8-cylinder injection engine

Chapter overview

• Technical data
  1
• 1 Engine number
  1
• 2 Engine data
  2
• 3 Numbering of cylinders
  3
• Removing and installing engine
  4
• 1 Removing and installing engine
  4
• 1.1 Securing engine to assembly stand
  11
• 1.2 Installing engine
  12
• 2 Assembly mountings
  16
• 2.1 Assembly overview - assembly mountings
  16
• 2.2 Supporting engine in installation position
  17
• 2.3 Removing and installing engine mounting
  19
• 2.4 Removing and installing engine bracket or engine mounting
  20
• Crankshaft group
  22
• 1 Dismantling and assembling engine
  22
• 1.1 Part I: assembly overview - toothed belt drive
  23
• 1.2 Assembly overview - part II, cylinder block
  25
• 1.3 Removing and installing poly-V belt
  26
• 1.4 Checking alignment of poly V-belt
  26
• 2 Assembly overview - sealing flanges and drive plate
  28
• 2.1 Removing and installing sealing flange at drive plate end
  30
• 2.2 Removing and installing drive plate
  31
• 2.3 Renewing crankshaft oil seal, vibration damper end
  33
• Cylinder head, valve gear
  35
• 1 Assembly overview - cylinder head
  35
• 1.1 Removing and installing cylinder head cover (right side)
  37
• 1.2 Removing and installing left cylinder head cover
  39
• 1.3 Removing, installing and tensioning toothed belt
  41
• 1.4 Removing and installing left cylinder head
  47
• 1.5 Removing and installing right cylinder head
  50
• 1.6 Checking compression
  53
• 2 Assembly overview - valve gear
  55
• 2.1 Camshafts, checking axial clearance
  58
• 2.2 Renewing camshaft oil seals
  59
• 2.3 Renewing Hall sender seals
  60
• 2.4 Removing and installing camshafts and camshaft adjusters - left cylinder head
  62
• 2.5 Removing and installing camshafts and camshaft adjusters - right cylinder head
  68
• 2.6 Removing and installing roller rocker finger
  73
• 2.7 Renewing valve stem seals
  74
• 2.8 Checking valve guides
  78
• 2.9 Reworking valve seats
  79
• Lubrication
  81
• 1 Removing and installing parts of lubrication system
  81
• 1.1 Engine oil
  81
• 1.2 Checking oil level
  82
• 1.3 Assembly overview - oil filter housing
  82
• 1.4 Removing and installing oil filter housing
  83
• 1.5 Assembly overview - sump
  84
• 1.6 Removing and installing lower part of sump
  85
• 1.7 Removing and installing upper part of sump
  87
• 1.8 Removing and installing oil level and oil temperature sender G266
  91
• 1.9 Assembly overview - dismantling and assembling oil pump
  92
• 1.10 Checking oil pressure and oil pressure switch
  95
• Cooling
  98
• 1 Removing and installing parts of cooling system
  98
• 1.1 Assembly overview - radiator
  98
• 1.2 Assembly overview - radiator fan
  100
• 1.3 Parts of cooling system, body side
  101
• 1.4 Parts of cooling system - engine side, front
  102
• 1.5 Parts of cooling system - engine side, rear
  103
• 1.6 Parts of cooling system - engine side, right
  104
• 1.7 Coolant hose connection diagram
  105
• 1.8 Draining and adding coolant
  106
• 1.9 Removing and installing fan mounting with fans
  109
• 1.10 Removing and installing radiator fans
  110
• 1.11 Removing and installing radiator
  111
• 1.12 Removing and installing coolant pump and thermostat
  113
• 1.13 Checking cooling system for leaks
  115
• Fuel supply system
  116
• 1 Removing and installing parts of fuel supply system
  116
• 1.1 Assembly overview - fuel tank with attachments and fuel filter
  116
• 1.2 Assembly overview - right side fuel delivery unit, fuel gauge sender and suction-jet pump
  118
• 1.3 Assembly overview - left side fuel delivery unit, fuel gauge sender and suction-jet pump
  120
• 1.4 Schematic diagram of fuel lines and components in fuel tank
  122
• 1.5 Safety regulations for working on fuel supply
  123
• 1.6 Rules for cleanliness
  124
• 1.7 Emptying fuel tank
  124
• 1.8 Removing and installing fuel delivery unit, fuel gauge sender and suction-jet pump, right side
  127
• 1.9 Removing and installing fuel delivery unit, fuel gauge sender and suction-jet pump, left side
  130
• 1.10 Removing and installing fuel tank with attachments and fuel filter
  132
• 1.11 Checking fuel pumps
  135
• 1.12 Checking electronic power control (EPC)
  143
• 2 Activated charcoal filter system
  146
• 2.1 Assembly overview - parts of activated charcoal filter system
  146
• 2.2 Checking activated charcoal filter system for leaks
  148
• 3 Activated charcoal filter system (vehicles with fuel system diagnostic pump V144 )
  151
• 3.1 Assembly overview - parts of activated charcoal filter system
  151
• Mixture preparation - injection
  153
• 1 Repairing injection system
  153
• 1.1 Assembly overview - intake manifold
  153
• 1.2 Assembly overview - fuel rail with injectors
  155
• 1.3 Assembly overview - air filter
  156
• 1.4 Vacuum hoses on intake manifold
  157
• 1.5 Removing and installing intake air duct to throttle valve module J338
  157
• 1.6 Safety precautions
  160
• 1.7 Rules for cleanliness
  161
• 1.8 Technical data
  161
• 2 Checking components
  162
• 2.1 Checking injectors
  162
• 2.2 Checking fuel pressure regulator and holding pressure
  164
• 3 Engine (motor) control unit
  168
• 3.1 Removing and installing engine control unit
  168
• 3.2 Reading and erasing engine control unit fault memory
  168
• Exhaust system
  170
• 1 Exhaust manifold, catalytic converters and silencers with mountings
  170
• 1.1 Assembly overview - exhaust manifold with starter catalytic converters and attachments
  170
• 1.2 Removing and installing starter catalytic converter with exhaust pipe
  173
• 1.3 Assembly overview - silencers with mountings
  173
• 2 Lambda probes
  176
• 2.1 Removing and installing Lambda probe G39
  176
• 2.2 Removing and installing Lambda probe after catalytic converter G130
  177
• 3 Secondary air system
  180
• 3.1 Assembly overview - parts of secondary air system, vehicle side
  180
• 3.2 Assembly overview - parts of secondary air system, engine side
  181
• Ignition system
  183
• 1 Repairing ignition system
  183
• 1.1 Assembly overview - parts of ignition system
  183
• 1.2 Safety precautions
  184
• 1.3 Removing and installing ignition coils with output stage
  184
• 1.4 Test data, spark plugs
  186