Fuel Injection System Components, Removing and Installing
Fuel Injection System Components, Removing and Installing
NOTES:
- The Engine Control Module (ECM) has On Board Diagnostic (OBD) capability Before carrying out troubleshooting and repairs, DTC memory must be checked. Vacuum hoses and connections must also be checked (unmetered air).
- Fuel lines in the engine compartment must only be secured using spring type clips. The use of clamp or screw type clips is not permissible.
- Components marked with a * are checked via the On Board Diagnostic (OBD). Testing and Inspection
- Components marked with a **can be checked with output Diagnostic Test Mode (DTM). Testing and Inspection
- For trouble-free operation of the electrical components, a voltage of at least 11.5 V is necessary.
- Do not use sealants containing silicone. Particles of silicone drawn into the engine will not be burned in the engine and will damage the oxygen sensor.
- When performing some repairs, it is possible that the control module will recognize a malfunction and store a DTC. After completing all checks and repairs DTC memory must be checked and, if necessary, erased Testing and Inspection
and the readiness code must be generated. Testing and Inspection
- Safety precautions. Technician Safety Information
- Rules of cleanliness. [1][2]Technician Safety Information
- Technical data. Specifications
- Checking engine operating mode, refer to "Functions, Checking". Testing and Inspection
1 - 25 Nm (18 ft lb)
2 - Intake manifold upper section
- Disassembling and assembling. Intake Manifold Upper Section, Disassembling and Assembling
3 - Vacuum connection
- From Leak Detection Pump (LDP) -V144-
- EVAP system
4 - 81-pin harness connector
- Only disconnect or connect with ignition switched off
- Release to disconnect
5 - Motronic Engine Control Module (ECM) -J220-*
- Located in plenum chamber
- Checking voltage supply. Testing and Inspection
- Procedure after voltage supply open circuit. Testing and Inspection
- Replacing. Service and Repair
- Coding. Testing and Inspection
- If replaced, carry out basic setting, refer to "ECM to Throttle Valve Control Module, Adaptation". Testing and Inspection
6 - 10 Nm (7 ft lb)
7 - Retaining frame
8 - 40-pin harness connector
- Only disconnect or connect with ignition switched off
- Release to disconnect
9 - From brake servo
10 - From Evaporative Emissions (EVAP) canister purge regulator valve -N80-
- EVAP system
11 - 3-pin harness connector
- White
- For Knock Sensor (KS) 1 -G61-
- Sensor and harness connector contacts are gold plated
12 - Supply connection
13 - Return flow connection
14 - Intake manifold lower section
- Disassembling and assembling. Intake Manifold Lower Section, Disassembling and Assembling
15 - Seal
- Always replace
16 - Bracket
- For Secondary Air Injection (AIR) pump motor -V101- and secondary air inlet valve
- Secondary air system
17 - Wiring harness
- With harness connectors for fuel injectors
18 - 5-pin harness connector
- Black
- For Mass Air Flow (MAF) sensor -G70- with Intake Air Temperature (IAT) sensor -G42-
- Sensor and harness connector contacts are gold plated
19 - 6 Nm (53 in. lb)
20 - Retaining clip
- Make sure it is seated securely
21 - O-ring
- Replace if damaged
22 - Thermostat housing
- Location, engine compartment overview. Service and Repair
23 - Engine Coolant Temperature (ECT) sensor -G62*
- Blue
- For Engine Control Module (ECM)
- With Engine Coolant Temperature (ECT) sensor -G2-
- If necessary, release pressure in cooling system before removing
- Connector terminals -1- and -3- for Engine Coolant Temperature (ECT) sensor -G62-
- Terminals -1- and -3- are gold plated
24 - Air cleaner
- Disassembling and assembling. Service and Repair
25 - Engine speed (RPM) sensor -G28-*
- Location, engine compartment overview. Service and Repair
- Checking. Testing and Inspection
26 - O-ring
- Always replace
27 - 4-pin harness connector
- Black
- For oxygen sensor behind Three Way Catalytic Converter (TWC) -G130- and heater for Lambda probe 1 -Z29-
- Located at right on underside of vehicle
- Terminals 3 and 4 gold plated
28 - Oxygen sensor behind Three Way Catalytic Converter (TWC) -G130-*
- 50 Nm (37 ft lb)
- Location: in rear of Three Way Catalytic Converter (TWC)
- Grease only threads with "G 052 112 A3" (grease must not get into slots on probe body)
- Remove and install using 3337
- Oxygen sensor heater voltage supply via Fuel Pump (FP) relay -J17-
- Checking oxygen sensor heater for oxygen sensor after Three Way Catalytic Converter (TWC). Testing and Inspection
- Checking oxygen sensor and Oxygen Sensor (O2S) control after Three Way Catalytic Converter (TWC). Testing and Inspection
29 - 6-pin harness connector
- Black
- For Heated Oxygen Sensor (HO2S) -G39- before Three Way Catalytic Converter (TWC) and Oxygen Sensor (O2S) heater -Z19-
- Located at right on underside of vehicle
30 - Heated Oxygen Sensor (HO2S) -G39- before Three Way Catalytic Converter (TWC)*
- 50 Nm (37 ft lb)
- Location: in front of Three Way Catalytic Converter (TWC)
- Grease only threads with "G 052 112 A3" (grease must not get into the slots on probe body)
- Remove and install using special tool 3337
- Oxygen sensor heater voltage supply via Fuel Pump (FP) relay -J17-
- Checking oxygen sensor heater before Three Way Catalytic Converter (TWC). Testing and Inspection
- Checking oxygen sensor and control before Three Way Catalytic Converter (TWC). Testing and Inspection
- Checking oxygen sensor aging oxygen sensor 1. Testing and Inspection
31 - Intake hose
- Make sure it is seated securely
- Press together at front to release
- To Secondary Injection Air (AIR) pump motor -V101-
32 - Connecting hose
- For crankcase breather
- From breather housing on cylinder head cover
33 - 2-pin harness connector
- Black
- For Positive Crankcase Ventilation (PVC) heating element -N79-
- Check heater element voltage supply between terminals -1- and -2- with engine running:
- Specified value: at least 11.5 V
34 - Bracket
- Secured to front of sump
35 - Vacuum reservoir
- For intake manifold change-over
36 - From Secondary Air Injection (AIR) solenoid valve -N112-
- Secondary air system
37 - Non-return valve
- Black valve side faces T-piece connection fuel pressure regulator/intake manifold upper section
38 - 2-pin harness connector
- Black
- For Secondary Air Injection (AIR) solenoid valve -N112-
39 - Secondary Air Injection (AIR) solenoid valve -N112-*/**
- Fitting location See engine compartment overview. Service and Repair
- Secondary air system
40 - Intake Manifold Tuning (IMT) valve -N156-*/**
- Location See engine compartment overview. Service and Repair
- Checking. Testing and Inspection
41 - 2-pin harness connector
- Black
- Intake Manifold Tuning (IMT) valve -N156-