Technical data
11 Safety information
11.1 Safety measures when working on fuel system
11.2 Safety measures when working on vehicles with start/stop system
11.4 Safety measures when working on cooling system
21.5 Safety measures when working on exhaust system
21.6 Safety precautions when working on the SCR system
31.7 Safety regulations for working on glow plug system
41.8 Safety measures when working on subframe
42 Identification
52.1 Engine number/engine data
53 Repair notes
73.1 Rules for cleanliness
73.2 General information
73.3 General repair notes
83.4 Adapting learnt value for SCR system
93.5 Foreign objects in engine
93.6 Contact corrosion
103.7 Routing and attachment of lines
103.8 Installing radiators and condensers
103.9 Checking vacuum system
10Removing and installing engine
121 Removing and installing motor
121.1 Removing motor
121.2 Separating engine and gearbox
341.3 Securing engine on engine and gearbox support
411.4 Installing engine
452 Assembly mountings
502.1 Assembly overview - assembly mountings
502.2 Removing and installing engine mounting
532.3 Removing and installing gearbox mountings
592.4 Supporting engine in installation position
603 Engine cover panel
643.1 Removing and installing engine cover
64Crankshaft group
681 Cylinder block (pulley end)
681.1 Assembly overview - cylinder block (pulley end)
681.2 Assembly overview - sealing flange, belt pulley end
711.3 Removing and installing poly-V belt
731.4 Removing and installing tensioner for poly V-belt
751.5 Removing and installing vibration damper
751.6 Removing and installing bracket for ancillaries
781.7 Removing and installing engine support
801.8 Renewing crankshaft oil seal - belt pulley end
811.9 Removing and installing sealing flange on pulley end
832 Cylinder block, gearbox end
882.1 Assembly overview - cylinder block, gearbox end
882.2 Removing and installing drive plate
882.3 Renewing crankshaft oil seal (gearbox end)
913 Crankshaft
943.1 Assembly overview - crankshaft
943.2 Crankshaft dimensions
963.3 Allocation of main bearing shells
973.4 Measuring axial clearance of crankshaft
983.5 Measuring radial clearance of crankshaft
993.6 Checking sender wheel
994 Balancer shaft
1014.1 Assembly overview - balance shaft
1014.2 Removing and installing balance shaft
1015 Pistons and conrods
1105.1 Assembly overview - pistons and conrods
1105.2 Removing and installing pistons
1145.3 Measuring piston projection at TDC
1155.4 Checking pistons and cylinder bores
1185.5 Checking radial clearance of conrods
120Cylinder head, valve gear
1211 Cylinder head
1211.1 Assembly overview - cylinder head
1211.2 Assembly overview - cylinder head cover
1241.3 Removing and installing cylinder head
1271.4 Removing and installing cylinder head cover
1361.5 Removing and installing injector seals
1421.6 Checking compression
1432 Cover for timing chain
1452.1 Assembly overview - cover for timing chain
1452.2 Removing and installing timing chain cover
1493 Chain drive
1623.1 Assembly overview - camshaft timing chains
1623.2 Assembly overview - drive chain for high pressure pump
1643.3 Assembly overview - drive chain for oil pump
1653.4 Assembly overview - intermediate drive
1653.5 Removing camshaft timing chain from camshafts
1663.6 Removing and installing camshaft timing chain
1793.7 Removing and installing drive chain for high-pressure pump
1913.8 Installing intermediate drive
1934 Valve gear
2024.1 Assembly overview - valve gear
2024.2 Measuring axial play of camshaft
2104.3 Measuring radial play of camshaft
2124.4 Removing and installing camshaft
2124.5 Checking hydraulic compensation elements
2284.6 Removing and installing valve stem seals
2305 Inlet and exhaust valves
2405.1 Reworking valve seats
2405.2 Checking valve guides
2405.3 Checking valves
2415.4 Valve dimensions
241Lubrication
2421 Sump, oil pump
2421.1 Assembly overview - sump/oil pump
2421.2 Engine oil:
2471.3 Removing and installing lower part of sump
2491.4 Removing and installing upper part of sump
2521.5 Removing and installing oil pump
2551.6 Removing and installing oil level and oil temperature sender G266
2582 Engine oil cooler
2592.1 Assembly overview - engine oil cooler
2592.2 Removing and installing engine oil cooler
2612.3 Removing and installing temperature regulator for engine oil cooler
2623 Crankcase ventilation
2643.1 Assembly overview - crankcase breather system
2643.2 Removing and installing oil separator
2654 Oil filter, oil pressure switch
2664.1 Assembly overview - oil filter
2664.2 Removing and installing oil pressure sender G10
2684.3 Checking oil pressure
2694.4 Removing and installing oil filter housing
2694.5 Removing and installing oil pressure regulating valve N428
2724.6 Removing and installing oil temperature sender 2 G664
272Cooling
2741 Cooling system/coolant
2741.1 Connection diagram - coolant hoses
2741.2 Checking cooling system for leaks
2781.3 Draining and adding coolant
2812 Coolant pump, regulation of cooling system
2922.1 Assembly overview - coolant pump
2922.2 Assembly overview - electric coolant pump
2942.3 Assembly overview - thermostat
2942.4 Assembly overview - coolant temperature sender
2962.5 Removing and installing electric coolant pump
2972.6 Removing and installing coolant pump
2992.7 Removing and installing thermostat housing
3012.8 Removing and installing thermostat
3032.9 Removing and installing coolant temperature sender G62
3032.11 Removing and installing coolant temperature sender 2 G802
3062.12 Removing and installing coolant valves
3073 Coolant pipes
3103.1 Assembly overview - coolant pipes
3103.2 Removing and installing coolant pipes
3154 Radiator, radiator fan
3284.1 Assembly overview - radiator/radiator fan
3284.2 Assembly overview - auxiliary radiator
3314.3 Removing and installing radiator
3324.4 Removing and installing radiator cowl
3384.5 Removing and installing radiator fan V7
3414.6 Removing and installing auxiliary radiator
341Turbocharging/supercharging
3441 Turbocharger
3441.1 Assembly overview - turbocharger
3441.2 Removing and installing turbocharger
3492 Charge air system
3542.1 Assembly overview - charge air system
3542.2 Assembly overview - charge-air hose connections
3552.3 Removing and installing charge air cooler
3562.4 Removing and installing charge pressure sender G31
3592.5 Checking charge air system for leaks
359Mixture preparation - injection
3641 Injection system
3641.1 Schematic overview - fuel system
3641.2 Overview of fitting locations - injection system
3651.3 Filling/bleeding fuel system
3721.4 Checking fuel system for leaks
3732 Vacuum system
3742.1 Connection diagram - vacuum system
3742.2 Checking vacuum system
3743 Injectors/high-pressure accumulator (rail)
3763.1 Assembly overview - injectors
3763.2 Testing injectors
3803.3 Adapting correction values for injectors
3813.4 Checking return flow rate of injectors with engine running
3823.5 Checking return flow rate of injectors at starter speed
3853.6 Testing jammed-open injectors
3883.7 Check pressure retention valve in fuel return line
3923.8 Removing and installing injectors
3933.9 Removing and installing high-pressure lines
3993.10 Removing and installing fuel rail
4014 Air filter
4064.1 Assembly overview - air filter housing
4064.2 Removing and installing air filter housing
4085 Intake manifold
4115.1 Assembly overview - intake manifold
4115.2 Removing and installing intake manifold upper part
4155.3 Removing and installing lower part of intake manifold
4205.4 Removing and installing intake manifold flap motor V157
4215.5 Removing and installing throttle valve module J338
4246 Senders and sensors
4266.1 Checking fuel pressure regulating valve N276
4266.2 Removing and installing fuel pressure regulating valve N276
4286.3 Removing and installing fuel pressure sender G247
4306.4 Removing and installing air mass meter G70
4336.5 Removing and installing pressure differential sender G505
4336.6 Removing and installing pressure differential sender 2 G524
4356.7 Removing and installing NOx sender G295
4366.8 Removing and installing NOx sender 2 G687
4386.9 Removing and installing particle sensor G784
4396.11 Removing and installing fuel temperature sender G81
4416.12 Removing and installing fuel pressure sender for low-pressure G410
4417 Engine control unit
4437.1 Assembly overview – motor control unit
4437.2 Removing and installing engine control unit J623
4438 High-pressure pump
4458.1 Assembly overview - high-pressure pump
4458.2 Removing and installing high-pressure pump
4489 Lambda probe
4549.1 Assembly overview - Lambda probe
4549.2 Removing and installing Lambda probe
456Exhaust system
4581 Exhaust pipes and silencers
4581.1 Assembly overview - silencers
4581.2 Removing and installing front exhaust pipe
4601.3 Separating exhaust pipes from silencers
4651.4 Removing and installing silencer
4661.5 Aligning exhaust system free of stress
4681.6 Checking exhaust system for leaks
4692 Emission control
4702.1 Assembly overview - emission control
4702.2 Removing and installing emission control module
4732.3 Removing and installing trap catalytic converter
4772.4 Removing and installing exhaust flap control unit J883
4793 SCR system (selective catalytic reduction)
4813.1 Assembly overview - tank for reducing agent
4813.2 Assembly overview - reducing agent supply line
4833.3 Assembly overview - control unit for reducing agent metering system
4843.4 Relieving pressure in SCR system
4853.5 Draining reducing agent tank
4863.6 Removing and installing reducing agent tank
4873.7 Removing and installing injector for reduction agent N474
4893.8 Assembly overview - injector for reducing agent
4913.9 Removing and installing control unit for reducing agent metering system J880
4923.10 Removing and installing reducing agent quality sensor G849
4934 Exhaust gas temperature regulation
4944.1 Assembly overview - exhaust gas temperature regulation
4944.2 Removing and installing exhaust gas temperature sender 1 G235
4954.3 Removing and installing exhaust gas temperature sender 2 G448
4974.4 Removing and installing exhaust gas temperature sender 3 G495
4984.5 Removing and installing exhaust gas temperature sender 4 G648
5005 Exhaust gas recirculation
5025.1 Assembly overview - exhaust gas recirculation
5025.2 Removing and installing exhaust gas recirculation valve
5075.3 Removing and installing exhaust gas recirculation cooler
5105.4 Removing and installing exhaust gas recirculation control motor 2 V339
5145.5 Removing and installing exhaust gas recirculation temperature sensor G98
5156 Exhaust manifold
5176.1 Assembly overview - exhaust manifold
5176.2 Removing and installing exhaust manifold
518Glow plug system
5231 Glow plug system
5231.1 Assembly overview - glow plug system
5231.2 Removing and installing glow plug
5251.3 Removing and installing automatic glow period control unit J179
5281.4 Removing and installing Hall sender G40
5291.5 Removing and installing engine speed sender G28
529