Procedures

CAUTION: Note instructions on connecting and disconnecting battery. Service Precautions

- Switch off ignition.
- Remove battery negative line.
- Remove complete splash guard
- Remove fan wheel.
- Removing Intake filter housing.
- Remove front center splash guard from engine together with complete underbody protection.




- Remove cover from injector valves.
- Remove cover from control unit box.




- Unfasten connection for ignition coils at junction with E-box.




- Mark relays (1 to 7) and remove.




- Unfasten plug connections from control unit (1 and 2).




- Unfasten hose clip (1).
- Open clips (2).
- Unfasten plug connection (3),
- Remove complete mass air flow sensor.




- Unfasten plug connection (1) from throttle valve potentiometer.




- Unfasten plug connection (1) from potentiometer for throttle valve on ASC+T.
- Remove complete throttle body.




- Unfasten plug connection (1) from tank vent valve.




Installation Note: Note line routing (1) on tank vent valve.




- Unfasten plug connections (1 and 2) on oxygen sensors and remove wiring harness from end of engine.




- Disconnect plug connection from VANOS solenoid valve.

- Remove intake air manifold.




- Unfasten plug connection (1) from alternator.
- Unfasten nut (2) and remove line.

Installation Note:
Tightening torque:
KI.D+ (M6) = 7 Nm.
KI.B+ (M8) = 13 Nm.




- Unfasten plug connection (1) on oil pressure switch.




- Unfasten nuts (1 and 2) from starter motor

Installation Note:
Tightening torque:
Terminal 30h (M5) 5 Nm.
Terminal 50 (M6) 6 Nm.
Terminal 30 (M8) 12 Nm.




Installation Note: Note line routing

- When fitting the nuts (1), ensure that the lines (2 and 3) are routed without sharp bends or chafing points




- Unfasten plug connection (1) from knock sensor
- Unfasten plug connection (2) at impulse sensor from vibration damper.
- Unfasten plug connection (3) of sensor for cylinder recognition.




- Disconnect plug connection on reversing light switch. Note wire routing!




- Unfasten plug connection (1) on coolant temperature sensor




- Unfasten nut (1) from line bracket




- Unfasten nut (2) from line bracket (3) and remove line bracket (3).




- Unfasten plug connection on oil level switch.
- Remove wiring harness from timing case cover.

Installation Note: Interrogate fault memory, check fault messages stored in memory, rectify faults then clear the fault memory.