Technical data
11 Safety information
11.1 Safety regulations for working on fuel supply
11.2 Safety measures when working on vehicles with a 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 instructions
63.1 Rules for cleanliness
63.2 General notes
63.3 General repair notes
73.4 Foreign objects in engine
73.5 Contact corrosion
73.6 Routing and attachment of lines
83.7 Fitting radiator and condensers
83.8 Checking vacuum system
8Removing and installing engine
91 Removing and installing engine
91.1 Removing engine
91.2 Securing engine on engine and gearbox support
211.3 Installing engine
232 Assembly mountings
272.1 Removing and installing engine and gearbox mounting
27Crankshaft group
301 Cylinder block (pulley end)
301.1 Assembly overview - poly V-belt drive
301.2 Removing and installing tensioner for poly V-belt
331.3 Removing and installing poly-V belt
341.4 Removing and installing bracket for ancillaries
361.5 Removing and installing vibration damper
391.6 Renewing crankshaft oil seal - belt pulley end
462 Cylinder block, gearbox end
492.1 Assembly overview - cylinder block, gearbox end
492.2 Removing and installing drive plate
502.3 Renewing needle bearing in drive plate
522.4 Removing and installing sealing flange on gearbox side
543 Pistons and conrods
593.1 Assembly overview - pistons and conrods
593.2 Checking pistons and cylinder bores
613.3 Separating new conrod
634 Crankshaft
654.1 Assembly overview - crankshaft
654.2 Allocation of main bearing shells
674.3 Crankshaft dimensions
694.4 Measuring axial clearance of crankshaft
694.5 Measuring radial clearance of crankshaft
704.6 Renewing needle bearing in crankshaft
71Cylinder head, valve gear
741 Cylinder head
741.1 Assembly overview - cylinder head
741.2 Removing and installing cylinder head
771.3 Checking compression
931.4 Removing and installing vacuum pump
952 Cover for timing chain
972.1 Assembly overview - cover for timing chain
972.2 Removing and installing timing chain cover
1003 Chain drive
1063.1 Assembly overview - camshaft timing chains
1063.2 Assembly overview - balancer shaft timing chain
1083.3 Removing and installing camshaft timing chain
1113.4 Removing and installing balance shaft timing chain
1163.5 Renewing balancer shaft for inlet camshaft
1193.6 Renewing balancer shaft for exhaust camshaft
1233.7 Checking valve timing
1264 Valve gear
1294.1 Assembly overview - valve gear
1294.2 Removing and installing camshaft
1314.3 Removing and installing valve stem seals
1444.4 Measuring axial play of camshaft
1554.5 Removing and installing camshaft control valve 1 N205
1565 Inlet and exhaust valves
1575.1 Checking valve guides
1575.2 Valve dimensions
158Lubrication
1591 Sump, oil pump
1591.1 Assembly overview - sump/oil pump
1591.2 Removing and installing lower part of sump
1621.3 Removing and installing upper part of sump
1641.4 Removing and installing oil pump
1691.5 Engine oil:
1712 Crankcase ventilation
1722.1 Removing and installing coarse oil separator
1723 Oil filter, oil pressure switch
1743.1 Assembly overview - oil filter housing, oil pressure switch
1743.2 Removing and installing oil pressure switch F22
1763.3 Checking oil pressure
1764 Engine oil cooler
1784.1 Removing and installing engine oil cooler
178Cooling
1801 Cooling system/coolant
1801.1 Draining and adding coolant
1801.2 Checking cooling system for leaks
1881.3 Connection diagram - coolant hoses
1912 Coolant pump, regulation of cooling system
1932.1 Assembly overview - coolant hoses
1932.2 Assembly overview - coolant pump, thermostat
1952.3 Removing and installing continued coolant circulation pump V51
1972.4 Removing and installing coolant temperature sender G62
1982.5 Removing and installing toothed belt for coolant pump
2002.6 Renewing oil seal for coolant pump drive
2022.7 Removing and installing coolant pump
2042.8 Removing and installing thermostat
2063 Radiator, radiator fan
2083.1 Assembly overview - radiator/radiator fan V7
2083.2 Assembly overview - radiator cowl and radiator fan V7
2103.3 Removing and installing radiator cowl with radiator fan V7
2103.4 Removing and installing radiator
212Turbocharging/supercharging
2171 Charge air system
2171.1 Assembly overview - charge air cooling
2171.2 Removing and installing pressure pipe
2191.3 Removing and installing charge pressure sender G31
2201.4 Removing and installing charge air cooler
2201.5 Checking charge air system for leaks
2242 Turbocharger
2272.1 Assembly overview - turbocharger
2272.2 Removing and installing turbocharger
2332.3 Checking vacuum unit for turbocharger
237Mixture preparation - injection
2401 Injection system
2401.1 Overview of fitting locations - injection system
2402 Injectors
2432.1 Assembly overview - fuel rail with injectors
2432.2 Removing and installing injectors
2452.3 Renewing seals on injectors
2482.4 Cleaning injectors
2513 Air filter
2533.1 Assembly overview - air filter housing
2533.2 Removing and installing air filter housing
2564 Senders and sensors
2584.1 Removing and installing air mass meter G70
2584.2 Removing and installing fuel pressure sender -G247-
2594.3 Checking fuel pressure sender G247
2614.4 Checking double non-return valve
2645 Intake manifold
2675.1 Assembly overview – intake manifold
2675.2 Removing and installing intake manifold
2695.3 Removing and installing throttle valve module J338
2735.4 Cleaning throttle valve module J338
2745.5 Checking intake manifold change-over
2756 High-pressure pump
2786.1 Assembly overview - high-pressure pump
2786.2 Removing and installing high-pressure pump
2806.3 Check fuel holding pressure upstream of high-pressure pump
2817 Engine control unit
2857.1 Removing and installing engine control unit
285Exhaust system
2871 Exhaust pipes and silencers
2871.1 Assembly overview – silencers
2871.2 Removing and installing centre silencer
2891.3 Removing and installing rear silencer
2911.4 Checking exhaust system for leaks
2921.5 Aligning exhaust system free of stress
2921.6 Installation position of clamp
2932 Emission control
2962.1 Removing and installing catalytic converter
296Ignition system
2981 Ignition system
2981.1 Assembly overview - ignition system
2981.2 Removing and installing ignition coils with output stage
2991.3 Removing and installing spark plugs
3021.4 Removing and installing knock sensor 1 G61
3041.5 Removing and installing engine speed sender G28
3041.6 Test data, spark plugs
306