Technical data
11 Technical data
11.1 Engine number
11.2 Engine data
1Removing and installing engine
31 Removing and installing engine
31.1 Removing engine
31.2 Securing engine to assembly stand
111.3 Installing engine
111.4 Specified torques
141.5 Additional information and assembly work for vehicles with air conditioner
142 Assembly mountings
152.1 Assembly mountings
15Crankshaft group
161 Dismantling and assembling engine
161.1 Assembly overview - parts l and ll
161.2 Assembly overview - part I, belt drive
181.3 Assembly overview - part II, cylinder block
191.4 Removing and installing poly V-belt
211.5 Removing and installing valve timing housing
221.6 Removing and installing ancillary bracket
262 Sealing flanges and flywheel
282.1 Assembly overview
282.2 Removing and installing engine speed sender G28
292.3 Renewing crankshaft oil seal - belt pulley end
302.4 Removing and installing crankshaft pulley
312.5 Renewing crankshaft sealing flange - flywheel end
343 Crankshaft
433.1 Assembly overview
433.2 Pulling needle bearing out of and driving into crankshaft
443.3 Crankshaft dimensions
454 Pistons and conrods
464.1 Assembly overview
464.2 Checking piston
474.3 Separating new conrod
484.4 Piston and cylinder dimensions
49Cylinder head, valve gear
501 Cylinder head
501.1 Assembly overview
501.2 Checking valve timing
531.3 Adjusting valve timing
561.4 Checking timing chain
641.5 Removing and installing timing chain and drive chain for oil pump
691.6 Removing and installing camshaft housing
771.7 Removing and installing cylinder head
831.8 Checking compression
862 Valve gear
892.1 Assembly overview
892.2 Checking camshaft axial clearance
912.3 Reworking valve seats
912.4 Checking valve guides
932.5 Renewing valve stem seals
93Lubrication
961 Parts of lubrication system
961.1 Engine oil, oil capacities, engine oil specification
961.2 Assembly overview - ► model year 2008
961.3 Assembly overview - model year 2009 ►
991.4 Removing and installing oil sump
1011.5 Removing and installing oil pump
1031.6 Checking oil pressure and oil pressure switch
105Cooling
1081 Parts of cooling system
1081.1 Assembly overview - parts of cooling system, body side
1091.2 Assembly overview - parts of cooling system, engine side
1101.3 Coolant hose schematic diagram
1111.4 Draining, filling and bleeding cooling system
1131.5 Removing and installing radiator fan V7 and radiator fan 2 V177
1161.6 Checking cooling system for leaks
1171.7 Removing and installing radiator
1181.8 Removing and installing coolant pump
1201.9 Removing and installing coolant circulation pump V50
121Fuel supply system
1241 Safety precautions
1241.1 Safety precautions when working on fuel supply system
1241.2 Releasing pressure in high-pressure area
1252 Fuel tank
1272.1 Assembly overview - fuel tank
1272.2 Emptying fuel tank
1292.3 Removing and installing fuel tank
1313 Repairing fuel supply system
1343.1 Rules for cleanliness
1343.2 Removing and installing fuel delivery unit
1343.3 Removing and installing fuel gauge sender G
1363.4 Crash fuel shut-off
1373.5 Checking fuel pump
1374 Electronic power control (EPC)
1484.1 Function of EPC system
1484.2 Assembly overview - accelerator module
1484.3 Removing and installing accelerator module
1495 Activated charcoal filter system
1525.1 Function
1525.2 Assembly overview - activated charcoal filter system
1525.3 Checking fuel tank breather
153Turbocharging/supercharging
1551 Turbocharger
1551.1 General repair instructions
1551.2 Safety precautions
1561.3 Rules for cleanliness
1561.4 Assembly overview - turbocharger
1571.5 Assembly overview - part I, turbocharger
1581.6 Assembly overview - part II, turbocharger
1591.7 Removing and installing turbocharger
1601.8 Removing and installing compressor housing and turbine housing
1651.9 Checking vacuum unit for turbocharger
1691.10 Removing and installing vacuum unit for turbocharger
1711.11 Adjusting vacuum unit for turbocharger
1742 Charge air system
1812.1 Assembly overview - charge air system
1812.2 Removing and installing radiator for charge air cooler
182Mixture preparation - injection
1841 Injection system
1841.1 General notes on injection
1841.2 Safety precautions
1851.3 Rules for cleanliness
1861.4 Technical data
1861.5 Assembly overview - parts l and II, intake manifold
1861.6 Assembly overview - part I, intake manifold
1881.7 Assembly overview - part II, intake manifold
1891.8 Assembly overview - intake manifold lower part/fuel rail with injectors
1901.9 Assembly overview - air filter
1911.10 Removing and installing air filter
1921.11 Removing and installing throttle valve module J338
1921.12 Cleaning throttle valve module J338
1951.13 Removing and installing intake manifold
1961.14 Assembly overview - high-pressure pump
1971.15 Checking fuel pressure in high-pressure section
1981.16 Removing and installing high-pressure pump
2011.17 Removing and installing injectors
2051.18 Renewing Teflon seal and support washer on injector
2072 Engine control unit J623
2112.1 Reading and erasing engine control unit fault memory
2112.2 Removing and installing engine control unit
212Exhaust system
2161 Parts of exhaust system
2161.1 Assembly overview - catalytic converter and attachments
2181.2 Assembly overview - silencers with mountings
2201.3 Separating and joining front and rear silencers
2211.4 Aligning exhaust system free of stress
2221.5 Installation position and specified torque of clamp
224Ignition system
2261 Ignition system
2261.1 Assembly overview - ignition system
2261.2 Removing and installing ignition coils with output stage
2271.3 Safety precautions
2281.4 Test data, spark plugs
229