8-cylinder injection engine (direct injection)

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine data
  1
• 1.2 Numbering of cylinders
  2
• Removing and installing engine
  3
• 1 Removing and installing engine
  3
• 1.1 Removing engine
  4
• Crankshaft group
  22
• 1 Cylinder block - belt pulley end
  22
• 1.1 Assembly overview - poly V-belt drive for alternator
  22
• 1.2 Removing and installing poly V-belt
  23
• 1.3 Removing and installing vibration damper
  24
• 1.4 Renewing crankshaft oil seal - belt pulley end
  25
• 2 Cylinder block - gearbox end
  28
• 2.1 Assembly overview - drive plate
  28
• 2.2 Removing and installing drive plate
  28
• 2.3 Renewing crankshaft oil seal on timing chain end
  29
• 2.4 Assembly overview - timing chain covers
  31
• 2.5 Removing and installing left and right timing chain covers
  32
• 2.6 Removing and installing lower timing chain cover
  35
• 2.7 Assembly overview - camshafts timing chains
  39
• 2.8 Removing camshaft timing chains from camshafts
  42
• 2.9 Removing and installing camshaft timing chains
  49
• 2.10 Assembly overview - drive chain for valve gear
  52
• 2.11 Removing and installing drive chain for valve gear
  54
• 2.12 Assembly overview - drive chain for auxiliary drives
  56
• 2.13 Removing and installing drive chain for auxiliary drives
  56
• 2.14 Assembly overview - auxiliary drives
  58
• 2.15 Renewing oil seals for auxiliary drives
  59
• 2.16 Removing and installing spur gear drive
  61
• 3 Crankshaft
  66
• 3.1 Assembly overview - crankshaft
  66
• 3.2 Allocation of main bearing shells for new crankshafts
  69
• 3.3 Allocation of main bearing shells for used and re-machined crankshafts
  71
• 3.4 Bearing bush for torque converter
  71
• 3.5 Crankshaft dimensions
  72
• 3.6 Measuring axial clearance
  72
• 3.7 Measuring radial clearance
  72
• 4 Pistons and conrods
  74
• 4.1 Assembly overview - pistons and conrods
  74
• 4.2 Piston and cylinder dimensions
  77
• 4.3 Measuring radial clearance of conrods
  77
• Cylinder head, valve gear
  79
• 1 Cylinder head
  79
• 1.1 Assembly overview - cylinder head
  79
• 1.2 Removing and installing left cylinder head cover
  80
• 1.3 Removing and installing cylinder head cover (right side)
  82
• 1.4 Removing and installing cylinder head
  84
• 1.5 Checking compression
  91
• 2 Valve gear
  94
• 2.1 Assembly overview - valve gear
  94
• 2.2 Checking axial clearance of camshafts
  96
• 2.3 Removing and installing camshafts
  97
• 2.4 Renewing valve stem seals
  105
• 2.5 Checking supporting elements with hydraulic clearance compensation
  109
• 2.6 Valve dimensions
  111
• 2.7 Checking valve guides
  111
• 2.8 Checking valves
  112
• Lubrication
  113
• 1 Parts of lubrication system
  113
• 1.1 Assembly overview - oil pump, lower part of sump
  113
• 1.2 Removing and installing lower part of sump
  116
• 1.3 Removing and installing oil pump
  120
• 1.4 Assembly overview - upper part of sump
  123
• 1.5 Removing and installing upper part of sump
  124
• 1.6 Assembly overview - oil retention valve and spray nozzle valve
  129
• 1.7 Removing and installing oil retention valve and spray nozzle valve
  130
• 1.8 Assembly overview - oil filter housing
  132
• 1.9 Removing and installing oil filter housing
  133
• 1.10 Removing and installing oil cooler
  133
• 1.11 Checking oil pressure and oil pressure switch F1
  134
• 1.12 Checking oil level
  137
• Cooling
  138
• 1 Parts of cooling system
  138
• 1.1 Assembly overview - radiator
  139
• 1.2 Assembly overview - radiator fan
  140
• 1.3 Removing and installing radiator fan mounting with fans
  141
• 1.4 Assembly overview - parts of cooling system, body side
  141
• 1.5 Coolant hose schematic diagram
  143
• 1.6 Draining and filling coolant
  144
• 1.7 Removing and installing radiator
  150
• 1.8 Assembly overview - coolant pipes
  151
• 1.9 Assembly overview - coolant pump and thermostat
  168
• 1.10 Removing and installing coolant pump
  169
• 1.11 Removing and installing recirculation pump V55
  171
• 1.12 Removing and installing map-controlled engine cooling thermostat F265
  171
• 1.13 Removing and installing coolant temperature sender G62
  172
• 1.14 Checking cooling system for leaks
  174
• Fuel supply system
  176
• 1 Safety precautions
  176
• 1.1 Safety precautions when working on fuel supply system
  176
• 1.2 Releasing pressure in high-pressure area
  177
• 2 Parts of fuel supply system
  179
• 2.1 Rules for cleanliness
  180
• 2.2 Assembly overview - fuel tank with attachments
  181
• 2.3 Assembly overview - fuel filter
  183
• 2.4 Renewing fuel filter
  183
• 2.5 Emptying fuel tank
  185
• 2.6 Removing and installing fuel gauge sender and suction-jet pumps
  188
• 2.7 Removing and installing fuel delivery unit and fuel gauge sender
  190
• 2.8 Removing and installing fuel tank with attached components
  193
• 2.9 Checking fuel pump
  197
• 3 Electronic power control (EPC)
  206
• 3.1 Function of EPC system
  206
• 3.2 Assembly overview - accelerator
  206
• 4 Activated charcoal filter system
  208
• 4.1 Assembly overview - activated charcoal filter system
  208
• 4.2 Checking fuel system for leaks
  208
• 5.1 Assembly overview - activated charcoal filter system
  213
• 5.2 Checking fuel system for leaks
  215
• 6 Activated charcoal filter system (vehicles for USA and Canada from 08.2006)
  222
• 6.1 Assembly overview - activated charcoal filter system
  223
• 6.2 Checking fuel system for leaks
  224
• Mixture preparation - injection
  232
• 1 Injection system (vehicles with aluminium intake manifold)
  232
• 1.1 Assembly overview - intake manifold
  232
• 1.2 Removing and installing intake manifold
  234
• 1.3 Assembly overview - injectors and fuel rail
  242
• 1.4 Removing and installing injectors
  244
• 1.5 Assembly overview - high-pressure pump
  249
• 1.6 Removing and installing high-pressure pump
  250
• 1.7 Rules for cleanliness
  252
• 1.8 Technical data
  252
• 2 Injection system (vehicles with plastic intake manifold)
  254
• 2.1 Assembly overview - intake manifold
  254
• 2.2 Removing and installing intake manifold
  255
• 2.3 Assembly overview - injectors and fuel rail
  258
• 2.4 Removing and installing injectors
  260
• 2.5 Assembly overview - high-pressure pump
  264
• 2.6 Removing and installing high-pressure pump
  266
• 2.7 Vacuum hose schematic diagram
  268
• 2.8 Assembly overview - fuel pipes and fuel rail
  269
• 2.9 Rules for cleanliness
  269
• 2.10 Technical data
  270
• 3 Assembly overview - air filter
  271
• 3.1 Removing and installing lower part of air filter
  271
• 3.2 Removing and installing air intake pipe
  273
• 3.3 Disconnecting connecting line to air suspension compressor
  274
• 4 Engine control unit J623
  276
• 4.1 Removing and installing anti-theft engine control unit J623
  276
• 4.2 Removing and installing engine control unit J623
  278
• Exhaust system
  279
• 1 Parts of exhaust system
  279
• 1.1 Assembly overview - exhaust manifold
  279
• 1.2 Removing and installing left exhaust manifold
  280
• 1.3 Removing and installing right exhaust manifold
  281
• 1.4 Assembly overview - catalytic converters, Lambda probes and attachments
  282
• 1.5 Removing and installing left main catalytic converter
  286
• 1.6 Removing and installing left starter catalytic converter
  287
• 1.7 Removing and installing right main catalytic converter
  290
• 1.8 Removing and installing right starter catalytic converter
  291
• 1.9 Assembly overview - silencers with mountings
  294
• 1.10 Separating front and rear silencers
  296
• 1.11 Aligning exhaust system free of stress
  297
• 1.12 Renewing tailpipes
  298
• 2 Secondary air system
  300
• 2.1 Assembly overview - secondary air system
  300
• 2.2 Removing and installing secondary air pump
  302
• 2.3 Checking combination valve for secondary air system
  302
• 2.4 Removing and installing combination valve for secondary air system
  303
• 3 Secondary air system (vehicles for USA and Canada from 06.2007)
  304
• 3.1 Assembly overview - secondary air system
  304
• 3.2 Removing and installing secondary air pump
  306
• 3.3 Checking combination valve for secondary air system
  307
• 3.4 Removing and installing combination valve for secondary air system
  308
• Ignition system
  310
• 1 Ignition system
  310
• 1.1 Assembly overview - cylinder bank 1
  310
• 1.2 Assembly overview - cylinder bank 2
  313
• 1.3 Safety precautions
  316
• 1.4 Removing and installing ignition coils with output stage
  316
• 1.5 Removing and installing engine speed sender G28
  318
• 1.6 Removing and installing knock sensors
  319
• 1.7 Test data, spark plugs
  320