankshaft
393.2 Crankshaft dimensions
403.3 Renewing needle bearing in crankshaft
404 Pistons and conrods
424.1 Assembly overview - pistons and conrods
424.2 Removing and installing pistons
434.3 Removing and installing oil spray jets
444.4 Checking piston and cylinder bore
464.5 Separating new conrod
47Cylinder head, valve gear
481 Cylinder head
481.1 Assembly overview - cylinder head
481.2 Removing and installing camshaft housing
511.3 Removing and installing cylinder head
561.4 Checking compression
592 Cover for timing chain
622.1 Removing and installing valve timing housing
623 Chain drive
663.1 Removing and installing timing chain and chain drive for oil pump
663.2 Checking valve timing
743.3 Adjusting valve timing
773.4 Checking timing chain
864 Valve gear
924.1 Assembly overview - valve gear
924.2 Measuring axial play of camshaft
944.3 Removing and installing camshaft
944.4 Removing and installing valve stem seals
955 Inlet and exhaust valves
975.1 Reworking valve seats
975.2 Checking valve guides
985.3 Valve dimensions
99Lubrication
1001 Sump, oil pump
1001.1 Assembly overview - sump / oil pump
1001.2 Engine oil
1031.3 Removing and installing oil sump
1031.4 Removing and installing oil pump
1052 Oil filter, oil pressure switch
1082.1 Checking oil pressure and oil pressure switch
108Cooling
1101 Cooling system, coolant
1101.1 Coolant hose schematic diagram
1101.2 Checking cooling system for leaks
1111.3 Draining and filling coolant
1132 Coolant pump, regulation of cooling system
1172.1 Assembly overview - thermostat
1172.2 Removing and installing coolant pump
1182.3 Removing and installing electric coolant pump
1193 Radiator, radiator fan
1223.1 Assembly overview - radiator/radiator fan
1223.2 Removing and installing radiator
1243.3 Removing and installing radiator fan V7 and radiator fan 2 V177
125Turbocharging/supercharging
1271 Turbocharger
1271.1 Assembly overview - turbocharger
1271.2 Removing and installing turbocharger
1311.3 Removing and installing compressor housing and turbine housing
1361.4 Checking vacuum unit for turbocharger
1401.5 Adjusting vacuum unit for turbocharger
1421.6 Renewing vacuum unit for turbocharger
1482 Charge air system
1512.1 Assembly overview - charge air system
1512.2 Removing and installing charge air cooler
152Mixture preparation - injection
1541 Injection system
1541.1 Assembly overview - fuel system
1541.2 Releasing high pressure in fuel system
1552 Injectors
1562.1 Assembly overview - fuel rail with injectors
1562.2 Removing and installing injectors
1572.3 Renewing seals on injectors
1603 Air filter
1653.1 Assembly overview - air filter housing
1653.2 Removing and installing air filter housing
1664 Intake manifold
1674.1 Assembly overview - intake manifold
1674.2 Removing and installing intake manifold
1684.3 Removing and installing throttle valve module J338
1694.4 Cleaning throttle valve module
1725 Senders and sensors
1745.1 Checking fuel pressure sender G247
1746 Engine control unit
1776.1 Removing and installing engine control unit J623
1776.2 Removing and installing engine control unit J623 with protective housing
1787 High-pressure pump
1817.1 Assembly overview - high-pressure pump
1817.2 Removing and installing high-pressure pump
182Exhaust system
1861 Exhaust pipes, silencers
1861.1 Assembly overview - silencers
1861.2 Separating exhaust pipes, silencers
1871.3 Installation position of clamp
1882 Emission control
1902.1 Assembly overview - emission control
190Ignition system
1921 Ignition system
1921.1 Assembly overview - ignition system
1921.2 Test data, spark plugs
1931.3 Removing and installing ignition coils with output stage
1941.4 Removing and installing engine speed sender G28
195