Technical data
11 Technical data
11.1 Engine number
11.2 Engine data
12 Safety instructions
22.1 Safety precautions when working on fuel supply system
22.3 Safety precautions when working on cooling system
33 General repair notes
43.1 Rules for cleanliness
43.2 Foreign objects in engine
4Removing and installing engine
51 Removing and installing engine
51.1 Removing engine
51.2 Removing engine from scissor-type assembly platform
131.3 Securing engine to assembly stand
151.4 Additional information and assembly work for vehicles with air conditioner
161.5 Installing engine
172 Assembly mountings
182.1 Assembly overview - engine mountings
182.2 Specified torques - Assembly mountings
18Crankshaft group
191 Dismantling and assembling engine
191.1 Dismantling and assembling engine, parts I-III
191.2 Removing and installing crankshaft
241.3 Removing and installing drive plate
251.4 Crankshaft bearing cap identification
261.5 Crankshaft dimensions
271.6 Renewing crankshaft oil seal - engine timing end
271.7 Renewing alternator shaft oil seal
282 Dismantling and assembling pistons and conrods
302.1 Assembly overview - pistons and conrods
302.2 Separating new conrods
312.3 Installation position and allocation of piston to cylinder
322.4 Checking piston ring gap
322.5 Checking ring-to-groove clearance
322.6 Checking cylinder bores
332.7 Piston and cylinder dimensions
33Cylinder head, valve gear
341 Overview - cylinder head
341.1 Assembly overview - cylinder head
341.2 Renewing pipe connection for coolant
361.3 Removing and installing camshaft drive gear
371.4 Setting engine to TDC No. 1 cylinder
411.5 Removing and installing cylinder head
421.6 Checking compression
442 Repairing valve gear
472.1 Assembly overview - valve gear
472.2 Reworking valve seats
512.3 Checking valve guides
532.4 Renewing valve stem seals
532.5 Removing and installing camshaft
55Lubrication
571 Engine oil
571.1 Oil capacities
571.2 Checking engine oil level
572 Parts of lubrication system
582.1 Assembly overview - oil pump, sump
582.2 Assembly overview - oil filter housing
592.3 Removing and installing oil sump
622.4 Checking oil pressure and oil pressure switch
64Cooling
671 Removing and installing parts of cooling system
671.1 Parts of cooling system, body side
681.2 Assembly overview - radiator fan
691.3 Removing and installing fan support
691.4 Parts of cooling system, engine side
701.5 Coolant hose schematic diagram
721.6 Draining and filling coolant
721.7 Removing and installing radiator
751.8 Removing and installing coolant pump
771.9 Checking oil cooler for leaks
82Fuel supply system
851 Removing and installing parts of fuel supply system
851.1 Rules for cleanliness
851.2 Safety precautions when working on fuel supply system
861.3 Assembly overview - fuel tank with attachments (► model year 08)
861.4 Assembly overview - fuel tank with attachments (model year 08 ►)
881.5 Assembly overview - fuel filter with fuel cooler
901.6 Emptying fuel tank
911.9 Removing and installing fuel tank with attached components
991.10 Checking fuel pumps
1021.11 Checking tandem pump
1041.12 Removing and installing tandem pump
1071.13 Assembly overview - accelerator mechanism
109Turbocharging/supercharging
1101 Charge air system with turbocharger
1101.1 Rules for cleanliness
1101.2 Turbocharger with attachments for engine codes BAC and BLK
1101.3 Removing and installing turbocharger for engine codes BAC and BLK
1111.4 Turbocharger with attachments (engine codes BPD and BPE)
1141.5 Removing and installing turbocharger (engine codes BPD and BPE)
1161.6 Removing and installing parts of charge air cooling
1191.7 Checking charge air system for leaks
1201.8 Hose connections
1221.9 Vacuum hose schematic diagram
123Mixture preparation - injection
1261 Repairing diesel direct injection system
1261.1 Safety precautions
1261.2 Rules for cleanliness
1271.3 Removing and installing wiring harness for unit injectors
1271.4 Removing and installing unit injector
1301.5 Assembly overview - unit injector
1331.6 Removing and installing O-rings for unit injector
1341.7 Assembly overview - intake manifold and fuel rail
1351.8 Repairing intake manifold flap
1371.9 Dismantling and assembling air filter
1392 Engine control unit
1402.1 Reading and deleting engine control unit event memory
1402.2 Removing and installing engine control unit J623
1412.3 Removing and installing anti-theft engine control unit J623
141Exhaust system
1451 Exhaust system
1451.1 Assembly overview - front exhaust pipe with catalytic converters
1451.2 Assembly overview - front exhaust pipe with particulate filter
1461.3 Removing and installing particulate filter
1481.4 Assembly overview - exhaust manifold (engine codes BPD, BPE)
1491.5 Removing and installing exhaust manifold (engine codes BPD, BPE)
1511.6 Silencer with mountings
1532 Exhaust gas recirculation system
1552.1 Assembly overview - exhaust gas recirculation
1552.2 Checking exhaust gas recirculation valve (mechanical)
159Glow plug system
1611 Glow plug system
1611.1 Characteristics of glow plugs
1611.2 Checking metal glow plugs
1611.3 Removing, installing and checking ceramic glow pin plugs
162