2.5DCI Engine Mechanical

Page 1 of 2
Accelerator Pedal with Pedal Position Sensor, Left Drive, Replace
J496030
Important: Ensure vehicle ignition is switched off.
Remove
1. Disconnect harness connector (1)

2. Remove sensor (2) from bracket
• Remove 3x nut
Install
3. Install new sensor (2) to bracket

• Install on 2x locator
• Install 3x nut
4. Connect harness connector (1)
Page 2 of 2
5. For vehicles with F4R 820 engine, program pedal position sensor using Tech 2.
Page 1 of 1
Accelerator Pedal, Right Drive, Replace
J815500
Remove
1. Remove accelerator pedal from support bracket

• Release link rod (2) from accelerator pedal
• Remove nut (1)
Install
2. Install new accelerator pedal to support bracket

• Install nut (1)
• Secure link rod (2) to accelerator pedal
Page 1 of 2
Actuator, Turbocharger Wastegate, Check
J470435
Measure
1. Remove turbocharger from vehicle – see operation “Turbocharger, Replace”

2. Install turbocharger to soft-jawed vice
3. Install suitable magnetic base (commercially available) and Dial Gauge MKM-571-B to turbocharger
• Position probe of dial gauge in contact with control actuator rod (arrowed)
• With probe of dial gauge on control actuator rod, set dial gauge reading to 0 (zero)
4. Check operation of wastegate actuator (3)

• Connect hose (1) of Pressure and Vacuum Pump MKM-667 (2) to
wastegate actuator
• Operate pressure and vacuum pump to apply vacuum of – 282 mbar
(– 4 psi) to wastegate actuator
– Check distance travelled by wastegate actuator rod when
vacuum is applied – see “Technical Data”
• Operate pressure and vacuum pump to apply vacuum of – 600 mbar
(– 9 psi) to wastegate actuator
– Check distance travelled by wastegate actuator rod when
vacuum is applied – see “Technical Data”
Page 2 of 2
5. Remove dial gauge and Pressure and Vacuum Pump MKM-667 from turbocharger
6. Remove turbocharger from soft-jawed vice
7. Install turbocharger to vehicle – see operation “Turbocharger, Replace”
Page 1 of 12
Alternator, Replace (with Air Conditioning)
J705100
Remove
1. Disconnect battery negative lead

2. Remove upper front panel – see operation “Upper Front Panel, Remove and Install or Replace”
3. Release pulley (1) from power steering pump (2)
• Release 3x bolt (3); do not remove at this stage
1 2
3
S 0012762
4. Remove engine and transmission undershield from vehicle

• Remove 8x bolt
5. Remove right splash panel

Note: Illustration shows the wheelarch liner removed for clarity.
• Release washer hose (if installed) from 2x clip
• Remove 2x bolt, screw
Page 2 of 12
6. Remove ribbed V-belt from engine

• Rotate tension roller clockwise, then lock using Locating Pin KM-
6130 (1)
7. Lower vehicle
8. Secure radiator assembly to front crossmember
Note: To allow access to the alternator.
• Use 2x cable tie
9. Remove pulley from power steering pump
• Remove 3x bolt
10. Release power steering feed hose from auxiliary support bracket, then
move to one side
• Pull off
Page 3 of 12
S 0012764
11. Remove bracket (1) from auxiliary support bracket and EGR valve
housing
• Remove 2x bolt (2)
• Release 2x harness from bracket
– Release 2x clip (3)
2
3 S 0012765
12. Release power steering pump from engine, then move to one side
• Remove 3x bolt
Page 4 of 12
S 0012766
13. Disconnect 2x harness connector from alternator

• Disconnect harness connector (1)
• Remove nut (2), then release terminal (3)
Page 5 of 12
14. Remove guide roller for ribbed V-belt

• Remove bolt (1)
15. Remove alternator from support bracket

Page 6 of 12
Install
16. Install new alternator to support bracket

• Install 2x bolt (1) 30 Nm
17. Connect 2x harness connector to alternator

• Install terminal (3), then secure nut (2)
• Connect harness connector (1)
Page 7 of 12
18. Install guide roller for ribbed V-belt to cylinder block

• Install bolt (1) 45 Nm
19. Secure power steering pump to engine

• Install 3x bolt 25 Nm
Page 8 of 12
S 0012766
20. Install bracket (1) to auxiliary support bracket and EGR valve housing
• Secure 2x harness to bracket
– Secure 2x clip (3)
Page 9 of 12
3 S 0012765
21. Secure power steering feed hose to auxiliary support bracket

• Push on
S 0012764
22. Install pulley (1) to power steering pump (2)

• Install 3x bolt (3); do not tighten at this stage
Page 10 of 12
1 2
3
S 0012762
23. Release radiator assembly from front crossmember

• Remove 2x cable tie
24. Install ribbed V-belt to engine

• Rotate tension roller clockwise, then remove Locating Pin KM-6031
(1)
Page 11 of 12
25. Raise vehicle

26. Install right splash panel
• Install 2x bolt 8 Nm , screw 6 Nm
• Secure washer hose (if installed) to 2x clip
Page 12 of 12
27. Install engine and transmission undershield to vehicle

28. Secure pulley (1) to power steering pump (2)

• Secure 3x bolt (3) 10 Nm
1 2
3
S 0012762
29. Install upper front panel – see operation “Upper Front Panel, Remove and Install or Replace”
30. Connect battery negative lead
31. Program all volatile memories
Page 1 of 8
Alternator, Replace (without Air Conditioning)
J705100
Remove

3. Release power steering feed hose (1) from auxiliary support bracket (2),
then move to one side
• Pull off
2
S 0012771

6130 (1)
Page 2 of 8
5. Lower vehicle
housing
Page 3 of 8
2
1
S 0012772
8. Disconnect harness from fuel pressure regulator
S 0012773

Page 4 of 8
10. Remove alternator from support bracket

S 0012779
Install
11. Install new alternator to support bracket

Page 5 of 8
S 0012779

13. Connect harness to fuel pressure regulator

Page 6 of 8
S 0012773
– Secure 2x clip (3) 2
1
S 0012772


(1)
Page 7 of 8
17. Secure power steering feed hose to auxiliary support bracket

• Push on
Page 8 of 8
S 0012771
Page 1 of 10
Camshaft Oil Seals, Replace
J462060
Remove
1. Remove timing belt – see operation "Timing Belt, Replace”

• G9T 720, G9T 722
• G9T 722 (with second generation common rail)
• G9T 750, G9U 750, G9U 754
• G9U 630
• G9U 632, G9U 650
• G9U 720
• G9U 720 (with second generation common rail)
• G9U 724
• G9U 730
2. Remove camshaft pulley hub (1) from exhaust camshaft

Note: 2x technician required.
• Remove bolt
3. Remove Locking/Measurement Tool KM-6205 (2) from exhaust
camshaft
• Remove bolt
4. Remove camshaft oil seal (1) from exhaust camshaft

Page 2 of 10
Install
5. Install stud of Installer KM-6300 into end of exhaust camshaft
6. Install Sleeve KM-6424-1 (2) over stud (1) onto end of camshaft
7. Locate new camshaft oil seal (3) on sleeve (2)
Page 3 of 10
8. Locate sleeve (2) of Installer KM-6300 against camshaft oil seal (3)
9. Loosely install nut (1) of Installer KM-6300 against sleeve (2)
10. Install camshaft oil seal to exhaust camshaft

• Tighten nut (1)
Note: Camshaft oil seal is fully installed when nut (1) is tight.
11. Remove nut (1) of Installer KM-6300 from stud (3)
12. Remove sleeve (2) of Installer KM-6300 from stud (3)
Page 4 of 10
13. Remove Sleeve KM-6424-1 (2) from stud (1)

14. Remove stud (1) of Installer KM-6300 from exhaust camshaft
15. Install Locking/Measurement Tool KM-6205 (2) to exhaust camshaft

• Install bolt
16. Install camshaft pulley hub (1) to exhaust camshaft
• Install bolt 44 Nm
Page 5 of 10
Remove
17. Remove camshaft pulley (1) from intake camshaft

• Remove 3x bolt
18. Remove camshaft pulley hub (1) from intake camshaft

• Remove bolt
19. Remove Locking/Measurement Tool KM-6204 (2) from intake camshaft
• Remove bolt
Page 6 of 10
20. Remove camshaft oil seal (1) from intake camshaft
Install
21. Install stud of Installer KM-6300 into end of intake camshaft

Page 7 of 10
22. Install Sleeve KM-6424-1 (2) over stud (1) onto end of intake camshaft
23. Locate new camshaft oil seal (3) on sleeve (2)
24. Locate sleeve (2) of Installer KM-6300 against camshaft oil seal (3)
25. Loosely install nut (1) of Installer KM-6300 against sleeve (2)
Page 8 of 10
26. Install camshaft oil seal to intake camshaft

• Tighten nut (1)
Note: Camshaft oil seal is fully installed when nut (1) is tight.
27. Remove nut (1) of Installer KM-6300 from stud (3)
28. Remove sleeve (2) of Installer KM-6300 from stud (3)
29. Remove Sleeve KM-6424-1 (2) from stud (1)

30. Remove stud (1) of Installer KM-6300 from intake camshaft
Page 9 of 10
31. Install Locking/Measurement Tool KM-6204 (2) to intake camshaft

• Install bolt
32. Install camshaft pulley hub (1) to intake camshaft
33. Install camshaft pulley (1) to intake camshaft

• Install 3x bolt; do not tighten at this stage
Page 10 of 10
34. Install timing belt – see operation "Timing Belt, Replace"

• G9T 720, G9T 722
• G9T 722 (with second generation common rail)
• G9T 750, G9U 750, G9U 754
• G9U 630
• G9U 632, G9U 650
• G9U 720
• G9U 720 (with second generation common rail)
• G9U 724
• G9U 730
Page 1 of 1
Camshaft Sensor, Replace
J491840
Remove
1. Remove camshaft sensor from high pressure pump

• Remove bolt
Install
2. Install new camshaft sensor to high pressure pump

Page 1 of 14
Camshafts, Replace
J314570
Remove

2. Remove cylinder head cover – see operation “Cylinder Head Cover, Replace"
• G9U 630
• G9U 730
3. Raise vehicle
• Remove 6x bolt

6. Remove left splash panel

7. Remove toothed belt cover
• Remove 8x bolt
8. Remove bolt (arrowed) from oil filter housing

Note: To allow installation of Positioning Pin KM-6203 .
Page 2 of 14
9. Install Positioning Pin KM-6203 (arrowed), through oil filter housing into
crankshaft
• Rotate engine clockwise, until positioning pin engages in crankshaft
to position No. 1 cylinder at top dead centre on compression stroke
Note: Top dead centre mark (1) on crankshaft pulley should be in
the vertical position.
Note: No. 1 cylinder is located at the flywheel end.
Page 3 of 14
10. Install Engine Support KM-6210-A to vehicle – see operation “Engine Support KM-6210-A, Install and Remove”
11. Lower vehicle
12. Remove support bracket (1) from engine
• Remove 4x bolt (2), nut (3)
Page 4 of 14
13. Remove engine damping block (1) from inner wing

14. Remove upper cover (1) from engine compartment

• Remove 3x bolt
Page 5 of 14
15. Install Locking/Measurement Tool KM-6205 and Locking Tool KM-6204 to 2x camshaft
• Install 2x bolt
16. Remove timing belt – see operation “Timing Belt, Replace”
• G9U 630
• G9U 730
17. Remove 2x hub for 2x camshaft pulley from engine
• Remove 2x bolt
18. Remove 2x rocker shaft from cylinder head

• Remove 12x bolt
19. Remove vacuum pump from cylinder head

• Remove 2x bolt
Page 6 of 14
20. Remove Locking/Measurement Tool KM-6205 and Locking Tool KM-6204 from 2x camshaft
• Remove 2x bolt
Important: Each camshaft cap must be marked to identify its position for
subsequent assembly.
21. Mark 12x camshaft cap as shown
22. Remove exhaust camshaft (1) from cylinder head

Note: Camshaft cap and respective bolt should remain together for
reinstallation.
• Remove 6x bolt
• Remove 6x exhaust camshaft cap from cylinder head
• Remove oil seal from exhaust camshaft
23. Remove intake camshaft (2) from cylinder head
Note: Camshaft cap and respective bolt should remain together for
reinstallation.
• Remove 6x bolt
• Remove 6x intake camshaft cap from cylinder head
Page 7 of 14
• Remove oil seal from intake camshaft
Install
24. Apply bead of sealant 2 mm thickness to cylinder head – see

“Sealants, Lubricants and Locking Compounds”
• A – Flywheel end
• B – Timing end
Page 8 of 14
S 0017908
Important: Apply clean engine oil to bearing journals of cylinder head and
camshaft.
25. Install new exhaust camshaft to cylinder head
• Position exhaust camshaft in cylinder head
• Loosely assemble 6x exhaust camshaft cap (1, 2, 3, 4, 5, 6) to
cylinder head
• Secure 2x exhaust camshaft cap (1, 6) 13 Nm
• Secure 4x exhaust camshaft cap (2, 3, 4, 5) 10 Nm
Important: Apply clean engine oil to bearing journals of cylinder head and
camshaft.
26. Install new intake camshaft to cylinder head
• Position intake camshaft in cylinder head
• Loosely assemble 6x intake camshaft cap (7, 8, 9, 10, 11, 12) to
cylinder head
• Secure 2x intake camshaft cap (7, 12) 13 Nm
• Secure 4x intake camshaft cap (8, 9, 10, 11) 10 Nm
Page 9 of 14
27. Install 2x new oil seal to 2x camshaft – see operation “Camshaft Oil Seal, Replace"
Important: Ensure that the flat surfaces (arrowed) on the end of the rocker
shafts are positioned to the timing side of the cylinder head.
28. Install exhaust rocker shaft to cylinder head
29. Install intake rocker shaft to cylinder head
30. Secure 12x bolt 13 Nm in sequence shown
Page 10 of 14
31. Install vacuum pump to cylinder head

• Clean mating surfaces
Page 11 of 14
32. Install Locking/Measurement Tool KM-6205 and Locking Tool KM-6204 to 2x camshaft
• Install 2x bolt
33. Install 2x camshaft pulley hub to 2x camshaft
34. Secure 2x camshaft pulley hub to 2x camshaft
• Secure 2x bolt 44 Nm
35. Remove Locking/Measurement Tool KM-6205 and Locking Tool KM-6204 from 2x camshaft
• Remove 2x bolt
36. Install new timing belt – see operation “Timing Belt, Replace”
• G9U 630
• G9U 730
37. Install cylinder head cover – see operation “Cylinder Head Cover, Replace"
• G9U 630
• G9U 730
38. Install upper cover (1) to engine

Page 12 of 14
39. Install engine damping block (1) to inner wing

Important: Secure support bracket to engine in correct stage and

sequence.
40. Install support bracket (1) to engine
• Install nut (4) 44 Nm
41. Secure engine damping block (1) to inner wing

Page 13 of 14
42. Raise vehicle

43. Remove Positioning Pin KM-6203 (arrowed) from oil filter housing
44. Install bolt (arrowed) to oil filter housing 22 Nm

• Apply sealant to bolt thread – see “Sealants, Lubricants and
Locking Compounds”
Page 14 of 14
45. Remove Engine Support KM-6210-A – see operation “Engine Support KM-6210-A, Install and Remove”
• Secure washer hose to 2x clip
47. Install left splash panel

49. Lower vehicle
Page 1 of 3
Charge Pressure Sensor, Replace
J741100
Remove
1. Disconnect pipe from intercooler

• Release clip
S 0012741
2. Raise vehicle
• Remove 8x bolt
4. Remove intercooler pipe from vehicle

• Disconnect intercooler pipe from exhaust gas
recirculation (EGR) valve housing
– Release clip (1) from transmission
– Release clip (3)
• Disconnect harness connector from charge
pressure sensor (4)
• Release coolant hose from clip (2)
Page 2 of 3
5. Remove charge pressure sensor from intercooler pipe

• Remove screw
S 0013245
Install
6. Install new charge pressure sensor to intercooler pipe

• Install new O ring seal
• Install screw
S 0013245
7. Install intercooler pipe to vehicle

• Secure coolant hose to clip (2)
• Connect harness connector to charge pressure
sensor (4)
• Secure intercooler pipe to exhaust gas
– Secure clip (1) to transmission
– Secure clip (3)
Page 3 of 3

9. Lower vehicle
10. Connect pipe to intercooler
• Secure clip
S 0012741
Page 1 of 2
Check alternator
The following table provides an overview of the alternator check procedure.
Battery check
Electrolyte level at least Fill with distilled water up to marking or

5 mm above the no
plate or separator 5 mm above the plate.
OK?
yes
Check electrolyte density if possible Charge battery
Minimum thickness 1.24 g/cm 3 no Measure control voltage
OK? Replace defective battery
yes
Charge battery
Test battery with tester KM-J-42000 no Measure control voltage
Replace defective battery
Battery OK?
Alternator check
Is battery connected to vehicle electronics? Connect battery

Ground connection battery/engine/body has good connection and is free Clean/replace ground connection
from corrosion/transfer resistance? battery/engine/body.
All alternator-related wiring harness plugs are properly seated and free Clean/replace wiring harness plugs
from corrosion/transfer resistance. Ensure V-belt tension complies with auto
V-belt tension OK no manufacturer data
OK?
yes
Measure control voltage:
Start cold engine (no consumers)
Engine speed 2000 rpm
Measure control voltage at alternator B+ connection and alternator Replace regulator/alternator
housing (not at battery terminals).
Control voltage: 13.7 - 14.8 V no
OK?
yes
Output check:
Position clamp-on ammeter as close to alternator B+ connection as
possible
Measure voltage at B+ and alternator housing
Start engine Replace alternator
Engine speed approx. 2000 rpm
Switch on all consumers in vehicle
During this time, control voltage must not drop below the test values. no
OK?
yes
Check alternator with oscilloscope
Oscilloscope image when alternator OK
OK? no Replace alternator

yes
Alternator OK
Page 2 of 2
Page 1 of 34
Common Rail, Replace
J491040
Remove
Warning: The diesel common rail system is under very high pressure (up to 1600 bar). Damage or personal injury may result if the safety
procedures are not followed. The system is very sensitive to contamination; damage may result if the precautions regarding cleanliness are
not followed – see "Safety Regulations – Engine, Fuel and Exhaust System" .
Do not loosen or remove fuel lines when the engine is running.
As soon as the fuel circuit is open, all openings must be plugged using kit available from Parts and Accessories, to prevent pollutants from
penetrating the fuel circuit. Do not clean the engine using a high pressure washer; this may damage connections and moisture may collect
in the connections causing electrical problems.
1. Before performing ANY work on fuel system or its components, switch OFF ignition and wait until pressure has dropped sufficiently
(approximately 30 seconds). This waiting period is absolutely essential for common rail to be depressurised
3. Disconnect hose (1) from oil filler on air cleaner assembly, then move to
one side
• Release clip (2)
1 2
S 0012751
4. Disconnect hose (2) from mass air flow meter (1)

• Release clip
5. Disconnect harness connector (3) from mass air flow meter
Page 2 of 34
2
1
3
S 0012749
6. Remove air intake duct (1) from air cleaner (2) and vehicle body
• Release 2x clip
S 0012752
7. Remove air cleaner assembly from support frame

• Pull off 4x locating peg (1)
Page 3 of 34
1
1
S 0012753
8. Release air flow meter harness (1) from air cleaner support frame (2)
1
2
3
S 0012861
9. Release coolant preheater harness (1) (if installed) from air cleaner
support frame (3)
Page 4 of 34
1 2
S 0012918
10. Release coolant preheater and bracket (1) (if installed) from air cleaner
support frame
• Remove bolt (3) 2
1 3
S 0012860
Page 5 of 34
1 2
3 S 0012862
11. Remove support frame (1) from engine compartment

• Remove 2x nut (2), 2x bolt (3)
12. Remove radiator grille from vehicle

• Remove 5x bolt
• Release 10x retaining clip
13. Disconnect inlet hose from intercooler

• Release clip
Page 6 of 34
S 0012741
14. Remove intercooler outlet pipe assembly

• Release 2x clip (1)
• Remove bolt (2)
15. Remove O ring from intercooler pipe
• Prise out using suitable tool
Page 7 of 34
2 S 0012714
16. Remove intercooler from upper front panel

• Release 2x locating pin of intercooler from 2x rubber guide
– Pull upwards
Page 8 of 34
17. Remove breather hose from cylinder head cover

• Release 2x integral clip
• Release from turbocharger intake hose
– Pull off
• Install new blanking plug to cylinder head cover
Page 9 of 34
S 0012865
18. Remove oil filler hose with adapter from cylinder head cover
• Rotate anti-clockwise, then pull off
S 0013060
19. Disconnect harness for oxygen sensor and turbocharger temperature

sensor from engine harness
• Disconnect 2x harness connector
Page 10 of 34
S 0013065
20. Release oxygen sensor and turbocharger temperature sensor harness

from fuel rail protector and bracket
• Release 4x clip
S 0013066
21. Remove fuel rail cover from engine

• Remove blanking plug
• Release 4x clip
• Install blanking plug
Page 11 of 34
S 0013067
22. Disconnect harness connector (1) from fuel temperature sensor
S 0012992
23. Disconnect 4x harness connector from 4x fuel injector (1)

Page 12 of 34
24. Disconnect 4x harness connector from 4x glow plug

25. Disconnect harness connector from fuel pressure sensor
S 0013069
26. Remove oil level dipstick (3) from guide tube (4)
27. Release harness from oil level dipstick guide tube
• Release from clip (1)
28. Remove upper section of guide tube (4) from engine
• Remove bolt (2)
• Release 2x clip
• Remove O ring
• Install new blanking plug
Page 13 of 34
1 2 3
S 0013070
Warning: Fuel escapes – observe safety measures and national

legislation.
Important: Clean all connections before disconnecting; use only lint-free
cleaning cloths.
29. Disconnect fuel return pipe from fuel temperature sensor
• Release 2x integral clip (1)
• Install 2x new blanking plug
30. Disconnect fuel feed pipe (1) from high pressure pump, then move to
one side
• Release from clip on engine lifting eye
Page 14 of 34
2 S 0012995
31. Disconnect fuel leak-off pipe (1) from 4x fuel injector

Important: Clips are not to be removed from injectors; if they are
they must be replaced.
• Release 4x clip from 4x fuel injector
– Push in
32. Disconnect fuel leak-off pipe (1) from common rail

Page 15 of 34
33. Release fuel leak-off pipe from cylinder head cover, then move to one side
• Release 3x clip
34. Disconnect high pressure pipe (2) from high pressure pump
• Release pipe union (3)
– Use Pipe Spanner KM-812 ; counterhold nut on high pressure
pump using suitable spanner 1 2
35. Remove fuel leak-off pipe (1) with fuel temperature sensor from high
pressure pump
• Release integral clip
3 S 0013000
36. Remove 2x insulation (2) from cylinder head cover

37. Remove 4x high pressure pipe (1) from 4x fuel injector and common rail
• Release 8x pipe union
– Use Pipe Spanner KM-812 ; counterhold nut on fuel injector
using suitable spanner
Page 16 of 34
38. Remove high pressure pipe from common rail and cylinder head cover
– Use Pipe Spanner KM-812
• Remove bolt (2)

• Release from clip
39. Remove common rail from cylinder head

Page 17 of 34
Install
40. Install new common rail to cylinder head

41. Install 4x high pressure pipe (1) to common rail and 4x fuel injector; do
not tighten at this stage
• Remove 16x blanking plug
42. Secure 4x high pressure pipe to common rail
• Secure 4x pipe union 22 Nm
Page 18 of 34
43. Secure common rail to cylinder head

S 0009855
44. Secure 4x high pressure pipe to 4x fuel injector

• Secure 4x pipe union (1) 25 Nm
45. Install 2x insulation to cylinder head cover

Note: Replace 2x insulation if deteriorated.
Page 19 of 34

47. Install high pressure pipe (1) to common rail; do not tighten at this stage
Page 20 of 34
48. Secure high pressure pipe to cylinder head cover

• Secure to clip
• Install bolt; do not tighten at this stage
49. Secure high pressure pipe to high pressure pump

• Secure pipe union (1) 27 Nm
pump using suitable spanner
50. Secure high pressure pipe to common rail

Page 21 of 34

• Secure bolt (1) 3 Nm
52. Install new fuel leak-off pipe with fuel temperature sensor to high pressure pump
• Secure integral clip
53. Connect fuel leak-off pipe to common rail
• Secure 2x integral clip
54. Connect fuel leak-off pipe to 4x fuel injector

• Secure 4x clip to 4x fuel injector
– Push in
55. Secure fuel leak-off pipe to cylinder head cover

• Secure to 3x clip
Page 22 of 34
56. Connect fuel feed pipe (1) to high pressure pump

• Secure 2x integral clip (2)
• Secure to clip on engine lifting eye
1
2 S 0012995
57. Connect fuel return pipe to fuel temperature sensor

Page 23 of 34
58. Install upper section of guide tube (4) for oil level dipstick to lower
section and engine
• Install new O ring 1 2 3
• Push into lower section of guide tube to secure to 2x clip
59. Secure harness to guide tube for oil level dipstick
• Secure clip (1)
60. Install oil level dipstick to guide tube 4
• Secure to clip (3)
S 0013070
61. Connect harness connector to fuel pressure sensor

Page 24 of 34
S 0013069
62. Connect 4x harness connector to 4x glow plug

63. Connect 4x harness connector to 4x fuel injector (1)
64. Connect harness connector (1) to fuel temperature sensor

Page 25 of 34
S 0012992
65. Install fuel rail cover to engine

• Secure 4x clip
S 0013067
66. Secure oxygen sensor and turbocharger temperature sensor harness to

fuel rail protector and bracket
• Secure 4x clip
Page 26 of 34
S 0013066
67. Connect harness for oxygen sensor and turbocharger temperature

sensor to engine harness
• Connect 2x harness connector
S 0013065
68. Install oil filler hose with adapter to cylinder head cover
• Push on, then rotate clockwise
Page 27 of 34
S 0013060
69. Connect breather hose to cylinder head cover

• Secure to turbocharger intake hose
– Push on
S 0012865
70. Install intercooler to upper front panel

• Secure 2x locating pin of intercooler to 2x rubber guide
– Push downwards
Page 28 of 34
71. Install intercooler outlet pipe assembly

• Install new O ring to intercooler pipe
• Install 2x clip (1)
• Install bolt (2)
Page 29 of 34
2 S 0012714
72. Connect inlet hose to intercooler

• Secure clip
Page 30 of 34
S 0012741
73. Install radiator grille to vehicle

• Secure 10x retaining clip
• Install 5x screw 4 Nm
Page 31 of 34
1 2
3 S 0012862
74. Install air cleaner assembly support frame (1) to engine compartment
• Install 2x bolt (3), 2x nut (2)
75. Install air flow meter harness (1) to air cleaner support frame (2)
• Secure clip (3)
1
2
3
S 0012861
76. Secure coolant preheater and bracket (1) (if installed) to air cleaner
support frame
• Secure clip (2)
Page 32 of 34
1 3
S 0012860
77. Secure coolant preheater harness (1) (if installed) to air cleaner support
frame (3)
• Secure clip (2)
1 2
S 0012918
78. Install air cleaner assembly to support frame

• Push on 4x locating peg (1)
Page 33 of 34
1
1
S 0012753
79. Install air intake duct (1) to air cleaner (2) and vehicle body
• Secure 2x clip
S 0012752
80. Connect harness connector (3) to mass air flow meter

81. Connect hose (2) to mass air flow meter (1)
• Secure clip
Page 34 of 34
2
1
3
S 0012749
82. Connect hose (1) to oil filler on air cleaner assembly

• Secure clip (2)
1 2
S 0012751

Page 1 of 12
Compression, Check
J451800
Remove
1. Remove engine immobiliser/instrument panel fuse

from interior fuse box
• Remove left ashtray housing from instrument
panel
– Release 4x clip
one side
Page 2 of 12
1 2
S 0012751

• Release clip
2
1
3
S 0012749
5. Remove air intake duct (1) from air cleaner assembly (2) and front panel
• Release 2x clip
Page 3 of 12
S 0012752

• Pull off of 4x locating peg (1)
1
1
S 0012753
7. Release harness (1) for mass air flow meter from support frame (2)
Page 4 of 12
1
2
3
S 0012861
8. Release harness for coolant heater assembly (if installed) from support
frame
9. Release bracket with coolant heater assembly (1) (if installed) from
2
support frame
• Remove bolt (3)
1 3
S 0012860
Page 5 of 12
1 2
3 S 0012862

11. Disconnect 4x harness connector (1) from 4x glow plug

• Pull off
12. Remove 4x glow plug (1) from cylinder head

Page 6 of 12
Measure
13. Install Compression Test Adapter KM-6211 (1) to glow plug hole of No.
1 cylinder 11 Nm
14. Install adapter (1) to Compression Test Adapter KM-6211

Page 7 of 12
15. Install compression tester (commercially available) to adapter
16. Crank engine and measure compression for cylinder No. 1

17. Remove compression tester from adapter
18. Remove adapter from Compression Test Adapter KM-6211
19. Remove Compression Test Adapter KM-6211 from glow plug hole of No. 1 cylinder
20. Repeat steps 13 to 19 for cylinders No. 2, No. 3 and No. 4
Install
21. Install 4x glow plug (1) 11 Nm to cylinder head

Page 8 of 12
22. Connect 4x harness connector (1) to 4x glow plug

• Push on
Page 9 of 12
1 2
3 S 0012862
23. Install support frame (1) to engine compartment

• Install 2x nut (2), 2x bolt (3) 8 Nm
24. Secure bracket with coolant heater assembly (1) (if installed) to support
frame
25. Secure harness for coolant heater assembly (if installed) to support
2
frame
• Secure clip (2)
1 3
S 0012860
26. Secure harness (1) for mass air flow meter to support frame (2)
• Secure clip (3)
Page 10 of 12
1
2
3
S 0012861

• Push on to 4x locating peg (1)
1
1
S 0012753
28. Install air intake duct (1) to air cleaner assembly (2) and front panel
• Secure 2x clip
Page 11 of 12
S 0012752

• Secure clip
2
1
3
S 0012749

• Secure clip (2)
Page 12 of 12
1 2
S 0012751
32. Install engine immobiliser/instrument panel fuse to interior fuse box

33. Install left ashtray housing to instrument panel
• Secure 4x clip
Page 1 of 12
Con-rod Bearing, Replace
Remove

2. Raise vehicle
Important: Observe relevant environmental regulations when disposing of
used engine oil.
4. Drain engine oil
• Remove drain plug (1) from oil pan (2)
– Place collecting container below
– Discard washer
• Install drain plug to oil pan 20 Nm
– Use new washer
– Remove collecting container
5. Release power steering pipe from bracket of oil filter housing

• Remove bolt (1)
6. Release power steering pipe from bracket for power steering pump
• Remove bolt
7. Remove oil pan from engine

• Remove 23x bolt, gasket
Page 2 of 12
8. Remove oil pump from cylinder block

• Manoeuvre oil pump sprocket (2) from drive chain (3)
Note: Prevent drive chain from falling into timing case, using
suitable tool.
9. Remove splash shield from engine

Page 3 of 12
10. Rotate crankshaft until No. 1 and No. 4 con-rod positioned at bottom
dead centre
11. Apply identification and alignment marking to 4x con-rod cap
Page 4 of 12
Important: No. 1 con-rod positioned at flywheel end of cylinder block.

12. Remove cap (1) from No. 1 con-rod
• Remove 2x bolt (2), then remove con-rod cap
• Reinstall bolt to con-rod (3), finger-tight
13. Raise con-rod until sufficient clearance attained to enable removal of
bearing (4)
• Lightly tap installed bolt, using suitable soft-headed hammer
– Remove bolt
• Remove bearing from con-rod
• Push out, using suitable tool
– Clean con-rod
Page 5 of 12
14. Remove bearing (2) from con-rod cap (1)

• Push out using suitable tool
– Clean con-rod cap
Page 6 of 12
Install
15. Install new bearing (2) to con-rod cap (1)

• Push fit
• Apply clean engine oil to contact surface of bearing
16. Install new bearing (4) to con-rod (3)

• Push fit
• Apply clean engine oil to contact surface of bearing
17. Install con-rod to crankshaft
• Apply clean engine oil to crankshaft
• Pull No. 1 piston downwards by hand until con-rod and bearing
contact crankshaft
Important: Observe identification and alignment marking.
18. Install con-rod cap (1) to con-rod
Page 7 of 12
• Install 2x new bolt (2); do not tighten at this stage

• Secure 2x bolt 25 Nm ± 55° ± 6°
19. Repeat procedure for No. 4 con-rod bearing

20. Ensure free rotation of crankshaft
• Rotate crankshaft 720°
21. Rotate crankshaft until No. 2 and No. 3 con-rod positioned at bottom dead centre
22. Repeat bearing replacement procedure for No. 2 and No. 3 con-rod bearing
23. Ensure free rotation of crankshaft
24. Install splash shield to engine

Page 8 of 12
25. Install oil pump to cylinder block

• Manoeuvre oil pump sprocket (2) into drive chain (3)
26. Secure oil pump to cylinder block

• Tighten 3x bolt (1) 25 Nm
• Tighten bolt (2) 10 Nm
Page 9 of 12
27. Secure splash shield to engine

• Tighten 3x bolt 10 Nm
28. Install oil pan to engine

• Apply continuous bead of sealant (approximately 1.6 mm) to 2x joint
(1) – see “Sealants, Lubricants and Locking Compounds”
• Install new gasket
• Install 23x oil pan bolt; do not tighten at this stage
Important: Tighten 23x oil pan bolt in stage and sequence shown.
29. Tighten 23x oil pan bolt
• Tighten 23x oil pan bolt 5 Nm in sequence shown
• Tighten 23x oil pan bolt 9 Nm in sequence shown
Page 10 of 12
30. Secure power steering pipe to bracket of oil filter housing

31. Secure power steering pipe to bracket for power steering pump
• Install bolt

33. Lower vehicle
35. Fill engine with oil to correct level
• Use clean engine oil
• Install oil filler cap
36. For G9U630 engine, remove engine

immobiliser/instrument panel fuse from interior fuse
box
panel
– Release 4x clip
Page 11 of 12
Page 12 of 12
37. For G9U730 engine, remove engine immobiliser/instrument panel fuse from interior fuse box
• Remove left ashtray housing from instrument panel
– Release 4x clip
38. Crank engine for five seconds

• Secure 4x clip
41. Check and adjust oil level if necessary
Note: Wait until engine oil has settled to correct level.
43. Refill engine oil to correct level
Page 1 of 1
Control Unit, Preheating System, Replace
Remove
1. Remove control unit (1) of preheating system from cover (2)

• Disconnect harness connector from control unit (1)
– Release clip
• Remove nut
Install
2. Install new control unit (1) of preheating system to cover (2)

• Install nut
• Connect harness connector to control unit (1)
– Secure clip
Page 1 of 22
Coolant Pump, Replace
J609100
Remove

2. Support radiator assembly using suitable method
3. Remove cap from coolant expansion tank
4. Raise vehicle
• Remove 8x bolt
6. Remove radiator undershield from support frame

• Remove 3x bolt (1, 2)
7. Remove splash panel, right side

Page 2 of 22

8. Remove radiator crossmember from vehicle

• Release power steering pipe assembly (1) from crossmember
– Remove 2x bolt (2)
• Release radiator assembly from crossmember
– Remove 2x clip (3), 2x washer
10. Connect suitable hose to radiator drain plug
11. Lower vehicle
Page 3 of 22
Important: Observe the relevant environmental regulations when disposing of used coolant.
12. Drain cooling system
• Place collecting container below
• Open radiator drain plug
• Allow coolant to drain into collecting container
one side
14. Release reservoir for power steering fluid from upper front panel, then
move to one side
Note: To prevent fluid loss ensure reservoir remains in vertical
position.
• Release clip, then slide off
15. Remove hose assembly from intercooler and turbocharger

• Remove bolt (2)
16. Remove O ring from hose assembly
Page 4 of 22
• Release clip
Page 5 of 22
19. Release air intake duct (1) from air cleaner assembly (2)
• Release 2x clip

Page 6 of 22
21. Close radiator drain plug

22. Remove hose from radiator drain plug
23. Release 2x fuel pipe (1) from bracket, then move to one side
• Release from 2x clip
24. Remove bracket with upper engine stabiliser from engine compartment
Page 7 of 22
25. Remove bracket for intercooler hose assembly from upper cover for timing belt
• Remove 2x bolt
26. Release 2x harness from upper cover for timing belt

• Release 2x clip
27. Remove upper cover for timing belt from engine

Page 8 of 22
28. Raise vehicle

29. Remove lower engine stabiliser (1) from bracket and subframe
30. Lower engine using Engine Support KM-6210-A

31. Remove cover (1) for coolant pump
• Remove gasket
Page 9 of 22
Important: If gear puller is not installed correctly

damage can occur.
32. Remove gear (2) from coolant pump
• Remove nut (1)
– Counterhold crankshaft pulley bolt
• Remove gear using puller (3) (commercially
available)
33. Remove coolant pump (1) from engine

• Remove O ring
Page 10 of 22
Install
34. Install new coolant pump (1) to engine

• Clean mating surface
• Install new O ring
35. Install gear to coolant pump

• Install nut 60 Nm
– Counterhold crankshaft pulley bolt
Page 11 of 22
36. Install cover (1) for coolant pump

37. Raise engine using Engine Support KM-6210-A

38. Install lower engine stabiliser (1) to bracket and subframe
Page 12 of 22
39. Lower vehicle

40. Install upper cover for timing belt to engine
41. Secure 2x harness to upper cover for timing belt

• Secure 2x clip
Page 13 of 22
42. Install bracket for intercooler hose assembly to upper cover for timing belt
Important: Ensure 3x bolt (3, 4, 5) are secured in the correct sequence.

43. Install bracket with upper engine stabiliser to engine compartment
• Install 4x bolt (2, 3, 4, 5), new nut (1); do not tighten at this stage
• Secure 3x bolt in sequence (4, 5, 3) 10 Nm
• Secure nut (1) 44 Nm
44. Secure 2x fuel pipe (1) to bracket

Page 14 of 22
45. Raise vehicle

46. Remove Engine Support KM-6210-A from vehicle – see operation “Engine Support KM-6210-A, Install and Remove”
47. Release power steering pipe assembly (1) from engine
• Remove bolt (2), nut (3)
Important: Observe the relevant environmental regulations when disposing of used engine oil.
48. Drain engine oil
• Remove drain plug
• Remove sealing washer
49. Install drain plug 25 Nm
• Install new sealing washer

Note: To remove residual coolant from the oil pan.
Page 15 of 22
51. Clean mating surfaces of cylinder block and oil pan

52. Clean inside of oil pan
53. Apply bead of sealant across 2x joint (1) between cylinder block and oil
seal housing – see “Sealants, Lubricants and Locking Compounds”

Important: Ensure 23x bolt are secured in the correct sequence.
• Install 23x bolt in sequence shown 5 Nm
• Secure 23x bolt in sequence shown 9 Nm
Page 16 of 22
55. Secure power steering pipe assembly (1) to engine

• Install nut (3), bolt (2)
Page 17 of 22
56. Remove cover with oil filter from housing

• Release cover until oil escape port allows oil to drain, then remove
fully
Important: Observe the relevant environmental regulations when disposing
of used oil filters.
57. Remove oil filter from cover
• Pull off
58. Remove seal ring from cover
59. Install new seal ring to cover
• Lubricate seal ring with clean engine oil
60. Install new oil filter to cover
• Push on
61. Install cover with oil filter to housing 25 Nm
Page 18 of 22
Page 19 of 22
62. Install radiator crossmember to vehicle

• Secure radiator assembly to crossmember
– Install 2x washer, 2x clip (3)
• Secure power steering pipe assembly (1) to crossmember
– Install 2x bolt (2)
63. Lower vehicle

64. Remove suitable support from radiator assembly
65. Install new O ring to hose assembly
66. Install hose assembly to turbocharger and intercooler
• Secure 2x clip (1)
Page 20 of 22
67. Secure reservoir for power steering fluid to upper front panel
• Slide on to secure clip
70. Remove oil filler cap
71. Fill engine oil to correct level
• Start engine to prime oil filter
• Stop engine
72. Bleed cooling system – see operation “Cooling System, Drain and Refill”
Note: Wait until the engine oil level has settled to correct level.
74. Raise vehicle
75. Install radiator splash shield
• Install 3x bolt (1, 2) 8 Nm
Page 21 of 22
76. Install splash panel, right side

Page 22 of 22

78. Lower vehicle
Page 1 of 1
Cooling System, Check for Leaks
1. Check coolant level is up to MAX mark on reservoir
2. Check coolant system for leaks, from above
3. Apply pressure to cooling system
Install coolant pressure checking equipment

Follow manufacturer's instructions
4. Raise vehicle
6. Check coolant system for leaks, from below
8. Lower vehicle
9. Remove coolant pressure checking equipment
Install coolant reservoir cap

Page 1 of 8
Cooling System, Drain and Refill
Remove

2. Raise vehicle
• Remove 8x bolt

Note: To gain access to the radiator drain plug.
• Remove 2x screw (1), bolt (2)

6. Lower vehicle
Page 2 of 8
one side

• Release clip
11. Remove air intake duct (1) from air cleaner assembly (2)
• Release 2x clip
Page 3 of 8

Install

15. Fill cooling system to top of coolant expansion tank
16. Open bleed screw (1) on coolant hose for heater core
• When coolant flow is free from bubbles, close bleed screw
17. Open bleed screw (2) on thermostat housing
Page 4 of 8
18. Open bleed screw on feed hose for coolant pre-heater

19. Open bleed screw on turbocharger feed hose
20. Raise vehicle
21. For vehicles with additional heater assembly, open 2x bleed screw (1)
• When coolant flow is free from bubbles, close 2x bleed screw
Page 5 of 8
22. Lower vehicle

24. Install air intake duct (1) to air cleaner assembly (2)
• Secure 2x clip
Page 6 of 8

• Secure clip

• Secure clip (2)
Page 7 of 8
28. Refill coolant expansion tank to maximum level

29. Install cap to coolant expansion tank
30. Switch OFF air conditioning (if installed)
31. Set heater fan switches to high speed and full heat
32. Start engine and allow to run at approximately 2500 RPM to remove any air locks present and cooling fans cut in
34. If heater is not blowing sufficient heat, repeat procedure for bleed screws
35. Raise vehicle
36. Install radiator undershield to support frame
• Install bolt (2), 2x screw (1)
Page 8 of 8

38. Lower vehicle
Page 1 of 2
Crankshaft Axial Play (End Float), Check
Disassemble
1. Remove crankshaft – see operation "Crankshaft, Replace”

• G9T 720, G9T 722, G9T 750, G9U 720, G9U 724, G9U 750, G9U 754
• G9U 630
• G9U 632, G9U 650
• G9U 730
2. Clean all bearing surfaces

3. Check crankshaft and shell bearings for damage and wear
4. Lubricate and Assemble crankshaft in crankcase, do not torque tighten

bearing cap bolts
5. Check end float, refer to “Technical Data"
6. Disassemble and adjust shims if necessary, refer to “Technical Data"

Page 2 of 2
Assemble
7. Lubricate crankshaft and shell bearings with engine oil and assemble
8. Torque tighten crankshaft cap bolts, refer to “Technical Data"
9. Install crankshaft – see operation "Crankshaft, Replace”

• G9T 720, G9T 722, G9T 750, G9U 720, G9U 724, G9U 750, G9U 754
• G9U 630
• G9U 632, G9U 650
• G9U 730
Page 1 of 4
Crankshaft Bearing Clearance, Check Using Plastigage Method
1. Position a length of Plastigage thread along complete length of each

crankshaft main bearing journal
Note: Plastigage (deformable plastic thread) is available in several
measuring ranges and can be ordered from "Opel/Vauxhall Workshop
Equipment" Catalogue. To prevent Plastigage thread from tearing when
removing engine crankcase, lightly lubricate each crankshaft main
bearing journal and bearing shell with clean engine oil
Important: To maintain integrity of Plastigage thread, do not allow

crankshaft to rotate when installing or removing engine crankcase
2. Install engine crankcase
• Tighten 10x main bearing bolt ( 20 Nm + 150° ±10° ) in sequence
shown
Note: 10x main bearing bolt can only be reused for checking
crankshaft bearing clearance
3. Install crankcase bolts

• Tighten 13x engine crankcase outer bolt ( 20 Nm ) in sequence
shown
Page 2 of 4
4. Remove engine crankcase

• 10x main bearing bolt
• 13x engine crankcase outer bolt
5. Measure compressed width of Plastigage thread with scale supplied and

determine crankshaft clearance of each main bearing journal, see
"Technical Data". If necessary, measure diameter of each crankshaft
main bearing journal. Replace main bearing shells if crankshaft is within
specification
Page 3 of 4
Important: Identify each connecting rod and bearing cap prior to removal to ensure correct installation
6. Remove 4x connecting rod bearing cap and 4x bearing shell from crankshaft
• Remove 8x bolt
7. Position Plastigage thread along complete length of each crankshaft

connecting rod journal
Note: To prevent Plastigage thread from tearing when removing
connecting rod bearing cap, lightly lubricate each crankshaft connecting
rod journal and bearing with clean engine oil
Important: To maintain integrity of Plastigage thread, do not allow crankshaft to rotate when installing or removing any connecting rod
bearing cap
8. Install 4x connecting rod bearing cap and 4x bearing shell in original position
• Install 8x original bolt ( 25 Nm + 55° ± 6° )
9. Remove 4x connecting rod bearing cap and 4x bearing shell from crankshaft
• Remove 8x bolt
10.
Measure compressed width of Plastigage thread with calibrated scale
and determine crankshaft clearance of each connecting rod journal, see
"Technical Data". If necessary, measure diameter of each crankshaft
connecting rod journal. Replace connecting rod bearing shells if
Page 4 of 4
crankshaft is within specification

Page 1 of 3
Crankshaft Inductive Pulse Pick-up, Replace
J794400
Remove
1. Raise vehicle
3. Disconnect harness connector (1) from crankshaft inductive pulse pick-
up
4. Release support bracket (2) from cylinder block
• Remove bolt (3)
5. Remove crankshaft inductive pulse pick-up from engine

• Depress spring (1), then remove crankshaft inductive pulse pick-up
Page 2 of 3
Install
6. Install new crankshaft inductive pulse pick-up to engine

• Depress spring (1), then install crankshaft inductive pulse pick-up
7. Secure support bracket (2) to cylinder block

8. Connect harness connector (1) to crankshaft inductive pulse pick-up
Page 3 of 3

10. Lower vehicle
Page 1 of 2
Related Literature Units
Crankshaft Oil Seal, Front, Replace
J463510
Remove
1. Remove crankshaft pulley – see operation “Crankshaft Pulley, Ribbed V-belt, Replace"
2. Remove crankshaft oil seal (1) from timing gear cover
Install
Important: Take care not to damage sealing faces.

3. Install stud of Installer KM-6298 into end of crankshaft
Page 2 of 2
4. Partially install new crankshaft oil seal (2), located on Sleeve KM-6424-3
(1), into timing gear cover
5. Fully install crankshaft oil seal into timing gear cover

• Locate sleeve (1) of Installer KM-6298 to crankshaft oil seal
• Tighten nut (2) of Installer KM-6298
6. Remove Installer KM-6298 and Sleeve KM-6424-3
• Remove nut (2) and sleeve (1) from stud
• Remove Sleeve KM-6424-3 from stud
• Remove stud from end of crankshaft
7. Install crankshaft pulley – see operation “Crankshaft Pulley, Ribbed V-belt, Replace"

- Crankshaft Pulley, Ribbed V-belt, Replace
Page 1 of 2
Crankshaft Pilot Bearing, Replace
J455010
Remove
1. Remove clutch assembly from flywheel – see operation “Clutch Assembly, Replace”
• G9U 630, G9U 730 without self-adjusting clutch
• G9U 730 with self-adjusting clutch
• M9R 630, M9R 692, M9R 780, M9R 782, M9R 784, M9R 786, M9R 788
2. Remove pilot bearing from crankshaft

Note: Flywheel shown removed for clarity.
• Use Remover KM-328-B with Adapter KM-328-70
Install
3. Install new pilot bearing (1) to crankshaft

Note: Flywheel shown removed for clarity.
• Use Installer KM-J-26516-A (2)
Page 2 of 2
4. Install clutch assembly to flywheel – see operation “Clutch Assembly, Replace”

• M9R 630, M9R 692, M9R 780, M9R 782, M9R 784, M9R 786, M9R 788
Page 1 of 8
Crankshaft Pulley, Ribbed V-belt, Replace
Remove
1. Raise vehicle

• Release washer hose from 2x clip
• Remove 2x bolt , screw

6130 (1)
Page 2 of 8

6. Install Positioning Pin KM-6203 (arrowed) into crankshaft

• Through oil filter housing
• Rotate engine clockwise until positioning pin engages in crankshaft
to position engine at top dead centre
Page 3 of 8
7. Install Flywheel Locking Tool KM-911 to flywheel
8. Remove Positioning Pin KM-6203 (arrowed) from crankshaft

Page 4 of 8
9. Install bolt (arrowed) 22 Nm to oil filter housing
10. Remove crankshaft pulley (2) from engine

• Remove bolt (1)
Page 5 of 8
Install
11. Install new crankshaft pulley (2) to engine

• Install new bolt (1) 50 Nm + 90°
12. Remove Flywheel Locking Tool KM-911 from flywheel

Page 6 of 8

(1)
Page 7 of 8

Page 8 of 8

16. Lower vehicle
Page 1 of 103
Crankshaft, Replace
J455000
Remove
Important: “Piston Protrusion, Check” is required after replacement of the following components: con-rods, crankshaft and cylinder block
– see operation “Piston Protrusion, Check”
1. Remove engine and transmission from vehicle – see operation “Engine with Transmission, Remove and Install”
of used lubricants.
2. Disconnect feed hose (1) from power steering pump
• Release clip
3. Release high pressure pipe from auxiliary support bracket

• Remove bolt
4. Disconnect high pressure pipe (1) from power steering pump
• Release union (2)
• Remove O ring
5. Remove power steering pipe assembly with fluid reservoir from engine and transmission assembly
Page 2 of 103
• Remove 4x bolt
6. Remove bracket (2), left side, from primary catalytic converter and
engine
• Release vacuum hose from clip on bracket
7. Remove bracket (3), right side, from primary catalytic converter and
engine
8. Remove primary catalytic converter (1) from turbocharger

• Remove 4x nut (2), gasket
Page 3 of 103
S 0012886
9. Remove oil return pipe (1) from turbocharger and engine

• Pull out from engine
• Remove gasket, O ring
• Install 4x new blanking plug 1
10. Remove oil feed pipe (3) from turbocharger and engine
• Release pipe union
• Release bracket from turbocharger

3
– Remove bolt
• Remove bolt 2 S 0016489
11. Remove bracket (1) from turbocharger and engine

Page 4 of 103
2
1
S 0012890
12. Remove turbocharger (1) from exhaust manifold (2)

• Remove 3x nut (3), gasket 1 2
S 0012891
13. Remove coolant pipe (1) from coolant pump and thermostat housing
• Remove bolt (2)
• Pull out coolant pipe
• Remove 2x O ring
Page 5 of 103
14. Remove support bracket (1) from cylinder block

15. Remove bracket from auxiliary support bracket and exhaust gas
Page 6 of 103
2 S 0009574
16. Remove EGR cooler from intake manifold and EGR valve housing
• Remove 7x bolt (1), gasket
S 0016494
17. Remove EGR valve housing (2) with support bracket from engine
Page 7 of 103
1 2
S 0013423
18. Remove upper section of guide tube for oil level dipstick from lower section
• Remove bolt
• Pull guide tube upwards, then release 2x clip
• Remove O ring
19. Remove lower section of guide tube for oil level dipstick from engine
• Remove bolt
• Withdraw lower section
• Install new blanking plug to engine
• Remove O ring
20. Remove starter from transmission

Page 8 of 103
S 0012968
21. Remove 2x coolant hose from oil cooler and thermostat housing
• Release 4x clip
22. Install engine with transmission to Engine Overhaul Stand KM-412

• Install 2x Stand Adapter KM-412-29 to cylinder block
• Install 6x bolt (1)
23. Install 2x Stand Adapter KM-412-29 to Engine Overhaul Stand KM-412
• Install 8x bolt 8x nut
Page 9 of 103
24. Remove lower cover for flywheel from transmission

• Remove 2x bolt
25. Release transmission from engine

• Remove 2x nut (1)
26. Remove 2x stud (2) from engine
Page 10 of 103
27. Install engine hoist to transmission

• Install lifting chain to transmission
• Adjust engine hoist until weight of transmission fully supported
28. Remove transmission from engine

Page 11 of 103
S 0016497
29. Release pulley (1) from power steering pump

Page 12 of 103

Note: Engine with air conditioning is shown.
6130 (1)
Page 13 of 103

• Remove 3x bolt
32. Remove power steering pump from auxiliary support bracket

Page 14 of 103

• Remove bolt (1)
Page 15 of 103
34. Remove alternator (2) from auxiliary support bracket

35. Remove ribbed V-belt tensioner (3) from engine
36. Remove air conditioning compressor (2) (if installed) from auxiliary
support bracket
Page 16 of 103
37. Remove timing belt from engine – see operation “Timing Belt, Replace”
S 0012717
39. Remove engine speed sensor from cylinder block

Page 17 of 103
40. Install Flywheel Holder KM-652 (1) to cylinder block


• Remove bolt (1)
Page 18 of 103
42. Remove timing gear cover from engine

• Remove 15x bolt
• Remove gasket
43. Remove nut (1) from gear for high pressure pump
Page 19 of 103
44. Install Locking Tool KM-6293 (1) to gear
45. Remove cap (1) from secondary intermediate gear

Page 20 of 103

damage can occur.
• Remove nut (1)
available)
47. Remove gear (1) from high pressure pump

• Apply alignment marking
• Install Gear Puller KM-6207 (2) to gear
• Rotate centre bolt (4) clockwise until gear released
48. Remove Gear Puller KM-6207 from gear
• Remove 3x bolt
Page 21 of 103
49. If installing new high pressure pump gear – see operation “High
Pressure Pump Gear, Replace (All G9 Engines)” for timing gear
compensation
50. Install Locking Clamp KM-6294 (1) to intermediate gear

• Ensure 2x bracket (3) locate correctly
• Tighten 2x bolt (2)
• Remove bolt (4)
Page 22 of 103
51. Remove intermediate gear (1), shaft (2) and washer (3) from engine
• Pull out
52. If installing new intermediate gear – see operation “Intermediate Timing
Gear, Replace (All G9 Engines)” for timing gear compensation
Page 23 of 103
53. Remove secondary intermediate gear (1) from engine

• Remove bolt (2)
54. Remove secondary intermediate shaft (1) and washer (2) from engine
• Pull out
Page 24 of 103
55. Remove gear (1) from crankshaft (2)

• Pull off
• Remove key (3) from crankshaft

– Remove O ring
Page 25 of 103

legislation.
cleaning cloths. Use new thinner, clean brushes and compressed air. Do not
use a high pressure washer.
– Push in

Page 26 of 103
59. Disconnect fuel leak-off pipe (1) from high pressure pump
60. Remove fuel leak-off pipe with fuel temperature sensor from engine
• Release 3x clip
61. Disconnect high pressure pipe from high pressure pump

Page 27 of 103
62. Disconnect high pressure pipe from common rail

63. Remove high pressure pipe from engine

• Release pipe support clip from cylinder head cover
• Release pipe bracket from cylinder head cover
• Remove bolt (2)
64. Remove high pressure pump from engine

• Remove O ring
Page 28 of 103
Warning: Alignment Tool KM-6165 must be installed to prevent the clutch

plate from falling during pressure plate removal.
65. Install Alignment Tool (1) KM-6165 to clutch plate
Page 29 of 103
66. Remove pressure plate from flywheel

• Apply alignment marking (if installing original clutch)
67. Remove clutch plate with Alignment Tool KM-6165 from flywheel
68. Remove flywheel from crankshaft

• Remove 7x bolt
Page 30 of 103
69. Remove Flywheel Holder KM-652 from cylinder block

• Remove bolt
72. Rotate engine 180°, using Engine Overhaul Stand KM-412
73. Remove oil pan from cylinder block
• Remove 23x bolt
• Remove gasket

Page 31 of 103
75. Remove timing gear case from cylinder block

• Remove 21x bolt
76. Remove timing gear case gasket
77. Remove auxiliary support bracket (1) from cylinder block

Page 32 of 103
78. Remove oil level sensor from cylinder block

• Remove O ring
79. Remove oil filter and cooler housing (1) from cylinder block
Page 33 of 103
S 0016496

82. Remove drive chain (1) with gear and oil deflector (2) from crankshaft
(3)
• Slide off
Page 34 of 103
83. Remove splash shield from cylinder block

84. Remove crankcase from cylinder block

• Remove 23x crankcase bolt
• Lift crankcase from cylinder block
• Remove O ring from oil pick-up
Page 35 of 103
Important: Apply identification marking (1) to 4x con-rod end cap before

removing.
85. Remove 4x con-rod end cap from 4x con-rod
• Remove 8x bolt
86. Remove crankshaft from cylinder block

• Lift out
• Remove rear main oil seal
Page 36 of 103
87. Remove 2x thrust washer from cylinder block

• Lift out
88. Remove 5x plain bearing (1) from crankcase (2)
89. Remove 5x grooved bearing from cylinder block

90. Remove 8x bearing (1) from 4x con-rod and 4x con-rod end cap
Note: Piston shown removed for clarity.
Page 37 of 103
Install
Important: Ensure oil ports (2) in cylinder block and oil ports in new
grooved bearing (1) align. Failure to ensure correct alignment of oil ports will
result in engine failure.
91. Install 5x new grooved bearing to cylinder block
• Apply clean engine oil to contact surfaces
• Push fit
92. Install 2x new thrust washer to cylinder block

• Push fit
Note: Apply small amount of clean grease to contact surfaces of
2x thrust washer to prevent them from falling during crankshaft
installation.
93. Install 5x new plain bearing (1) to crankcase (2)
• Push fit
– Apply clean engine oil to contact surfaces
Page 38 of 103
94. Install new crankshaft to cylinder block

• Apply clean engine oil to crankshaft journals
Important: 23x original crankcase bolt must be replaced with 23x new bolt
after following procedure.
95. Install crankcase to cylinder block
• Clean all mating surfaces
• Install 10x original bolt 20 Nm in sequence shown
• Secure 10x bolt 150° ± 10° in sequence shown
Page 39 of 103
96. Measure crankshaft axial play – see operation “Crankshaft Axial Play,
Check”
• Check crankshaft for free rotation
– Adjust thrust washer size until correct axial clearance attained
97. Remove crankcase from cylinder block

• Remove 10x bolt
98. Install 8x new bearing (1) to 4x con-rod and 4x con-rod end cap
Note: Piston shown removed for clarity.
• Push fit
– Apply clean engine oil to contact surfaces
Page 40 of 103
Important: Observe identification marking (1) before installing 4x con-rod

end cap.
99. Install 4x con-rod end cap to 4x con-rod
• Install 8x new bolt; do not tighten at this stage
100. Apply sealing compound to cylinder block – see “Sealants, Lubricants

and Locking Compounds”
• Apply a bead of 2 mm thickness
Page 41 of 103
S 0017910
101. Install crankcase to cylinder block

• Install 10x new bolt 20 Nm using tightening sequence shown
• Secure 10x bolt 150° ± 10° using tightening sequence shown
Important: Install 13x new crankcase outer bolt in sequence shown.

102. Install 13x bolt to crankcase
• Secure 13x bolt 20 Nm in sequence shown
Page 42 of 103
103. Secure 4x con-rod end cap to 4x con-rod in stage shown

• Secure 8x bolt (1) 25 Nm , then 55° ± 6°
Page 43 of 103
104. Check crankshaft for free rotation

106. Transfer oil filter and cooler housing to soft jawed vice
• Release cover until oil escape port allows oil to drain, then remove fully
Important: Observe the relevant environmental regulations when disposing of used oil filters.
• Pull off
• Push on
Page 44 of 103
113. Remove oil filter and cooler housing from soft jawed vice
114. Install oil filter and cooler housing (1) to cylinder block
• Clean mating surface of cylinder block 1
S 0016496
115. Remove 4x high pressure pipe (1) from 4x fuel injector and common
rail
116. Release 4x fuel injector (1) from cylinder head

• Remove 8x bolt from 4x fuel injector clamp
Page 45 of 103
117. Assemble Puller KM-6212-20 (1) of Remover KM-6212-B

• Use Leg KM-6212-21 and Leg KM-6212-22
118. Install Puller KM-6212-20 to fuel injector
119. Install Remover KM-6212-B (1) to cylinder head cover

• Install bolt (2) to puller
120. Release fuel injector from cylinder head
• Turn bolt clockwise until fuel injector released
121. Disconnect Remover KM-6212-B from cylinder head cover
• Remove bolt from puller
122. Remove fuel injector and puller from cylinder head
• Install 2x new blanking plug to fuel injector and cylinder head
123. Remove remaining 3x fuel injector, in accordance with above
procedure
124. If one or more fuel injector cannot be removed using Fuel Injector
Remover KM-6212-B – see operation “Removal of Seized Fuel
Injector”
Page 46 of 103
125. Remove 4x glow plug (1) from cylinder head

Page 47 of 103
127. Remove fuel rail protector (1) and gasket from cylinder head
• Remove 2x bolt
• Release grommet (2) from breather pipe connection
128. Remove cylinder head cover (1) from cylinder head

• Remove 19x bolt
Page 48 of 103
1 S 0013075
129. Remove 2x rubber gasket, 7x seal from cylinder head cover

• Pull out
130. Remove intake manifold (1) from cylinder head

• Remove 5x bolt
Page 49 of 103
131. Remove 8x seal from intake manifold

132. Remove intake rocker shaft from cylinder head
• Remove 6x bolt
133. Remove exhaust rocker shaft from cylinder head
• Remove 6x bolt
134. Remove cylinder head from cylinder block

• Remove 10x bolt
Page 50 of 103
135. Remove cylinder head gasket from cylinder block

• Release from 2x dowel
136. Measure piston protusion – see operation “Piston Protusion, Check”
• Check crankshaft for free rotation
– Adjust thrust washer size until correct axial clearance attained
137. Check crankshaft for free rotation

138. Rotate engine 180° using Engine Overhaul Stand KM-412
139. Install splash shield to cylinder block
140. Install drive chain (1) with gear and oil deflector (2) to crankshaft (3)
• Push fit
Page 51 of 103


Page 52 of 103
143. Secure splash shield to engine

Note: Oil pump removed for clarity.
144. Install oil level sensor to cylinder block

• Re-cut thread for 2x bolt
– Apply locking compound to thread of 2x bolt – see “Sealants,
Lubricants and Locking Compounds”
Page 53 of 103

Important: Ensure oilways are not blocked.
146. Install timing gear case to cylinder block
• Install new gasket to cylinder block
• Ensure gasket and timing case locate correctly on 2x dowel
Important: Tighten 21x bolt for new timing gear case

in stage and sequence shown.
147. Secure timing gear case to cylinder block
• Secure bolt Nos. 7, 18, 5, 14, 10, 3, 16, 20,
then 12 10 Nm
• Secure bolt No. 1, then No. 2 30 Nm
• Secure bolt Nos. 3 to 21 inclusive 12 Nm

Page 54 of 103
149. Apply continuous bead of sealant 2 mm thickness to 2x joint (1)

between cylinder block and timing gear housing – see “Sealants,

• Install 23x bolt 5 Nm in sequence shown

152. Install new seal ring (1) to Installer KM-6308
Page 55 of 103
Important: Do not lubricate seal ring mating surfaces. Ensure mating

surfaces are clean and dry.
153. Install seal ring to cylinder block using Installer KM-6308 (1)

154. Install new seal ring to cylinder block using Installer EN-49069
• Install seal ring to inner section (1) of installer
• Install inner section of installer with seal ring to crankshaft
• Install outer section (4) of installer to inner section of installer
– Install nut (3)
• Rotate nut clockwise until seal ring fully installed into cylinder
block
Page 56 of 103
1 2
3 4
S 0016510
155. Install Positioning Pin KM-6203 (arrowed) through oil filter housing
into crankshaft
• Rotate engine clockwise, until positioning pin engages in
crankshaft to position No. 1 cylinder at top dead centre on
compression stroke
Page 57 of 103
S 0012717
156. Install flywheel to crankshaft

– Apply locking compound to 7x bolt – see “Sealants,
157. Install Flywheel Positioning Tool KM-6403 (1) to cylinder block and
flywheel
• Push fit
– Position flywheel as necessary to ensure full location of tool
Page 58 of 103
158. Install Flywheel Holder KM-652 to cylinder block

• Install bolt
159. Remove Flywheel Positioning Tool KM-6403 (1) from cylinder block
and flywheel
• Pull out

Page 59 of 103
S 0012717
161. Secure flywheel to crankshaft

• Secure 7x bolt 20 Nm + 45° ± 6° symmetrically
Important: Side (A) must be installed facing clutch pressure plate end.
162. Install clutch plate with Alignment Tool KM-6165 to flywheel
Page 60 of 103
S 0017939
Important: Tighten 6x bolt symmetrically to avoid clutch distortion.

163. Install pressure plate to flywheel
Note: Observe alignment marking when installing original clutch.
164. Install engine speed sensor to cylinder block

• Secure clip (1)
Page 61 of 103

• Remove bolt
166. Install Positioning Pin KM-6203 (arrowed) to oil filter housing

compression stroke
S 0012717

• Install bolt
Page 62 of 103
S 0012717
169. Install auxiliary support bracket (1) to cylinder block

170. Clean mating surface of cylinder block

Important: Remove all fluids from the threaded holes in the cylinder block
to ensure the correct tightening of the cylinder head bolts. Use a syringe to
remove any oil/coolant.
171. Install new cylinder head gasket to cylinder block
• Locate cylinder head gasket onto 2x dowel
Page 63 of 103
Important: Install 10x new cylinder head bolts. Do not lubricate cylinder
head bolts.
172. Install cylinder head to cylinder block
Note: 2x technician are required.
Note: Do not re-tighten cylinder head bolts after carrying out the
following procedure.
• Install 10x cylinder head bolt 30 Nm in sequence shown
• Check torque of 10x cylinder head bolt is 30 Nm in sequence
shown
• Secure 10x cylinder head bolt 300° ± 6° in sequence shown
Note: The exhaust camshaft pulley and both flanges are shown
removed for clarity.
Page 64 of 103
176. Clean mating surface of cylinder head

177. Install 8x new seal to intake manifold
• Clean mating surfaces of intake manifold
Page 65 of 103
178. Install 2x new rubber gasket, 7x new seal to cylinder head cover
• Clean all mating surfaces of cylinder head cover
179. Install intake manifold (1) to cylinder head

Page 66 of 103
180. Apply 8x bead of sealant (arrowed) to cylinder head – see “Sealants,

181. Install cylinder head cover to cylinder head

• Install 13x bolt in sequence shown; do not tighten at this stage
– Apply sealant to 7x bolt thread (1, 2, 3, 4, 5, 7, 13) – see
Page 67 of 103
182. Pre-tighten cylinder head cover to cylinder head

183. Secure cylinder head cover to cylinder head

Page 68 of 103
184. Pre-tighten cylinder head cover to intake manifold

185. Secure intake manifold to cylinder head

Page 69 of 103
186. Secure cylinder head cover to intake manifold

187. Install fuel rail protector (1) and gasket to cylinder head
• Clean mating surfaces, then apply suitable sealant – see
• Position drain hose to rear of engine
• Secure grommet (2) to breather pipe connection
Page 70 of 103
188. Secure timing side of fuel rail protector to cylinder head

1
S 0013077
189. Install common rail to cylinder head

Page 71 of 103
190. Install 4x glow plug to cylinder head 11 Nm

191. Clean fuel injector bores using Cleaner EN-47632
Important: Use a suitable injector cleaning product. Do not use wire brush, emery cloth or ultrasonic cleaner.
192. Clean 4x fuel injector nozzle
• Remove 4x blanking plug from 4x fuel injector
193. Install 4x new seal to 4x fuel injector
Important: Replacement parts for injector bolts are available in a kit from
Parts and Accessories. The kit includes, studs, spacers and nuts. The
following procedure must be followed when installing fuel injectors.
194. Clean 8x thread in cylinder head for 8x new stud of 4x fuel injector
clamp
195. Install 2x stud (5) 2 Nm to cylinder head
• Lubricate 2x stud with clean engine oil
196. Install 2x new spacer (4) to 2x stud
• Lubricate 2x spacer with clean engine oil
197. Loosely install fuel injector (1) and clamp (3) to cylinder head
• Remove blanking plug from cylinder head
198. Secure clamp to fuel injector
• Install new nut (2) to stud on timing side 6 Nm
• Install new nut (2) to stud on flywheel side 6 Nm
• Secure nut (2) on flywheel side 360° ± 30°
199. Install remaining 3x fuel injector to cylinder head, in accordance with
above procedure
Page 72 of 103
200. Install high pressure pump (1) to engine

• Apply locking compound to thread of 3x bolt – see “Sealants,
Page 73 of 103
201. Secure high pressure pump to engine


Page 74 of 103
204. Install high pressure pipe to common rail

• Connect pipe union (1); do not tighten at this stage
205. Connect high pressure pipe to high pressure pump

• Connect pipe union (1); do not tighten at this stage
Page 75 of 103
206. Secure fuel rail protector to cylinder head

1
S 0013082

209. Secure 4x high pressure pipe (1) to 4x fuel injector


Page 76 of 103

212. Secure high pressure pipe to cylinder head

• Install pipe support clip to cylinder head cover, then secure 2x bolt
(3)

– Use Pipe Spanner KM-812 ; counterhold nut on high
pressure pump using suitable spanner
Page 77 of 103
214. Secure flywheel side of fuel rail protector to cylinder head

• Secure bolt 12 Nm
215. Install new fuel leak-off pipe (1) with fuel temperature sensor to high
pressure pump
216. Connect fuel leak-off pipe (1) to 4x fuel injector

– Push in

Page 78 of 103
218. Connect fuel leak-off pipe (1) to common rail

219. Install coolant pump (1) to engine

Page 79 of 103
220. Install gear (1) to crankshaft (2)

• Install key (3) to crankshaft
• Push fit
221. Install intermediate shaft and secondary intermediate shaft (2) with 2x
washer (1) to engine
• Ensure location pin of each intermediate shaft engages fully into
slot, then install 2x washer
• Push fit
Page 80 of 103
222. Install secondary intermediate gear (1) to engine

• Install new bolt (2)
223. If installing new intermediate gear – see operation “Intermediate

Timing Gear, Replace (All G9 Engines)” for timing gear
compensation
224. Install intermediate gear to engine
Page 81 of 103

• Remove bolt
226. Install Positioning Pin KM-6203 (arrowed) to oil filter housing

compression stroke
S 0012717

• Install bolt
Important: Marking “2” on gear for high pressure pump must align with
marking “3” on timing case. This action is necessary to correctly align gear
for high pressure pump and camshaft position sensor for engine timing.
228. Install gear to high pressure pump
– Ensure 2x mark (2, 3) align
compensation
Page 82 of 103
230. Remove Locking Tool (1) KM-6293 from gear for high pressure pump
231. Install gear (2) to coolant pump

Page 83 of 103
232. Install new gasket for timing gear cover to timing gear case
233. Remove oil seal for crankshaft pulley (1) from timing gear cover
• Prise out oil seal, using suitable tool
234. Remove oil seal for secondary intermediate gear (2) from timing gear
cover
235. Install timing gear cover to engine

• Install 15x bolt in stage and sequence shown
• Secure bolt Nos. 10, 4, 8, 7, 12 then 2 11 Nm
• Secure bolt Nos. 13, 14, then 15 25 Nm
Page 84 of 103
Important: Do not over-tighten Installer KM-6298 .

236. Install new oil seal for crankshaft pulley to timing gear cover
• Install threaded stud of Installer KM-6298 into crankshaft
• Partially install crankshaft oil seal (2) located on Sleeve KM-6424-
3 (1) into timing gear cover
237. Fully install oil seal for crankshaft pulley to timing gear cover
• Use Installer KM-6298
• Locate Sleeve KM-6243-3 (1) onto oil seal
• Rotate nut (2) clockwise, until oil seal fully installed into housing
Note: Stop tightening nut immediately when resistance
experienced.
Page 85 of 103

238. Install new oil seal (1) for secondary intermediate gear to timing gear
cover
• Remove bolt
• Install threaded stud of Installer KM-6299 (2) into shaft for
secondary intermediate gear
• Partially install oil seal located on Adapter KM-6424-2 (3) into
timing gear cover
239. Fully install oil seal for secondary intermediate gear to timing gear
cover
experienced.
Page 86 of 103
240. Secure secondary intermediate gear

• Secure bolt (1) 25 Nm + 35° ± 6°
Page 87 of 103
241. Install new cap (1) to secondary intermediate gear

Note: Timing gear cover removed for clarity.
242. Install crankshaft pulley (2) to engine

• Install bolt (1) 50 Nm + 90° ± 6°
Page 88 of 103

• Remove bolt
244. Install new timing belt to engine – see operation “Timing Belt, Replace”
S 0012717

Page 89 of 103
S 0012716
247. Install air conditioning compressor (2) (if installed) to auxiliary support
bracket
248. Install alternator (2) to auxiliary support bracket

249. Install new ribbed V-belt tensioner (3) to engine
Page 90 of 103
250. Install new guide roller for ribbed V-belt

251. Install power steering pump to engine

252. Install pulley to power steering pump
253. Install new ribbed V-belt to engine

• Rotate tension roller clockwise, then remove Locating Pin KM-
6130 (1)
Page 91 of 103
254. Secure pulley (1) to power steering pump

Page 92 of 103

Important: To avoid damage to the slave cylinder assembly, do not

lubricate the splines of the clutch plate and input shaft of transmission with
grease.
256. Install transmission to engine
Page 93 of 103
S 0016497
257. Secure transmission to engine

• Install 2x stud (2) to engine
• Install 2x nut (1) 45 Nm
Page 94 of 103
258. Install lower cover for flywheel to transmission

• Install 2x bolt
259. Install engine hoist to engine and transmission assembly
• Install lifting chain to 2x engine lifting eye
• Adjust engine hoist until weight of engine and transmission fully supported
260. Remove engine with transmission from Engine Overhaul Stand KM-
412
• Remove 2x Stand Adapter KM-412-29 from cylinder block
• Remove 8x nut, 8x bolt
Page 95 of 103
261. Install 2x coolant hose to oil cooler and thermostat housing

• Secure 4x clip
262. Install starter to transmission

Page 96 of 103
S 0012968
263. Install lower section of guide tube for oil level dipstick to engine
• Remove blanking plug from engine
264. Install upper section of guide tube for oil level dipstick to lower section and engine
265. Install EGR valve housing (2) with support bracket to engine
• Secure clip (1)
Page 97 of 103
1 2
S 0013423
Important: The EGR pipe must be replaced whenever it is released from

the cylinder head.
266. Remove EGR pipe (2) from bypass control valve for EGR cooler
• Remove clip (1)
267. Install new EGR pipe (2) to bypass control valve for EGR cooler
• Install new clip (1)
268. Install EGR cooler to intake manifold and EGR valve housing
Page 98 of 103
S 0016494
269. Install bracket to auxiliary support bracket and EGR valve housing
1
2 S 0009574
270. Install engine mount bracket (1) to cylinder block

Page 99 of 103
271. Install coolant pipe (1) to coolant pump and thermostat housing
• Install 2x new O ring
– Apply suitable lubricant
• Push fit
272. Install turbocharger (1) to exhaust manifold (2)

• Install new gasket, 3x new nut (3); do not tighten at this stage
Page 100 of 103
1 2
S 0012891
273. Install bracket (1) to turbocharger and engine

2
1
S 0012890
274. Secure turbocharger to exhaust manifold

• Secure 3x nut 28 Nm
275. Secure bracket to turbocharger and engine
276. Install new oil feed pipe (3) to turbocharger and engine
• Secure pipe union 22 Nm
• Secure bracket on oil feed pipe to turbocharger
– Install bolt
Page 101 of 103
277. Install oil return pipe (1) to turbocharger and engine

• Install new gasket, new O ring
• Push in to engine
2 S 0016489
278. Install primary catalytic converter (1) to turbocharger

• Clean mating surfaces 1
• Install new gasket, 4x new nut (2) 24 Nm
S 0012886
279. Install bracket (2), left side to primary catalytic converter and engine
• Secure vacuum hose to clip on bracket
280. Install bracket (3), right side to primary catalytic converter and engine
Page 102 of 103
281. Install power steering pipe assembly with fluid reservoir to engine and transmission assembly
282. Connect high pressure pipe (1) to power steering pump

• Secure union 24 Nm
283. Secure high pressure pipe to auxiliary support bracket

Page 103 of 103
284. Connect feed hose (1) to power steering pump

• Secure clip
285. Install engine and transmission to vehicle – see operation “Engine with Transmission, Remove and Install”
288. Install oil filler cap
Page 1 of 1
Cylinder Block, Check for Plane Surface
Measure
1. Check upper surface of cylinder block for deformation

• Use suitable straight edge and feeler gauges
• Check for deformation along length and across width
• Check for warping across 2x diagonal
• See “Technical Data” for maximum permissible deformation
Note: If deformation exceeds limit, cylinder block must be replaced.
– F4R 820
– G9U 630
– G9U 730
– M9R 630, M9R 692, M9R 780, M9R 782, M9R 784, M9R 786,
M9R 788
Page 1 of 58
Cylinder Head Cover, Replace
J463810
Remove
one side
1 2
S 0012751

• Release clip
Page 2 of 58
2
1
3
S 0012749
6. Remove air intake duct (1) from air cleaner (2) and vehicle body 2
• Release 2x clip
S 0012752

Page 3 of 58
1
1
S 0012753
8. Release air flow meter harness (1) from air cleaner support frame (2) 1
2
3
S 0012861
support frame (3)
Page 4 of 58
1 2
S 0012918
10. Release coolant preheater and bracket (1) (if installed) from air cleaner 2
support frame
• Remove bolt (3) 1 3
S 0012860
Page 5 of 58
1 2
3 S 0012862


• Remove 5x bolt

• Release clip
Page 6 of 58
S 0012741

• Remove bolt (2)
Page 7 of 58
2 S 0012714

– Pull upwards
Page 8 of 58

• Release 2x integral clip from engine cover
– Pull off
Page 9 of 58
S 0012865
S 0013060

Page 10 of 58
S 0013065

• Release 4x clip
S 0013066

• Release 4x clip
Page 11 of 58
S 0013067
22. Release clamp from turbocharger heat shield

• Release bolt until upwards movement of clamp is restricted by rivet
S 0012872
23. Raise vehicle

• Remove 8x bolt
25. Remove heat shield (1) from turbocharger

Page 12 of 58
S 0012873
26. Release fuel rail protector drain hose from engine assembly
• Release 2x clip
27. Disconnect harness connector from exhaust gas recirculation (EGR) module
29. Lower vehicle
30. Release fluid reservoir for power steering from upper front panel
• Release clip, then pull upwards
• Remove bolt (2)
• Release 2x clip
• Remove O ring
Page 13 of 58
• Install new blanking plug 1 2 3
S 0013070
S 0013069

Page 14 of 58

37. Disconnect harness connector (1) from coolant temperature sensor
• Release clip

39. Disconnect harness connector (2) from fuel pressure regulator
Page 15 of 58
2 S 0012969
40. Disconnect harness connector (1) from camshaft sensor
41. Release engine harness from EGR control solenoid harness

Page 16 of 58
1 2
S 0013073
42. Disconnect harness connector (1) from EGR vacuum control solenoid
(2)
2
1
S 0013074
43. Release engine harness cover from intake manifold, then move to side
• Remove screw (1)
Page 17 of 58

legislation.
cleaning cloths.
one side
Page 18 of 58
2 S 0012995

– Push in

Page 19 of 58
• Release 3x clip
49. Disconnect high pressure pipe (2) from high pressure pump 1 2
pressure pump
3 S 0013000

Page 20 of 58
• Remove bolt (2)

Important: Apply identification marking to each fuel injector before

removing from the cylinder head to ensure correct installation position.
Page 21 of 58


61. Remove remaining 3x fuel injector, in accordance with above procedure
Injector”
Page 22 of 58
63. Remove 4x glow plug from cylinder head

• Remove 2x bolt
Page 23 of 58
66. Remove harness support bracket from front lifting eye

• Release clip for engine harness
• Remove 2x bolt
67. Release vacuum control valve with support bracket from cylinder head cover, then move to one side
• Remove 3x screw
68. Remove support bracket for 2x fuel pipe from cylinder head cover
• Remove 2x screw (1)
69. Release cylinder head cover from valve housing of EGR

Page 24 of 58
70. Release 2x fuel pipe (1) from engine mount, then move to one side 1
S 0012715
71. Remove engine mount with torque reaction link from engine and vehicle
body
Page 25 of 58
2 S 0012721

• Remove 19x bolt
1 S 0013075

• Pull out
Page 26 of 58

• Remove 5x bolt

Page 27 of 58
Install

78. Install 2x new rubber gasket, 7x new seal to new cylinder head cover
Page 28 of 58


Page 29 of 58


Page 30 of 58


Page 31 of 58


Page 32 of 58
87. Install engine mount with torque reaction link to engine and vehicle
body
• Install 4x bolt (2), new nut (1); do not tighten at this stage
1
2 S 0012721
88. Secure engine mount to engine assembly

89. Secure torque reaction link to vehicle body
90. Secure engine mount to vehicle body
Page 33 of 58
3 S 0012724
92. Secure 2x fuel pipe (1) to engine mount 1

S 0012715
93. Secure vacuum control valve with support bracket to cylinder head cover
• Install 3x screw
94. Install support bracket for 2x fuel pipe to cylinder head cover
• Install 2x screw (1)
Page 34 of 58
95. Secure cylinder head cover to housing of EGR valve

• Secure clip (1)
96. Install harness support bracket to front lifting eye

• Install 2x bolt
• Secure clip for engine harness
• Clean mating surfaces, then apply suitable sealant – see “Sealants,
Page 35 of 58
98. Secure timing side of fuel rail protector to cylinder head 1

S 0013077

Page 36 of 58

clamp
above procedure
Page 37 of 58
110. Install 4x high pressure pipe to common rail and 4x fuel injector; do
Page 38 of 58
112. Secure fuel rail protector to cylinder head 1

S 0013082



Page 39 of 58

117. Install high pressure pipe (1) to common rail; do not tighten at this
stage
Page 40 of 58

• Secure to clip


Page 41 of 58



• Secure 4x clip
Page 42 of 58
127. Connect fuel feed pipe (1) to high pressure pump 1

2 S 0012995

Page 43 of 58
129. Install upper section of guide tube (4) for oil level dipstick to lower 1 2 3
section and engine
130. Secure harness to guide tube for oil level dipstick 4
• Secure clip (1)
131. Install oil level dipstick to guide tube
S 0013070
132. Secure engine harness cover to intake manifold

• Install screw (1)
Page 44 of 58
133. Connect harness connector (1) to EGR vacuum control solenoid (2) 2
1
S 0013074
134. Secure engine harness to EGR control solenoid harness

Page 45 of 58
1 2
S 0013073
135. Connect harness connector (2) to fuel pressure regulator

2 S 0012969
137. Connect harness connector (1) to camshaft sensor

Page 46 of 58
138. Connect harness connector (1) to coolant temperature sensor

• Secure clip

Page 47 of 58
S 0013069
142. Secure power steering reservoir and support bracket to upper front panel
• Secure to clip
143. Raise vehicle
145. Connect harness connector to EGR module
146. Secure fuel rail protector drain hose to engine assembly
• Secure 2x clip
147. Install heat shield (1) to turbocharger

Page 48 of 58
S 0012873

149. Lower vehicle
150. Secure clamp to turbocharger heat shield
S 0012872

• Secure 4x clip
Page 49 of 58
S 0013067
152. Secure oxygen sensor and turbocharger temperature sensor harness

to fuel rail protector and bracket
• Secure 4x clip
S 0013066

Page 50 of 58
S 0013065
S 0013060

– Push on
Page 51 of 58
S 0012865

– Push downwards
Page 52 of 58

Page 53 of 58
2 S 0012714

• Secure clip
Page 54 of 58
S 0012741

Page 55 of 58
1 2
3 S 0012862
161. Install air flow meter harness (1) to air cleaner support frame (2) 1
• Secure clip (3)
2
3
S 0012861
support frame
• Secure clip (2)
Page 56 of 58
1 3
S 0012860
163. Secure coolant preheater harness (1) (if installed) to air cleaner
support frame (3)
1 2
• Secure clip (2)
S 0012918

Page 57 of 58
1
1
S 0012753
165. Install air intake duct (1) to air cleaner (2) and vehicle body 2
• Secure 2x clip
S 0012752

• Secure clip
Page 58 of 58
2
1
3
S 0012749

• Secure clip (2)
1 2
S 0012751

Page 1 of 1
Cylinder Head, Check for Plane Surface
Measure
Warning: Ensure that cylinder head is safely supported.

1. Measure cylinder head for deformation along length and width, also for
warping along diagonals. Maximum deformation of plane surface is 0.05
mm
Note: Replace cylinder head if deformation exceeds limit.
• Use suitable straight edge and feeler gauges
Page 1 of 3
Differential Pressure Sensor, Diesel Particulate Filter, Replace
L502910
Remove
1. Raise vehicle
2. Disconnect hose assembly (1) for differential pressure sensor from front
exhaust pipe (2), then move to one side
• Counterhold adapter and release union (3)
2 S 0012883
3. Disconnect hose assembly for differential pressure sensor from diesel

particulate filter
• Counterhold adapter (3) and release union (2)
4. Release hose assembly for differential pressure sensor from heatshield
support
• Release from 2x clip (1), then move to one side
3 S 0014340
5. Remove differential pressure sensor (1) from vehicle

• Remove nut (3)
Page 2 of 3
2
3
S 0014341
Install
6. Install new differential pressure sensor (1) to vehicle

• Install nut (3)
1
2
3
S 0014341
7. Connect hose assembly for differential pressure sensor to diesel

particulate filter
• Apply suitable sealant to hose assembly
• Counterhold adapter (3) and secure union (2) 21 Nm
8. Secure hose assembly for differential pressure sensor to heatshield
support
• Secure to 2x clip (1)
Page 3 of 3
3 S 0014340
9. Connect hose assembly (1) for differential pressure sensor to front

exhaust pipe (2)
• Apply suitable sealant to hose assembly 1
• Counterhold adapter and secure union (3) 21 Nm
2 S 0012883
10. Lower vehicle

Page 1 of 7
Engine Control Unit, Replace (with MTA)
J745500
Remove
1. For vehicles with SPS function, download data from engine control unit using Tech 2 or MDI (M9R 692)
Note: Vehicles with IMA injectors, record IMA injector code with Tech 2 or MDI (M9R 692) for reprogramming.
3. For vehicles with M9R 780, M9R 782, M9R 784, M9R 786, M9R 788 or
M9R 692 engine, disconnect intake hose from intercooler
• Release clip
S 0012741
4. Release coolant expansion tank from bracket

• Remove bolt (2)
• Release 2x coolant hose from 2x clip (1)
1 2
S 0012901
5. Remove bonnet closure switch (if installed) from upper front panel
• Remove bolt
Page 2 of 7
6. Release charge pressure control valve (1) from cover

• Pull off 1 2
7. Release preheater control unit (2) from cover
• Remove nut (3)
S 0012902
8. Release harness from cover

• Release 2x clip
9. Remove transmission control unit from bracket

• Release rubber strap (1) 1
• Disconnect 2x harness connector (2)
2 S 0012999
10. Remove bracket for transmission control unit from cover

• Release harness from bracket
• Remove nut (1), bolt (2)
Page 3 of 7
1
2
3 S 0013002
11. Remove shield (1) (if installed) from cover

• Remove security bolt
– Use suitable tool
12. Remove cover from bracket

Note: If a tamper-proof shield is not installed, 3 bolts are removed.
• Remove nut, 2x bolt
• Release cover with lower locating peg
13. Remove engine control unit from bracket

– Release 3x clip
• Remove 4x bolt
Page 4 of 7
Install
14. Install new engine control unit to bracket

• Connect 3x harness connector (1)
– Secure 3x clip
15. Install cover to bracket

• Locate cover with lower locating peg
• Install 2x bolt, nut
16. Install shield (1) (if installed) to cover

Note: Replace security bolt if damaged.
• Install security bolt
Page 5 of 7
17. Install bracket for transmission control unit to cover

• Secure harness to bracket 1
– Secure clip (3)
2
3 S 0013002
18. Install transmission control unit to bracket

• Secure rubber strap (1)
Page 6 of 7
2 S 0012999
19. Secure harness to cover

• Secure 2x clip
20. Secure preheater control unit (2) to cover

• Install nut (3) 1 2
21. Secure charge pressure control valve (1) to cover
• Push on
S 0012902
22. Install bonnet closure switch (if installed) to upper front panel
• Install bolt
23. Secure coolant expansion tank to bracket

• Secure 2x coolant hose to 2x clip (1)
Page 7 of 7
1 2
S 0012901
24. For vehicles with M9R 780, M9R 782, M9R 784, M9R 786, M9R 788 or
M9R 692 engine, connect intake hose to intercooler
• Secure clip
S 0012741
25. For vehicles with G9U 630 engine, change engine oil and filter – see operation "Engine Oil and Filter, Change”
27. For vehicles with SPS function, program engine control unit using Tech 2 or MDI (M9R 692)
Page 1 of 5
Engine Control Unit, Replace
J745500
Remove
1. For vehicles with SPS function, download data from engine control unit using Tech 2 or MDI (M9R 630 or M9R 692)
Note: Vehicles with IMA injectors, record IMA injector code with Tech 2 or MDI (M9R 630 or M9R 692) for reprogramming.
3. For vehicles with M9R engine, disconnect intake hose from intercooler
• Release clip
S 0012741
4. Release coolant expansion tank from bracket

• Remove bolt (2)
• Release 2x coolant hose from 2x clip (1)
1 2
S 0012901
5. Remove bonnet closure switch (if installed) from upper front panel
• Remove bolt
Page 2 of 5
6. Release charge pressure sensor (if installed) from cover

• Pull off 1 2
7. Release charge pressure control valve (1) (if installed) from cover
• Pull off
8. Release preheater control unit (2) (if installed) from cover
• Remove nut (3)
S 0012902
9. Release harness from cover

• Release 2x clip
10. Remove shield (1) (if installed) from cover

• Remove security bolt
11. Remove cover from support bracket

Note: If a tamper-proof shield is not installed, 4 bolts are removed.
• Remove nut, 3x bolt
• Release cover with lower locating peg
12. Remove engine control unit from support bracket

– Release 3x clip
• Remove 4x bolt
Page 3 of 5
Install
13. Install new engine control unit to support bracket

– Secure 3x clip
14. Install cover to support bracket

• Locate cover with lower locating peg
• Install 3x bolt, nut
15. Install shield (1) (if installed) to cover

Note: Replace the security bolt if damaged.
• Install security bolt
Page 4 of 5
16. Secure harness to cover

• Secure 2x clip
17. Secure preheater control unit (2) to cover

• Install nut (3) 1 2
18. Secure charge pressure control valve (1) to cover
• Push on
19. Secure charge pressure sensor (if installed) to cover
• Push on
S 0012902
20. Install bonnet closure switch (if installed) to upper front panel
• Install bolt
21. Secure coolant expansion tank to bracket

• Secure 2x coolant hose to 2x clip (1)
Page 5 of 5
1 2
S 0012901
22. For vehicles with M9R engine, connect intake hose to intercooler
• Secure clip
S 0012741
23. For vehicles with G9U 630 engine, change engine oil and filter – see operation "Engine Oil and Filter, Change”
25. For vehicles with SPS function, program engine control unit using Tech 2 or MDI (M9R 630 or M9R 692)
27. For vehicles with F4R 820 engine, road test vehicle
• In every gear, accelerate under full throttle then decelerate
Page 1 of 2
Engine Damping Block, Left Side, Replace
J472200
Remove
1. Raise vehicle
4. Lower vehicle
5. Release coolant expansion tank from support bracket and inner wing
• Remove bolt
• Release from inner wing, move to one side
6. Release engine damping block (1) from transmission bracket and

chassis
• Remove nut (2), 2x bolt (3)
7. Raise vehicle
8. Lower Engine Support KM-6210-A until transmission bracket and engine damping block separate
9. Lower vehicle
10. Remove engine damping block from transmission bracket
Install
11. Raise vehicle

12. Raise engine to original position using Engine Support KM-6210-A
13. Lower vehicle
14. Install new engine damping block (1) to transmission bracket and
chassis
• Install 2x bolt (3), nut (2); do not tighten at this stage
• Secure 2x bolt (3) 44 Nm , nut (2) 60 Nm
Page 2 of 2
15. Secure coolant expansion tank to support bracket and inner wing
• Secure to inner wing
• Install bolt
16. Raise vehicle
17. Remove Engine Support KM-6210-A from vehicle

19. Lower vehicle
Page 1 of 8
Engine Damping Block, Left Side, Replace
J472200
Remove

2. Raise vehicle
5. Lower vehicle
• Release clip
2
7. Disconnect harness connector (3) from mass air flow meter 1
3
S 0012749
one side 1 2
S 0012751
Page 2 of 8
• Release 2x clip 2
S 0012752

1
1
S 0012753
11. Remove air intake duct from vehicle

12. Release coolant expansion tank from support bracket and inner wing
• Remove bolt
• Release from inner wing, move to one side
13. Remove transmission control unit from bracket

• Release rubber strap (1)
Page 3 of 8
2 S 0012999
14. Remove bracket for transmission control unit from cover

• Release harness from bracket
– Release clip (3) 1
• Remove nut (1), bolt (2)
2
3 S 0013002
15. Release engine damping block (1) from transmission bracket and
chassis
• Remove nut (2), 2x bolt (3)
Page 4 of 8
16. Raise vehicle

17. Lower Engine Support KM-6210-A until transmission bracket and engine damping block separate
18. Lower vehicle
19. Remove engine damping block from transmission bracket
Install
20. Raise vehicle

21. Raise engine to original position using Engine Support KM-6210-A
22. Lower vehicle
23. Install new engine damping block (1) to transmission bracket and
chassis
• Install 2x bolt (3), nut (2); do not tighten at this stage
• Secure 2x bolt (3) 44 Nm , nut (2) 60 Nm
24. Install bracket for transmission control unit to cover

Page 5 of 8

• Secure harness to bracket
– Secure clip (3) 1
2
3 S 0013002
25. Install transmission control unit to bracket

1
2 S 0012999
26. Secure coolant expansion tank to support bracket and inner wing
• Secure to inner wing
• Install bolt
27. Install air intake duct to vehicle
Page 6 of 8
1
1
S 0012753
29. Secure air intake duct (1) to air cleaner assembly (2) and front panel
• Secure 2x clip 2
S 0012752

• Secure clip (2)
Page 7 of 8
1 2
S 0012751
31. Connect harness connector (3) to mass air flow meter (1)
32. Connect hose (2) to mass air flow meter 2
• Secure clip
1
3
S 0012749
33. Raise vehicle

Page 8 of 8

36. Lower vehicle
Page 1 of 6
Engine Damping Block, Right Side, Replace
J472100
Remove
1. Raise vehicle
3. Install Engine Support KM-6210-A to vehicle – see operation “Engine
Support KM-6210-A, Install and Remove”
4. Lower vehicle
5. Release power steering reservoir from front panel, then move to side
• Release from integral clip
Page 2 of 6
6. Release harness (1) and fuel pipe (2) from support bracket
7. Release upper stabiliser from chassis

• Release bolt (1)
8. Remove support bracket (1) from engine

Page 3 of 6
9. Remove damping block (1), from inner wing

Install
10. Install new engine damping block (1), to inner wing

Page 4 of 6
Important: Ensure 3x bolt (2, 3, 4) are secured in correct sequence.

11. Install support bracket to engine
• Install 3x bolt in sequence (3, 4, 2) 10 Nm
12. Secure upper stabiliser to chassis

Page 5 of 6
13. Secure engine damping block (1), to inner wing

14. Secure harness (1) and fuel pipe (2) to support bracket
• Secure to clip
Page 6 of 6
15. Secure power steering reservoir to front panel

• Secure to integral clip
16. Raise vehicle

19. Lower vehicle

- Engine Support KM-6210-A, Install and Remove
Page 1 of 2
FC9 FLA
CHT CHT CHT 10A 40A
4528 4533 4538 105 101
RD 0.5
30 30
RD 7
VT 0.75
VT 0.75
VT 2
1 3
85 30
FB2 X24 X23
1 1 1 1
86 87 15A
K18 1 1
2 5 Y28.1 Y28.2 Y28.3 Y28.4 B34
2 2 2 2 1 2
WH 0.5
BG 0.5
GY 0.5
BN 4/7
GN 0.75
VT 0.75
X24
2 4 3 FB1
4527
25A
CHT ~AC 3136
GN 0.5
AC 3220
GY 0.5
BG 0.5
PK 0.5
VT 0.5
VT 0.5
VT 0.5
WH 2
OG 2
GN 2
GY 2
BG 2
BG 2
BG 2
BG 2
BN 2
MK
PK 2
VT 2
3729
ACK
X54 X56 X55 X54
E3 C4 H1 D1 M3 M4 G1 L1 M1 L4 M4 L3 M3 L2 M2 E1 F1
A25
C4 F3 E2 H2 K2 J1 G2 D4 A3 A4 B3 B4 K4 K3 J2 M1 M2 D1 E2 B2 C2 L4 B1
X56 X54 X55 X54 X55 X54 X55 X54

GY 0.5
GN 0.75
WH 0.5
WH 0.5
WH 0.5
WH 0.5
WH 0.5
OG 0.5
OG 0.5
OG 0.5
GN 0.5
GN 0.5
BG 0.5
GY 0.5
GY 0.5
BN 0.5
BN 0.5
BN 0.5
BN 0.5
BN 0.5
PK 0.5
VT 0.5
VT 0.5
VT 0.5
VT 0.5
VT 0.5
VT 0.5
VT 0.5
VT 0.5
1103
VT 1
VT 1
CLS
X103
3 1 3 4 2 1 6 5 4
1 2 3 1 3 6 4 5
2 6 1 5 4 3
2 1 2
S114 Y29 B46 B35 Y8 Y74 Y75

2 1 2 5 4 6 1 2 1
BK 0.5
BK 1
B117 Y4
1 2
BK 40
16
2800 1 2 3 4 5 6 7 8 9 2810 1 2 3 4 5 6 7 8 9 2820 1 2 3 4 5 6 7 8 9 2830 1 2 3 4 5 6 7 8 9 2840 1 2 3 4 5 6 7 8 9

ENG9U630 P115583
Vivaro, model year 2007

Page 2 of 2
Systems
ENG9U630 Engine G9U 630, EDC16 C36
Components
A25 Control unit - Diesel, common rail Y4 Solenoid valve - Exhaust gas recirculation
B34 Impulse sensor - Crankshaft Y8 Solenoid valve - Boost pressure regulation
B35 Sensor - Camshaft Y28.1 Injector - Cylinder 1
B46 Air mass meter Y28.2 Injector - Cylinder 2
B117 Sensor - Oxygen, mixture control, heated Y28.3 Injector - Cylinder 3
FB1 Fuse Y28.4 Injector - Cylinder 4
FB2 Fuse Y29 Throttle valve - Positioner
K18 Relay - Engine control unit Y74 Solenoid Valve - Fuel metering
Solenoid valve - Bypass, exhaust gas recirculation
S114 Switch - Water level, fuel filter Y75
cooler
Connectors
X23 Engine & Body front X55 Engine & Control unit - Diesel, common rail X55
X24 Engine & Extension harness, coolant heater X56 Engine & Control unit - Diesel, common rail X56
Engine & Extension harness, solenoid valve -
X54 Engine & Control unit - Diesel, common rail X54 X103
Exhaust gas recirculation
Grounding Points
16 Battery
Abbreviations
10A 10 Ampere CHT Coolant heater
30 Constant voltage CLS Clutch switch
40A 40 Ampere FC9 Fuse FC9
~AC Not air conditioning FLA Main fuse FLA
AC Air conditioning MK Engine cooling
ACK Air conditioning, compressor
Color codes
BG Beige OG Orange
BK Black PK Pink
BN Brown RD Red
GN Green VT Violet
GY Gray WH White
Page 1 of 2
FL11 FC7
70A 10A DIAG HSCAN-L HSCAN-H HSCAN-L HSCAN-H SLS SLS MK MK MK MTA AC ACK
401 147 441 531 533 541 543 732 733 3136 3235 3220 3026 3712 3729
30 15
AC AC AC AC AC
B19
2 3 4 1 6 5
VT 0.5
VT 0.5
WH 0.5
WH 0.5
OG 0.5
BG 0.5
GY 0.5
BG 0.5
BN 0.5
PK 0.5
PK 0.5
VT 0.5
PK 1
X1 X23 X1 X23 X1
A4 A3 2 3 B7 4 C4 C3 C2 C6 C7 C5
YE 0.5/0.75
3018
GN 0.75
VT 0.75
WH 0.5
WH 0.5
WH 0.5
WH 0.5
MTA OG 0.5
OG 0.5
OG 0.5
GN 0.5
GY 0.5
BG 0.5
GY 0.5
BG 0.5
BN 0.5
BN 0.5
PK 0.5
VT 0.5
X56 X54 X56 X55 X54 X56

D1 B4 A3 A4 A2 A1 E3 E4 B1 C1 B2 B4 D3 H3 H2 G2 F4 F3 F2
A25
D2 F4 J2 G3 G4 H1 H4 J4 H4 A2 B3 H1 F2 G1 D2 C2 E1 G2 F3 B1 K2 H3 C3 A4 D3 E3 C1 G3 A3
X54 X56 X55

AC AC AC DPF DPF DPF DPF DPF DPF DPF
GY 0.5
WH 0.75
BG 0.75
BN 0.75
WH 0.5
WH 0.5
OG 0.5
OG 0.5
OG 0.5
GN 0.5
GN 0.5
GY 0.5
BG 0.5
BG 0.5
BG 0.5
BN 0.5
BN 0.5
BN 0.5
BN 0.5
VT 0.5
VT 0.5
VT 0.5
WH 0.5
RD 7
126
BG 0.5
VT 0.5
STA
X23
4 8 3 2 3 1
2 3 1 1 2 3 8 7 6
3 1 2 1 1
P P
U U
A9 B12 B60 B18 B120 B154 B155 B157 B156
2 7 1 6 2 2 1 2 2
WH 0.5
GY 0.5
PK 0.5
GY 2.5
BN 2.5
PK 2.5
VT 2.5
BK 2
BK 2
BK 2
BK 2
A C B
1P 1P 1P 1P
P
U
B29
R8.1 R8.2 R8.3 R8.4
BK 7
2700 1 2 3 4 5 6 7 8 9 2710 1 2 3 4 5 6 7 8 9 2720 1 2 3 4 5 6 7 8 9 2730 1 2 3 4 5 6 7 8 9 2740 1 2 3 4 5 6 7 8 9

ENG9U630 P115572

Page 2 of 2
Systems
ENG9U630 Engine G9U 630, EDC16 C36
Components
A9 Control unit - Glow time B154 Sensor - Temperature, Exhaust Gas
A25 Control unit - Diesel, common rail B155 Sensor - Temperature, exhaust gas
B12 Sensor - Coolant temperature B156 Sensor - Temperature, exhaust gas
B18 Sensor - Load pressure B157 Sensor - Pressure, exhaust gas
B19 Sensor - Pedal position R8.1 Glow plug - Cylinder 1
B29 Sensor - Pressure, air conditioning R8.2 Glow plug - Cylinder 2
B60 Sensor - Fuel temperature R8.3 Glow plug - Cylinder 3
B120 Sensor - Fuel rail pressure R8.4 Glow plug - Cylinder 4
Connectors
X1 Instrument panel & Engine X55 Engine & Control unit - Diesel, common rail X55
X23 Engine & Body front X56 Engine & Control unit - Diesel, common rail X56
X54 Engine & Control unit - Diesel, common rail X54
Grounding Points
7 Engine
Abbreviations
10A 10 Ampere FC7 Fuse FC7
15 Ignition voltage FL11 Main fuse FL11
30 Constant voltage HSCAN-H High speed CAN-bus - High
70A 70 Ampere HSCAN-L High speed CAN-bus - Low
AC Air conditioning MK Engine cooling
ACK Air conditioning, compressor MTA Manual transmission automatically shifted
DIAG Diagnostic link SLS Stop lamp switch
DPF Diesel particle filter STA Start & Charging
Color codes
BG Beige PK Pink
BK Black RD Red
BN Brown VT Violet
GN Green WH White
GY Gray YE Yellow
OG Orange
Page 1 of 2
Engine G9U 630, EDC16 C36
15 30
B12 M19
B18 M20
B19 R27
B29 Y8
B34 Y10
B35 Y28.1
B46 Y28.2
B60 Y28.3
B120 Y28.4
B154 Y74
B155 Y75
B156
A25 R8.1
R8.2
B157 A9
R8.3
R8.4
G2 B117
S43 X13
S95.3 Y4
S104 Y29
S114
A1
HSCAN
A30
A42
H1
31 P122640
Block Diagram Vivaro, model year 2007
Page 2 of 2
Components
A1 Control unit - Airbag M19 Motor - Radiator fan
A9 Control unit - Glow time M20 Motor - Radiator fan
A25 Control unit - Diesel, common rail R8.1 Glow plug - Cylinder 1
Control unit - Manual transmission automatically
A30 R8.2 Glow plug - Cylinder 2
shifted
Control unit - Anti-Lock Brake System &
A42 R8.3 Glow plug - Cylinder 3
Electronic stability program
B12 Sensor - Coolant temperature R8.4 Glow plug - Cylinder 4
B18 Sensor - Load pressure R27 Heating resistor - Coolant heater
B19 Sensor - Pedal position S43 Switch - Stop lamp, double
B29 Sensor - Pressure, air conditioning S95.3 Switch - Air conditioning
B34 Impulse sensor - Crankshaft S104 Switch - Clutch Pedal
B35 Sensor - Camshaft S114 Switch - Water level, fuel filter
B46 Air mass meter Y4 Solenoid valve - Exhaust gas recirculation
B60 Sensor - Fuel temperature Y8 Solenoid valve - Boost pressure regulation
B117 Sensor - Oxygen, mixture control, heated Y10 Clutch - Compressor, air conditioning
B120 Sensor - Fuel rail pressure Y28.1 Injector - Cylinder 1
B154 Sensor - Temperature, Exhaust Gas Y28.2 Injector - Cylinder 2
B155 Sensor - Temperature, exhaust gas Y28.3 Injector - Cylinder 3
B156 Sensor - Temperature, exhaust gas Y28.4 Injector - Cylinder 4
B157 Sensor - Pressure, exhaust gas Y29 Throttle valve - Positioner
G2 Alternator Y74 Solenoid Valve - Fuel metering
Solenoid valve - Bypass, exhaust gas recirculation
H1 Instrument Y75
cooler
Connectors
X13 Diagnostic link
Abbreviations
15 Ignition voltage 31 Ground
30 Constant voltage HSCAN High speed CAN-bus
Page 1 of 3
Engine Oil and Filter, Change
J451900
Remove

2. Raise vehicle
• Remove 8x bolt
4. Drain engine oil

• Release cover until oil escape port allows oil to drain, then remove
fully
of used oil filters.
• Pull off
S 0012523
Page 2 of 3
Install

• Push on
11. Remove collecting container
S 0012523

13. Remove collecting container
15. Lower vehicle
• Stop engine
• Check and adjust oil level if necessary
Important: Procedure must be completed within 100 seconds after switching on ignition.
Page 3 of 3
17. Reset oil life monitor (if installed)

• Switch on ignition, but do not start engine
Depress accelerator fully and hold in this position
• Apply brake pedal three times consecutively
• Release accelerator pedal
• Release brake pedal
• Turn off ignition
• Wait 5 seconds for oil life monitor to illuminate
Important: Ignition should not be off for longer than 3 seconds.
• Turn off ignition, then on
Note: Oil life monitor should be extinguished.
Note: If reset is unsuccessful, turn off ignition then repeat procedure.
Page 1 of 3
Engine Oil Level Sensor, Replace
N221950
Remove
1. Raise vehicle
3. Remove oil level sensor from cylinder block
Install
4. Install new seal ring to new oil level sensor

• Lubricate new seal ring with clean engine oil
Page 2 of 3
5. Install oil level sensor to cylinder block

Page 3 of 3

7. Lower vehicle
Page 1 of 3
Engine Oil Pressure, Check (with Air Conditioning)
J451700
Remove

2. Remove upper front panel – see operation ”Upper Front Panel, Remove and Install or Replace”
3. Raise vehicle
• Remove 8x bolt
5. Lower vehicle
6. Remove oil pressure switch (2) from engine oil filter housing
1
2
S 0013130
Measure
7. Install Adapter KM-6286 to engine oil filter housing

8. Install Fluid Pressure Gauge KM-498-B to Adapter KM-6286
Page 2 of 3

Important: Ensure the engine is at normal operating temperature before checking the engine oil pressure.
10. Measure engine oil pressure at idle
• Start engine, then run engine at idle
• For M9R 630 engine, oil pump is within specification if recorded pressure is 0.9 bar (Min.)
• For M9R 692 engine, oil pump is within specification if recorded pressure is 1.2 bar (Min.)
11. For M9R 630 engine, measure engine oil pressure at 3000 rpm
• Raise engine speed to 3000 rpm
• Oil pump is within specification if recorded pressure is 4.0 bar (Min.)
12. For M9R 692 engine, measure engine oil pressure at 2000 rpm
13. Stop engine
15. Remove Fluid Pressure Gauge KM-498-B from Adapter KM-6286
Page 3 of 3
16. Remove Adapter KM-6286 from engine oil filter housing
Install
17. Install oil pressure switch (2) 20 Nm to engine oil filter housing
• Install new seal ring to oil pressure switch
18. Raise vehicle

20. Lower vehicle
21. Install upper front panel – see operation ”Upper Front Panel, Remove and Install or Replace”
24. Check engine oil level, top up if necessary
Page 1 of 2
Engine Oil Pressure, Check
J451700
Remove

2. Raise vehicle
• Remove 8x bolt
4. Remove oil pressure switch (1) from oil filter housing (2) 1 2
• Disconnect harness connector
S 0013032
Measure
5. Install Adapter KM-135 to oil filter housing

6. Install Fluid Pressure Gauge KM-498-B to Adapter KM-135
7. Lower vehicle
Important: Ensure the engine is at normal operating temperature before checking the engine oil pressure.
9. Measure engine oil pressure at 1000 rpm
• Start engine, then raise engine speed to 1000 rpm
10. Measure engine oil pressure at 3000 rpm
11. Stop engine
13. Raise vehicle
14. Remove Fluid Pressure Gauge KM-498-B from Adapter KM-135
15. Remove Adapter KM-135 from oil filter housing
Page 2 of 2
Install
16. Install oil pressure switch (1) to oil filter housing (2) 20 Nm
1 2
• Connect harness connector
S 0013032

18. Lower vehicle
21. Check engine oil level; adjust if necessary
Page 1 of 4
Engine Oil with Oil Filter, Replace (G9U 730)
Remove

2. Raise vehicle
3. Remove engine undershield
4. Drain engine oil

– Place collecting container below
– Discard washer
5. Remove oil filter

• Remove oil filter with cover (1) from oil filter housing
– Use Oil Filter Wrench KM-6206
• Remove oil filter from cover

6. Remove seal ring (2) from cover
Page 2 of 4
Install
7. Install new oil filter

• Install new seal ring (2) to cover
– Lubricate seal ring with clean engine oil
• Install oil filter to cover
• Install oil filter with cover (1) to oil filter housing
– Use Oil Filter Wrench KM-6206 ( 25 Nm )
8. Install drain plug ( 25 Nm )

• Use new washer
Page 3 of 4
9. Install engine undershield

• Install 6x bolt (1) ( 6 Nm )
Page 4 of 4
10. Lower vehicle

• Stop engine
Page 1 of 13
Engine Pressure Loss, Check
J451500
Adjust

2. Raise vehicle
• Remove 8x bolt

S 0012716
crankshaft
Page 2 of 13
7. Apply match mark (1) on crankshaft pulley, 180° fro m top dead centre
(2), 2x match mark (3) on crankshaft pulley and engine
Note: These provide reference marks for positioning crankshaft when
checking cylinders 2, 3, & 4.
Page 3 of 13
8. Remove Positioning Pin KM-6203 (arrowed) from crankshaft and oil filter
housing

• Apply sealant to bolt thread – see “Sealants, Lubricants and Locking
Compounds”
Page 4 of 13
Remove
10. Lower vehicle

one side
• Release clip
Page 5 of 13
14. Remove air intake duct (1) from air cleaner assembly (2) and front
panel
• Release 2x clip

Page 6 of 13
17. Release harness for coolant heater assembly from support frame
18. Release bracket with coolant heater assembly (1) from support frame
• Remove bolt (3)
Page 7 of 13


21. Remove engine oil level dipstick
22. Remove glow plug from No. 1 cylinder
Measure
Page 8 of 13
Important: Crankshaft must not turn during checking procedure. To avoid

this, engage first gear and apply parking brake.
23. Install Adapter KM-6211 (3) to No. 1 cylinder 11 Nm
Note: No. 1 cylinder is located at flywheel end.
24. Install Adapter KM-533-1 (2) to Adapter KM-6211 (3)
25. Install and connect pressure loss tester (1) (commercially available) to
Adapter KM-533-1 (2)
Warning: Wear eye protection when using pressure loss tool.

26. Connect pressure loss tester to compressed air system, then calibrate
(observe manufacturer's instructions)
27. Regulate pressure to 100 psi (6.9 bar) and record pressure loss from
tester
Note: For vehicles with PA6 or PF6R transmission a second
technician is required to counterhold the crankshaft pulley.
28. Measure corresponding pressure loss of each cylinder in firing order 1-
3-4-2, turning engine in direction of rotation until next mark on
crankshaft pulley aligns with mark on engine. Repeat for each cylinder
Note: Investigate any acoustically perceivable escape of compressed
air from the intake manifold, turbocharger, exhaust, glow plug bores
and crankcase and any formation of bubbles in the coolant expansion
tank. The maximum permissible pressure loss difference between
individual cylinder approximately 10%. The maximum pressure loss of
one cylinder should not exceed 25%.
Warning: Air supply must be reduced to 0 (zero) before disconnecting

pressure loss tool.
29. Disconnect and remove pressure loss tester (1) from Adapter KM-533-
1 (2)
30. Remove Adapter KM-533-1 (2) from Adapter KM-6211 (3)
Page 9 of 13
Install
31. Install glow plug to No. 1 cylinder 11 Nm

33. Install engine oil level dipstick
34. Disengage first gear
35. Raise vehicle
38. Lower vehicle
Page 10 of 13

• Secure clip (3)
41. Secure bracket with coolant heater assembly (1) to support frame
42. Secure harness for coolant heater assembly to support frame
• Secure clip (2)
Page 11 of 13

44. Secure air intake duct (1) to air cleaner assembly (2) and front panel
• Secure 2x clip
Page 12 of 13
46. Connect hose (2) to mass air flow meter
• Secure clip

• Secure clip (2)
Page 13 of 13

Page 1 of 2
Engine Stabiliser, Lower, Replace
J338000
Remove
1. Raise vehicle
3. Remove lower engine stabiliser (1) from engine mount bracket and
subframe
Install
4. Install new lower engine stabiliser to engine mount bracket and

subframe
Page 2 of 2

6. Lower vehicle

Page 1 of 2
Engine Stabiliser, Upper, Replace
J339100
Remove
1. Remove upper engine stabiliser (1) from support bracket and chassis
Install
2. Install new upper engine stabiliser to support bracket and chassis

• Install 2x bolt (1, 2); do not tighten at this stage
Page 2 of 2

Page 1 of 83
Engine with Transmission, Remove and Install
J450100
Important: Never lower the vehicle onto its wheels without the drive shafts installed correctly, as this will damage the wheel bearings.
Remove
(approximately 30 seconds). This waiting period is absolutely essential for fuel rail to be depressurised
Important: Observe the relevant safety regulations when working on air conditioning systems.
2. For vehicle with air conditioning, evacuate refrigerant from air conditioning circuit – see operation “Air Conditioning System, Evacuate
and Fill”
5. Raise vehicle
• Remove 8x bolt

8. Remove radiator undershield from support crossmember

Page 2 of 83
9. Release radiator with air conditioning condenser (if installed) from

support crossmember
• Remove 2x clip (1), 2x washer
Page 3 of 83
10. Lower vehicle

Important: Observe relevant environmental regulations when disposing of
used coolant.
• Connect suitable hose to radiator drain plug (1) 1
• Close radiator drain plug
S 0012760
one side
Page 4 of 83
1 2
S 0012751
• Release clip
2
1
3
S 0012749
• Release 2x clip
Page 5 of 83
S 0012752

1
1
S 0012753
Page 6 of 83
1
2
3
S 0012861
support frame (3)
1 2
S 0012918
support frame
• Remove bolt (3)
Page 7 of 83
1 3
S 0012860
22. Remove support frame for air cleaner assembly from engine compartment
• Remove 2x nut
23. Remove heater fan housing assembly from bulkhead

• Remove bolt, 3x nut
24. Remove air deflector from vehicle

• Release from locator
Page 8 of 83
S 0012834
25. Disconnect upper coolant hose from radiator

26. Disconnect lower coolant hose (1) from radiator

• Release clip
Page 9 of 83
27. Release harness from fan support housing

• Disconnect 2x harness connector from 2x cooling fan
• Release 6x clip
28. Disconnect harness connector (2) (if installed) from pressure sensor (1)
for air conditioning
29. Remove 2x air deflector (1) from radiator

• Release 2x clip
• Release from 2x locator
Page 10 of 83
S 0012835
30. Disconnect 2x refrigerant pipe (1) (if installed) from air conditioning
condenser (3)
• Remove 2x bolt (2), then move to one side
31. Remove radiator assembly with air conditioning condenser (if installed) from support crossmember
32. Disconnect harness connector from air conditioning compressor (if installed)
• Disconnect intercooler pipe from exhaust gas
pressure sensor (4)
Page 11 of 83

• Remove bolt (2)
• Install new blanking plug to turbocharger
2 S 0014441
36. Disconnect breather hose from cylinder head cover

37. Remove breather hose from turbocharger intake hose
• Pull off
Page 12 of 83
S 0012865
38. Remove hose (1) from turbocharger

• Release clip
• Release 2x heater hose and vacuum pipe from hose
– Release from 6x retainer 1
S 0012870

• Release 2x clip
Page 13 of 83
S 0012722
40. Remove 2x wheel cover

41. Release 2x nut (1) from 2x drive shaft; do not remove 2x nut at this
stage
• Apply parking brake
42. Raise vehicle

of used transmission fluid.
43. Drain transmission fluid
• Remove drain plug (1) from transmission
• Remove sealing washer from drain plug
44. Install drain plug (1) to transmission 18 Nm
Page 14 of 83
45. Install 2x support stand to front of vehicle

46. Lower vehicle to suitable working height
47. Remove 2x front wheel
• Remove 10x bolt
48. Remove 2x nut (1) from 2x drive shaft
49. Release and support 2x brake caliper

• Release 2x brake hose (1) from 2x clip
– Pull out
Page 15 of 83
50. Release 2x tie rod end from 2x steering knuckle

Note: Use the clamping tool if the ball joint of the tie rod end turns
when removing the nut.
• Install Clamping Tool CH-47658 (3) with Adaptor CH-47658-12 (2) 1
to steering knuckle
• Tighten rod (4)
• Remove clamping tool with adaptor from steering knuckle
• Use Remover KM-507-C
2
3
4 S 0016919
51. Release 2x steering knuckle from 2x strut assembly

• Remove 4x bolt, 4x nut (1)
Page 16 of 83
Important: Observe orientation of the bearing retainer plate for installation

purposes.
52. Release drive shaft from transmission, right side
• Release retainer plate
53. Release drive shaft from wheel hub, right side

• Use Remover KM-6218
Page 17 of 83
54. Remove drive shaft from vehicle, right side

55. Support steering knuckle on strut assembly, right side

56. Release drive shaft from wheel hub, left side

Page 18 of 83
57. Remove drive shaft from vehicle, left side

58. Support steering knuckle on strut assembly, left side

59. Remove wheelarch liner, left side

• Remove screw
• Remove 3x clip using Trim Remover KM-475
60. Release earth lead from vehicle body
• Remove bolt
61. Raise vehicle
Page 19 of 83
2 S 0012883
63. Disconnect primary temperature sensor from body harness

• Release from clip (2), then slide off
1
2 S 0012884
64. Release front exhaust pipe from primary catalytic converter

65. Remove front exhaust pipe from diesel particulate filter
Page 20 of 83
S 0012885
66. Disconnect harness connector (1) from crankshaft inductive pulse pick-
up
67. Release harness from 2x bracket, then move to one side
• Release 2x clip (2, 3)
Page 21 of 83
2 3
1
S 0013176
68. Release trunking (1) from transmission

• Remove bolt (arrowed)
S 0013177
69. Disconnect 2x power steering pipe (1) from steering gear

• Remove bolt
• Secure 2x power steering pipe to engine using suitable method
Page 22 of 83
70. For right drive vehicles, release power steering pipe from bracket on
steering gear
• Remove nut (1)
S 0012504
71. Remove lower engine stabiliser from bracket and subframe

Page 23 of 83
72. Lower vehicle

• Release 4x clip
• Release 4x clip
S 0013067

Page 24 of 83
S 0013069

• Release clip
Page 25 of 83
80. Release harness for crankshaft inductive pulse pick-up from rear engine lifting eye
• Release clip

Page 26 of 83
2 S 0012969
(2)
2
1
S 0013074
84. Disconnect harness connector from EGR module

Page 27 of 83
• Remove 3x screw
87. Disconnect 2x hose for coolant expansion tank from thermostat housing
• Release 2x clip
88. Disconnect 2x coolant hose (1) from EGR cooler

• Release 2x clip
S 0014493
89. Disconnect coolant hose for EGR cooler from thermostat housing
• Release clip
90. Disconnect hose (1) from coolant preheater

• Release clip
Page 28 of 83
S 0014494
91. Disconnect coolant hose for EGR cooler from turbocharger coolant hose (if installed)
• Release clip
housing
2
3 S 0012765
93. Disconnect engine harness connector from EGR control solenoid

harness
Page 29 of 83
S 0013268
94. Disconnect harness connector (1) from oil level sensor

95. Disconnect harness connector from oil pressure switch

Page 30 of 83
97. Disconnect harness lead from starter

• Remove nut (1), disconnect harness connector (2)
98. Disconnect positive lead from starter, then move to one side
• Remove nut (3), captive nut, then release from clip
1
3 2 S 0014185
99. For vehicles with PF6 transmission, release 2x gearshift cable (1, 4)
from transmission
• Release 2x ball joint (3, 5) using Remover KM-569-A
• Release 2x cable from bracket (2)
– Pull 2x locking ring rearwards, then slide off bracket and move
to one side
Page 31 of 83
100. For vehicles with PF6 transmission, disconnect harness connector (1)
from reverse lamp switch
Page 32 of 83
101. For vehicles with PF6 transmission, disconnect harness connector (1)
from vehicle speed sensor (if installed)
102. For vehicles with tachograph, disconnect harness connector (1) from
vehicle speed sensor
Note: As the tamper-proof seal is not cut, seal replacement and
calibration will not be required.
Page 33 of 83

of used clutch fluid.
103. For vehicles with PF6 transmission, disconnect clutch pressure pipe
assembly from clutch slave cylinder (1)
2 S 0013387
104. Release earth lead from transmission, then move to one side
• Remove bolt (1)
Page 34 of 83
105. For vehicles with PF6R transmission, disconnect harness connector

(1) from hydraulic shifting assembly, then move to one side
2 S 0009699
106. Release trunking (2) from transmission

• Remove bolt (1)
• Release clip
Page 35 of 83
1
S 0013178
107. For vehicles with PF6R transmission, remove transmission control unit
from bracket
• Release rubber strap (1)
1
108. For vehicles with PF6R transmission, release harness from cover
• Release 2x clip
2 S 0012999
109. For vehicles without protection cover, disconnect 2x harness

connector (1) from fuel filter housing and water sensor (if installed)
• Release harness from fuel pipe
– Release 2x clip
Page 36 of 83
S 0012800
Warning: Fuel escapes – observe safety measures and national legislation.

Important: Clean all connections before disconnecting; use only lint-free cleaning cloths.
110. For vehicles without protection cover, disconnect fuel feed pipe for high pressure pump from fuel filter housing
111. For vehicles with protection cover, disconnect fuel pipe (1) from fuel
filter housing
• Release clip
112. Release fuel filter housing from support bracket
113. For vehicles with protection cover, disconnect harness connector (2)
from fuel filter housing
114. Disconnect harness connector from sensor for water ingress (if
installed)
115. Remove protection cover (1) from fuel filter housing
• Rotate locking ring anti-clockwise, then lift off
116. Disconnect fuel feed pipe (3) for high pressure pump from fuel filter
housing
Page 37 of 83
• Release clip

Page 38 of 83
S 0012715
119. Disconnect pipe (1) from vacuum pump, then move to one side
120. Disconnect vacuum hose (1) from wastegate actuator

• Pull off
Page 39 of 83
S 0014492
121. Disconnect refrigerant pipe (1) from air conditioning compressor (if
installed)
• Remove bolt (2), then move to one side
• Remove O ring
122. Release power steering hose assembly from radiator support crossmember
• Remove 2x bolt
123. Remove radiator support crossmember from vehicle

Page 40 of 83
Important: Observe relevant environmental regulations when disposing of used power steering fluid.
124. Drain fluid from power steering reservoir
• Remove cap
125. Position power steering reservoir with power steering pipe assembly to engine
• Secure using suitable method
S 0013060

128. Remove bracket with upper engine stabiliser from engine

compartment
Page 41 of 83
2 S 0012721
129. Release mounting for damping block from transmission bracket

• Remove nut (1)
S 0013299
130. Remove lower splash shield from vehicle, left side

• Remove 2x clip
131. Release harness for ambient temperature sensor (if installed) from lower front crossmember
• Release clip
Important: The lower front crossmember must be reinstalled as soon as

the engine and transmission assembly have been removed from the vehicle.
This action is necessary to prevent vehicle chassis distortion.
132. Remove lower front crossmember from vehicle
• Remove 8x bolt, 8x nut
Note: Illustration shows engine and transmission assembly
Page 42 of 83
133. Remove engine and transmission assembly from vehicle

134. Install lower front crossmember to vehicle
• Install 8x bolt, 8x nut 44 Nm
Install
Important: The lower front crossmember must be reinstalled as soon as

the engine and transmission assembly have been removed from the vehicle.
This action is necessary to prevent vehicle chassis distortion.
135. Remove lower front crossmember from vehicle
• Remove 8x bolt, 8x nut
Note: Illustration shows engine and transmission assembly
136. Position engine and transmission assembly to vehicle

• Adjust height of engine hoist until correct installation height attained
137. Secure mounting for damping block to transmission bracket

• Install new nut (1) 60 Nm
Page 43 of 83
S 0013299

2
• Secure nut (1) 44 Nm 1
3
5 4 S 0013084
139. Remove engine hoist from engine and transmission assembly

• Remove lifting chain from 2x engine lifting eye
140. Install lower front crossmember to vehicle
• Install 8x bolt, 8x nut 44 Nm
141. Secure harness for ambient temperature sensor (if installed) to lower front crossmember
• Secure clip
142. Install lower splash shield to vehicle, left side
• Install 2x clip
Page 44 of 83
S 0013060
144. Release power steering reservoir with power steering pipe assembly from engine
• Position to one side for installation at a later stage
145. Install radiator support crossmember to vehicle

146. Secure power steering hose assembly to radiator support crossmember

• Install 2x bolt

Page 45 of 83
S 0012715

149. For vehicles without protection cover, connect fuel feed pipe for high pressure pump to fuel filter housing
150. For vehicles without protection cover, connect 2x harness connector

(1) to fuel filter housing and water sensor (if installed)
• Secure engine harness to bracket for engine damping block
– Secure to clip
Page 46 of 83
S 0012800
151. For vehicles with protection cover, connect fuel feed pipe (3) for high
pressure pump to fuel filter housing
• Secure clip
152. Install protection cover (1) to fuel filter housing
• Push on, then rotate locking ring clockwise
153. Connect harness connector (2) to fuel filter housing
154. Connect harness connector to sensor for water ingress (if installed)
155. For vehicles with protection cover, secure fuel filter housing to support
bracket
• Secure to clip
156. Connect fuel pipe (1) to fuel filter housing
• Secure clip
Page 47 of 83
157. Connect refrigerant pipe (1) to air conditioning compressor (if

installed)
• Apply lubricant to new O ring – see “Sealants, Lubricants and
• Install O ring
158. Connect pipe (1) to vacuum pump

Page 48 of 83
159. For vehicles with PF6R transmission, install transmission control unit
to bracket
1
160. For vehicles with PF6R transmission, secure harness to cover
• Secure 2x clip
2 S 0012999
161. Secure trunking (2) to transmission

• Secure clip
Page 49 of 83
1
S 0013178
162. Secure earth lead to transmission

163. For vehicles with PF6R transmission, connect harness connector (1)
to hydraulic shifting assembly
• Secure clip (2)
Page 50 of 83
2 S 0009699

of used clutch fluid.
164. For vehicles with PF6 transmission, connect clutch pressure pipe
assembly to clutch slave cylinder (1)
• Secure clip (2)
2 S 0013387
165. For vehicles with tachograph, connect harness connector (1) to

vehicle speed sensor
Note: As the tamper-proof seal is cut, seal replacement and
calibration will be required.
Page 51 of 83
166. For vehicles with PF6 transmission, connect harness connector (1) to
vehicle speed sensor (if installed)
167. For vehicles with PF6 transmission, connect harness connector (1) to
reverse lamp switch
Page 52 of 83
168. For vehicles with PF6 transmission, secure 2x gearshift cable (1, 4) to
transmission
• Secure to bracket (2)
– Slide on
• Secure 2x ball joint (3, 5)
– Push on
Page 53 of 83
169. Connect positive lead to starter

• Secure to clip, then install nut (3) 8 Nm , captive nut 5 Nm
170. Connect harness lead to starter
• Install nut (1) 8 Nm , connect harness connector (2)
Page 54 of 83
3 2 S 0014185

172. Connect harness connector to oil pressure switch

173. Connect harness connector (1) to oil level sensor
Page 55 of 83
174. Connect engine harness connector to EGR control solenoid harness
S 0013268
Page 56 of 83
3 S 0012765
176. Connect coolant hose for EGR cooler to turbocharger coolant hose (if installed)
• Secure clip
177. Connect hose (1) to coolant preheater

• Secure clip
S 0014494
178. Connect coolant hose for EGR cooler to thermostat housing

• Secure clip
179. Connect 2x coolant hose (1) to EGR cooler

• Secure 2x clip
Page 57 of 83
S 0014493
180. Connect 2x hose for coolant expansion tank to thermostat housing

• Secure 2x clip


184. Connect harness connector (1) to EGR vacuum control solenoid (2)
Page 58 of 83
2
1
S 0013074

2 S 0012969

• Secure clip
Page 59 of 83


Page 60 of 83
S 0013069

• Secure 4x clip
• Secure 4x clip
S 0013067

Page 61 of 83
194. Secure harness for crankshaft inductive pulse pick-up to rear engine lifting eye
• Secure clip
195. Raise vehicle
196. Secure trunking (1) to transmission
• Install bolt (arrowed)
S 0013177
197. Connect vacuum hose (1) to wastegate actuator

• Push on
Page 62 of 83
S 0014492
198. Connect harness connector (1) to crankshaft inductive pulse pick-up

199. Secure harness to 2x bracket
• Secure 2x clip (2, 3)
2 3
1
S 0013176
200. Install lower engine stabiliser to bracket and subframe

Page 63 of 83
201. Install front exhaust pipe to diesel particulate filter

• Install 2x new nut (2), gasket; do not tighten at this stage
202. Secure front exhaust pipe to primary catalytic converter
• Install 2x new nut (1), gasket; do not tighten at this stage
203. Secure 4x nut 21 Nm
Page 64 of 83
S 0012885
exhaust pipe (2)
Page 65 of 83
2 S 0012883
205. Connect primary temperature sensor to body harness

– Slide on
1
2 S 0012884
206. Connect 2x power steering pipe (1) to steering gear

• Release 2x power steering pipe from engine
• Position collecting container below
• Apply lubricant to 2x new O ring – see “Sealants, Lubricants and
• Install 2x O ring
• Install bolt
Page 66 of 83
207. For right drive vehicles, secure power steering pipe to bracket on
steering gear
• Install nut (1)
S 0012504
208. Remove 2x output seal from transmission housing

• Use suitable tool to lever out
Important: Ensure the apertures are clean and not damaged.
209. Lubricate 2x aperture using clean transmission fluid
210. Remove guide sleeve (1) from drive shaft, right side
Page 67 of 83
211. Install new output seal (3) to transmission housing, right side
• Position guide sleeve (2) with output seal (3) into Installer KM-
6434 (1)
• Use soft-faced hammer
212. Install new output seal to transmission housing, left side

• Position output seal into Installer DT-48354
• Use soft-faced hammer
214. Release steering knuckle from strut assembly, right side
• Remove bolt (1)
Page 68 of 83
Important: Ensure that the bearing retaining plate is installed in the correct
orientation as observed on removal.
215. Install drive shaft to transmission, right side
• Install new retainer plate
– Install new O ring
216. Release steering knuckle from strut assembly, left side

• Remove bolt (1)
Page 69 of 83
Important: 2nd technician is required to guide the drive shaft into the transmission to prevent damage to the seal.
217. Install drive shaft to transmission, left side
218. Secure 2x steering knuckle to 2x strut assembly
• Install 4x bolt, 4x new nut (1) 180 Nm
219. Secure 2x tie rod end to 2x steering knuckle

when installing the nut.
• Install 2x new nut (1) 37 Nm
• Install Clamping Tool CH-47658 (3) with Adaptor CH-47658-12 (2)
to steering knuckle
• Tighten rod (4)
Page 70 of 83
2
3
4 S 0016919
220. Secure 2x brake caliper to 2x steering knuckle

• Apply locking compound to thread of 4x new bolt – see “Sealants,
• Secure 2x brake hose (1) to 2x clip
– Push fit
221. Install 2x new nut (1) to 2x drive shaft; do not tighten at this stage
Page 71 of 83
222. Secure earth lead to vehicle body

• Install bolt
223. Install wheelarch liner, left side
• Install screw
• Install 3x clip
224. Install 2x front wheel
225. Raise vehicle
226. Remove 2x support stand from front of vehicle
227. Withdraw guide sleeve (1) from output seal and locate in retaining
groove (2) on drive shaft, right side
Page 72 of 83
228. Remove filler plug (1) from transmission

• Remove sealing washer from filler plug
Important: Use specified oil – see ”Technical Data”
229. Fill transmission fluid to correct level
230. Install filler plug (1) to transmission
Page 73 of 83
231. Lower vehicle

Important: Ensure the parking brake is applied. This action is necessary to
prevent vehicle movement when attempting to secure left side and right side
drive shaft nut.
232. Secure 2x nut (1) 280 Nm to 2x drive shaft
233. Secure 2x front wheel

234. Install 2x wheel cover
• Secure 2x clip
Page 74 of 83
S 0012722
236. Install hose (1) to turbocharger

• Secure clip
• Secure 2x heater hose and vacuum pipe to hose
– Secure to 6x retainer 1
S 0012870
237. Install breather hose to turbocharger intake hose

• Push on
• Remove blanking plug from cylinder head cover
• Push on to secure 2x integral clip (1)
Page 75 of 83
S 0012865

• Remove blanking plug from turbocharger
• Secure clip (1)
2 S 0014441

• Connect harness connector to charge
pressure sensor (4)
• Secure intercooler pipe to exhaust gas
– Secure clip (3)
Page 76 of 83
242. Connect harness connector to air conditioning compressor (if installed)

243. Install radiator assembly with air conditioning condenser (if installed) to support crossmember
244. Connect 2x refrigerant pipe (1) (if installed) to air conditioning
condenser (3)
• Apply lubricant to 2x new O ring – see “Sealants, Lubricants and
• Install 2x O ring
245. Install 2x air deflector (1) to radiator

• Secure to 2x locator
• Secure 2x clip
Page 77 of 83
S 0012835
246. Connect harness connector (2) to pressure sensor (1) for air
conditioning (if installed)
247. Secure harness to fan support housing

• Connect 2x harness connector to 2x cooling fan
• Secure 6x clip
248. Connect lower coolant hose (1) to radiator

• Secure clip
Page 78 of 83
249. Connect upper coolant hose to radiator

• Secure clip (1)
250. Install air deflector to vehicle

• Secure to locator
Page 79 of 83
S 0012834
251. Raise vehicle

252. Secure radiator assembly with condenser (if installed) to support
crossmember
• Install 2x washer, 2x clip (1)
253. Lower vehicle

254. Install heater fan housing assembly to bulkhead
• Install bolt, 3x nut
Page 80 of 83
255. Install support frame for air cleaner assembly to engine compartment
• Install 2x nut 8 Nm
• Secure clip (3)
1
2
3
S 0012861
257. Secure bracket with coolant heater assembly (1) (if installed) to
support frame
frame
• Secure clip (2)
Page 81 of 83
1 3
S 0012860
260. Refill air conditioning system – see operation “Air Conditioning System, Evacuate and Charge”
261. Bleed power steering system – see operation “Hydraulic System, Bleed”
262. Bleed hydraulic clutch system – see operation “Hydraulic Clutch Operation, Bleed”
• For PF6
• For PF6R
265. Bleed hydraulic shifting assembly (if required) – see operation “Hydraulic Shifting Assembly, Bleed”
Note: The hydraulic shifting assembly will require bleeding if air has entered the system when replacing the relevant components
whilst the hydraulic shifting assembly was removed.
266. Program hydraulic shifting assembly – see operation “Hydraulic Shifting Assembly, Program”
Note: The Turbocharger will only require priming
if the engine with transmission is being installed
after performing an engine overhaul operation
and if the oil circuit has been opened.
panel
– Release 4x clip
Page 82 of 83
269. To prime oil circuit, crank engine until the oil pressure indicator lamp is extinguished then continue for two seconds
• Secure 4x clip
272. Start engine and allow to run until normal operating temperature attained
273. Stop engine
275. Raise vehicle
276. Install radiator undershield to support crossmember

Page 83 of 83

279. Lower vehicle
Page 1 of 43
Engine, Replace
J450075
Remove
of used lubricants.
2. Disconnect feed hose (1) from power steering pump
• Release clip
3. Release high pressure pipe from auxiliary support bracket

• Remove bolt
4. Disconnect high pressure pipe (1) from power steering pump
• Remove O ring
5. Remove power steering pipe assembly with fluid reservoir from engine and transmission assembly
• Remove 4x bolt
Page 2 of 43
engine
engine

Page 3 of 43
S 0012886

• Release pipe union 1

– Remove bolt
3
• Remove bolt
2 S 0016489

Page 4 of 43
2
1
S 0012890

1 2
S 0012891
• Remove bolt (2)
Page 5 of 43
14. Remove support bracket (1) from cylinder block

15. Disconnect pipe (1) from vacuum pump

• Remove O ring
Page 6 of 43
16. Remove exhaust gas recirculation (EGR) vacuum control solenoid (1)
with bracket from cylinder head cover
1
S 0013280
17. Remove bracket from auxiliary support bracket and EGR valve housing
Page 7 of 43
2 S 0009574
18. Disconnect 2x coolant hose from oil cooler

• Release 2x clip
S 0016515
19. Remove 6x coolant hose (1) from thermostat housing

• Release 6x clip
20. Remove EGR cooler from intake manifold and EGR valve housing
Page 8 of 43
S 0016494
1 2
S 0013423
22. Remove upper section of guide tube for oil level dipstick from lower section
• Remove bolt
• Remove O ring
• Remove bolt
• Remove O ring
24. Remove starter from transmission

Page 9 of 43
S 0012968

• Install 8x bolt 8x nut
Page 10 of 43
27. Remove lower cover for flywheel from transmission

• Remove 2x bolt
28. Release transmission from engine

29. Remove 2x stud (2) from engine
Page 11 of 43

31. Remove transmission from engine

Page 12 of 43
S 0016497
32. Release pulley (1) from power steering pump

Page 13 of 43

6130 (1)
Page 14 of 43

• Remove 3x bolt
35. Remove power steering pump from auxiliary support bracket

Page 15 of 43

• Remove bolt (1)
Page 16 of 43
37. Remove alternator (2) from auxiliary support bracket

38. Remove ribbed V-belt tensioner (3) from engine
39. Remove air conditioning compressor (2) (if installed) from auxiliary
support bracket
Page 17 of 43
40. Remove engine speed sensor from cylinder block


• Install bolt
Warning: Alignment Tool KM-6165 must be installed to prevent the clutch

plate from falling during pressure plate removal.
42. Install Alignment Tool (1) KM-6165 to clutch plate
Page 18 of 43
43. Remove pressure plate from flywheel

• Apply alignment marking (if installing original clutch)
44. Remove clutch plate with Alignment Tool KM-6165 from flywheel

• Remove 7x bolt
Page 19 of 43

• Remove bolt
S 0012852
47. Remove exhaust manifold from cylinder head

• Remove 9x nut, 9x spacer, gasket
48. Remove drain hose for fuel rail protector from engine
• Remove bolt
Page 20 of 43
• Install sealing washer
51. Install engine hoist to engine
• Install lifting chain to engine
• Adjust engine hoist until weight of engine fully supported
52. Remove engine from Engine Overhaul Stand KM-412
• Remove 6x bolt
53. Install oil filler cap to engine
Install
Important: The oil filler cap is removed to prevent it from being damaged, when the lifting chain is fully supporting the weight of the
engine.
55. Install engine hoist to new engine
• Install lifting chain to engine
• Adjust engine hoist until weight of engine fully supported
• Install 6x bolt
• Install 8x bolt, 8x nut

Page 21 of 43
S 0012716
59. Install Positioning Pin KM-6203 through oil filter housing into crankshaft
Page 22 of 43
PMH
S 0017785

– Apply locking compound to 7x bolt – see “Sealants, Lubricants
Page 23 of 43
flywheel
• Push fit
– Position flywheel as necessary to ensure full location of tool

• Install bolt
63. Remove Flywheel Positioning Tool KM-6403 (1) from cylinder block
and flywheel
• Pull out
Page 24 of 43
S 0012717

Page 25 of 43
66. Install bolt (arrowed) to oil filter housing

• Apply suitable sealant to thread
S 0012716
Important: Side (A) must be installed facing clutch pressure plate end.
67. Install clutch plate with Alignment Tool KM-6165 to flywheel
Page 26 of 43
S 0017939
Important: Tighten 6x bolt symmetrically to avoid clutch distortion.

68. Install pressure plate to flywheel
Note: Observe alignment marking when installing original clutch.

• Remove bolt
70. Install engine speed sensor to cylinder block

• Secure clip (1)
Page 27 of 43
2 9
6 4
5 1 3
7 8
S 0012859
71. Install exhaust manifold to cylinder head

• Install new gasket, 9x spacer, 9x new nut 30 Nm in sequence shown
72. Install drain hose for fuel rail protector to engine

• Install bolt
• Secure clip (1)
Page 28 of 43
73. Install air conditioning compressor (2) (if installed) to auxiliary support
bracket
74. Install alternator (2) to auxiliary support bracket

Page 29 of 43

77. Install power steering pump to engine

78. Install pulley to power steering pump

(1)
Page 30 of 43
80. Secure pulley (1) to power steering pump

Page 31 of 43

Important: To avoid damage to the slave cylinder assembly, do not

lubricate the splines of the clutch plate and input shaft of transmission with
grease.
82. Install transmission to engine
Page 32 of 43
S 0016497
83. Secure transmission to engine

• Install 2x stud (2) to engine
• Install 2x nut (1) 45 Nm
Page 33 of 43
84. Install lower cover for flywheel to transmission

• Install 2x bolt
87. Remove engine with transmission from Engine Overhaul Stand KM-412
• Remove 6x bolt
88. Install starter to transmission

Page 34 of 43
S 0012968
90. Install upper section of guide tube for oil level dipstick to lower section and engine
• Secure clip (1)
Page 35 of 43
1 2
S 0013423

the cylinder head.
• Remove clip (1)
94. Install EGR cooler to intake manifold and EGR valve housing
Page 36 of 43
S 0016494
S 0016515
95. Install 6x coolant hose (1) to thermostat housing

• Secure 6x clip
96. Connect 2x coolant hose to oil cooler

• Secure 2x clip
97. Install bracket to auxiliary support bracket and EGR valve housing
Page 37 of 43
2 S 0009574
98. Install EGR vacuum control solenoid (1) with bracket to cylinder head
cover
1
S 0013280

Page 38 of 43

• Tighten 4x bolt (2) 50 Nm
• Push fit
Page 39 of 43

1 2
S 0012891

Page 40 of 43
2
1
S 0012890

• Secure bracket on oil feed pipe to turbocharger 1
– Install bolt

3
2 S 0016489

Page 41 of 43
S 0012886
Page 42 of 43
111. Install power steering pipe assembly with fluid reservoir to engine and transmission assembly
112. Connect high pressure pipe (1) to power steering pump

113. Secure high pressure pipe to auxiliary support bracket

Page 43 of 43
114. Connect feed hose (1) to power steering pump

• Secure clip
Page 1 of 36
Exhaust Manifold, Replace
J470300
Remove

one side
1 2
S 0012751

• Release clip
• Release 2x clip
Page 2 of 36
S 0012752

• Pull off from 4x locating peg (1)
1
1
S 0012753
frame
support frame
• Remove bolt (3)
Page 3 of 36
Page 4 of 36
1 2
3 S 0012862


• Remove bolt (2)
Page 5 of 36
2 S 0012714

• Pull off
Page 6 of 36
S 0012865

• Release clip
1
– Release from 6x retainer
S 0012870

• Release 2x clip
Page 7 of 36
S 0012722

S 0012872
18. Raise vehicle to suitable working height

• Remove 2x wheel cover
• Remove 10x bolt
20. Release 2x link from stabiliser bar

• Remove 2x nut
Note: If the ball joint turns when removing the nut, counterhold
centre of the ball joint with an allen key.
Page 8 of 36

when removing the nut. 1
to steering knuckle
• Tighten rod (4)
2
3
4 S 0016919
22. Release 2x harness (if installed) for 2x ABS sensor from subframe and 2x lower arm
• Release from 2x bracket
23. Raise vehicle
• Remove 8x bolt
25. Release 2x brake pipe from subframe
• Release 2x clip

Page 9 of 36
27. Release intermediate shaft (1) from steering gear (2)

• Remove nut (3), bolt 1 2 3 4
28. Disconnect 2x power steering pipe assembly (4) from steering gear
• Remove bolt (5)
5
S 0012879
29. Install suitable jack to subframe

• Secure subframe to jack using suitable strap
30. Release 2x reaction link from subframe

Note: Illustration shows jack removed for clarity.
Page 10 of 36
31. Release 2x reaction link from chassis

Note: For vehicles with additional heater, the bolt and the reaction
link, left side, are removed.
• Release 2x bolt (1)
• Position 2x reaction link to one side
32. Release 2x control arm (1) from 2x ball joint (3)

Page 11 of 36
1 2
3
S 0012881
33. Remove subframe with steering gear and 2x lower arm from vehicle
Page 12 of 36
2 S 0012883

1
2 S 0012884

Page 13 of 36
S 0012885
engine
engine
Page 14 of 36

Page 15 of 36
S 0012873
41. Remove 2x clip from 2x harness for oxygen sensor and turbocharger temperature sensor
• Remove 4x nut (2), gasket 1
S 0012886
43. Disconnect 2x coolant hose (1) (if installed) from turbocharger

• Release 2x clip
Page 16 of 36
– Use pipe spanner KM-812 1

– Remove bolt
• Remove bolt
2
46. Disconnect hose (5) from wastegate actuator
• Pull off
5
4
3 S 0012887

2
1
S 0012890

Page 17 of 36
1 2
S 0012891
S 0012852
49. Remove exhaust manifold from cylinder head

• Remove 9x nut, 9x spacer, gasket
Install
Page 18 of 36
2 9
6 4
5 1 3
7 8
S 0012859
50. Install new exhaust manifold to cylinder head

• Install new gasket, 9x spacer, 9x new nut 30 Nm in sequence shown

• Clean mating surfaces 1 2
S 0012891

Page 19 of 36
2
1
S 0012890

55. Connect hose (5) to wastegate actuator

1
– Use pipe spanner KM-812
2
• Secure bracket to turbocharger
– Install bolt

5
• Push in to engine 4
58. Connect 2x coolant hose (1) (if installed) to turbocharger
• Secure 2x clip
3 S 0012887

Page 20 of 36
S 0012886

• Install 2x bolt (2) 8 Nm 1
S 0012873
61. Install bracket (2), left side, to primary catalytic converter and engine
62. Install bracket (3), right side, to primary catalytic converter and engine
Page 21 of 36
63. Install 2x clip to 2x harness for oxygen sensor and turbocharger temperature sensor
• Install 2x new nut; do not tighten at this stage
Page 22 of 36
S 0012885
exhaust pipe (2)
Page 23 of 36
2 S 0012883

1
– Slide on
2 S 0012884
69. Install subframe with steering gear and 2x lower arm to vehicle
• Apply locking compound to 2x bolt – see “Sealants, Lubricants and
Page 24 of 36
70. For vehicles with additional heater, install reaction link, left side to
chassis
• Install bolt (1); do not tighten at this stage
71. Secure 2x reaction link to subframe

Page 25 of 36
72. Secure 2x reaction link to chassis

73. Remove jack from subframe

74. Connect 2x power steering pipe assembly (4) to steering gear (2)
75. Secure intermediate shaft (1) to steering gear
• Install bolt, new nut (3) 20 Nm
Page 26 of 36
1 2 3 4
5
S 0012879

77. Secure 2x control arm (1) to 2x ball joint (3)

Page 27 of 36
1 2
3
S 0012881
78. Secure 2x brake pipe to subframe

• Secure 2x clip
when installing the nut. 1
to steering knuckle
• Tighten rod (4)
2
3
4 S 0016919
81. Secure 2x harness (if installed) for 2x ABS sensor to subframe and 2x lower arm
• Secure to 2x bracket
82. Secure 2x link to stabiliser bar

• Install 2x new nut 44 Nm
Note: If the ball joint turns when installing the nut, counterhold
Page 28 of 36
83. Raise vehicle

87. Lower vehicle
S 0012872

• Secure 2x clip
Page 29 of 36
S 0012722

• Secure clip
1
– Secure to 6x retainer
S 0012870

• Push on
Page 30 of 36
S 0012865

Page 31 of 36
2 S 0012714
Page 32 of 36
1 2
3 S 0012862

• Secure clip (3)
1
2
3
S 0012861
frame
frame
• Secure clip (2)
Page 33 of 36
1 3
S 0012860

1
1
S 0012753
102. Secure air intake duct (1) to air cleaner assembly (2)
• Secure 2x clip
Page 34 of 36
S 0012752
104. Connect hose (2) to mass air flow meter 2
• Secure clip
1
3
S 0012749

• Secure clip (2)
Page 35 of 36
1 2
S 0012751

panel
– Release 4x clip
Page 36 of 36
109. To prime turbocharger, crank engine until the oil pressure indicator lamp is extinguished then continue for two seconds
• Secure 4x clip
114. Start engine, and run until the oil pressure indicator lamp is extinguished
115. Stop engine
Page 1 of 4
Filter Element, Air Cleaner, Replace
J817900
Remove
1. Release oil filler cap assembly from air cleaner assembly, then move to
one side
Note: The securing screws are part of the oil filler cap assembly.
• Release 2x screw (1) 1
S 0012711
2. Remove cover (1) of air cleaner assembly

• Disconnect hose (3) from mass air flow meter
– Release clip
• Disconnect harness connector (2) from mass air flow meter
• Release 2x screw (4)
Note: The securing screws are part of the air cleaner cover.
3. Remove air cleaner element (5)
Page 2 of 4
Install
4. Install new air cleaner element (5)

5. Install cover (1) of air cleaner assembly
• Secure 2x screw (4) 3 Nm
• Connect harness connector (2) to mass air flow meter
• Connect hose (3) to mass air flow meter
– Secure clip
Page 3 of 4
6. Secure oil filler cap assembly to air cleaner assembly

• Secure 2x screw (1) 3 Nm
Page 4 of 4
S 0012711
Page 1 of 3
Fuel Injector Leak-off, Check (All Common Rail Engines)
J491100
Remove
not followed. Refer to "Safety Regulations – Engine, Fuel and Exhaust System" . Do not loosen or remove fuel lines when the engine is
running. As soon as the fuel circuit is open, all openings must be plugged using kit available from Parts and Accessories, to prevent
pollutants from penetrating the fuel circuit. Do not clean the engine using a high pressure washer; this may damage connections and
moisture may collect in the connections causing electrical problems.
1. Remove air cleaner assembly and necessary components to gain access to fuel leak-off pipe
Important: Clean pipe connections before disconnecting with lint-free cloth.
2. Disconnect fuel leak-off pipe from 4x fuel injector
• Release 4x spring clip
– Push in
3. Install 4x protective cap to fuel leak-off pipe
4. Connect 4x hose of Leak-off Measurement Tool EN-

47655 to 4x fuel injector leak-off port
Page 2 of 3
Important: Take care not to restrict any of the hoses of

Leak-off Measurement Tool EN-47655 when installing
the air cleaner assembly.
5. Loosely install air cleaner assembly and necessary
components to enable engine starting
Measure
6. Check fuel injector leak-off performance

If vehicle starts:
• Start engine and allow to idle
• Stop engine when one container of Leak-off Measurement Tool EN-47655 is at maximum level (50 ml)
• Check level of 4x container
Note: The maximum permissible leak-off quantity of any fuel injector is 3 times that of the fuel injector with the lowest leak-off
quantity.
7. Check fuel injector leak-off performance
If vehicle does not start:
Important: Only repeat the cranking procedure if necessary; repeated cranking may damage the starter.
• Crank engine for 10 – 15 seconds
• Check quantity of fuel in 4x hose of Leak-off Measurement Tool EN-47655
Note: The maximum permissible leak-off quantity of any fuel injector is 3 times that of the fuel injector with the lowest leak-off
quantity.
Install
8. Remove air cleaner assembly

9. Disconnect 4x hose of Leak-off Measurement Tool EN-47655 from 4x fuel injector leak-off port
10. Remove 4x protective cap from 4x fuel leak-off pipe
• Release 4x spring clip
Important: The fuel leak-off pipe and temperature sensor assembly must
always be replaced once disconnected.
11. Replace fuel leak-off pipe and temperature sensor assembly
Page 3 of 3
12. Install air cleaner assembly and components previously removed in step 1
Page 1 of 37
Fuel Injector Pipe, Replace
J491060
Remove
one side
1 2
S 0012751

• Release clip
Page 2 of 37
2
1
3
S 0012749
• Release 2x clip
S 0012752

Page 3 of 37
1
1
S 0012753
1
2
3
S 0012861
support frame (3)
Page 4 of 37
1 2
S 0012918
support frame
1 3
S 0012860
Page 5 of 37
1 2
3 S 0012862


• Remove 5x bolt

• Release clip
Page 6 of 37
S 0012741

• Remove bolt (2)
Page 7 of 37
2 S 0012714

– Pull upwards
Page 8 of 37

– Pull off
Page 9 of 37
S 0012865
S 0013060

Page 10 of 37
S 0013065

• Release 4x clip
S 0013066

• Release 4x clip
Page 11 of 37
S 0013067
S 0013069

Page 12 of 37

• Release clip

Page 13 of 37
2 S 0012969
29. Disconnect engine harness from EGR control solenoid harness

Page 14 of 37
1 2
S 0013073
(2)
2
1
S 0013074
Page 15 of 37
1 2 3
• Remove bolt (2)
• Release 2x clip
• Remove O ring
4
S 0013070

legislation.
cleaning cloths.
Page 16 of 37
one side
• Release 2x integral clip (2) 1
2 S 0012995

– Push in
Page 17 of 37

• Release 3x clip

Page 18 of 37
pressure pump
Install
Important: The common rail must be released to prevent excess stress

being applied to the new fuel injector pipes.
43. Release common rail from cylinder head
Page 19 of 37
44. Install 4x new high pressure pipe (1) to common rail and 4x fuel
injector; do not tighten at this stage

Page 20 of 37
S 0009855



Page 21 of 37
pressure pump


– Push in

Page 22 of 37

1
2 S 0012995

Page 23 of 37
section and engine
• Secure clip (1)
S 0013070

Page 24 of 37
2
1
S 0013074
61. Connect engine harness to EGR control solenoid harness

Page 25 of 37
1 2
S 0013073

2 S 0012969

Page 26 of 37

• Secure clip

Page 27 of 37
S 0013069

• Secure 4x clip
Page 28 of 37
S 0013067

• Secure 4x clip
S 0013066

Page 29 of 37
S 0013065
S 0013060

– Push on
Page 30 of 37
S 0012865

– Push downwards
Page 31 of 37

Page 32 of 37
2 S 0012714

• Secure clip
Page 33 of 37
S 0012741

Page 34 of 37
1 2
3 S 0012862
• Secure clip (3)
1
2
3
S 0012861
support frame
• Secure clip (2)
Page 35 of 37
1 3
S 0012860
frame (3)
• Secure clip (2)
1 2
S 0012918

Page 36 of 37
1
1
S 0012753
• Secure 2x clip
S 0012752

• Secure clip
Page 37 of 37
2
1
3
S 0012749

• Secure clip (2)
1 2
S 0012751

Page 1 of 43
Fuel Injectors, Replace
J491070
Remove
2. For vehicles with SPS function, download data from engine control unit using Tech 2
Note: Vehicles with IMA injectors, record IMA injector code with Tech 2 for reprogramming.
one side
1 2
S 0012751

• Release clip
Page 2 of 43
2
1
3
S 0012749
• Release 2x clip
2
S 0012752

Page 3 of 43
1
1
S 0012753
1
2
3
S 0012861
support frame (3)
Page 4 of 43
1 2
S 0012918
support frame 2
• Remove bolt (3)
1 3
S 0012860
Page 5 of 43
1 2
3 S 0012862


• Remove 5x bolt

• Release clip
Page 6 of 43
S 0012741

• Remove bolt (2)
Page 7 of 43
2 S 0012714

– Pull upwards
Page 8 of 43

– Pull off
Page 9 of 43
S 0012865
S 0013060

Page 10 of 43
S 0013065

• Release 4x clip
S 0013066

• Release 4x clip
Page 11 of 43
S 0013067
S 0013069

Page 12 of 43

• Release clip

Page 13 of 43
2 S 0012969
30. Disconnect engine harness from exhaust gas recirculation (EGR)

control solenoid harness
Page 14 of 43
1 2
S 0013073
(2) 2
1
S 0013074
Page 15 of 43
1 2 3
• Remove bolt (2)
• Release 2x clip
• Remove O ring
4
S 0013070

legislation.
cleaning cloths.
Page 16 of 43
one side 1
2 S 0012995

– Push in
Page 17 of 43

• Release 3x clip
pressure pump
Page 18 of 43
1 2
3 S 0013000

• Remove bolt (2)

Page 19 of 43


Page 20 of 43

Injector”
Install
Important: Each fuel injector used in the EDC 16 fuel injection system is
calibrated with a specific code sequence to ensure correct and precise flow.
This process, known as IMA calibration, requires that a specific seven-digit
code must be programmed into the engine control unit with Tech 2. This
code (1) is printed on the fuel injector.
55. For each new fuel injector, carefully record code (1) and cylinder to
which injector is to be installed
Note: No. 1 cylinder is at the transmission end of the engine.
Note: The letters J and Q, and the numbers 0 and 9 are not used in
IMA coding. To assist identification of characters in the code, compare
other characters displayed on the injector. In the illustation, the IMA
code shown is 68HV7i1.
Page 21 of 43
S 0014633

57. Install 4x new seal to 4x new fuel injector
clamp
above procedure
Page 22 of 43

Page 23 of 43

Page 24 of 43
S 0009855



Page 25 of 43

• Secure to clip

Page 26 of 43


Page 27 of 43
Important: New clips must be used.

– Push in


Page 28 of 43
2 S 0012995

section and engine
• Secure clip (1)
Page 29 of 43
1 2 3
S 0013070

Page 30 of 43
2
1
S 0013074

1 2
S 0013073

Page 31 of 43
2 S 0012969

• Release clip
Page 32 of 43


Page 33 of 43
S 0013069

• Secure 4x clip
S 0013067

• Secure 4x clip
Page 34 of 43
S 0013066

S 0013065
Page 35 of 43
S 0013060

– Push on
S 0012865

– Push downwards
Page 36 of 43

Page 37 of 43
2 S 0012714

• Secure clip
Page 38 of 43
2 S 0012714

Page 39 of 43
1 2
3 S 0012862
• Secure clip (3)
Page 40 of 43
1
2
3
S 0012861
support frame 2
• Secure clip (2)
1 3
S 0012860
support frame (3)
• Secure clip (2)
Page 41 of 43
1 2
S 0012918

1
1
S 0012753
• Secure 2x clip
Page 42 of 43
S 0012752

111. Connect hose (2) to mass air flow meter (1) 2
• Secure clip
1
3
S 0012749

• Secure clip (2)
Page 43 of 43
1 2
S 0012751

114. For vehicles with SPS function, program engine control unit using Tech 2
Page 1 of 26
Fuel Leak-off Pipe with Temperature Sensor, Replace
J491850
Remove
one side

• Release clip
Page 2 of 26
2
1
3
S 0012749
• Release 2x clip
2
S 0012752

Page 3 of 26
1
1
S 0012753
1
2
3
S 0012861
frame
support frame
• Remove bolt (3)
Page 4 of 26
1 3
S 0012860
1 2
3 S 0012862

12. Remove radiator grille

• Remove 5x screw
Page 5 of 26
13. Disconnect pipe from intercooler and move to one side

Page 6 of 26
S 0013151

• Remove bolt (2)
15. Remove O ring seal from hose assembly
Page 7 of 26
2 S 0012714
16. Remove intercooler from reinforcement panel

– Pull upwards
Page 8 of 26
Page 9 of 26
S 0013060
18. Disconnect harness for oxygen sensor and turbocharger temperature sensor from engine harness
19. Release harness from 4x clip (3) on fuel rail cover, then move to one side
21. Remove fuel rail cover (1) from engine
• Release 4x clip
22. Install new blanking plug to cylinder head cover
• Pull off
Page 10 of 26
S 0012992
25. Disconnect 3x harness connector (1) from 3x fuel injector

Note: The connector to fuel injector for No. 1 cylinder is not
disconnected.

Page 11 of 26
S 0013069
27. Remove oil level dipstick (3) from guide tube

28. Remove upper section (4) of guide tube for oil level dipstick from lower
1 2 3
section
• Release harness (1) from guide tube
• Remove bolt (2)
• Install new blanking plug to lower section
• Remove O ring seal
S 0013070

legislation.
cleaning cloths.
Page 12 of 26
30. Disconnect fuel feed pipe (2) from high pressure pump
1 2
• Release from clip on engine
3
S 0012928

• Release 4x clip
– Push in
Page 13 of 26

34. Remove fuel leak-off pipe from engine

• Release 3x clip
Install
35. Install new fuel leak-off pipe to engine

• Secure 3x clip

Page 14 of 26

• Secure 4x clip
– Push in
38. Connect fuel leak-off pipe (3) to high pressure pump

• Secure to clip on engine
Page 15 of 26
1 2
S 0012928

41. Install upper section (4) of guide tube for oil level dipstick to lower
section
• Secure harness (1) to guide tube
42. Install oil level dipstick (3) to guide tube
Page 16 of 26
1 2 3
S 0013070
S 0012992
44. Connect 3x harness connector (1) to 3x fuel injector

Note: The connector to fuel injector for No. 1 cylinder was not
disconnected.
Page 17 of 26
S 0013069
Page 18 of 26
46. Remove blanking plug from cylinder head cover

47. Install fuel rail cover (1) to engine
• Ensure seal is correctly located to cover
• Secure 4x clip
• Push on
50. Connect harness for oxygen sensor and turbocharger temperature sensor to engine harness
51. Secure harness to 4x clip (3) on fuel rail cover
S 0013060
Page 19 of 26
53. Install intercooler to reinforcement panel

– Push downwards
54. Install new O ring seal to hose assembly

Page 20 of 26
2 S 0012714
56. Connect pipe to intercooler

• Secure clip (1)
Page 21 of 26
S 0013151
57. Install radiator grille

Page 22 of 26
Page 23 of 26
1 2
3 S 0012862

frame 2
frame 1 3
• Secure clip (2)
S 0012860
• Secure clip (3)
Page 24 of 26
1
2
3
S 0012861

1
1
S 0012753
63. Install air intake duct (1) to air cleaner assembly (2) and front panel
• Secure 2x clip
Page 25 of 26
S 0012752

65. Connect hose (2) to mass air flow meter (1) 2
• Secure clip
1
3
S 0012749

• Secure clip (2)
Page 26 of 26
1 2
S 0012751

Page 1 of 8
Fuel Pressure Regulator, Replace (with Air Conditioning)
J491020
Remove

3. Release pulley (1) from power steering pump (2)
1 2
3
S 0012762

6130 (1)
Page 2 of 8
5. Rotate tension roller clockwise, then remove locating pin

6. Remove tension roller (1) from engine
• Remove 2x bolt (arrowed)
Page 3 of 8

• Remove 3x bolt
8. Release power steering pump (2) from engine, then position to one side
Note: The power steering hoses are not disconnected; this avoids fluid
loss and eliminates the need to bleed the hydraulic system.
Page 4 of 8
9. Remove fuel pressure regulator from high pressure pump

Page 5 of 8
S 0012988
Install
10. Install new pressure regulator to high pressure pump

• Install 2x new O ring seal, new gasket, 3x bolt (1) 3 Nm , then 6 Nm
1
S 0012988
11. Secure power steering pump (2) to engine

Page 6 of 8
12. Install new tension roller (1) to engine

• Install 2x bolt (arrowed) 21 Nm
Page 7 of 8
13. Install pulley (1) to power steering pump (2)

1 2
3
S 0012762
14. Rotate tension roller clockwise, then lock into position using Locating Pin KM-6130
(1)
Page 8 of 8
16. Secure pulley to power steering pump

20. For vehicles as of MY 2008, program fuel pressure regulator using Tech 2
Page 1 of 2
Fuel Pressure Regulator, Replace (without Air Conditioning)
J491020
Remove

3. Release power steering feed hose (1) from auxiliary bracket (2), then
move to one side
• Pull off
2
S 0012771
4. Remove fuel pressure regulator from high pressure pump

1
S 0012989
Install
Page 2 of 2
5. Install new fuel pressure regulator to high pressure pump

• Install 2x new O ring seal, new gasket, 3x bolt (1) 3 Nm , then 6 Nm
1
S 0012989
6. Secure power steering feed hose to auxiliary bracket

• Push on
S 0012771
10. For vehicles as of MY 2008, program fuel pressure regulator using Tech 2
Page 1 of 1
Functional Description: Engine Management System

Specifications
G9U 632 (low G9U 630 and G9U G9U 650 (low G9U 650 (high
Engine
output) 632 (high output) output) output)
Bosch EDC 16
Engine management system - Bosch EDC 16 C36 Bosch EDC 16 C36 Bosch EDC 16 C36
C36
Exhaust emission standards - Euro IV Euro IV Euro IV Euro IV
No. of cylinders/configuration - 4 in line 4 in line 4 in line 4 in line
No. of valves - 16 16 16 16
Capacity cm 3 2463 2463 2463 2463
Bore diameter mm 89 89 89 89
Stroke mm 99 99 99 99
Firing order - 1–3–4–2 1–3–4–2 1–3–4–2 1–3–4–2
Power output kW/rpm 88/3500 107/3500 74/3500 88/3500
Torque Nm/rpm 300/1500 320/1500 260/1600 290/1600
Diagram of Engine Management System
1. High pressure 14. Turbocharger

pump
2. Fuel temperature 15. Compressor
sensor
3. Common rail 16. Intercooler
4. Fuel pressure 17. Charge pressure sensor
sensor
5. Fuel filter 18. Coolant temperature
sensor
6. Fuel tank 19. Exhaust gas recirculation
valve
7. Fuel pressure 20. Engine control unit
regulator
8. Mass air flow meter 21. Oil level sensor
9. Oil pressure valve 22. Crankshaft inductive
pulse pickup
10. Air flap 23. Exhaust gas bypass
11. Camshaft sensor 24. Exhaust gas regulator
12. Fuel injector 25. Primary catalytic
converter
13. Glow plug
Page 1 of 91
Gasket, Cylinder Head, Replace
J457500
Remove
one side
1 2
S 0012751

• Release clip
Page 2 of 91
2
1
3
S 0012749
S 0012752

Page 3 of 91
1
1
S 0012753
1
2
3
S 0012861
• Remove bolt (3)
Page 4 of 91
1 3
S 0012860
• Remove 2x nut

• Remove bolt (2)
1
2 S 0014441

• Pull off
Page 5 of 91
S 0012865

• Release clip
1
– Release from 6x retainer
S 0012870

• Release 2x clip
Page 6 of 91
S 0012722

• Release 4x clip
S 0013066

Page 7 of 91
S 0012872
21. Raise vehicle

• Remove 8x bolt

Note: Illustration shows the wheelarch liner removed for clarity.

• Remove bolt
25. Lower vehicle
Note: Observe the relevant environmental regulations when disposing
of used coolant.
• Connect suitable hose to radiator drain plug (1)
Page 8 of 91

1
S 0012760
29. Raise vehicle

30. Install 2x support stand to front of vehicle
• Remove 10x bolt

• Remove 2x nut

to steering knuckle
• Tighten rod (4)
Page 9 of 91

• Use Remover KM-507-C 1
2
3
4 S 0016919
36. Raise vehicle
• Release 2x clip


• Remove nut (3), bolt
• Remove bolt (5)
Page 10 of 91
1 2 3 4
5
S 0012879



Page 11 of 91

1 2
3
S 0012881
Page 12 of 91
exhaust pipe (2), then move to one side 1
2 S 0012883

Page 13 of 91
2 S 0012884

Page 14 of 91
S 0012885
engine
51. Remove bracket (3), right side from primary catalytic converter and
engine
Page 15 of 91

Page 16 of 91
S 0012873
• Remove 4x nut (2), gasket 1
S 0012886

• Release 2x clip
Page 17 of 91
– Use pipe spanner KM-812 1

– Remove bolt
• Remove bolt
2
• Pull off
5
4
3 S 0012887

2
1
S 0012890

Page 18 of 91
1 2
S 0012891

S 0012716
crankshaft
Page 19 of 91
PMH
S 0017785
64. Lower vehicle
Page 20 of 91
S 0012715
2 S 0012721
• Remove 2x bolt

Page 21 of 91
S 0012718
69. Align 2x camshaft

• Align flat surfaces (1) of each camshaft to vertical position
• Position small flat surface (2) on left side
Note: Camshaft pulleys and flanges shown removed for clarity.
70. Raise vehicle

72. Lower vehicle
73. Remove lower cover for timing belt from engine
• Remove 9x bolt
Page 22 of 91
S 0012723

• Release 3x bolt (arrowed) for exhaust camshaft pulley
• Adjust camshaft if necessary
Note: Ensure Locking/Measurement Tool KM-6205 locates
correctly. If the tool does not locate correctly on camshaft, or bolt
cannot be installed, adjust the camshaft.
– Rotate camshaft by turning bolt in centre of pulley
• Secure bolt
75. Install Locking Tool KM-6204 (2) to intake camshaft
• Release 3x bolt (arrowed) for intake camshaft pulley
Note: Ensure Locking Tool KM-6204 locates correctly. If the tool
does not locate correctly on camshaft, or bolt cannot be installed,
adjust the camshaft.
• Secure bolt
76. Release timing belt tensioner (1)

Page 23 of 91
77. Remove timing belt (2) with intake camshaft pulley (1)
• Remove 3x bolt
78. Remove timing belt tensioner from engine

• Remove bolt
Page 24 of 91
79. Remove guide roller from engine

• Remove bolt
Page 25 of 91
S 0013060

• Release 4x clip
S 0013067

Page 26 of 91
S 0013069

Page 27 of 91
86. Disconnect pipe (1) from vacuum pump, then move to one side

Page 28 of 91

2 S 0012969
90. Disconnect engine harness from exhaust gas recirculation (EGR)

control solenoid harness
Page 29 of 91
1 2
S 0013073
91. Disconnect harness connector (1) EGR vacuum control solenoid (2)
2
1
S 0013074
92. Disconnect harness connector from EGR module

Page 30 of 91
1 2 3
• Remove bolt (2)
• Release 2x clip
• Remove O ring
4
S 0013070

legislation.
cleaning cloths.
Page 31 of 91
one side 1
2 S 0012995

– Push in
Page 32 of 91

• Release 3x clip
pressure pump
Page 33 of 91
1 2
3 S 0013000

105. Remove 4x high pressure pipe (1) from 4x fuel injector and common
rail
• Remove bolt (2)

Page 34 of 91


Page 35 of 91

114. Remove remaining 3x fuel injector, in accordance with above
procedure
Injector”

Page 36 of 91
118. Remove fuel rail protector (1) from engine

• Remove 2x bolt

• Remove 2x bolt
• Remove 3x screw
Page 37 of 91


• Remove 19x bolt
Page 38 of 91
1 S 0013075

• Pull out

• Remove 5x bolt
Page 39 of 91
127. Remove intake rocker shaft from cylinder head

• Remove 6x bolt
128. Remove exhaust rocker shaft from cylinder head
• Remove 6x bolt
Page 40 of 91
1 2 S 0006446
129. Release thermostat housing from cylinder head

Note: Coolant hoses shown removed for clarity.
• Withdraw thermostat housing from coolant pump return pipe (2)
– Slide off
• Remove O ring, gasket
130. Release EGR pipe from cylinder head

• Remove 2x bolt
131. Remove cylinder head from cylinder block

Page 41 of 91
• Remove 10x bolt
132. Transfer cylinder head to suitable work station

133. Remove cylinder head gasket from cylinder block
• Release from 2x dowel
• Clean mating surfaces of cylinder head
• Clean mating surfaces of cylinder block
134. Check plane surface of cylinder head – see operation “Cylinder Head, Check for Plane Surface”
Install
Important: Remove all fluids from the threaded holes in the cylinder block
to ensure the correct tightening of the cylinder head bolts. Use a syringe to
remove any oil/coolant.
135. Install new cylinder head gasket to cylinder block
• Locate cylinder head gasket onto 2x dowel
Page 42 of 91
Important: Install 10x new cylinder head bolts. Do not lubricate cylinder
head bolts.
136. Install cylinder head to cylinder block
Note: Do not re-tighten cylinder head bolts after carrying out the
following procedure.
• Install 10x cylinder head bolt 30 Nm in sequence shown
• Check torque of 10x cylinder head bolt is 30 Nm in sequence
shown
• Secure 10x cylinder head bolt 300° ± 6° in sequence shown
Page 43 of 91
1 2 S 0006446
137. Secure thermostat housing to cylinder head

• Position thermostat housing to coolant pump return pipe (2)
– Slide on

the cylinder head.
• Remove clip (1)
140. Secure EGR pipe to cylinder head

Page 44 of 91

Note: The exhaust camshaft pulley and both flanges are shown

Page 45 of 91

Page 46 of 91


Page 47 of 91


Page 48 of 91


Page 49 of 91

Page 50 of 91

• Secure clip (1)

• Install 2x bolt
• Clean mating surfaces, then apply suitable sealant – see
Page 51 of 91

1
S 0013077

Page 52 of 91

clamp
above procedure
Page 53 of 91
Page 54 of 91

1
S 0013082



Page 55 of 91

stage
Page 56 of 91

• Secure to clip


Page 57 of 91



• Secure 4x clip
Page 58 of 91

1
2 S 0012995

Page 59 of 91
section and engine 1 2 3
• Secure clip (1)
4
S 0013070

Page 60 of 91
2
1
S 0013074

Page 61 of 91
1 2
S 0013073

2 S 0012969

Page 62 of 91


Page 63 of 91


Page 64 of 91
S 0013069

• Secure 4x clip
S 0013067
Page 65 of 91
S 0013060
208. Install new guide roller to engine

Important: Locate the rear plate of tensioner behind Locking/Measurement

Tool KM-6205 before installing the bolt.
209. Install new timing belt tensioner to engine
• Locate groove (1) of timing belt tensioner to dowel pin (2)
Page 66 of 91
210. Install new timing belt (2) with intake camshaft pulley (1)
Note: Ensure the timing belt locates centrally on the pulleys; the
camshaft pulleys locate correctly on the camshafts, and that the
bolts are in the centre of the slots.
Page 67 of 91
211. Check lever arm of Locking/Measurement Tool KM-6205 moves freely

212. Pre-tension timing belt
• Rotate timing belt tensioner anti-clockwise, until surface (1) of
lever arm, is level with body of Locking/Measurement Tool KM-
6205 for exhaust camshaft
• Secure timing belt tensioner
– Secure bolt 25 Nm
213. Check timing belt tensioner

• Pointer (1) of tensioner should be in position shown in illustration
Page 68 of 91
214. Secure 2x camshaft pulley to 2x camshaft

• Secure 6x bolt (arrowed) 10 Nm
Note: Check that the camshaft pulleys locate correctly on the
camshafts, and that the bolts are in the centre of the slots.
camshaft
• Remove bolt
216. Remove Locking Tool KM-6204 (2) from intake camshaft
• Remove bolt
217. Raise vehicle

Page 69 of 91
S 0012717
219. Rotate crankshaft 720° clockwise

220. Install Positioning Pin KM-6203 (arrowed), through oil filter housing
into crankshaft
compression stroke
Page 70 of 91
PMH
S 0017785
221. Lower vehicle

• Secure bolt
Page 71 of 91
• Secure bolt

226. Tension timing belt

• Rotate timing belt tensioner clockwise, until raised surface (1) of
lever arm is level with body of Locking/Measurement Tool KM-
6205
• Pointer of timing belt tensioner should be aligned within groove
Page 72 of 91

camshafts, so that the bolts are in the centre of the slots.
camshaft
• Remove bolt
• Remove bolt
Page 73 of 91
230. Install lower cover for timing belt to engine

S 0012723
231. Raise vehicle

233. Lower vehicle
Page 74 of 91
S 0012718

2
1
3
5 4 S 0013084

Page 75 of 91
S 0012715
238. Raise vehicle

S 0012717

Page 76 of 91
S 0012716
S 0012891

Page 77 of 91
2
1
S 0012890


1
2
– Install bolt

5
• Push in to engine 4
• Secure 2x clip
3 S 0012887

Page 78 of 91
S 0012886

S 0012873
Page 79 of 91
Page 80 of 91
S 0012885
exhaust pipe (2)
Page 81 of 91
2 S 0012883

1
– Slide on
2 S 0012884
Page 82 of 91
chassis

Page 83 of 91


Page 84 of 91
1 2 3 4
5
S 0012879


Page 85 of 91
1 2
3
S 0012881

• Secure 2x clip
when installing the nut. 1
to steering knuckle
• Tighten rod (4)
2
3
4 S 0016919

Page 86 of 91

275. Raise vehicle
276. Remove 2x support stand from front of vehicle
277. Lower vehicle
S 0012872

• Secure 4x clip
Page 87 of 91
S 0013066

• Secure 2x clip
S 0012722

• Secure clip
– Secure to 6x retainer
Page 88 of 91
S 0012870

• Push on
S 0012865

• Secure clip (1)
Page 89 of 91
2 S 0014441
• Secure clip (3)
1
2
3
S 0012861
support frame
frame
• Secure clip (2)
Page 90 of 91
1 3
S 0012860

panel
– Release 4x clip
Page 91 of 91
• Secure 4x clip
302. Stop engine
304. Raise vehicle

308. Lower vehicle
Page 1 of 8
Glow Plug, Replace
J486000
Remove
one side
1 2
S 0012751

• Release clip
2
1
3
S 0012749
• Release 2x clip
Page 2 of 8
S 0012752

1
1
S 0012753
Page 3 of 8
1
2
3
S 0012861
7. Release harness for coolant heater assembly (1) from support frame
8. Release bracket with coolant heater assembly from support frame
• Remove bolt (3)
2
1 3
S 0012860
Page 4 of 8
1 2
3 S 0012862

10. Disconnect harness connector (1) from glow plug

11. Remove glow plug from cylinder head
Install
12. Install new glow plug to cylinder head 11 Nm

13. Connect harness connector (1) to glow plug
Page 5 of 8
1 2
3 S 0012862

• Secure clip (3)
Page 6 of 8
1
2
3
S 0012861
16. Secure bracket with coolant heater assembly (1) to support frame
17. Secure harness for coolant heater assembly to support frame
• Secure clip (2)
2
1 3
S 0012860

Page 7 of 8
1
1
S 0012753
• Secure 2x clip
S 0012752

• Secure clip
Page 8 of 8
2
1
3
S 0012749

• Secure clip (2)
1 2
S 0012751
Page 1 of 5
Guide Roller, Ribbed V-belt, Replace
J607320
Remove
1. Raise vehicle

6130 (1)
Page 2 of 5
5. Remove guide roller (1) from engine

• Remove bolt
Page 3 of 5
Install
6. Install new guide roller (1) to engine


(1)
Page 4 of 5

Page 5 of 5

10. Lower vehicle
Page 1 of 16
Guide Tube for Oil Level Dipstick, Replace
J461400
Remove

one side
1 2
S 0012751

• Release clip
2
4. Disconnect harness connector (3) from mass air flow meter 1
3
S 0012749
• Release 2x clip
Page 2 of 16
S 0012752

1
1
S 0012753
7. Release harness (1) for mass air flow meter from air cleaner support
frame (2)
Page 3 of 16
1
2
3
S 0012861
support frame (3) 1 2
S 0012918
support frame
• Remove bolt (3)
Page 4 of 16
1 3
S 0012860
1 2
3 S 0012862


• Remove 5x bolt
Page 5 of 16

• Release clip
S 0012741

• Remove bolt (2)
Page 6 of 16
2 S 0012714

– Pull upwards
Page 7 of 16
16. Raise vehicle

• Remove 8x bolt
18. Release lower section of guide tube for oil level dipstick from engine
• Remove bolt (1)
19. Release harness for EGR from lower section of guide tube
• Release clip
Page 8 of 16
S 0012906
20. Lower vehicle

22. Remove upper and lower guide tube assembly from engine
1 2 3
compartment
• Remove bolt (2)
• Remove O ring seal
S 0013070
Install
23. Raise vehicle

24. Install new lower section of guide tube for oil level dipstick to engine
25. Secure harness for EGR to lower section of guide tube
• Secure clip
Page 9 of 16
S 0012906
26. Lower vehicle

27. Install new upper section (4) of guide tube for oil level dipstick
1 2 3
S 0013070
29. Raise vehicle

31. Lower vehicle
– Push downwards
Page 10 of 16

Page 11 of 16
2 S 0012714

• Secure clip
Page 12 of 16
S 0012741

Page 13 of 16
1 2
3 S 0012862
37. Install harness (1) for mass air flow meter to air cleaner support frame
(2) 1
• Secure clip (3)
2
3
S 0012861
support frame
• Secure clip (2)
Page 14 of 16
1 3
S 0012860
frame (3) 1 2
• Secure clip (2)
S 0012918

Page 15 of 16
1
1
S 0012753
S 0012752

• Secure clip
Page 16 of 16
2
1
3
S 0012749

• Secure clip (2) 1 2
S 0012751

Page 1 of 26
High Pressure Pipe, Replace
J491030
Remove
one side
1 2
S 0012751

• Release clip
Page 2 of 26
2
1
3
S 0012749
• Release 2x clip
S 0012752

Page 3 of 26
1
1
S 0012753
support frame (3)
1 2
S 0012918
support frame
• Remove bolt (3)
Page 4 of 26
1 3
S 0012860
1 2
3 S 0012862


• Remove 5x bolt
Page 5 of 26

• Release clip
S 0012741

• Remove bolt (2)
Page 6 of 26
2 S 0012714

– Pull upwards
Page 7 of 26
16. Disconnect breather hose from engine

– Pull off
Page 8 of 26
S 0012865
S 0013060

Page 9 of 26
S 0013065

• Release 4x clip
S 0013066

• Release 4x clip
Page 10 of 26
S 0013067

legislation.
cleaning cloths.
Page 11 of 26

• Release 4x clip
– Push in

Page 12 of 26
• Release 3x clip
26. Disconnect high pressure pipe from high pressure pump

pressure pump
28. Remove high pressure pipe (1) from common rail and cylinder head
cover
• Remove bolt (2)

Page 13 of 26
Install

Page 14 of 26
S 0009855
30. Connect high pressure pipe (1) to common rail; do not tighten at this
stage

32. Install new high pressure pipe to common rail and high pressure pump
• Connect 2x pipe union (1, 4); do not tighten at this stage
• Secure high pressure pipe to clip (3)
34. Secure high pressure pipe to common rail and high pressure pump
• Secure 2x pipe union (1, 4) 27 Nm
Page 15 of 26

35. Install new fuel leak-off pipe (5) to high pressure pump


• Secure 4x clip
Page 16 of 26


Page 17 of 26

• Secure 4x clip
S 0013067

• Secure 4x clip
Page 18 of 26
S 0013066

S 0013065
Page 19 of 26
S 0013060
45. Connect breather hose to engine

– Push on
S 0012865

– Push downwards
Page 20 of 26

Page 21 of 26
2 S 0012714

• Secure clip
Page 22 of 26
S 0012741

Page 23 of 26
1 2
3 S 0012862
support frame
• Secure clip (2) 2
• Push on 4x locating peg
1 3
S 0012860
frame (3)
• Secure clip (2)
Page 24 of 26
1 2
S 0012918

1
1
S 0012753
• Secure 2x clip
Page 25 of 26
S 0012752

• Secure clip
2
1
3
S 0012749

• Secure clip (2)
Page 26 of 26
1 2
S 0012751

Page 1 of 47
High Pressure Pump, Replace
J491010
Remove
one side
1 2
S 0012751

• Release clip
Page 2 of 47
2
1
3
S 0012749
• Release 2x clip
S 0012752

Page 3 of 47
1
1
S 0012753
1
2
3
S 0012861
• Remove bolt (3)
Page 4 of 47
1 3
S 0012860
• Remove 2x nut
13. For vehicles with air conditioning, release pulley (1) from power
steering pump (2)
1 2
3
S 0012762
14. Raise vehicle

• Remove 8x bolt

Note: Illustration shows wheel arch liner removed for clarity.
Page 5 of 47
17. For vehicles with air conditioning, remove ribbed V-belt from engine
6130 (1)
Page 6 of 47
18. For vehicles with air conditioning, rotate tension roller clockwise, then remove Locating Pin KM-6130
19. For vehicles with air conditioning, remove idler roller for ribbed V-belt
from engine
• Remove bolt (1)
Page 7 of 47
20. For vehicles with air conditioning, remove tensioner (1) for ribbed V-belt
from engine

Page 8 of 47
S 0012716
crankshaft
Page 9 of 47
PMH
S 0017785
23. Lower vehicle

25. For vehicles with air conditioning, remove pulley from power steering pump
• Remove 3x bolt
26. For vehicles without air conditioning, release power steering feed hose
from auxiliary support bracket, then move to one side
• Pull off
Page 10 of 47
S 0012764
27. Remove bracket (1) from auxiliary support bracket and exhaust gas
2
3 S 0012765
28. For vehicles with air conditioning, release power steering pump from
engine, then move to one side
• Remove 3x bolt
Page 11 of 47
S 0012766
29. Secure upper coolant hose for radiator to engine using suitable method
Note: To allow access to the EGR cooler.
30. Disconnect engine harness connector from EGR control solenoid
harness
Page 12 of 47
S 0013268
31. Release EGR cooler from intake manifold and EGR valve housing
• Disconnect vacuum hose
• Remove 7x bolt (1), then move to one side
• Remove gasket
S 0013422

• Disconnect intercooler pipe from EGR valve
housing
pressure sensor (4)
Page 13 of 47
33. Secure lower coolant hose for radiator to transmission, using suitable method
Note: To allow access to the EGR valve housing.
1 2
S 0013423

36. Remove upper section (4) of guide tube for oil level dipstick from lower
section
• Remove bolt (2)
Page 14 of 47
• Remove O ring
1 2 3
S 0013070
• Remove bolt (1)
• Remove O ring
S 0012906

Page 15 of 47
2 S 0012969
40. Release camshaft sensor from casing of high pressure pump, then
move to one side
Note: The harness connector is not disconnected.
• Remove bolt (1), O ring
S 0012908
Page 16 of 47
41. Disconnect harness for oxygen sensor and turbocharger temperature sensor from engine harness
42. Release harness from 4x clip (3) on fuel rail cover, then move to one side
• Release 4x clip
45. Install new blanking plug to cylinder head cover
• Pull off

legislation.
cleaning cloths.
Page 17 of 47
48. Disconnect 3x harness connector (1) from 3x fuel injector

Note: The connector to fuel injector for No. 1 cylinder is not
disconnected.

– Push in

Page 18 of 47
• Release 3x clip
52. Release high pressure pipe from common rail and cylinder head cover
• Remove bolt (2)

one side
Page 19 of 47
2 S 0012995
54. Remove high pressure pipe (2) from high pressure pump
pressure pump
3 S 0013000
Important: Ensure that the casing of the high pressure pump is not
damaged when removing blanking cover.
56. Remove blanking cover (1) from casing of high pressure pump
Page 20 of 47
S 0012929
57. Install Gear Puller KM-6207 (1) to casing of high pressure pump
Note: If gear puller cannot be installed, remove Positioning Pin KM-
6203 , rotate engine 360 degrees and reinstall positioning pin.
• Remove centre bolt (2) from Gear Puller KM-6207
• Install 4x bolt
58. Raise vehicle

Page 21 of 47
S 0012717

S 0012716
61. Remove flywheel cover from transmission

62. Lock flywheel to prevent clockwise rotation of engine
• Install Locking Tool KM-911 (2) to flywheel
• Insert suitable tool through transmission clutch housing to prevent
movement of locking tool
Page 22 of 47
63. Lower vehicle

64. Remove centre nut (1) from high pressure pump
Page 23 of 47
S 0012931
65. Release high pressure pump from engine

Page 24 of 47
66. Remove high pressure pump from engine

• Install centre bolt (2) to Gear Puller KM-6207 (1), then turn centre
bolt clockwise, until high pressure pump is released from engine
• Remove 3x bolt from rear of high pressure pump
• Remove centre bolt from Gear Puller KM-6207
Page 25 of 47
Install
67. Install new high pressure pump to soft-jawed vice

68. Prime high pressure pump
• Connect suitable hose to high pressure pump inlet port
– Remove blanking plug from inlet port
• Fill hose with diesel fuel
• Install Pressure and Vacuum Pump MKM-667
– Use suitable adaptor
• Remove blanking plug from high pressure pump outlet port
Warning: Maximum pressure must not exceed 1.5 bar .
• Apply pressure until diesel fuel flows from outlet port and is clear
and free from bubbles
• Install blanking plug to high pressure pump outlet port
• Remove Pressure and Vacuum Pump MKM-667 and adaptor from
hose
• Remove hose from high pressure pump inlet port
• Install blanking plug to high pressure pump inlet port
Page 26 of 47
S 0012933
69. Transfer high pressure pump to vehicle

70. Install high pressure pump to engine
Page 27 of 47
71. Install centre nut (1) to high pressure pump; do not tighten at this stage
Page 28 of 47
S 0012931
72. Raise vehicle

73. Lock flywheel to prevent anti-clockwise rotation of engine
• Reposition Locking Tool KM-911 (1) to flywheel
• Insert suitable tool through transmission clutch housing to prevent
movement of locking tool
S 0012934
74. Lower vehicle

76. Secure centre nut 90 Nm to high pressure pump
77. Remove Pump Extractor KM-6207 from casing of high pressure pump
• Remove 4x bolt
78. Install new blanking cover to casing of high pressure pump
• Use Cover Installer KM-6208
pressure pump
Page 29 of 47

1 2
S 0012928

• Release 2x bolt
82. Install high pressure pipe to common rail and high pressure pump
• Secure to clip
• Connect 2x pipe union (1, 3); do not tighten at this stage
Page 30 of 47




Page 31 of 47
87. Secure fuel leak-off pipe to engine

• Secure 3x clip

Page 32 of 47

– Push in
90. Connect 3x harness connector (1) to 3x fuel injector

Note: The connector to fuel injector for No. 1 cylinder was not
disconnected.
Page 33 of 47

Page 34 of 47
92. Remove blanking plug from cylinder head cover

• Ensure seal is correctly located to cover
• Secure 4x clip
• Push on
96. Connect harness for oxygen sensor and turbocharger temperature sensor to engine harness
97. Secure harness to 4x clip (3) on fuel rail cover
98. Raise vehicle

99. Remove Locking Tool KM-911 (1) from flywheel
• Remove suitable tool previously inserted through transmission
clutch housing
S 0012934
Page 35 of 47
100. Install flywheel cover to transmission

• Install 2x bolt
S 0012906
102. Lower vehicle

103. Install upper section (4) of guide tube for oil level dipstick to lower
section
• Push into lower section of guide tube to secure to 2x clip 1 2 3
S 0013070
105. Secure camshaft sensor to casing of high pressure pump

Note: The harness connector was not disconnected.
Page 36 of 47
S 0012908

2 S 0012969
• Secure clip (1)
Page 37 of 47
1 2
S 0013423
109. Release lower coolant hose for radiator from transmission

110. Position EGR cooler to engine
• Connect harness connector to charge
pressure sensor (4)
• Secure intercooler pipe to EGR valve housing
– Secure clip (3)

the cylinder head.
112. Remove EGR pipe from bypass control valve for EGR cooler
• Remove clip
113. Install new EGR pipe to bypass control valve for EGR cooler
• Install new clip
Page 38 of 47
114. Secure EGR cooler to intake manifold and EGR valve housing
• Connect vacuum hose 1
S 0013422
115. Connect engine harness connector to EGR control solenoid harness
S 0013268
116. Release upper coolant hose for radiator from engine

117. For vehicles with air conditioning, secure power steering pump to
engine
Page 39 of 47
S 0012766
Page 40 of 47
3 S 0012765
119. For vehicles without air conditioning, secure power steering feed hose
to auxiliary support bracket
• Push on
S 0012764
120. For vehicles with air conditioning, install pulley (1) to power steering
pump (2)
Page 41 of 47
1 2
3
S 0012762

122. Raise vehicle
123. For vehicles with air conditioning, install new guide roller for ribbed V-
belt to engine
124. For vehicles with air conditioning, install new tensioner (1) for ribbed
V-belt to engine
Page 42 of 47
125. For vehicles with air conditioning, install ribbed new V-belt to engine
6031 (1)
Page 43 of 47

Page 44 of 47

128. Lower vehicle
129. For vehicles with air conditioning, secure pulley (1) to power steering
pump (2)
1 2
3
S 0012762
• Secure clip (3)
Page 45 of 47
1
2
3
S 0012861
support frame
2
frame
• Secure clip (2)
1 3
S 0012860

Page 46 of 47
1
1
S 0012753
• Secure 2x clip
S 0012752
• Secure clip
Page 47 of 47
2
1
3
S 0012749

• Secure clip (2)
1 2
S 0012751
142. Program fuel pressure regulator using Tech 2 (if required)
Note: Tech 2 programming may be required depending on the evolution of the new high pressure pump supplied.
Page 1 of 58
Intake Manifold, Replace
J471500
Remove
one side
1 2
S 0012751

• Release clip
Page 2 of 58
2
1
3
S 0012749
S 0012752

Page 3 of 58
1
1
S 0012753
1
2
3
S 0012861
support frame (3)
Page 4 of 58
1 2
S 0012918
support frame 2
• Remove bolt (3)
1 3
S 0012860
Page 5 of 58
1 2
3 S 0012862


• Remove 5x bolt

• Release clip
Page 6 of 58
S 0012741

• Remove bolt (2)
Page 7 of 58
2 S 0012714

– Pull upwards
Page 8 of 58

– Pull off
Page 9 of 58
S 0012865
S 0013060

Page 10 of 58
S 0013065

• Release 4x clip
S 0013066

• Release 4x clip
Page 11 of 58
S 0013067

S 0012872
23. Raise vehicle

• Remove 8x bolt

Page 12 of 58
S 0012873
26. Release fuel rail protector drain hose from engine assembly
• Release 2x clip
27. Disconnect harness connector from exhaust gas recirculation (EGR) module
29. Lower vehicle
30. Release fluid reservoir for power steering from upper front panel
• Remove bolt (2)
• Release 2x clip
• Remove O ring
Page 13 of 58

1 2 3
S 0013070
S 0013069

Page 14 of 58

• Release clip

Page 15 of 58
2 S 0012969
41. Release engine harness from EGR control solenoid harness

Page 16 of 58
1 2
S 0013073
(2) 2
1
S 0013074
Page 17 of 58

legislation.
cleaning cloths.
one side
Page 18 of 58
2 S 0012995

– Push in

Page 19 of 58
• Release 3x clip
• Release pipe union (3) 1 2
pressure pump
3 S 0013000

Page 20 of 58
• Remove bolt (2)


Page 21 of 58


Injector”
Page 22 of 58

• Remove 2x bolt
Page 23 of 58

• Remove 2x bolt
• Remove 3x screw

Page 24 of 58
70. Release 2x fuel pipe (1) from engine mount, then move to one side
1
S 0012715
71. Remove engine mount with torque reaction link from engine and vehicle
body
Page 25 of 58
2 S 0012721

• Remove 19x bolt
1 S 0013075

• Pull out
Page 26 of 58

• Remove 5x bolt

Page 27 of 58
Install

77. Install 8x new seal to new intake manifold
Page 28 of 58


Page 29 of 58


Page 30 of 58


Page 31 of 58


Page 32 of 58
87. Install engine mount with torque reaction link to engine and vehicle
body
• Install 4x bolt (2), new nut (1); do not tighten at this stage
2 S 0012721

89. Secure torque reaction link to vehicle body
90. Secure engine mount to vehicle body
Page 33 of 58
3 S 0012724
92. Secure 2x fuel pipe (1) to engine mount

1
S 0012715
Page 34 of 58

• Secure clip (1)

• Install 2x bolt
• Clean mating surfaces, then apply suitable sealant – see “Sealants,
Page 35 of 58

1
S 0013077

Page 36 of 58

clamp
above procedure
Page 37 of 58
Page 38 of 58

1
S 0013082



Page 39 of 58

stage
Page 40 of 58

• Secure to clip


Page 41 of 58



• Secure 4x clip
Page 42 of 58

1
2 S 0012995

Page 43 of 58
section and engine 1 2 3
• Secure clip (1)
4
S 0013070

Page 44 of 58
2
1
S 0013074
134. Secure engine harness to EGR control solenoid harness

Page 45 of 58
1 2
S 0013073

2 S 0012969

Page 46 of 58

• Secure clip

Page 47 of 58
S 0013069
142. Secure power steering reservoir and support bracket to upper front panel
• Secure to clip
143. Raise vehicle
146. Secure fuel rail protector drain hose to engine assembly
• Secure 2x clip

Page 48 of 58
S 0012873

149. Lower vehicle
S 0012872

• Secure 4x clip
Page 49 of 58
S 0013067

• Secure 4x clip
S 0013066

Page 50 of 58
S 0013065
S 0013060

– Push on
Page 51 of 58
S 0012865

– Push downwards
Page 52 of 58

Page 53 of 58
2 S 0012714

• Secure clip
Page 54 of 58
S 0012741

Page 55 of 58
1 2
3 S 0012862
• Secure clip (3)
1
2
3
S 0012861
support frame
• Secure clip (2)
Page 56 of 58
1 3
S 0012860
• Secure clip (2)
S 0012918

Page 57 of 58
1
1
S 0012753
S 0012752

• Secure clip
Page 58 of 58
2
1
3
S 0012749

S 0012751

Page 1 of 15
Intercooler, Replace
J600400
Remove
one side
1 2
S 0012751

• Release clip
2
1
3
S 0012749
4. Remove air intake duct (1) from air cleaner (2)

• Release 2x clip
Page 2 of 15
S 0012752

1
1
S 0012753
Page 3 of 15
1
2
3
S 0012861
support frame (3)
1 2
S 0012918
support frame
• Remove bolt (3)
Page 4 of 15
1 3
S 0012860

• Release clip
S 0012741
Page 5 of 15
1 2
3 S 0012862

11. Disconnect outlet hose from intercooler

S 0014169

– Pull upwards
Page 6 of 15
13. Remove air deflector (2) from intercooler

• Remove 2x clip (1)
Page 7 of 15
S 0014170
14. Remove 2x rubber mount (1) from intercooler

• Prise off using suitable tool
Page 8 of 15
Install
15. Install 2x rubber mount (1) to new intercooler
16. Install air deflector (2) to intercooler

Page 9 of 15
S 0014170

– Push downwards
Page 10 of 15
18. Connect outlet hose to intercooler

• Secure clip (1)
Page 11 of 15
S 0014169
1 2
3 S 0012862

• Secure clip
Page 12 of 15
S 0012741
• Secure clip (3)
1
2
3
S 0012861
support frame
• Secure clip (2)
Page 13 of 15
1 3
S 0012860

1
1
S 0012753
24. Install air intake duct (1) to air cleaner (2)

• Secure 2x clip
Page 14 of 15
S 0012752

• Secure clip
2
1
3
S 0012749

• Secure clip (2)
Page 15 of 15
1 2
S 0012751
Page 1 of 2
Mass Air Flow Meter, Replace
J741000
Remove
1. Remove mass air flow meter (2) from cover (1) of air cleaner assembly
• Disconnect harness connector (4) from mass air flow meter
• Release harness for mass air flow meter from air cleaner assembly
– Release from clip
• Disconnect hose (3) from mass air flow meter, then move to one side
– Release clamp
2. Remove mass air flow meter from cover of air cleaner assembly
• Remove 2x screw
Install
3. Install new mass air flow meter (2) to cover (1) of air cleaner assembly
• Secure clamp
Page 2 of 2
• Secure harness for mass air flow meter to air cleaner assembly
– Secure to clip
• Connect harness connector (4) to mass air flow meter
Page 1 of 1
Oil Consumption, Measure

General
1. Oil consumption for a combustion engine refers to the amount of oil consumed as a result of the combustion process. Oil consumption
is not to be equated with oil loss resulting from leaks from components such as the oil pan and cylinder head cover.
The role of engine oil is to:
1. separate surfaces that slide against each other by means of an oil film, i.e. to prevent dry friction
2. dissipate heat generated by friction
3. lead away combustion residue
These tasks lead to a certain amount of oil consumption. Thus, the expectation that further development of the combustion engine will
eventually mean that engines will not consume any oil is wrong.
Outside operating conditions, driving style and manufacturing tolerances do, however, have an impact on oil consumption.
It is imperative that oil be filled when the level has fallen below the "MIN" mark on the dipstick.
It is also important to ensure that the oil level is not above the "MAX" mark on the dipstick as this could result in increased oil
consumption.
As oil consumption is affected by technical factors, the conclusion is reached that the engine does not consume oil in special operating
conditions that lead to oil dilution.
During conditions such as frequent cold starts and driving before the engine reaches operating temperature, it is only the oil flowing
back to the oil pan that carries away scalding fuel components and precipitates. This "dilutes" the oil and leads to the erroneous
assumption that the engine consumes no oil.
Such diluted oil loses its ability to lubricate and could cause engine damage if the prescribed oil change intervals are not observed.
Driving in predominately urban traffic and frequently running a cold engine at rpm above idle speed are the main causes of oil dilution.
As oil consumption does not stabilise until after a few thousand kilometres of travel, oil consumption measurements are not reliable until
after a distance of about 7,500 km.
Before measuring consumption, ensure that the engine is not losing oil due to leakage.
The oil dipstick can only be used to check oil level. It cannot be used for measurement. The engine must have been off at least 10
minutes, (for F9Q engines 15 minutes) before checking oil level. If after an engine oil change the maximum oil capacity does not match
the maximum level of the dipstick, this is due to necessary manufacturing tolerances.
All information on permissible engine oil consumption and capacities are found in the Owner's Manual.
1. The check is carried out with the vehicle parked on a level surface with the engine at operating temperature (engine oil
temperature at least 80°C).
2. Drain the engine oil immediately after switching off the engine - drainage time = approximately 30 minutes (this value has been
obtain through technical trials).
3. The quantity of drained engine oil is determined via a measuring container. The container is then filled with fresh oil up to the
maximum engine oil capacity minus the volume remaining in the unchanged oil filter.
4. With this engine oil quantity, the customer should be able to travel at 1000 km without needing to top up engine oil (the distance
profile and customer driving style should be maintained).
5. Then, the preceding procedure (points 1 and 2) should be repeated with the exact same engine drainage time.
6. The oil quantity now "missing" from the measuring container is equal to the engine oil consumption for that distance.
7. Oil consumption is calculated as follows:
filled oil quantity (l) – drained oil quantity (l) x 1000 = oil consumption (l/1000 km) total distance driven (km)
See table below.
Vehicle 1 to 2 litres 6 litres 7.5 litres
S8U 772, S9W 700, S9W 702, F9Q 770, F9Q
772, F9Q 774, G9T 720, G9T 722, G9U 720,
Movano
G9U 724, G9T 750, G9U 750, G9U 754, G9U
632, G9U 650, ZD3 200, ZD3 202
F4R 720, F4R 820, F9Q 760, F9Q 762, G9U
Vivaro 730, G9U 630, M9R 630, M9R 692, M9R 780,
M9R 782, M9R 784, M9R 786, M9R 788
Page 1 of 5
Oil Filter and Cooler Housing, Replace
J460400
Remove

3. Raise vehicle
• Remove 8x bolt


Page 2 of 5

8. For vehicles with air conditioning, release power steering pipe assembly
(3) from oil cooler housing (2)
1 2
• Remove bolt
9. Disconnect harness connector (1) from oil pressure switch
3 S 0014335
10. Remove oil cooler housing (1) from cylinder block

1 2
• Disconnect 2x coolant hose from oil cooler housing
• Remove 3x bolt (3), gasket 3
S 0014336
Install
11. Install new oil cooler housing (1) to cylinder block

• Clean mating surface of cylinder block
• Install new gasket, 3x bolt (3) 25 Nm
• Connect 2x coolant hose to oil cooler
Page 3 of 5
1 2
S 0014336
12. For vehicles with air conditioning, secure power steering pipe assembly
(3) to oil cooler housing (2) 1 2
• Install bolt
13. Connect harness connector (1) to oil pressure switch
3 S 0014335

16. Lower vehicle
panel
– Release 4x clip
Page 4 of 5
21. To prime oil filter and cooler housing, crank engine until the oil pressure indicator lamp is extinguished then continue for two seconds
• Secure 4x clip
25. Stop engine
27. Raise vehicle
Page 5 of 5

30. Lower vehicle
Page 1 of 5
Oil Pan, Replace
J456500
Remove
1. Remove oil filler cap from engine

3. Raise vehicle
4. Remove engine and undershield from vehicle
5. Drain engine oil
7. Release pressure hose of power steering from oil filter housing

• Remove bolt (1)
8. Release pressure hose of power steering from support bracket for

engine speed sensor
• Remove nut (1)
Page 2 of 5

Install
10. Clean mating surfaces of cylinder block and oil pan

11. Apply bead of sealant across 2x joint (1) between cylinder block and oil
seal housing – see “Sealants, Lubricants and Locking Compounds”
Page 3 of 5
Important: Ensure 23x bolt are secured in the correct sequence.

12. Install new oil pan to engine
• Install 23x bolt in sequence shown 5 Nm
Page 4 of 5
13. Secure pressure hose of power steering to oil filter housing

Page 5 of 5
14. Secure pressure hose of power steering to support bracket for engine
speed sensor
• Install nut (1)

16. Lower vehicle
• Stop engine
Note: Wait until engine oil has settled to check level.
Page 1 of 4
Oil Pump, Drive Chain and Gear, Replace
Remove
1. Remove engine and transmission from vehicle – see operation “Engine and Transmission, Remove and Install”
• G9U 630
• G9U 730
2. Remove timing gear case from engine – see operation “Timing Gear Case, Replace”
3. Remove drive chain (1) with crankshaft sprocket (2) from crankshaft (3)
and oil pump sprocket (4)

5. Remove drive chain (1) with gear and oil deflector (2) from crankshaft (3)
Page 2 of 4
• Slide off
Install
6. Install new oil deflector (3) to new gear (4) using Installer KM-6296 (5)
• Position Installer KM-6296 into suitable vice
• Install gear into Installer KM-6296
• Install oil deflector onto gear, then position cover (2) above
• Rotate bolt (1) clockwise until oil deflector fully installed
– Remove Installer KM-6296 from gear and oil deflector
7. Install new drive chain (1) with gear and oil deflector (2) to crankshaft (3)
• Push fit
Page 3 of 4

• Install 4x bolt (1), finger-tight
Important: Secure oil pump in stage and sequence shown.

Page 4 of 4
10. Install timing gear case to engine – see operation “Timing Gear Case, Replace”
11. Install engine and transmission to vehicle – see operation “Engine and Transmission, Remove and Install”
• G9U 630
• G9U 730

- Engine with Transmission, Remove and Install
- Timing Gear Case and Gears, Replace
Page 1 of 3
Oil Pump, Replace
J456600
Remove
1. Remove oil pan from engine – see operation “Oil Pan, Replace”
2. Remove oil pump (1) from cylinder block
• Release oil pump sprocket from chain
3. Clean mating surfaces
Install
4. Install new oil pump (1) to cylinder block

• Position oil pump sprocket into chain
Page 2 of 3
5. Secure 3x 13mm bolt (1, 2, 3) 25 Nm in sequence shown

• Secure 10mm bolt (4) 10 Nm
6. Install oil pan to engine – see operation “Oil Pan, Replace”

7. For G9U630 engine, remove engine
immobiliser/instrument panel fuse from interior fuse
box
panel
– Release 4x clip
Page 3 of 3
8. For G9U730 engine, remove engine immobiliser/instrument panel fuse from interior fuse box
• Remove left ashtray housing from instrument panel
– Release 4x clip
9. To prime oil pump, crank engine until the oil pressure indicator lamp is extinguished then continue for two seconds
• Secure 4x clip
13. Stop engine
14. Raise vehicle
15. Check for oil leaks
16. Lower vehicle
Page 1 of 5
Oil Pump, Replace
J456600
Remove

3. Raise vehicle
• Remove 8x bolt
5. Drain engine oil

• Remove 20x bolt
• Use Seal Breaker KM-J-37228
8. Remove oil pick-up (2) from cylinder block

• Remove O ring
Page 2 of 5
S 0014635
9. Remove oil pump (1) from cylinder block

Note: One bolt is also used for securing the oil splash shield to the 2
cylinder block.
1
• Release oil pump sprocket from chain
3 S 0014636
Install
10. Install new oil pump (1) to cylinder block

• Position oil pump sprocket into chain
Page 3 of 5
2
1
3 S 0014636
11. Install oil pick-up (2) to cylinder block

S 0014635

13. Apply sealing compound to cylinder block – see “Sealants, Lubricants
• Apply a bead of 5 mm thickness
Page 4 of 5
S 0014219
Important: Follow correct tightening sequence.

14. Install oil pan to cylinder block 7 8
• Install 20x bolt 5 Nm 9
• Secure 20x bolt 16 Nm 6 10
11
5
12
3 4
13
2
14
1 15
20
19 16
18 17
S 0014220

16. Lower vehicle
19. Install oil filler cap
panel
– Release 4x clip
Page 5 of 5
21. To prime oil circuit, crank engine until the oil pressure indicator lamp is extinguished then continue for two seconds
• Secure 4x clip
Page 1 of 3
Oil Seal, Intermediate Shaft, Replace
J463520
Remove
1. Remove timing belt – see operation ”Timing Belt, Replace”

• G9U 630
• G9U 730
2. Remove blanking cap (1) from intermediate shaft gear

Important: Take care not to damage intermediate shaft gear.
• Use screwdriver to pierce centre of blanking cap (1) and lever out
3. Remove bolt (3) from intermediate shaft gear
• Raise vehicle
• Install Flywheel Locking Tool KM-911 to flywheel
• Lower vehicle
4. Remove seal (2) from intermediate shaft gear
Important: Take care not to damage sealing faces.
Install
5. Install new seal to Seal Installer KM-6424-2

Page 2 of 3
6. Install Seal Installer KM-6424-2 (1) and seal (2) to intermediate shaft
gear
7. Install seal to intermediate shaft gear and ancillary drive housing
• Install Seal Installer KM-6299 (3) to Seal Installer KM-6424-2
– Install stud of Seal Installer KM-6299 through centre of
intermediate shaft gear
– Install nut (4) of Seal Installer KM-6299 to stud
• Turn nut (4) clockwise, until seal is fully installed to intermediate
shaft gear and ancillary drive housing
8. Remove Seal Installer KM-6299 from Seal Installer KM-6424-2

9. Remove Seal Installer KM-6424-2 from intermediate shaft gear
10. Install bolt (1) 25 Nm to intermediate shaft gear
11. Install new blanking cap (2) to intermediate shaft gear
Page 3 of 3
12. Install new timing belt – see operation ”Timing Belt, Replace”
• G9U 630
• G9U 730

- Engine Cover, Replace
Page 1 of 16
Oxygen Sensor, Primary Catalytic Converter, Replace
J980400
Remove
one side
1 2
S 0012751

• Release clip 2
1
3
S 0012749
4. Remove air intake duct (1) from air cleaner (2)

• Release 2x clip
Page 2 of 16
S 0012752

1
1
S 0012753
Page 3 of 16
1
2
3
S 0012861
S 0012918
support frame
• Remove bolt (3)
Page 4 of 16
1 3
S 0012860
1 2
3 S 0012862
9. Remove air cleaner support frame (1) from engine compartment


• Remove bolt (2)
Page 5 of 16
2 S 0012714

Page 6 of 16
S 0013065

• Release 4x clip
S 0013066
14. Remove breather hose from engine

– Pull off
Page 7 of 16
S 0012865

S 0012872
16. Raise vehicle

• Remove 8x bolt

Page 8 of 16
S 0012873
19. Lower vehicle

20. Remove temperature sensor from turbocharger
1
21. Remove oxygen sensor (2) from primary catalytic converter, using
Socket KM-6179
S 0012927
Install
22. Install new oxygen sensor (2) to primary catalytic converter, using
Socket KM-6179
• Apply assembly paste to threads – see “Sealants, Lubricants and
23. Install temperature sensor to turbocharger
• Apply assembly paste to threads – see “Sealants, Lubricants and
• Secure union (1)
Page 9 of 16
S 0012927
24. Raise vehicle

S 0012873

27. Lower vehicle
Page 10 of 16
S 0012872

• Secure 4x clip
S 0013066

Page 11 of 16
S 0013065
31. Install breather hose to engine

– Push on
S 0012865

Page 12 of 16
2 S 0012714
Page 13 of 16
1 2
3 S 0012862
33. Install air cleaner support frame (1) to engine compartment

• Secure clip (3)
1
2
3
S 0012861
support frame
• Secure clip (2)
Page 14 of 16
1 3
S 0012860
frame (3) 1 2
• Secure clip (2)
S 0012918

Page 15 of 16
1
1
S 0012753
38. Install air intake duct (1) to air cleaner (2)

• Secure 2x clip
2
S 0012752

• Secure clip
Page 16 of 16
2
1
3
S 0012749

S 0012751
Page 1 of 1
Piston Protrusion, Check

Note: The operation “Piston Protrusion, Check” is required after replacement of pistons, connecting rods, crankshaft and/or cylinder block.
Adjustments can only be achieved by piston selection or head gasket thickness selection – see “Piston Selection”
F9Q engine
G9 engine
Measure
Important: Ensure that mating surfaces are clean.

1. Place Dial Gauge MKM-571-B (1) and Measuring Bar KM-301 (2) on
cylinder block
2. With probe of dial gauge on cylinder block, set dial gauge reading to 0
(zero)
Important: When measuring piston protrusion, the probe must be
positioned on the centre line of the engine.
3. Measure piston protrusion
• Position probe of dial gauge on piston
• Rotate crankshaft clockwise until piston is at top dead centre (TDC)
• Record dial gauge reading
4. If piston protrusion is outside tolerance – see “Technical Data”
• F9Q 760 or F9Q 762
• F9Q 770
• F9Q 772
• F9Q 774
• G9T 720 or G9T 722
• G9T 750, G9U 750 or G9U 754
• G9U 630
• G9U 632, G9U 650
• G9U 720 or G9U 724
• G9U 730
Page 1 of 3
Piston Rings, Replace
Disassemble
Important: Take care not to damage piston skirt during piston ring replacement.
1. Remove piston with con-rod from engine
2. Install piston with con-rod to soft-jawed vice
3. Remove 3x piston ring from piston (4)
• Remove squared ring (1), tapered ring (2), then
oil control ring (3), in that order
– Use piston ring pliers (5) (commercially
available)
• Thoroughly clean location groove for each piston
ring
– Use removed piston ring as scraper
4. Measure horizontal clearance for each piston ring

• Install new piston ring (3) into respective location groove of piston (1)
• Measure horizontal clearance using feeler gauge (2)
• See “Technical Data" for maximum permissible clearance
– G9U 630
– G9U 730
Page 2 of 3
Important: Measurements must only be taken from length of cylinder bore

in which piston travels.
5. Measure vertical clearance for piston ring
• Clean cylinder bore
• Install new piston ring into cylinder bore
• Measure vertical clearance in cylinder bore at 3x position
1. Top
1.1. Middle
1.1.1 Bottom
• See “Technical Data" for maximum permissible clearance

– G9U 630
– G9U 730
Assemble
Important: Piston rings must be installed in sequence shown.

Important: Ensure that, when installing 3x new piston ring, marking “Top”
is uppermost
6. Install 3x new piston ring to piston (4)
• Install new piston ring in sequence shown using piston ring pliers
1. Install oil control ring (1)
1.1. Install tapered ring (2)
1.1.1 Install squared ring (3)
Important: Piston rings must be positioned on piston as shown, ensuring

that each ring gap avoids alignment with any other ring gap before installing
piston to cylinder block.
7. Position gap (A) of squared ring (1) 120° (approx.) from gap (B) of
tapered ring (2)
• Position gap (C) of oil control ring (3) 120° (appr oximately.) from gap
(B) of tapered ring
Page 3 of 3
8. Remove piston with con-rod from soft-jawed vice

9. Install piston with con-rod to engine
10. Repeat procedure for remaining 3x piston

- Technical Data (group J)
- Piston with Con-rod, Remove and Install
Page 1 of 4
Primary Temperature Sensor, Diesel Particulate Filter, Replace
L502930
Remove
1. Raise vehicle
1
2 S 0012884
3. Remove primary temperature sensor from front exhaust pipe

Page 2 of 4
S 0014337
Install
4. Install new primary temperature sensor to front exhaust pipe

• Apply sealant to primary temperature sensor – see “Sealants,
Page 3 of 4
S 0014337

– Slide on
Page 4 of 4
2 S 0012884
6. Lower vehicle
Page 1 of 5
Radiator Fan and Motor Assembly, Replace
J606800
Remove

2. Raise vehicle
• Remove 8x bolt

5. Lower vehicle
7. Release harness from cooling fan support housing
Page 2 of 5

• Release 6x clip
S 0012835

• Release 2x clip
9. Remove cooling fan support housing (1) from radiator

Note: Radiator with cooling fan support shown removed for clarity.
10. Remove cooling fan motor (1) from cooling fan support housing
Page 3 of 5
Install
11. Install new cooling fan motor (1) to cooling fan support housing
12. Install cooling fan support housing (1) to radiator

Page 4 of 5
S 0012835

• Secure 2x clip
14. Secure harness to cooling fan support housing

• Secure 6x clip
16. Raise vehicle
Page 5 of 5

19. Lower vehicle
Page 1 of 13
Radiator, Replace
J600500
Remove

3. Raise vehicle
• Remove 8x bolt

6. Release radiator with condenser (if installed) from radiator support

crossmember
Page 2 of 13
• Remove 2x clip (1), 2x washer

Note: Observe the relevant environmental regulations when disposing
of used coolant.
• Connect suitable hose to radiator drain plug (1)
9. Lower vehicle
11. Remove air deflector from vehicle
• Release from locator
Page 3 of 13
12. Disconnect upper coolant hose from radiator

13. Disconnect lower coolant hose (1) from radiator

• Release clip
• Remove collecting container
Page 4 of 13
14. Release harness from fan support housing

• Release 6x clip

• Release 2x clip
Warning: The condenser must be supported to prevent damage to the

refrigerant pipes.
16. Release condenser (1) (if installed) from radiator
Page 5 of 13
17. Remove radiator from support crossmember

18. Remove 2x upper mounting (1) from radiator
• Pull out
Page 6 of 13
19. Remove fan support housing (1) from radiator

20. Remove 2x fan support housing retainer (1) from radiator

• Slide from 2x locator, then pull off
Page 7 of 13
Install
21. Install 2x fan support housing retainer (1) to new radiator

• Push on, then slide to 2x locator
22. Install fan support housing (1) to radiator

Page 8 of 13
23. Install 2x upper mounting (1) to radiator

• Push fit
24. Install radiator to support crossmember

25. Secure condenser (1) (if installed) to radiator
Page 9 of 13

• Secure 2x clip
Page 10 of 13
27. Secure harness to fan support housing

• Secure 6x clip
28. Connect lower coolant hose (1) to radiator

• Secure clip
29. Connect upper coolant hose to radiator

• Secure clip (1)
Page 11 of 13
30. Install air deflector to vehicle

• Secure to locator
31. Raise vehicle

32. Secure radiator with condenser (if installed) to radiator support
crossmember
• Install 2x washer, 2x clip (1)
Page 12 of 13
33. Lower vehicle

38. Raise vehicle
Page 13 of 13

41. Lower vehicle
Page 1 of 4
Removal of Seized Fuel Injector
Remove
1. If replacing fuel injectors, download data from engine control unit using Tech 2 (For vehicles with SPS function).
Note: Vehicles with IMA injectors, record IMA injector code with Tech 2 for reprogramming.
2. Remove solenoid from fuel injector

• Rotate anti-clockwise using suitable tool
• Lift off with spring, spacer
Note: Take care not to drop any components into the fuel injector bore.
3. Remove components from fuel injector casing

• Press washer downwards, then remove clip using suitable magnet
• Remove spring
4. Remove all remaining components from fuel injector casing
• Remove plunger retainer from fuel injector using key (1) from
Remover Kit EN-48175-A
• Use suitable magnet to withdraw components
Page 2 of 4
5. Install Remover Kit EN-48175-A to fuel injector

• Install threaded rod (2) to fuel injector
– Secure using suitable tool
Important: Ensure threaded holes are clean and
free of debris. Ensure support rods are correctly
seated to the cylinder head.
• Install 2x support rod to cylinder head
– Secure using suitable tool
• Install brace (1) to threaded rod and 2x support
rod
Important: The two support collars are identified
by grooves and the internal recesses are of
different depths; ensure correct installation.
• Install support collar No. 1 (marked with one
groove) to timing side of fuel injector
• Install support collar No. 2 (marked with two
grooves) to flywheel side of fuel injector
• Install plate, bearing assembly, nut, to threaded
Page 3 of 4
rod and 2x support collar
S 0018298

• Install Handle KM-956-1 to plate (1) of Remover Kit EN-48175-A 1 2
Important: Apply torque rapidly to break the seal. Do not use power
tools.
• Counterhold Handle KM-956-1 and tighten nut of Remover Kit EN-
48175-A to extract fuel injector from cylinder head
• Remove Handle KM-956-1 from plate of Remover Kit EN-48175-A
7. Remove fuel injector from cylinder head
S 0018299
8. Remove 2x support rod from cylinder head

9. Remove sealing washer from fuel injector bore
10. Install new blanking plug to fuel injector bore
11. Install fuel injector to soft-jawed vice
12. Remove Remover Kit EN-48175-A from fuel injector
Important: Each fuel injector used in the EDC 16 fuel injection system is
calibrated with a specific code sequence to ensure correct and precise flow.
This process, known as IMA calibration, requires that a specific seven-digit
code must be programmed into the engine control unit with Tech 2. This
code is printed on the fuel injector.
Page 4 of 4
13. Record corrective value (1) on each new fuel injector

Note: Record the relevant cylinder that the fuel injector is to be
installed.
• Record information for subsequent data input to engine control unit
Note: The corrective value input process is performed after the
battery negative lead has been reconnected and all volatile
memories have been programmed.
1
S 0013310
Important: After installation the fuel injectors must be calibrated with their corrective values to ensure precise fuel flow.
14. If replacing fuel injectors, program engine control unit using Tech 2 (For vehicles with SPS function).
Page 1 of 2
Ribbed V-Belt, Replace (with or without Air Conditioning)
J607000
Remove
1. Raise vehicle

6130 (1)
Install
Page 2 of 2

(1)

8. Lower vehicle
Page 1 of 10
Seal Ring, Rear, Crankshaft, Replace
J456100
Remove
1. Remove clutch assembly from flywheel – see operation “Clutch Assembly, Replace”

• Remove 7x bolt

• Remove nut, bolt
Important: Take care not to damage the sealing faces.

4. Remove crankshaft oil seal (1) from crankshaft
Page 2 of 10
Install
5. Install new seal ring (1) to Installer KM-6308

6. Install seal ring to cylinder block using Installer KM-6308 (1)

7. Install new seal ring to cylinder block using Installer EN-49069
• Install seal ring to inner section (1) of installer
• Install inner section of installer with seal ring to crankshaft
• Install outer section (4) of installer to inner section of installer
Page 3 of 10
– Install nut (3)

• Rotate nut clockwise until seal ring fully installed into cylinder block 1 2
3 4
S 0016510

Page 4 of 10
S 0012716
crankshaft
Page 5 of 10
PMH
S 0017785

– Clean 7x thread in crankshaft
– Apply locking compound to 7x bolt – see “Sealants, Lubricants
Page 6 of 10
11. Remove bracket (3) from cylinder block

• Release bracket (1), position to one side
2 3
– Remove nut (2)
S 0013137
12. Remove crankshaft inductive pulse pick-up (2) from cylinder block
• Depress spring clip (1), then withdraw from aperture in spring clip
and cylinder block
Page 7 of 10
S 0013138
flywheel
• Push fit
– Move flywheel as necessary to ensure full location of
positioning tool

• Install bolt
15. Remove Flywheel Positioning Tool KM-6403 (1) from transmission

housing and flywheel
• Pull out
Page 8 of 10
S 0012717

Page 9 of 10
18. Install bolt (arrowed) to oil filter housing

• Apply suitable sealant to thread
S 0012716
19. Secure crankshaft inductive pulse pick-up (2) to cylinder block

Important: Ensure the tip of the crankshaft inductive pulse pick-up
does not touch the flywheel.
• Depress spring clip (1), then position through aperture in spring clip
and to cylinder block
– Release spring clip to secure to cylinder block
Page 10 of 10
S 0013138
20. Install bracket (3) to cylinder block

• Secure bracket (1)
2 3
– Install nut (2)
S 0013137
21. Install clutch assembly to flywheel – see operation “Clutch Assembly, Replace”
Page 1 of 2
Secondary Temperature Sensor, Diesel Particulate Filter, Replace
L502920
Remove
1. Raise vehicle
2. Disconnect secondary temperature sensor from body harness
1
2 S 0014338
3. Remove secondary temperature sensor from diesel particulate filter

2 S 0014339
Install
4. Install new secondary temperature sensor to diesel particulate filter

Page 2 of 2
• Apply sealant to secondary temperature sensor – see “Sealants,

1
2 S 0014339
5. Connect secondary temperature sensor to body harness

– Slide on
1
2 S 0014338
6. Lower vehicle
Page 1 of 2
Sensor, Accelerator Pedal Position, Right Drive, Replace
J496030
Important: Ensure vehicle ignition is switched off.
Remove
1. Disconnect harness connector (1)

2. Release link rod (3) from sensor (2)
3. Remove sensor (2) from bracket
• Remove 3x nut
Install
4. Install new sensor (2) to bracket

• Install on 2x locator
• Install 3x nut
5. Secure link rod (3) to sensor (2)
6. Connect harness connector (1)
Page 2 of 2
7. For vehicles with F4R 820 engine, program pedal position sensor using Tech 2.
Page 1 of 6
Sensor, Coolant Temperature, Replace
J740500
Remove

one side
1 2
S 0012751

• Release clip
2
1
3
S 0012749
• Release 2x clip
Page 2 of 6
S 0012752

1
1
S 0012753

Page 3 of 6
8. Remove coolant temperature sensor (1) from thermostat housing

• Remove clip (arrowed)
Install
9. Install new coolant temperature sensor (1) to thermostat housing

• Install new seal ring, clip (arrowed)
Page 4 of 6

Page 5 of 6
1
1
S 0012753
14. Install air intake duct (1) to air cleaner assembly (2)
• Secure 2x clip
S 0012752

• Secure clip
Page 6 of 6
2
1
3
S 0012749

• Secure clip (2)
1 2
S 0012751
Page 1 of 35
Sensor, Diesel Fuel High Pressure, Replace
J491050
Remove
one side
1 2
S 0012751

• Release clip
Page 2 of 35
2
1
3
S 0012749
• Release 2x clip
S 0012752

Page 3 of 35
1
1
S 0012753
1
2
3
S 0012861
support frame (3)
Page 4 of 35
1 2
S 0012918
support frame
1 3
S 0012860
Page 5 of 35
1 2
3 S 0012862


• Remove 5x bolt

• Release clip
Page 6 of 35
S 0012741

• Remove bolt (2)
Page 7 of 35
2 S 0012714

– Pull upwards
Page 8 of 35

– Pull off
Page 9 of 35
S 0012865
S 0013060

Page 10 of 35
S 0013065

• Release 4x clip
S 0013066

• Release 4x clip
Page 11 of 35
S 0013067
S 0012992

Page 12 of 35

S 0013069
• Remove bolt (2)
• Release 2x clip
• Remove O ring
Page 13 of 35
1 2 3
S 0013070

legislation.
cleaning cloths.
one side
Page 14 of 35
2 S 0012995

– Push in

Page 15 of 35
• Release 3x clip
pressure pump
3 S 0013000

Page 16 of 35
• Remove bolt (2)


Page 17 of 35
40. Install common rail to soft-jawed vice

41. Remove fuel pressure sensor (1) from common rail
Install
42. Install new fuel pressure sensor (1) to common rail 70 Nm

• Apply locking compound to thread of fuel pressure sensor – see
43. Remove common rail from soft-jawed vice
Page 18 of 35

Page 19 of 35

S 0009855


Page 20 of 35

Page 21 of 35

• Secure to clip


Page 22 of 35


– Push in

Page 23 of 35

1
2 S 0012995

Page 24 of 35
section and engine
• Secure clip (1)
S 0013070

Page 25 of 35
S 0013069


Page 26 of 35
S 0012992

• Secure 4x clip
S 0013067

• Secure 4x clip
Page 27 of 35
S 0013066

S 0013065
Page 28 of 35
S 0013060

– Push on
S 0012865

– Push downwards
Page 29 of 35

Page 30 of 35
2 S 0012714

• Secure clip
Page 31 of 35
S 0012741

Page 32 of 35
1 2
3 S 0012862
• Secure clip (3)
1
2
3
S 0012861
support frame
• Secure clip (2)
Page 33 of 35
1 3
S 0012860
frame (3)
• Secure clip (2)
1 2
S 0012918

Page 34 of 35
1
1
S 0012753
• Secure 2x clip
S 0012752

• Secure clip
Page 35 of 35
2
1
3
S 0012749

• Secure clip (2)
1 2
S 0012751

Page 1 of 3
30
FLB FL4
60A 15 15
175A 323
15A 15A
30
224
FLA FLD 1P
RD 7
YE 5
YE 5
YE 5
YE 5
40A 40A
.1 .2
B1 A2 A1
40A 40A
30 15 15A
FLU St A M D FC27 FC28 FC29 BCM1 BCM5 BCM1 FC7
A B
RD 3
RD 3
30
10A 25A 10A FC6 10A
15 FC30 FC31
15A 30A
15A 15A
50
FB6 X4 50
S1
RD 4
RD 4
20A B2
A1
YE 1.5
YE 1/3
YE 1.5
YE 1.5
YE 2
YE 4
YE 3
WH 3
3817 ABS 3819 ABS

3908 ESP 3910 ESP
RD 2
RD 3
1608 2036 HZG 1614 1617 5507 BCM1

X1 ZIG 3704 AC ACS ACS 1300 WI
YE 0.5/0.75
A1
YE 0.5
YE 2.5
RD 7
2903
YE 2
3003
FC9 FC10 FC11 MTA MTA FC7
10A
MTA 10A 30A 15A 144 X7 X1
WH 4
WH 4
2210 F4R820 15 222 BCM1 5514

2413 F9Q760 5703 TFL 1 BCM5 5542 B1
2617 M9R780 5 1 FB7

YE 0.5/0.75/1
YE 2.5
2816 G9U630 87 86 1501 INS
RD 2
RD 2
5A
5402 ZH
RD 1.5
30 85
K24 M9R780
5503 BCM1 5505 BCM1 3 2
5531 BCM5 5533 BCM5
2508 X1
4830 EMP
G9U630 A8 5007 CID
YE 0.5/0.75
2707
G9U630
G9U630
FLC 5207 TEL

YE 0.5
CAL2 F4R/F9Q 2921 2915

YE 1
RD 25/40
CAL4 G9U/M9R 3021 3015

OG 0.5
RD 0.5
RD 0.5
BG 0.5
GY 0.5
VT 0.5
RD 40
RD 25
X102 MTA MTA

WH 4
119 2901 2201 F4R820

X1 1P
STA 3001 2305 F9Q760
438 DIAG
2505 M9R780
M9R780
M9R780
M9R780
M9R780
G9U630
G9U630
MTA
F9Q760
F4R820
+ B2 30 50
1518 INS
2704 G9U630
3303 IMO 30 50
3333 CDL
G1 3934 ESP
RD 0.5
- B+ 2 1
5512 BCM1
B+ F L
5540 BCM5
M G
2208 F4R820
31 31 B-
2411 F9Q760 M1 G2
2615 M9R780 31
2814 G9U630 FI D
BK 16/25
BK 25/40
11 16 16
100 1 2 3 4 5 6 7 8 9 110 1 2 3 4 5 6 7 8 9 120 1 2 3 4 5 6 7 8 9 130 1 2 3 4 5 6 7 8 9 140 1 2 3 4 5 6 7 8 9

STA+CHA P115313
VOLT

Page 2 of 3
Systems
STA+CHA Start & Charging VOLT Voltage distribution
Components
FB6 Fuse FLA Main fuse
FB7 Fuse FLB Main fuse
FC6 Fuse FLC Main fuse
FC7 Fuse FLD Main fuse
FC9 Fuse FLU Fuse unit - Main fuse
FC10 Fuse FLU.1 Main fuse
FC11 Fuse FLU.2 Main fuse
FC27 Fuse G1 Battery
FC28 Fuse G2 Alternator
FC29 Fuse K24 Relay - Starter
FC30 Fuse M1 Starter
FC31 Fuse S1 Switch - Starter
Connectors
X1 Instrument panel & Engine X7 Instrument panel & Extension harness, radio
X4 Instrument panel & Chassis X102 Engine & Extension harness, starter
Grounding Points
11 Crossmember, below vehicle 16 Battery
Abbreviations
10A 10 Ampere F9Q760 Engine F9Q 760
15 Ignition voltage FC7 Fuse FC7
30 Constant voltage FI Petrol
60A 60A FL4 Main fuse FL4
ABS Anti-Lock Brake System G9U630 Engine G9U 630
AC Air conditioning HZG Heating
ACS Accessory socket IMO Immobiliser
BCM1 Body control module 2001 INS Instrument
BCM5 Body control module 2005 M9R780 Engine M9R 780
CDL Central door locking MTA Manual transmission automatically shifted
CID Color Info Display STA Start & Charging
D Diesel TEL Telephone
DIAG Diagnostic link TFL Daytime running light
EMP Radio WI Wiper
ESP Electronic stability program ZH Add-on heater, fuel fired
F4R820 Engine F4R 820 ZIG Cigarette lighter
Color codes
Page 3 of 3
BG Beige RD Red
BK Black VT Violet
GY Gray WH White
L Light YE Yellow
OG Orange
Page 1 of 3
Starter, Replace
J700100

2. Disconnect hose from intercooler, then move to one side
• Release clip
S 0012741
3. Raise vehicle
• Remove 8x bolt
5. Remove intercooler hose from engine assembly

• Disconnect harness from boost pressure sensor
(4)
• Release from 3x clip (1,2,3)
Page 2 of 3
6. Disconnect harness lead from starter

• Remove nut (1), disconnect harness connector (2)
7. Disconnect positive lead from starter, then move to one side
• Remove nut (3), captive nut, then release from clip
1
3 2 S 0014185
8. Remove starter from transmission housing

• Remove 3x bolt
Install
9. Install new starter to transmission housing

10. Connect positive lead to starter

• Secure to clip, then install nut (3) 8 Nm , captive nut 5 Nm
11. Connect harness lead to starter
• Install nut (1) 8 Nm , connect harness connector (2)
1
3 2 S 0014185
12. Install intercooler hose to engine assembly

• Secure to 3x clip (1, 2, 3)
• Connect harness to boost pressure sensor (4)
Page 3 of 3

14. Lower vehicle
15. Connect hose to intercooler
• Secure clip
S 0012741

Page 1 of 2
Switch, Engine Oil Pressure, Replace
N318500
Remove

2. Raise vehicle
• Remove 8x bolt
4. Remove oil pressure switch (1) from oil filter housing (2) 1 2
S 0013032
Install
5. Install new oil pressure switch (1) 20 Nm to oil filter housing (2)
1 2
S 0013032
Page 2 of 2

7. Lower vehicle
10. Check engine oil level; adjust if necessary
Page 1 of 5
Tension Roller, Ribbed V-belt, Replace
J607300
Remove
1. Raise vehicle

6130 (1)
Page 2 of 5
5. Rotate tension roller clockwise, then remove locating pin

6. Remove tension roller (1) from engine
• Remove 2x bolt (arrowed)
Page 3 of 5
Install
7. Install new tension roller (1) to engine

• Install 2x bolt (arrowed) 21 Nm
8. Rotate tension roller clockwise, then lock into position using suitable locating pin
(1)
Page 4 of 5

Page 5 of 5

12. Lower vehicle
Page 1 of 13
Thermostat Housing, Replace
J608500
Remove

3. Raise vehicle
• Remove 8x bolt


7. Lower vehicle
Page 2 of 13
one side
1 2
S 0012751
• Release clip
2
1
3
S 0012749
• Release 2x clip
Page 3 of 13
S 0012752

1
1
S 0012753
Page 4 of 13
1
2
3
S 0012861
15. Release coolant heater assembly harness (1) (if installed) from air
cleaner support frame (3)
1 2
S 0012918
16. Release coolant heater assembly and bracket (1) (if installed) from air
cleaner support frame
• Remove bolt (3)
Page 5 of 13
1 3
S 0012860
1 2
3 S 0012862


• Pull off
Page 6 of 13
S 0012865

• Release clip
S 0012870
Page 7 of 13
1 2
S 0006887

22. Disconnect 6x coolant hose (1) from thermostat housing, then move to one side
• Release 6x clip
1 2 S 0006446
23. Remove thermostat housing from cylinder head

• Withdraw thermostat housing from coolant pump return pipe (2)
– Slide off
Page 8 of 13
24. Remove coolant temperature sensor from thermostat housing

• Remove clip
• Remove O ring
25. Remove bleed screw from thermostat housing
Install
26. Install coolant temperature sensor to new thermostat housing

• Install clip
27. Install bleed screw to thermostat housing
1 2 S 0006446
29. Install thermostat housing to cylinder head

• Install new O ring, new gasket
• Position thermostat housing to coolant pump return pipe (2)
– Slide on
Page 9 of 13
1 2
S 0006887
30. Connect 6x coolant hose (1) to thermostat housing

• Secure 6x clip

33. Remove suitable hose from radiator drain plug
• Secure clip
S 0012870

• Push on
Page 10 of 13
S 0012865
1 2
3 S 0012862
• Secure clip (3)
Page 11 of 13
1
2
3
S 0012861
39. Secure coolant heater assembly and bracket (1) (if installed) to air
cleaner support frame
• Secure clip (2) 2
1 3
S 0012860
40. Secure coolant heater assembly harness (1) (if installed) to air cleaner
support frame (3)
• Secure clip (2)
Page 12 of 13
1 2
S 0012918

44. Raise vehicle
Page 13 of 13

47. Lower vehicle
Page 1 of 22
Timing Belt, Replace
J462400
Remove

2. Raise vehicle
• Remove 8x bolt


S 0012716
Page 2 of 22
crankshaft
PMH
S 0017785
8. Lower vehicle
• Remove bolt (2)
Page 3 of 22
2 S 0012714
Page 4 of 22
S 0012715
2 S 0012721
• Remove 2x bolt

• Release 2x clip
Page 5 of 22
S 0012722
15. Remove upper cover for timing belt from engine 1

S 0012718
16. Check camshaft alignment

• Flat surfaces (1) of each camshaft should be aligned in vertical
position
• Small flat surface (2) should be on left side
Note: Camshaft pulleys and flanges shown removed for clarity.
Note: If incorrectly aligned, remove Positioning Pin KM-6203 ,
rotate crankshaft 360° clockwise and reinstall posi tioning pin.
Page 6 of 22
17. Raise vehicle

19. Lower vehicle
20. Remove lower cover for timing belt from engine
• Remove 9x bolt
S 0012723

• Secure bolt
Page 7 of 22

• Secure bolt

24. Remove timing belt (2) with intake camshaft pulley (1)
• Remove 3x bolt
Page 8 of 22
25. Remove timing belt tensioner from engine

• Remove bolt
26. Remove guide roller from engine

• Remove bolt
Page 9 of 22
Install
27. Install new guide roller to engine

Important: Locate the rear plate of tensioner behind Locking/Measurement

Tool KM-6205 before installing the bolt.
28. Install new timing belt tensioner to engine
• Locate groove (1) of timing belt tensioner to dowel pin (2)
Page 10 of 22
29. Install new timing belt (2) with intake camshaft pulley (1)
Note: Ensure the timing belt locates centrally on the pulleys; the
camshaft pulleys locate correctly on the camshafts, and that the
bolts are in the centre of the slots.
Page 11 of 22

31. Pre-tension timing belt
• Rotate timing belt tensioner anti-clockwise, until surface (1) of lever
arm, is level with body of Locking/Measurement Tool KM-6205 for
exhaust camshaft
32. Check timing belt tensioner

• Pointer (1) of tensioner should be in position shown in illustration
Page 12 of 22

camshafts, and that the bolts are in the centre of the slots.
camshaft
• Remove bolt
• Remove bolt
36. Raise vehicle

Page 13 of 22
S 0012717
38. Rotate crankshaft 720° clockwise

crankshaft
Page 14 of 22
PMH
S 0017785
40. Lower vehicle

• Secure bolt
Page 15 of 22
• Secure bolt

45. Tension timing belt

• Rotate timing belt tensioner clockwise, until raised surface (1) of
lever arm is level with body of Locking/Measurement Tool KM-6205
• Pointer of timing belt tensioner should be aligned within groove
Page 16 of 22

camshafts, so that the bolts are in the centre of the slots.
camshaft
• Remove bolt
• Remove bolt
Page 17 of 22
49. Install lower cover for timing belt to engine

S 0012723
50. Raise vehicle

52. Lower vehicle
Page 18 of 22
S 0012718

• Secure 2x clip
S 0012722

Page 19 of 22
2
1
3
5 4 S 0013084
57. Secure 2x fuel pipe (1) to bracket 1

S 0012715

Page 20 of 22
2 S 0012714
60. Raise vehicle

Page 21 of 22
S 0012717

S 0012716
Page 22 of 22

66. Lower vehicle
Page 1 of 60
Timing Gear Case and Gears, Replace
J463040
Remove
• G9U 630
• G9U 730

of used lubricants.
2. For G9U 630, disconnect feed hose (1) from power steering pump
• Release clip
3. For G9U 630, release high pressure pipe from auxiliary support bracket
• Remove bolt
4. For G9U 630, disconnect high pressure pipe (1) from power steering
pump
• Remove O ring
Page 2 of 60
5. For G9U 630, remove power steering pipe assembly with fluid reservoir from engine and transmission assembly
• Remove 4x bolt
engine
engine

Page 3 of 60
S 0012886

1

– Remove bolt
• Remove bolt
2 S 0016489

• Pull off
12. Disconnect breather pipe (1) from hose
Page 4 of 60
13. For G9U 630, remove bracket (1) from turbocharger and engine
2
1
S 0012890
14. For G9U 730, remove exhaust heat shield from exhaust manifold
Page 5 of 60
15. For G9U 630, remove turbocharger (1) from exhaust manifold (2)
• Remove 3x nut (3), gasket 1 2
S 0012891
16. For G9U 730, remove exhaust manifold with turbocharger (1) from
cylinder head
Note: Turbocharger shown removed for clarity.
• Remove 9x nut, 9x washer (2)
• Remove gasket
Page 6 of 60
• Remove bolt (2)
18. Remove heat shield (1) (if installed) from engine mount bracket
Page 7 of 60
19. Remove engine mount bracket (1) from cylinder block

20. Remove support bracket (if installed) from power steering pump and
and exhaust gas recirculation (EGR) valve housing
• Remove 2x bolt
Page 8 of 60
21. Disconnect harness connector from EGR valve

the cylinder head.
22. Remove pipe (1) from cylinder head and EGR valve housing
• Remove 4x bolt
• Remove 2x gasket
23. Remove EGR valve housing (2) from engine

• Remove 3x bolt
• Release clip for 2x coolant hose from EGR valve housing
Page 9 of 60
24. For G9U 730, remove guide tube (2) for oil level dipstick (1) from
engine
• Pull out
25. For G9U 630, remove upper section of guide tube for oil level dipstick from lower section
• Remove bolt
• Remove O ring
26. For G9U 630, remove lower section of guide tube for oil level dipstick from engine
• Remove bolt
• Remove O ring
27. For G9U 730, disconnect 2x harness connector (1) from starter (2),
then move to side
Page 10 of 60
28. For G9U 730, release harness from transmission bracket

• Remove nut
29. Remove starter from transmission housing

• Remove 3x bolt

• Install 8x nut, bolt
Page 11 of 60

6130 (1)
Page 12 of 60

• Remove bolt (1)
Page 13 of 60
34. Remove tensioner (1) for ribbed V-belt from engine

35. Remove timing belt from engine – see operation “Timing Belt, Replace”
• G9U 630
• G9U 730

Page 14 of 60
37. Remove camshaft sensor (2) from casing of high pressure pump
• Remove bolt
Important: Ensure that the casing of the high pressure pump is not
damaged when removing blanking cover.
38. Remove blanking cover (1) from casing of high pressure pump
Page 15 of 60
40. Install Flywheel Locking Tool KM-911 to flywheel

• Push fit
Note: Flywheel Locking Tool KM-911 must be installed to prevent
crankshaft rotation during removal/installation of crankshaft pulley
bolt. Position at opposite sides of the flywheel as necessary.

• Remove bolt (1)
Page 16 of 60
42. Remove guide roller (2) for timing belt from engine
• Remove bolt (1)
Page 17 of 60
43. Remove timing gear cover from engine

• Remove 15x bolt
• Remove gasket
Note: Alternator, V-belt tensioner, compressor, oil pan and power steering pump removed for clarity.
44. Reposition Flywheel Locking Tool KM-911 to opposite side of flywheel

• Push fit
45. Remove nut (1) from gear for high pressure pump
Page 18 of 60
46. Install Locking Tool KM-6293 (1) to gear
47. Remove cap (1) from secondary intermediate gear

Page 19 of 60
48. Reposition Flywheel Locking Tool KM-911 to opposite side of flywheel

• Push fit

damage can occur.
• Remove nut (1)
available)
50. Remove gear (1) from high pressure pump

• Apply alignment marking
• Install Gear Puller KM-6207 (2) to gear
• Rotate centre bolt (4) clockwise until gear released
Page 20 of 60
51. Remove Gear Puller KM-6207 from gear

• Remove 3x bolt
compensation
53. Install Locking Clamp KM-6294 (1) to intermediate gear

• Ensure 2x bracket (3) locate correctly
• Tighten 2x bolt (2)
• Remove bolt (4)
Page 21 of 60
54. Remove intermediate gear (1), shaft (2) and washer (3) from engine
• Pull out
Page 22 of 60
56. Remove secondary intermediate gear (1) from engine

• Remove bolt (2)
57. Remove secondary intermediate shaft (1) and washer (2) from engine
• Pull out
Page 23 of 60
58. Remove crankshaft gear (1) from crankshaft (2)

• Pull off
• Remove gear key (3) from crankshaft

– Remove O ring
Page 24 of 60

• Release drain hose (3) from 2x clip, then pull off

legislation.
cleaning cloths. Use new thinner, clean brushes and compressed air. Do not
use a high pressure washer.
61. Disconnect fuel leak-off (1) from common rail
62. Disconnect high pressure pipe from common rail

Page 25 of 60
65. Disconnect fuel feed pipe (3) from high pressure pump
66. Remove high pressure pipe from cylinder head cover

• Remove bolt, clip
67. Disconnect fuel leak-off pipe from 4x fuel injector

– Push in
68. Remove fuel leak-off pipe with fuel temperature sensor from cylinder
head cover
Page 26 of 60
69. Remove high pressure pump (1) from engine

• Remove O ring
70. Release timing gear case from oil pan (2)

Page 27 of 60
71. Remove timing gear case from cylinder block

• Remove 21x bolt
72. Remove timing case gasket

Page 28 of 60
Install
Important: Ensure oilways are not blocked.

73. Install new timing gear case to cylinder block
• Install new gasket to cylinder block
• Ensure gasket and timing case locate correctly on 2x dowel (1)
Page 29 of 60
Important: Tighten 21x bolt for new timing gear case

in stage and sequence shown.
74. Secure timing gear case to cylinder block
• Secure bolt Nos. 7, 18, 5, 14, 10, 3, 16, 20,
then 12 10 Nm
• Secure bolt No. 1, then No. 2 30 Nm
Page 30 of 60
75. Install high pressure pump (1) to engine


77. Install high pressure pipe to common rail and high pressure pump; do
Page 31 of 60

• Secure to clip
79. Install new fuel leak-off pipe with fuel temperature sensor to 4x fuel
injector
– Push in

Page 32 of 60
81. Secure high pressure pipe (1) to high pressure pump

82. Connect fuel leak-off pipe (2) to high pressure pump


Page 33 of 60

• Secure drain hose (3) to 2x clip
– Push fit
87. Install coolant pump (1) to engine

Page 34 of 60
88. Install crankshaft gear (1) to crankshaft (2)

• Install gear key (3) to crankshaft
• Push fit
89. Install intermediate shaft and secondary intermediate shaft (2) with 2x
washer (1) to engine
• Ensure location pin of each intermediate shaft engages fully into
slot, then install 2x washer
• Push fit
Page 35 of 60
90. Install secondary intermediate gear (1) to engine

• Install new bolt (2)

92. Install intermediate gear to engine
Page 36 of 60
93. Remove Flywheel Locking Tool KM-911

crankshaft
Page 37 of 60
95. Install Flywheel Locking Tool KM-911

• Push fit
Important: Marking “2” on gear for high pressure pump must align with
marking “3” on timing case. This action is necessary to correctly align gear
for high pressure pump and camshaft position sensor for engine timing.
96. Install gear to high pressure pump
– Ensure 2x mark (2, 3) align
compensation
Page 38 of 60
98. Remove Locking Tool (1) KM-6293 from gear for high pressure pump
99. Install gear (2) to coolant pump

Page 39 of 60
100. Install new gasket for timing gear cover to timing gear case
101. Remove oil seal for crankshaft pulley (1) from timing gear cover
102. Remove oil seal for secondary intermediate gear (2) from timing gear
cover
103. Install timing gear cover to engine

• Install 15x bolt in stage and sequence shown
• Secure bolt Nos. 10, 4, 8, 7, 12 then 2 11 Nm
• Secure bolt Nos. 13, 14, then 15 25 Nm
Page 40 of 60

104. Install new oil seal for crankshaft pulley to timing gear cover
• Install threaded stud of Installer KM-6298 into crankshaft
• Partially install crankshaft oil seal (2) located on Sleeve KM-6424-
3 (1) into timing gear cover
105. Fully install oil seal for crankshaft pulley to timing gear cover
• Locate Sleeve KM-6243-3 (1) onto oil seal
experienced.
Page 41 of 60

106. Install new oil seal (1) for secondary intermediate gear to timing gear
cover
• Remove bolt
• Install threaded stud of Installer KM-6299 (2) into shaft for
secondary intermediate gear
• Partially install oil seal located on Adapter KM-6424-2 (3) into
timing gear cover
107. Fully install oil seal for secondary intermediate gear to timing gear
cover
experienced.
Page 42 of 60
108. Secure secondary intermediate gear

• Secure bolt (1) 25 Nm + 35° ± 6°
Page 43 of 60
109. Install new cap (1) to secondary intermediate gear

Note: Timing gear cover removed for clarity.
110. Install new guide roller (2) for timing belt to engine
Page 44 of 60
111. Install crankshaft pulley (2) to engine

• Install bolt (1) 50 Nm + 90° ± 6°
112. Remove Flywheel Locking Tool KM-911

113. Install new blanking cover (1) to casing of high pressure pump
• Use Cover Installer KM-6208
114. Install camshaft sensor (2) to high pressure pump
Page 45 of 60
116. Install new timing belt to engine – see operation “Timing Belt, Replace”
• G9U 630
• G9U 730

Page 46 of 60


6130 (1)
Page 47 of 60
120. Rotate engine/transmission 180°, using Engine Overh aul Stand KM-412
• Remove remaining 19x bolt
• Remove gasket
• Clean mating surface of oil pan and cylinder block
Page 48 of 60
122. Install new gasket to cylinder block

• Apply continuous bead of sealant across 2x joint (1) between
cylinder block and timing gear case – see “Sealants, Lubricants
123. Install oil pan to cylinder block

• Install 23x bolt 5 Nm , then 9 Nm in sequence shown
Page 49 of 60
124. Rotate engine/transmission 180°, using Engine Overh aul Stand KM-412
126. Remove engine with transmission from Engine Overhaul Stand KM-
412
• Remove 8x nut, bolt
Page 50 of 60
127. Install starter to transmission housing

Page 51 of 60
128. For G9U 730, connect 2x harness connector (1) to starter (2)
• Secure 13 mm nut (3) 9 Nm
• Secure 8 mm nut (3) 5 Nm
129. For G9U 730, connect harness to transmission bracket

• Install nut
130. For G9U 730, install guide tube (2) for oil level dipstick (1) to engine
• Push fit
Page 52 of 60
131. For G9U 630, install lower section of guide tube for oil level dipstick to engine
132. For G9U 630, install upper section of guide tube for oil level dipstick to lower section and engine
133. Install EGR valve housing (2) to engine

• Secure clip (1)
• Secure clip for 2x coolant hose to EGR valve housing
134. Install new pipe (1) to cylinder head and EGR valve housing
• Install 2x new gasket
Page 53 of 60
135. Connect harness connector to EGR valve
136. Install support bracket (if installed) to power steering pump and EGR
valve housing
• Install 2x bolt

Page 54 of 60
138. Install heat shield (1) (if installed) to engine mount bracket
• Push fit
Page 55 of 60
140. For G9U 730, install exhaust manifold with turbocharger to cylinder
head
Note: Turbocharger shown removed for clarity.
• Install new gasket, 9x spacer, 9x new nut 30 Nm in sequence
shown
141. For G9U 730, install exhaust heat shield to exhaust manifold
Page 56 of 60
142. For G9U 630, install turbocharger (1) to exhaust manifold (2)
• Install 3x new nut (3); do not tighten at this stage
S 0012891
143. For G9U 630, install bracket (1) to turbocharger and engine
Page 57 of 60
2
1
S 0012890
144. For G9U 630, secure turbocharger to exhaust manifold

145. For G9U 630, secure bracket to turbocharger and engine
• Secure bracket on oil feed pipe to turbocharger 1
– Install bolt

2 S 0016489

• Push fit
149. Connect breather pipe (1) to hose
Page 58 of 60

• Clean mating surfaces 1
S 0012886
Page 59 of 60
153. For G9U 630, install power steering pipe assembly with fluid reservoir to engine and transmission assembly
154. For G9U 630, connect high pressure pipe (1) to power steering pump
155. For G9U 630, secure high pressure pipe to auxiliary support bracket
Page 60 of 60
• G9U 630
• G9U 730
Page 1 of 36
Turbocharger, Replace
J470400
Remove

one side
1 2
S 0012751

• Release clip
2
1
3
S 0012749
• Release 2x clip
Page 2 of 36
S 0012752

1
1
S 0012753
frame
support frame
• Remove bolt (3)
Page 3 of 36
1 3
S 0012860
1
2
3
S 0012861
Page 4 of 36
1 2
3 S 0012862


• Remove bolt (2)
Page 5 of 36
2 S 0012714

• Pull off
Page 6 of 36
S 0012865

• Release clip
S 0012870

• Release 2x clip
Page 7 of 36
S 0012722

S 0012872
18. Raise vehicle to suitable working height

• Remove 10x bolt

• Remove 2x nut
Page 8 of 36

to steering knuckle
• Tighten rod (4)
2
3
4 S 0016919
23. Raise vehicle
• Remove 8x bolt
• Release 2x clip

Page 9 of 36

• Remove nut (3), bolt
1 2 3 4
• Remove bolt (5)
5
S 0012879


Page 10 of 36


Page 11 of 36
1 2
3
S 0012881
Page 12 of 36
2 S 0012883

1
2 S 0012884

Page 13 of 36
S 0012885
engine
engine
Page 14 of 36

Page 15 of 36
S 0012873
S 0012886

• Release 2x clip
Page 16 of 36
• Release bracket from turbocharger 1

– Remove bolt
• Remove bolt
46. Disconnect hose (5) from wastegate actuator 2
• Pull off
5
4
3 S 0012887

2
1
S 0012890

Page 17 of 36
1 2
S 0012891
49. Remove temperature sensor from turbocharger

1
S 0012899
Install
50. Install temperature sensor to new turbocharger

Page 18 of 36
1
S 0012899

1 2
S 0012891

Page 19 of 36
2
1
S 0012890


1
2
– Install bolt
57. Install oil return pipe (2) to turbocharger and engine 5

4
• Install 2x bolt (3) 8 Nm 3 S 0012887
• Secure 2x clip

Page 20 of 36
S 0012886

S 0012873
Page 21 of 36
Page 22 of 36
S 0012885
exhaust pipe (2)
Page 23 of 36
2 S 0012883

– Slide on
1
2 S 0012884
Page 24 of 36
chassis

Page 25 of 36


Page 26 of 36
1 2 3 4
5
S 0012879


Page 27 of 36
1 2
3
S 0012881

• Secure 2x clip
when installing the nut.
to steering knuckle
• Tighten rod (4)
2
3
4 S 0016919

Page 28 of 36
83. Raise vehicle

87. Lower vehicle
S 0012872

• Secure 2x clip
Page 29 of 36
S 0012722

• Secure clip
S 0012870

• Push on
Page 30 of 36
S 0012865

Page 31 of 36
2 S 0012714
Page 32 of 36
1 2
3 S 0012862

• Secure clip (3)
1
2
3
S 0012861
frame
frame
• Secure clip (2)
Page 33 of 36
1 3
S 0012860

1
1
S 0012753
• Secure 2x clip
Page 34 of 36
S 0012752
• Secure clip
2
1
3
S 0012749

• Secure clip (2)
Page 35 of 36
1 2
S 0012751

108. Change engine oil and filter – see operation “Engine Oil and Filter, Change”
panel
– Release 4x clip
Page 36 of 36
• Secure 4x clip
116. Stop engine
Page 1 of 2
Valve Springs, Replace
J459000
Remove
1. Remove cylinder head from cylinder block – see operation "Gasket, Cylinder Head, Replace”
• G9U 630
• G9U 730
2. Install cylinder head to suitable work stand
3. Remove valve spring from valve
• Compress spring cap and valve spring
– Use valve spring compressor (commercially available)
• Remove split collar from valve stem
• Remove valve spring and spring cap
• Release, then remove valve spring compressor
4. Remove remaining 15x valve spring in accordance with above procedure
Install
5. Install new valve spring to valve

• Locate valve spring and spring cap to valve stem
• Compress valve spring
– Use valve spring compressor
• Install split collar to valve stem and spring cap
– Release valve spring compressor
6. Install remaining 15x valve spring in accordance with above procedure

Page 2 of 2
7. Remove cylinder head from suitable work stand

8. Install cylinder head to cylinder block – see operation "Gasket, Cylinder Head, Replace”
• G9U 630
• G9U 730

- Gasket, Cylinder Head, Replace
Page 1 of 4
Valve Stem Seals, Replace
J459015
Remove
1. Remove cylinder head from cylinder block – see operation "Gasket, Cylinder Head, Replace”
• G9U 630
• G9U 730
2. Install cylinder head to suitable work stand
3. Remove valve spring from one intake valve
– Use valve spring compressor (commercially available)
• Remove split collar from valve stem
• Remove valve spring and spring cap
• Release, then remove valve spring compressor
Important: Observe the following steps to ensure correct installation height

of each new seal.
4. Position cylinder head horizontally on work surface
Note: Ensure intake valve remains installed.
5. Slide Installer KM-6292-06 over valve stem
• Ensure Installer (1) makes contact with metal collar of valve stem
seal
Page 2 of 4
Important: The following sequence prevents damage of the new seal

during installation. The tube and installer are adjusted to existing seal height
to allow precise installation of new seals.
6. Slide Tube KM-6292-01 (1) over Installer KM-6292-06 (2)
• Ensure Tube (1) makes contact with cylinder head
• Secure Tube (1) to Installer (2)
– Tighten screw (3)
Note: Installer (2) and Tube (1) are set to ensure correct
installation of new valve stem seal.
7. Remove Tube (1) and Installer (2) assembly from valve stem
8. Install identification label to Installer (2)
• Attach masking tape, marked INTAKE
9. Position cylinder head as shown

10. Remove remaining 7x valve spring from 7x intake valve
• Use valve spring compressor
11. Position cylinder head horizontally on suitable work stand

Note: Ensure all intake valves remain installed.
12. Remove 8x valve stem seal (1) from 8x intake valve guide
Page 3 of 4
Install
Important: Do not lubricate new valve stem seals.

13. Lubricate 8x intake valve guide
14. Partially install new valve stem seal (1) to intake valve stem
• Install Guide KM-6292-11 (2) to valve stem
• Install valve stem seal (1)
• Push fit
15. Fully install valve stem seal to intake valve guide

• Slide Tube KM-6292-01 (1) and Installer KM-6292-06 (2) assembly
over intake valve stem
• Push Installer (2) downwards until Tube (1) makes contact with
cylinder head
– Use hand pressure only
16. Remove Tube (1) and Installer (2) assembly from valve stem
17. Install remaining 7x new seal to 7x intake valve guide
Page 4 of 4
18. Position cylinder head on work surface, as shown

19. Install valve spring to intake valve
• Locate valve spring and spring cap to valve stem
– Use valve spring compressor
• Install split collar to valve stem and spring cap
– Release valve spring compressor
20. Install remaining 7x valve spring to 7x intake valve, in accordance with

above procedure
21. Replace 8x valve stem seal on 8x exhaust valve guide in accordance with procedure 8x intake valve
22. Remove cylinder head from suitable work stand
23. Install cylinder head to cylinder block – see operation "Gasket, Cylinder Head, Replace”
• G9U 630
• G9U 730

- Gasket, Cylinder Head, Replace
Page 1 of 11
Valve Timing, Check
J491730
Remove

2. Raise vehicle
• Remove 8x bolt


S 0012716
Page 2 of 11
crankshaft
PMH
S 0017785
8. Lower vehicle
• Remove bolt (2)
Page 3 of 11
2 S 0012714
Page 4 of 11
S 0012715
2 S 0012721
• Remove 2x bolt

• Release 2x clip
Page 5 of 11
S 0012722

1
S 0012718
Inspect
Important: Ensure locking tools locate correctly. If tools do not locate

correctly on camshafts, or bolts cannot be installed, then engine is not in
correct position. If incorrectly aligned, remove Positioning Pin KM-6203 ,
rotate crankshaft 360° clockwise and reinstall posi tioning pin.
• Install bolt
Note: If the bolt can be installed when the locking tool is correctly
located on camshaft and cylinder head, the timing of the exhaust
camshaft is correct.
•
Install bolt
Note: If the bolt can be installed when the locking tool is correctly
located on camshaft and cylinder head, the timing of the intake
Page 6 of 11
camshaft is correct.
camshaft
• Remove bolt
• Remove bolt
Install

1
S 0012718

• Secure 2x clip
Page 7 of 11
S 0012722

2
1
3
5 4 S 0013084

Page 8 of 11
S 0012715

Page 9 of 11
2 S 0012714
27. Raise vehicle

Page 10 of 11
S 0012717

S 0012716
Page 11 of 11

33. Lower vehicle
Page 1 of 1
Valve, Grind-in
Important: Examine condition of valve and seat to determine which grade

of grinding paste (coarse or fine) is required.
1. Lubricate valve stem with oil
2. Grind valve
• Use suitable grinding paste, ensure even distribution around valve
head, grind valve rhythmically
Note: If coarse grinding paste is used, always finish grinding with
fine grinding paste. Clean valve and cylinder head thoroughly before
applying fine grinding paste.
3. Inspect valve and seat for correct contact over entire circumference
4. Clean valve and cylinder head

2.5DCI Engine Mechanical

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Page 1 of 2

Accelerator Pedal with Pedal Position Sensor, Left Drive, Replace

Important: Ensure vehicle ignition is switched off.

1. Disconnect harness connector (1)

3. Install new sensor (2) to bracket

Accelerator Pedal, Right Drive, Replace

1. Remove accelerator pedal from support bracket

2. Install new accelerator pedal to support bracket

Actuator, Turbocharger Wastegate, Check

1. Remove turbocharger from vehicle – see operation “Turbocharger, Replace”

4. Check operation of wastegate actuator (3)

Alternator, Replace (with Air Conditioning)

1. Disconnect battery negative lead

4. Remove engine and transmission undershield from vehicle

5. Remove right splash panel

6. Remove ribbed V-belt from engine

13. Disconnect 2x harness connector from alternator

14. Remove guide roller for ribbed V-belt

15. Remove alternator from support bracket

16. Install new alternator to support bracket

17. Connect 2x harness connector to alternator

18. Install guide roller for ribbed V-belt to cylinder block

19. Secure power steering pump to engine

21. Secure power steering feed hose to auxiliary support bracket

22. Install pulley (1) to power steering pump (2)

23. Release radiator assembly from front crossmember

24. Install ribbed V-belt to engine

25. Raise vehicle

27. Install engine and transmission undershield to vehicle

28. Secure pulley (1) to power steering pump (2)

Alternator, Replace (without Air Conditioning)

1. Disconnect battery negative lead

4. Remove ribbed V-belt from engine

8. Disconnect harness from fuel pressure regulator

9. Disconnect 2x harness connector from alternator

10. Remove alternator from support bracket

11. Install new alternator to support bracket

12. Connect 2x harness connector to alternator

13. Connect harness to fuel pressure regulator

15. Release radiator assembly from front crossmember

16. Install ribbed V-belt to engine

17. Secure power steering feed hose to auxiliary support bracket

Camshaft Oil Seals, Replace

1. Remove timing belt – see operation "Timing Belt, Replace”

2. Remove camshaft pulley hub (1) from exhaust camshaft

4. Remove camshaft oil seal (1) from exhaust camshaft

5. Install stud of Installer KM-6300 into end of exhaust camshaft

10. Install camshaft oil seal to exhaust camshaft

13. Remove Sleeve KM-6424-1 (2) from stud (1)

15. Install Locking/Measurement Tool KM-6205 (2) to exhaust camshaft

17. Remove camshaft pulley (1) from intake camshaft

18. Remove camshaft pulley hub (1) from intake camshaft

20. Remove camshaft oil seal (1) from intake camshaft

21. Install stud of Installer KM-6300 into end of intake camshaft

26. Install camshaft oil seal to intake camshaft

29. Remove Sleeve KM-6424-1 (2) from stud (1)

31. Install Locking/Measurement Tool KM-6204 (2) to intake camshaft

33. Install camshaft pulley (1) to intake camshaft

34. Install timing belt – see operation "Timing Belt, Replace"

Camshaft Sensor, Replace

1. Remove camshaft sensor from high pressure pump

2. Install new camshaft sensor to high pressure pump

1. Disconnect battery negative lead