Technical data
11 Identification
11.1 Engine number/engine data
12 Safety information
22.1 Safety precautions when working on the cooling system
22.2 Safety regulations for working on fuel supply
32.3 Safety precautions when working on ignition system
42.5 Safety precautions when working on injection system
43 Technical data
63.1 Technical data - injection system
64 Repair instructions
74.1 Rules for cleanliness when working on fuel supply system/injection system
74.2 General notes on ignition system
74.3 General notes on injection
74.4 Foreign objects in engine
8Removing and installing engine
91 Removing and installing engine
91.1 Removing engine
91.2 Securing engine on engine and gearbox support
131.3 Installing engine
142 Assembly mountings
162.1 Overview - assembly mountings
16Crankshaft group
181 Cylinder block (pulley end)
181.1 Assembly overview - poly V-belt drive
181.2 Assembly overview - cylinder block
221.3 Removing and installing poly-V belt
231.4 Renewing crankshaft oil seal - belt pulley end
251.5 Removing and installing sealing flange on pulley end
272 Cylinder block, gearbox end
312.1 Assembly overview - cylinder block, gearbox end
312.2 Removing and installing sealing flange on gearbox side
323 Crankshaft
343.1 Assembly overview - crankshaft
343.2 Allocation of main bearing shells
353.3 Removing and installing sender wheel
363.4 Crankshaft dimensions
364 Pistons and conrods
374.1 Assembly overview - pistons and conrods
374.2 Bearing shells - installation position
384.3 Checking pistons and cylinder bores
384.4 Piston and cylinder dimensions
40Cylinder head, valve gear
411 Cylinder head
411.1 Assembly overview - cylinder head
411.2 Removing and installing cylinder head
431.3 Checking compression
482 Toothed belt drive
512.1 Assembly overview - toothed belt drive
512.2 Removing and installing toothed belt
532.3 Checking semi-automatic toothed belt tensioner
592.4 Removing and installing toothed belt guard
593 Valve gear
603.1 Assembly overview - valve gear
603.2 Removing and installing camshaft oil seal
623.3 Removing and installing camshaft
643.4 Measuring axial play of camshaft
693.5 Removing and installing valve stem seals
693.6 Checking hydraulic compensation elements
714 Inlet and exhaust valves
734.1 Reworking valve seats
734.2 Checking valve guides
744.3 Valve dimensions
75Lubrication
761 Sump, oil pump
761.1 Assembly overview - sump/oil pump
761.2 Removing and installing oil sump
791.3 Removing and installing oil pump
811.4 Engine oil:
812 Oil filter, oil pressure switch
832.1 Assembly overview - oil filter/oil pressure switch
832.2 Checking oil pressure and oil pressure switch
852.3 Measuring oil consumption
86Cooling
881 Cooling system/coolant
881.1 Connection diagram - coolant hoses
881.2 Draining and adding coolant
891.3 Checking cooling system for leaks
962 Coolant pump, regulation of cooling system
982.1 Assembly overview - coolant pump, thermostat
982.2 Removing and installing coolant pump
992.3 Removing and installing thermostat
1013 Radiator, radiator fan
1033.1 Assembly overview - radiator/radiator fan
1033.2 Removing and installing radiator
1043.3 Removing and installing radiator fan V7 and radiator fan 2 V177
106Mixture preparation - injection
1081 Injection system
1081.1 Bleeding fuel system
1082 Injectors
1112.1 Assembly overview - fuel rail with injectors
1112.2 Removing and installing injectors
1112.3 Checking injectors
1123 Senders and sensors
1173.1 Checking fuel pressure regulator and holding pressure
1173.2 Checking fuel pressure regulator and holding pressure
1194 Intake manifold
1224.1 Assembly overview - intake manifold
1224.2 Assembly overview - intake manifold
1244.3 Removing and installing lower part of intake manifold
1254.4 Removing and installing lower part of intake manifold
1274.5 Removing and installing intake manifold
1294.6 Removing and installing intake manifold
1334.7 Checking intake manifold change-over
1365 Air filter
1385.1 Assembly overview - air filter housing
1386 Engine (motor) control unit
1396.1 Removing and installing engine control unit J623
1396.2 Removing and installing anti-theft engine control unit J623
140Exhaust system
1421 Exhaust pipes and silencers
1421.1 Assembly overview - silencers
1421.2 Separating exhaust pipes from silencers
1421.3 Installation position of clamp
1441.4 Check exhaust system for leaks
1441.5 Aligning exhaust system free of stress
1442 Exhaust gas cleaning
1462.1 Assembly overview - emission control
1462.2 Removing and installing front exhaust pipe with catalytic converter
1473 Exhaust gas recirculation
1493.1 Assembly overview - exhaust gas recirculation
1494 Secondary air system
1514.1 Assembly overview - secondary air system
1514.2 Assembly overview - secondary air system
1524.3 Function of secondary air system
1534.4 Checking combination valve
1535 Exhaust manifold
1555.1 Removing and installing exhaust manifold
155Ignition system
1571 Ignition system
1571.1 Assembly overview - ignition system
1571.2 Test data, spark plugs
158