CONTENTS

Technical data

• Safety information
• Safety regulations for working on fuel supply
• Safety measures when working on vehicles with a start/stop system
• Safety precautions when using testers and measuring instruments during a road test
• Safety precautions when working on the cooling system
• Safety precautions when working on ignition system
• Identification
• Engine number/engine data
• Repair instructions
• Rules for cleanliness
• Foreign objects in engine
• Contact corrosion
• Routing and attachment of lines
• Fitting radiator and condensers

Removing and installing engine

• Removing engine
• Separating engine and gearbox
• Securing engine on engine and gearbox support
• Installing engine
• Assembly mountings
• Removing and installing engine mounting
• Removing and installing gearbox mounting
• Removing and installing pendulum support
• Supporting engine in installation position

Crankshaft group

• Cylinder block (pulley end)
• Assembly overview - poly V-belt drive
• Assembly overview - sealing flange, belt pulley end
• Removing and installing poly-V belt
• Removing and installing tensioner for poly V-belt
• Removing and installing vibration damper
• Removing and installing engine support
• Renewing crankshaft oil seal - belt pulley end
• Removing and installing sealing flange on pulley end
• Cylinder block, gearbox end
• Removing and installing flywheel
• Removing and installing sealing flange on gearbox side
• Crankshaft
• Crankshaft dimensions
• Renewing needle bearing in crankshaft
• Measuring axial clearance of crankshaft
• Assembly overview - pistons and conrods
• Separating new conrod
• Removing and installing pistons
• Removing and installing oil spray jets
• Checking pistons and cylinder bores
• Checking radial clearance of conrods
• Setting piston to TDC position

Cylinder head, valve gear

• Assembly overview - camshaft housing
• Removing and installing cylinder head
• Removing and installing camshaft housing
• Checking compression
• Toothed belt drive
• Assembly overview - toothed belt cover
• Assembly overview - toothed belt
• Removing and installing toothed belt guard
• Preassembling and installing valve timing tool
• Checking valve timing
• Adjusting valve timing
• Removing toothed belt from camshaft
• Removing and installing toothed belt
• Valve gear
• Assembly overview - valve gear
• Removing and installing camshaft oil seal
• Removing and installing camshaft adjuster
• Removing and installing toothed belt pulley
• Removing and installing camshaft control valve 1 N205
• Removing and installing exhaust camshaft control valve 1 N318
• Removing and installing valve stem seals
• Removing and installing cam actuators
• Inlet and exhaust valves
• Checking valve guides
• Checking valves
• Valve dimensions

Lubrication

• Sump, oil pump
• Engine oil
• Removing and installing lower part of sump
• Removing and installing upper part of sump
• Removing and installing oil pump
• Removing and installing oil level and oil temperature sender G266
• Engine oil cooler
• Assembly overview - engine oil cooler
• Removing and installing engine oil cooler
• Crankcase ventilation
• Assembly overview - crankcase breather system
• Removing and installing oil separator
• Oil filter, oil pressure switch
• Assembly overview - oil filter/oil pressure switch
• Removing and installing oil pressure switch F1
• Removing and installing oil pressure switch for reduced oil pressure F378
• Checking oil pressure
• Removing and installing oil pressure regulating valve N428

Cooling

• Cooling system/coolant
• Connection diagram - coolant hoses
• Checking cooling system for leaks
• Draining and adding coolant
• Coolant pump, regulation of cooling system
• Assembly overview - coolant pump, thermostat
• Assembly overview - electric coolant pump
• Assembly overview - coolant temperature sender
• Removing and installing electric coolant pump
• Removing and installing coolant pump
• Removing and installing thermostat
• Removing and installing toothed belt pulley for coolant pump
• Removing and installing coolant temperature sender G62
• Removing and installing radiator outlet coolant temperature sender G83
• Coolant pipes
• Removing and installing coolant pipes
• Radiator, radiator fan
• Removing and installing radiator
• Removing and installing water radiator for charge air cooling circuit
• Removing and installing radiator cowl with radiator fan
• Removing and installing radiator fan V7

Turbocharging/supercharging

• Exhaust turbocharger
• Removing and installing turbocharger
• Removing and installing charge pressure positioner V465
• Removing and installing connection for turbocharger
• Charge air system
• Removing and installing charge air cooler
• Removing and installing charge pressure sender GX26
• Checking charge air system for leaks
• Removing and installing air intake pipe

Mixture preparation – injection

• Injection system
• Injectors
• Assembly overview - fuel rail with injectors
• Removing and installing fuel rail
• Removing and installing injectors
• Cleaning injectors
• Air filter
• Removing and installing air filter housing
• Removing and installing resonator for intake air
• Intake manifold
• Removing and installing intake manifold
• Removing and installing throttle valve module GX3
• Cleaning throttle valve module GX3
• Senders and sensors
• Removing and installing fuel pressure sender G247
• Checking fuel pressure sender G247
• Removing and installing intake manifold sender GX9
• Removing and installing engine (motor) control unit J623
• Removing and installing engine (motor) control unit J623 with protective housing
• Removing and installing high-pressure pump
• Removing and installing high-pressure pipe
• Lambda probe
• Removing and installing Lambda probe

Exhaust system

• Separating exhaust pipes from silencers
• Removing and installing silencer
• Aligning exhaust system free of stress
• Check exhaust system for leaks
• Exhaust gas cleaning
• Assembly overview - emission control
• Removing and installing catalytic converter

Ignition system

• Removing and installing ignition coils with output stage
• Removing and installing knock sensor 1 G61
• Removing and installing Hall sender
• Removing and installing engine speed sender G28