Astra G: Engine and Engine Aggregates

Also for this vehicle: Astra, Astra F, Astra H, Astra J.

Choose Sections to see everything in a chapter, or a chapter title to start at its first page.

1. 01General Vehicle InformationGeneral Vehicle Information: Sections
2. 02Maintenance, Body and Chassis Sheet Metal Parts, FrameMaintenance, Body and Chassis Sheet Metal Parts, Frame: Sections
3. 03PaintPaint: Sections
4. 04Body EquipmentBody Equipment: Sections
5. 05Heating, Ventilation, Air Conditioning (HVAC)Heating, Ventilation, Air Conditioning (HVAC): Sections
6. 06Front Wheel Suspension, Wheels and TyresFront Wheel Suspension, Wheels and Tyres: Sections
7. 07Rear Axle and Rear Wheel SuspensionRear Axle and Rear Wheel Suspension: Sections
8. 08BrakesBrakes: Sections
9. 09Engine and Engine AggregatesEngine and Engine Aggregates: Sections
   • Repair Instructions4 pages

     • Special Service Tools
     • Recommended Torque Values
     • Application of "silicone sealing compound" for particular engine versions
     • Reprogrammable Electronic Control Units all Petrol Vaariants
   • Description and Operation20 pages

     • Introduction Division of new technical developments Astra G brochure
     • Engine, engine attaching parts General
     • Engine, engine attaching parts Engine identification
     • Engine, engine attaching parts Overview of engines and engine management systems
     • Engine, engine attaching parts Engine/transmission bearing position
     • Engine, engine attaching parts Electronic cruise control
     • Engine, engine attaching parts Modular mimic display
     • Techline Diagnosis software
     • Techline Diagnostic plug layout
     • Inspection system New developments to be noted in the case of the Astra G
     • Inspection system Opel Service Manual, MY 98 1/2
     • Inspection system Inspection brochure
     • Inspection system Pre-delivery inspection
     • Special service tools Engine, engine attaching parts
     • Introduction Division of new technical developments Astra G brochure
     • Introduction The product
     • General Type and model code
     • General View - saloon, 3-door
     • General View - saloon, 5-door
     • General View - estate, 5-door
     • General Dimensions
   • Specifications2 pages

     • Engine, engine attaching parts Overview of engines and engine management systems
     • Recommended Torque Values
   • Special Tools and Equipment › Special Service Tools
   • Other Information2 pages

     • Application of "silicone sealing compound" for particular engine versions
     • Reprogrammable Electronic Control Units all Petrol Vaariants
   • Technical Service Bulletins37 pages

     • Abrasion, Wear › Ribbed belt - Premature wear
     • Noise, Vibration, Rattle › Turbocharger - Trouble-Shooting Procedure
     • Inoperative - Totally, Partially4 pages

       • Engine or drivetrain - Damaged due to Tuning
       • Petrol engines - Refuelled with diesel fuel
       • Diesel Engines - Usage of Gasoline instead of Diesel Fuel
       • Two-mass flywheel - Diagnosis
     • Won't Maintain Adjustment › Diesel Fuel - Contains up to 7% Bio Diesel (FAME)
     • Poor Operation, Incorrect Operation7 pages

       • Jerking at constant speed 40 - 80 km/h, acceleration, overrun
       • Air Cleaner Housing - Water Ingress
       • Engine or drivetrain - Damaged due to Tuning
       • Petrol engines - Refuelled with diesel fuel
       • New P&A engines with ECU - TC P0602 (44)
       • Diesel Engines - Usage of Gasoline instead of Diesel Fuel
       • Engine X14XE, X16XE, X16XEL - Cylinder head cover assembly problem
     • Excessive Effort, Hard Work2 pages

       • Diesel Engines - Usage of Gasoline instead of Diesel Fuel
       • Engine X14XE, X16XE, X16XEL - Cylinder head cover assembly problem
     • No Start › Engine X20DTL/H - Bad cold start behaviour
     • Cold Driveability2 pages

       • Petrol engines - Refuelled with diesel fuel
       • Engine X20DTL/H - Bad cold start behaviour
     • Detonation, Knock › Petrol engines - Refuelled with diesel fuel
     • Poor Start › Temperature sensor - None or insufficient function
     • Rough Idle2 pages

       • Engine Stalls - Idle Air Control dirty
       • Temperature sensor - None or insufficient function
     • Sluggish, Power Loss3 pages

       • Jerking at constant speed 40 - 80 km/h, acceleration, overrun
       • Air Cleaner Housing - Water Ingress
       • Turbocharger - Trouble-Shooting Procedure
     • Stalls2 pages

       • Engine Stalls - Idle Air Control dirty
       • Temperature sensor - None or insufficient function
     • Warning Lights, Telltale4 pages

       • Engine - telltale illuminates, fault code P0400
       • Check Control - Engine telltale lights up
       • Jerking at constant speed 40 - 80 km/h, acceleration, overrun
       • New P&A engines with ECU - TC P0602 (44)
     • Poor Fit › Engine X14XE, X16XE, X16XEL - Cylinder head cover assembly problem
     • Leaks3 pages

       • Oil filter - Tightening torque changed
       • Turbocharger - Trouble-Shooting Procedure
       • Leak in coolant pump
     • Smoke, Odour, Fumes › Turbocharger - Trouble-Shooting Procedure
   • Technical Information › 19982 pages

     • Application of "silicone sealing compound" for particular engine versions
     • Reprogrammable Electronic Control Units all Petrol Vaariants
   • OHC Petrol Engine253 pages

     • Repair Instructions › Recommended Torque Values
     • Description and Operation2 pages

       • Engine, engine attaching parts X 16 SZR OHC-I petrol engine
       • Engine, engine attaching parts Ribbed V-belt tensioner
     • Specifications › Recommended Torque Values
     • Technical Service Bulletins2 pages

       • Rough Idle › Engine Driveability - Bad idling
       • Stalls › Engine Driveability - Bad idling
     • General50 pages

       • Repair Instructions33 pages

         • Measuring oil consumption
         • OHC I Petrol Engine (X 16 SZR, Z 16 SE) - Engine Identification/Engine Number
         • Compression, Check
         • Pressure Loss, Check
         • Oil Temperature, Measure
         • Oil Pressure, Check
         • Oil Consumption, Measure
         • Illustration (X 16 SZR)
         • Cooling System, Charge and Bleed
         • Cooling System, Check for Leaks
         • Engine, Check for Leaks, (CO Content in Cooling System)
         • Fan Motor, Remove and Install (with Air Conditioning)
         • Auxiliary Fan Motor, Remove and Install
         • Radiator (With Air Conditioning), Remove and Install
         • Coolant Pipe, Remove and Install
         • Control Unit - Cooling module, Remove and Install
         • Engine, Remove and Install
         • Engine, Repair Using Short-block
         • Engine Compartment Survey (X 16 SZR) - Multec
         • Intake Air Preheating, Check (X 16 SZR)
         • Fuel Pump Relay, Remove and Install
         • Accelerator Pedal, Remove and Install
         • Immobiliser with Immobiliser Control Unit Transponder, Remove and Install
         • Special Service Tools
         • Checking and Adjustment Values
         • Coolant Circuit
         • Engine Management
         • Recommended Torque Values
         • Engine Vent Flange, Remove and Install
         • Illustration (Z 16 SE)
         • Engine Compartment Survey (Z 16 SE) - Multec S
         • Intake Air Temperature Sensor, Remove and Install (Z 16 SE)
         • Attaching Parts - Cylinder Head, Remove and Install
       • Description and Operation8 pages

         • Engine, engine attaching parts Electronic immobiliser with transponder
         • Engine, engine attaching parts Layout in the vehicle
         • Engine, engine attaching parts Function
         • Engine, engine attaching parts Functional diagram
         • Engine, engine attaching parts Car pass
         • Engine, engine attaching parts Description of individual components Transponder
         • Engine, engine attaching parts Immobiliser control unit
         • Engine, engine attaching parts System programming
       • Component Locator6 pages

         • OHC I Petrol Engine (X 16 SZR, Z 16 SE) - Engine Identification/Engine Number
         • Illustration (X 16 SZR)
         • Engine Compartment Survey (X 16 SZR) - Multec
         • Intake Air Preheating, Check (X 16 SZR)
         • Illustration (Z 16 SE)
         • Engine Compartment Survey (Z 16 SE) - Multec S
       • Specifications
       • Special Tools and Equipment › Special Service Tools
       • Other Information2 pages

         • OHC I Petrol Engine (X 16 SZR, Z 16 SE) - Engine Identification/Engine Number
         • Sealants, Lubricants and Locking Agents
     • Seals and Seal Rings18 pages

       • Repair Instructions15 pages

         • Seal Ring in Front Camshaft Housing, Replace
         • Seal Ring in Rear Camshaft Housing, Replace
         • Exhaust Manifold, Remove and Install (X 16 SZR)
         • Intake Manifold, Remove and Install (X 16 SZR)
         • Cylinder Head, Remove and Install
         • Seal Ring - Rear Crankshaft, Replace
         • Seal Ring - Oil Pump, Replace / Front Seal Ring - Crankshaft, Replace
         • Oil Pan, Remove and Install
         • Oil Pump, Remove and Install
         • Thermostat, Remove and Install
         • Coolant Pump, Remove and Install
         • Throttle Valve Injection Housing, Remove and Install (X 16 SZR)
         • Throttle Valve Injection Housing, Upper Part, Remove and Install (X 16 SZR)
         • Injectors, Remove and Install (X 16 SZR)
         • Recommended Torque Values
       • Specifications › Recommended Torque Values
       • Technical Service Bulletins › Leaks2 pages

         • Loss of oil from oil pump seal and exhaust pipe becoming detached
         • Cracks in intake manifold gasket
     • Ribbed V-Belt7 pages

       • Repair Instructions5 pages

         • Ribbed V-belt Tension, Check
         • Ribbed V-belt, Remove and Install
         • Ribbed V-belt Tensioner, Remove and Install
         • Ribbed V-belt - Toothed Belt
         • Recommended Torque Values
       • Specifications2 pages

         • Ribbed V-belt - Toothed Belt
         • Recommended Torque Values
     • Fuel Pump5 pages

       • Repair Instructions3 pages

         • Engine Management
         • Recommended Torque Values
         • Fuel Pressure, Check (Z 16 SE)
       • Specifications2 pages

         • Engine Management
         • Recommended Torque Values
     • Engine Damping Block6 pages

       • Repair Instructions5 pages

         • Front Engine Damping Block, Remove and Install
         • Rear Engine Damping Block, Remove and Install
         • Engine Damping Block, Left, Remove and Install
         • Engine Damping Block, Right, Remove and Install
         • Recommended Torque Values
       • Specifications › Recommended Torque Values
     • Oil Circulating20 pages

       • Repair Instructions17 pages

         • Oil Temperature, Measure
         • Oil Pressure, Check
         • Oil Consumption, Measure
         • Oil Filter, Replace
         • Bypass Valve, Replace
         • Seal Ring - Oil Pump, Replace / Front Seal Ring - Crankshaft, Replace
         • Oil Pan, Remove and Install
         • Dynamic Oil Level Control, Remove and Install
         • Oil Pump, Remove and Install
         • Oil Pump, Check
         • Safety Valve, Remove and Install
         • Oil Intake Pipe, Remove and Install
         • Oil Baffle Plate, Remove and Install
         • Oil Pressure Switch, Remove and Install
         • Oil Dipstick Guide Tube, Remove and Install
         • Oil Circuit
         • Recommended Torque Values
       • Specifications2 pages

         • Oil Circuit
         • Recommended Torque Values
       • Technical Service Bulletins › Leaks › Loss of oil from oil pump seal and exhaust pipe becoming detached
     • Timing Gear Case21 pages

       • Repair Instructions11 pages

         • Timing, Check
         • Timing, Adjust
         • Toothed Belt Tension, Check
         • Toothed Belt Tension, Adjust
         • Toothed Belt Cover, Upper Part, Remove and Install
         • Toothed Belt Cover, Lower Part, Remove and Install
         • Toothed Belt, Remove and Install
         • Toothed Belt Tension Roller, Remove and Install
         • Rear Toothed Belt Cover, Remove and Install
         • Ribbed V-belt - Toothed Belt
         • Recommended Torque Values
       • Specifications2 pages

         • Ribbed V-belt - Toothed Belt
         • Recommended Torque Values
       • Technical Service Bulletins8 pages

         • Abrasion, Wear2 pages

           • Toothed belt diagnosis - Possible causes and remedys
           • Toothbelt - Service intervall overview
         • Noise, Vibration, Rattle › Toothed belt diagnosis - Possible causes and remedys
         • Inoperative - Totally, Partially › Toothed belt diagnosis - Possible causes and remedys
         • Loose, Missing, Broken2 pages

           • Toothed belt diagnosis - Possible causes and remedys
           • Toothbelt - Service intervall overview
         • Chip, Crack2 pages

           • Toothed belt diagnosis - Possible causes and remedys
           • Toothbelt - Service intervall overview
     • Cylinder Block45 pages

       • Repair Instructions4 pages

         • Crank Drive, Cylinder Block
         • Recommended Torque Values
         • Cylinder Block, Check for Plane Surface
         • Engine Vent Flange, Remove and Install
       • Specifications2 pages

         • Crank Drive, Cylinder Block
         • Recommended Torque Values
       • Starter Ring Gear2 pages

         • Repair Instructions › Recommended Torque Values
         • Specifications › Recommended Torque Values
       • Guide Bearing in Crankshaft2 pages

         • Repair Instructions › Recommended Torque Values
         • Specifications › Recommended Torque Values
       • Crankshaft Bearing Shell3 pages

         • Repair Instructions2 pages

           • Crankshaft, Remove and Install
           • Recommended Torque Values
         • Specifications › Recommended Torque Values
       • Piston5 pages

         • Repair Instructions4 pages

           • Piston with Con-rod, Remove and Install
           • Piston Rings, Remove and Install
           • Piston, Replace
           • Recommended Torque Values
         • Specifications › Recommended Torque Values
       • Crankshaft11 pages

         • Repair Instructions10 pages

           • Seal Ring - Rear Crankshaft, Replace
           • Con-rod Bearing, Replace
           • Crankshaft, Remove and Install
           • Crankshaft, Check - Crankshaft Longitudinal Play, Check
           • Crankshaft Bearing Play, Check (Determine Bearing Play with Plastigage)
           • Crankshaft Bearing Play, Check (Determine Crankshaft Bearing Play Using External Micrometer and Inside Micrometer)
           • Seal Ring - Oil Pump, Replace / Front Seal Ring - Crankshaft, Replace
           • Reference Gap Between Crankshaft Pulse Pickup and Increment Disc, Check (X 16 SZR)
           • Recommended Torque Values
           • Crankshaft Out-of-round, Check
         • Specifications › Recommended Torque Values
       • Con Rod Bearing5 pages

         • Repair Instructions4 pages

           • Con-rod Bearing, Replace
           • Con-rod Bearing Play, Check (Determine Bearing Play with Plastigage)
           • Con-rod Bearing Play, Check (Determine Bearing Play with Micrometer and Inside Micrometer)
           • Recommended Torque Values
         • Specifications › Recommended Torque Values
       • Con Rod5 pages

         • Repair Instructions4 pages

           • Piston with Con-rod, Remove and Install
           • Con-rod Bearing, Replace
           • Piston, Replace
           • Recommended Torque Values
         • Specifications › Recommended Torque Values
       • Flywheel4 pages

         • Repair Instructions3 pages

           • Drive Disc, Remove and Install
           • Flywheel, Remove and Install
           • Recommended Torque Values
         • Specifications › Recommended Torque Values
       • Cylinder Bore2 pages

         • Repair Instructions › Recommended Torque Values
         • Specifications › Recommended Torque Values
     • Cylinder Head75 pages

       • Repair Instructions30 pages

         • Cylinder head and attaching parts, check and measure - Survey
         • Cylinder head height, check
         • Cylinder head, check for plane surface
         • Valve, measure
         • Inner diameter of valve guide, check
         • Valve stem play, determine
         • Installation height of valves, check
         • Installation height of valve guide, check
         • Cylinder head, overhaul
         • Cylinder head, attach to assembly tool set KM-6215
         • Cylinder head, disassemble
         • Valves, remove
         • Valve seat, cut (in cylinder head)
         • Valve guide, ream
         • Valve, grind
         • Valve, grind in
         • Valve stem seals, replace
         • Cylinder head, assemble
         • Cylinder head machining table of contents
         • Exhaust Manifold, Remove and Install (X 16 SZR)
         • Intake Manifold, Remove and Install (X 16 SZR)
         • Heat Shields, Remove and Install
         • Cylinder head
         • Recommended Torque Values
         • Exhaust Manifold, Remove and Install (Z 16 SE)
         • Intake Manifold, Remove and Install (Z 16 SE)
         • Engine Compartment Survey (Z 16 SE) - Multec S
         • Camshaft Sensor, Remove and Install (Z 16 SE)
         • Coolant Temperature Sensor, Remove and Install (Z 16 SE)
         • Attaching Parts - Cylinder Head, Remove and Install
       • Component Locator › Engine Compartment Survey (Z 16 SE) - Multec S
       • Specifications2 pages

         • Cylinder head
         • Recommended Torque Values
       • Special Tools and Equipment › Cylinder head machining special tools
       • Hydraulic Valve Lifter3 pages

         • Repair Instructions2 pages

           • Hydraulic Valve Lifter, Replace (Cylinder Head Installed)
           • Recommended Torque Values
         • Specifications › Recommended Torque Values
       • Rocker Arm3 pages

         • Repair Instructions2 pages

           • Camshaft and Cam Follower, Remove and Install (Cylinder Head Installed)
           • Recommended Torque Values
         • Specifications › Recommended Torque Values
       • Camshaft4 pages

         • Repair Instructions3 pages

           • Camshaft and Cam Follower, Remove and Install (Cylinder Head Installed)
           • Camshaft, Remove and Install (Cylinder Head Removed)
           • Recommended Torque Values
         • Specifications › Recommended Torque Values
       • Camshaft Housing6 pages

         • Repair Instructions5 pages

           • Seal Ring in Front Camshaft Housing, Replace
           • Seal Ring in Rear Camshaft Housing, Replace
           • Camshaft Housing, Check for Plane Surface
           • Camshaft Housing, Replace
           • Recommended Torque Values
         • Specifications › Recommended Torque Values
       • Valves2 pages

         • Repair Instructions › Recommended Torque Values
         • Specifications › Recommended Torque Values
       • Spark Plug19 pages

         • Repair Instructions2 pages

           • Recommended Torque Values
           • Spark Plugs, Remove and Install
         • Specifications › Recommended Torque Values
         • Technical Service Bulletins16 pages

           • Noise, Vibration, Rattle › Spark plug damages - possible causes and failure modes
           • Inoperative - Totally, Partially › Engine - Spark plugs wet
           • Excessive, Indifferent Play › Engine - Spark plugs wet
           • Loose, Missing, Broken › Spark plug damages - possible causes and failure modes
           • Shudder › Spark plug damages - possible causes and failure modes
           • No Start2 pages

             • Engine - Spark plugs wet
             • Spark plug damages - possible causes and failure modes
           • Cold Driveability2 pages

             • Engine - Spark plugs wet
             • Spark plug damages - possible causes and failure modes
           • Backfires, Misfires › Spark plug damages - possible causes and failure modes
           • Hesitation › Spark plug damages - possible causes and failure modes
           • Poor Fuel Economy › Spark plug damages - possible causes and failure modes
           • Poor Start2 pages

             • Engine - Spark plugs wet
             • Spark plug damages - possible causes and failure modes
           • Rough Idle › Spark plug damages - possible causes and failure modes
           • Surge, Miss, Chuggle › Spark plug damages - possible causes and failure modes
       • Cylinder Head Housing4 pages

         • Repair Instructions3 pages

           • Cylinder Head, Remove and Install
           • Cylinder Head, Check for Plane Surface
           • Recommended Torque Values
         • Specifications › Recommended Torque Values
   • DOHC Petrol Engine365 pages

     • Description and Operation17 pages

       • Engine, engine attaching parts X 12 XE DOHC-0 petrol engine
       • Engine, engine attaching parts Engine view X 12 XE - intake side
       • Engine, engine attaching parts Engine view X 12 XE - exhaust side
       • Engine, engine attaching parts Torque and performance curve, X 12 XE
       • Engine, engine attaching parts Intake module (intake manifold), X 12 XE
       • Engine, engine attaching parts X 14 XE & X 16 XEL DOHC-I petrol engine Intake module/intake manifold
       • Engine, engine attaching parts X 18 XE1 DOHC-I petrol engine
       • Engine, engine attaching parts Engine view X 18 XE1 - intake side
       • Engine, engine attaching parts Engine view X 18 XE1 - exhaust side
       • Engine, engine attaching parts Torque and performance curve, X 18 XE1
       • Engine, engine attaching parts Toothed belt tensioning roller, X 18 XE1
       • Engine, engine attaching parts Intake module/intake manifold, X 18 XE1
       • Engine, engine attaching parts Functionally switched intake system, X 18 XE1
       • Engine, engine attaching parts Coolant pump X 18 XE1
       • Engine, engine attaching parts Simtec 70, X 18 XE1 and X 20 XEV Engine compartment survey, X 18 XE1
       • Engine, engine attaching parts Engine compartment survey, X 20 XEV
       • Engine, engine attaching parts Ribbed V-belt tensioner
     • Technical Service Bulletins4 pages

       • Poor Operation, Incorrect Operation › Poor handling
       • Poor Start › Poor handling
       • Sluggish, Power Loss › Engine stalls when idling, possibly in conjunction with DTC 0505
       • Stalls › Engine stalls when idling, possibly in conjunction with DTC 0505
     • General65 pages

       • Repair Instructions44 pages

         • Measuring oil consumption
         • DOHC I Petrol Engines (X 14 XE, Z 14 XE, X 16 XEL, Z 16 XE,Z 16 YNG, X 18 XE1, Z 18 XE, Z 18 XEL)
         • Check compression (X 14 XE, Z 14 XE, X 16 XEL, Z 16 XE, Z 16 YNG, X 18 XE1)
         • Pressure Loss, Check
         • Illustration, X 14 XE, Z 14 XE, X 16 XEL, Z 16 XE, Z 16 YNG
         • Illustration: X 18 XE1, Z 18 XE, Z 18 XEL
         • Cooling System, Charge and Bleed
         • Cooling System, Check for Leaks
         • Engine, Check for Leaks, (CO Content in Cooling System)
         • Fan Motor, Remove and Install (without Air Conditioning)
         • Fan Motor, Remove and Install (with Air Conditioning)
         • Auxiliary Fan Motor, Remove and Install
         • Radiator, Remove and Install (Without Air Conditioning)
         • Radiator (With Air Conditioning), Remove and Install
         • Coolant Pipe, Remove and Install
         • Control Unit - Cooling module, Remove and Install
         • Engine, Remove and Install
         • Engine, Repair Using Short-block
         • Check fuel pressure (X 14 XE, Z 14 XE, X 16 XEL, Z 16 XE, Z 16 YNG)
         • Fuel pump relay, Remove and Install (X 14 XE, X 16 XEL)
         • Accelerator Pedal, Remove and Install (X 14 XE, X 16 XEL, X 18 XE1)
         • Immobiliser Control Unit, Remove and Install
         • DOHC II Petrol Engine (X 20 XEV, X 20 XER, Z 20 LET) Engine Identification/Engine Number
         • Compression, Check
         • Pressure Loss, Check
         • Illustration: Air Cleaner Housing, Air Ducts (X 20 XEV, X 20 XER)
         • Cooling System, Charge and Bleed
         • Cooling System, Check for Leaks
         • Engine, Check for Leaks, (CO Content in Cooling System)
         • Fan Motor, Remove and Install (with Air Conditioning)
         • Auxiliary Fan Motor, Remove and Install
         • Radiator (With Air Conditioning), Remove and Install
         • Engine, Remove and Install
         • Engine, Repair Using Short-block
         • Engine Compartment Survey
         • Fuel Pressure, Check
         • Fuel Pump Relay, Remove and Install
         • Accelerator Pedal, Remove and Install
         • Immobiliser Control Unit, Remove and Install
         • Special Service Tools
         • Sealants, Lubricants and Locking Agents
         • Specifications
         • Checking and Adjustment Values
         • Coolant Circuit
         • Recommended Torque Values
         • Compression, Check
         • Pressure Loss, Check
         • Illustration X 12 XE
         • Engine, Check for Leaks, (CO Content in Cooling System)
         • Control Unit - Cooling module, Remove and Install
         • Engine, Remove and Install (X 12 XE, Z 12 XE)
         • Engine, Repair Using Short-block
         • Fuel Pressure, Check
         • Immobiliser Control Unit, Remove and Install
         • Accelerator Pedal, Remove and Install (X 12 XE)
         • Specifications
         • Recommended Torque Values
         • Starter, Check (Starter Removed and Disassembled)
         • Valeo Starter, Disassemble and Reassemble
         • Alternator, Check
         • Components of the Alternator, Check
         • Bosch Compact Alternator, Disassemble and Reassemble
         • Attaching Parts - Cylinder Head, Remove and install
       • Description and Operation8 pages

         • Engine, engine attaching parts Electronic immobiliser with transponder
         • Engine, engine attaching parts Layout in the vehicle
         • Engine, engine attaching parts Function
         • Engine, engine attaching parts Functional diagram
         • Engine, engine attaching parts Car pass
         • Engine, engine attaching parts Description of individual components Transponder
         • Engine, engine attaching parts Immobiliser control unit
         • Engine, engine attaching parts System programming
       • Component Locator8 pages

         • DOHC I Petrol Engines (X 14 XE, Z 14 XE, X 16 XEL, Z 16 XE,Z 16 YNG, X 18 XE1, Z 18 XE, Z 18 XEL)
         • Illustration, X 14 XE, Z 14 XE, X 16 XEL, Z 16 XE, Z 16 YNG
         • Illustration: X 18 XE1, Z 18 XE, Z 18 XEL
         • DOHC II Petrol Engine (X 20 XEV, X 20 XER, Z 20 LET) Engine Identification/Engine Number
         • Illustration: Air Cleaner Housing, Air Ducts (X 20 XEV, X 20 XER)
         • Engine Compartment Survey
         • Engine Identification Code / Engine Number
         • Illustration X 12 XE
       • Specifications
       • Special Tools and Equipment1 page

         • Special Service Tools
         • Special Service Tools
         • Special Service Tools
       • Other Information4 pages

         • DOHC I Petrol Engines (X 14 XE, Z 14 XE, X 16 XEL, Z 16 XE,Z 16 YNG, X 18 XE1, Z 18 XE, Z 18 XEL)
         • Sealants, Lubricants and Locking Compounds - DOHC-I -
         • DOHC II Petrol Engine (X 20 XEV, X 20 XER, Z 20 LET) Engine Identification/Engine Number
         • Sealants, Lubricants and Locking Agents
     • Seals and Seal Rings38 pages

       • Repair Instructions36 pages

         • Cylinder Head Cover, Remove and Install
         • Seal Ring - Camshaft, Replace
         • Exhaust Manifold, Remove and Install (X 14 XE, X 16 XEL)
         • Exhaust Manifold, Remove and Install (X 18 XE1)
         • Intake Manifold, Remove and Install (X 14 XE, X 16 XEL)
         • Intake Manifold Flange, Remove and Install (X 14 XE, Z 14 XE, X 16 XEL, Z 16 XE)
         • Intake Manifold, Remove and Install (X 18 XE1)
         • Cylinder Head, Remove and Install (X 14 XE, Z 14 XE, X 16 XEL, Z 16 XE, Z 16 YNG)
         • Cylinder Head, Remove and Install (X 18 XE1)
         • Seal Ring - Rear Crankshaft, Replace
         • Engine bleed flange, Remove and Install (X 14 XE, Z 14 XE, X 16 XEL, Z 16 XE, Z 16 YNG)
         • Seal Ring - Oil Pump, Replace
         • Oil Pan, Remove and Install
         • Oil Pump, Remove and Install
         • Thermostat, Remove and Install (X 14 XE, Z 14 XE, X 16 XEL, Z 16 XE, Z 16 YNG)
         • Thermostat Housing, Remove and Install (X 14 XE, Z 14 XE, X 16 XEL, Z 16 XE)
         • Thermostat, Remove and Install (X 18 XE1, Z 18 XE, Z 18 XEL)
         • Coolant Pump, Remove and Install
         • Throttle Body, Remove and Install (X 14 XE, X 16 XEL)
         • Injection valves, Remove and Install (X 14 XE, Z 14 XE, X 16 XEL, Z 16 XE, Z16 YNG)
         • Throttle Body (Throttle Valve Adjuster), Remove and Install (X 18 XE1)
         • Injectors, Remove and Install (X 18 XE1, Z 18 XE, Z 18 XEL)
         • Cylinder Head Cover, Remove and Install
         • Seal Ring - Camshaft, Replace
         • Exhaust Manifold, Remove and Install (X 20 XEV)
         • Intake Manifold, Remove and Install (X 20 XEV, X 20 XER)
         • Cylinder Head, Remove and Install
         • Seal Ring - Rear Crankshaft, Replace
         • Seal Ring - Oil Pump, Replace; Front Seal Ring - Crankshaft, Replace
         • Lower Part of Oil Pan, Remove and Install
         • Oil Pan - Upper Part, Remove and Install; Oil Intake Pipe, Remove and Install
         • Oil Pump, Remove and Install
         • Thermostat, Remove and Install
         • Coolant Flange (DIS Ignition Module Adapter), Remove and Install
         • Coolant Pump, Remove and Install
         • Throttle Body, Remove and Install (X 20 XEV, X 20 XER)
         • Injectors, Remove and Install
         • Timing Case, Remove and Install
         • Timing Case Seal Ring, Replace
         • Cylinder Head Cover, Remove and Install
         • Injectors, Remove and Install (X 12) Fuel Distributor Pipe, Remove and Install (X 12 XE)
         • Engine Vent Flange, Remove and Install
       • Technical Service Bulletins › Leaks2 pages

         • Loss of oil from oil pump seal and exhaust pipe becoming detached
         • Engine-Gasket Exhaust Manifold leaking
     • Ribbed V-Belt15 pages

       • Repair Instructions10 pages

         • Ribbed V-belt Tension, Check
         • Ribbed V-belt, Remove and Install
         • Ribbed V-belt Tensioner, Remove and Install
         • Ribbed V-belt Tension, Check
         • Ribbed V-belt, Remove and Install (Without Air Conditioning)
         • Ribbed V-belt, Remove and Install (With Air Conditioning)
         • Ribbed V-belt Tensioner, Remove and Install (without Air Conditioning)
         • Ribbed V-belt Tensioner, Remove and Install (with Air Conditioning)
         • Toothed Belt Cover, Upper Part, Remove and Install
         • Special Service Tools
         • Ribbed V-belt
         • Ribbed V-belt, Remove and Install
         • Ribbed V-belt Tensioner, Remove and Install
       • Description and Operation › Engine, engine attaching parts X 20 XEV DOHC-II petrol engine Ribbed V-belt tensioner, X 20 XEV
       • Specifications3 pages

         • Ribbed V-belt
         • Toothed belt
         • Ribbed V-belt
         • Ribbed V-Belt - Engine Timing
       • Special Tools and Equipment › Special Service Tools
     • Engine Damping Block › Repair Instructions6 pages

       • Front Engine Damping Block, Remove and Install
       • Rear Engine Damping Blocks, Remove and Install
       • Engine Damping Block, Left, Remove and Install
       • Engine Damping Block, Right, Remove and Install
       • Front Engine Damping Block, Remove and Install
       • Rear Engine Damping Block, Remove and Install
       • Engine Damping Block, Left, Remove and Install
       • Engine Damping Block, Right, Remove and Install
       • Front Engine Damping Block, Remove and Install
       • Rear Engine Damping Block, Remove and Install
       • Engine Damping Block, Left, Remove and Install
       • Engine Damping Block, Right, Remove and Install
       • Engine, Remove and Install (X 12 XE, Z 12 XE)
     • Oil Circulating34 pages

       • Repair Instructions26 pages

         • Oil Temperature, Measure
         • Oil Pressure, Check
         • Oil Consumption, Measure
         • Oil Filter, Replace (X 14 XE, Z 14 XE, X 16 XEL, Z 16 XE, Z 16 YNG, Z 18 XE and Z 18 XEL as of MY 2002)
         • Engine Oil with Oil Filter, Change (X 18 XE1, Z 18 XE and Z 18 XEL up to MY 2001)
         • Oil Filter Housing, Remove and Install (X 18 XE1, Z 18 XE and Z 18 XEL up to MY 2001)
         • Bypass Valve, Replace
         • Seal Ring - Oil Pump, Replace
         • Oil Pan, Remove and Install
         • Dynamic Oil Level Control, Remove and Install
         • Oil Pump, Remove and Install
         • Oil Pump, Check
         • Safety Valve, Remove and Install
         • Oil Intake Pipe, Remove and Install
         • Oil baffle plate, Remove and Install (X 14 XE, Z 14 XE, X 16 XEL, Z 16 XE, Z 16 YNG)
         • Oil Pressure Switch, Remove and Install
         • Oil Dipstick Guide Tube, Remove and Install
         • Oil Temperature, Measure
         • Oil Pressure, Check
         • Oil Consumption, Measure
         • Oil Filter, Replace
         • Bypass Valve, Replace
         • Seal Ring - Oil Pump, Replace; Front Seal Ring - Crankshaft, Replace
         • Lower Part of Oil Pan, Remove and Install
         • Oil Pan - Upper Part, Remove and Install; Oil Intake Pipe, Remove and Install
         • Dynamic Oil Level Control, Remove and Install
         • Oil Pump, Remove and Install
         • Oil Pump, Check
         • Safety Valve, Remove and Install
         • Oil Baffle Plate, Remove and Install
         • Oil Pressure Switch, Remove and Install
         • Oil Dipstick Guide Tube, Remove and Install
         • Oil circulation
         • Oil Temperature, Measure
         • Oil Pressure, Check
         • Oil Consumption, Measure
         • Engine Oil with Filter Change
         • Air Cleaner Housing, Remove and Install
         • Oil Pressure Switch, Remove and Install
         • Oil Pan, Remove and Install
         • Oil Intake Pipe, Remove and Install
         • Oil Baffle Plate, Remove and Install
         • Oil Pressure Regulating Valve, Remove and Install
         • Oil Pump, Remove and Install
         • Oil Pump, Check
       • Description and Operation4 pages

         • Engine, engine attaching parts Oil pan, X 18 XE1
         • Engine, engine attaching parts Oil filter, oil filter housing, X 18 XE1
         • Engine, engine attaching parts Oil pump, X 18 XE1
         • Engine, engine attaching parts Internal crankcase ventilation, X 18 XE1
       • Specifications2 pages

         • Oil Circuit
         • Oil circulation
         • Oil circulation
       • Technical Service Bulletins2 pages

         • Warning Lights, Telltale › MID - "Check fluid level" warning lamp illuminates
         • Leaks › Loss of oil from oil pump seal and exhaust pipe becoming detached
     • Timing Gear Case33 pages

       • Repair Instructions19 pages

         • Timing, Check
         • Timing, Adjust
         • Toothed Belt Tension, Check
         • Toothed Belt Tension, Adjust
         • Toothed Belt Cover, Upper Part, Remove and Install
         • Toothed Belt Cover, Lower Part, Remove and Install
         • Toothed Belt, Remove and Install
         • Toothed Belt Tension Roller, Remove and Install
         • Toothed Belt Guide Rollers, Remove and Install
         • Rear Toothed Belt Cover, Remove and Install
         • Camshaft Sprockets, Remove and Install
         • Seal Ring - Camshaft, Replace
         • Timing, Check
         • Timing, Adjust
         • Toothed Belt Tension, Check
         • Toothed Belt Tension, Adjust
         • Toothed Belt Cover, Lower Part, Remove and Install
         • Toothed Belt, Remove and Install
         • Toothed Belt Tension Roller, Remove and Install
         • Toothed Belt Guide Rollers, Remove and Install
         • Rear Toothed Belt Cover, Remove and Install
         • Camshaft Pulleys, Remove and Install
         • Seal Ring - Camshaft, Replace
         • Oil Pressure Switch, Remove and Install
         • Special Service Tools
         • Ribbed V-belt
         • Recommended Torque Values
         • Timing, Check
         • Timing, Adjust
         • Timing Case, Remove and Install
         • Timing Case Seal Ring, Replace
         • Camshaft Sprockets, Remove and Install
       • Specifications3 pages

         • Recommended Torque Values
         • Ribbed V-belt
         • Recommended Torque Values
         • Ribbed V-Belt - Engine Timing
       • Special Tools and Equipment › Special Service Tools
       • Technical Service Bulletins9 pages

         • Abrasion, Wear2 pages

           • Toothed belt diagnosis - Possible causes and remedys
           • Toothbelt - Service intervall overview
         • Noise, Vibration, Rattle2 pages

           • Bearing noise due to vibration of toothed belt guide roller when idling, Astra G only
           • Toothed belt diagnosis - Possible causes and remedys
         • Inoperative - Totally, Partially › Toothed belt diagnosis - Possible causes and remedys
         • Loose, Missing, Broken2 pages

           • Toothed belt diagnosis - Possible causes and remedys
           • Toothbelt - Service intervall overview
         • Chip, Crack2 pages

           • Toothed belt diagnosis - Possible causes and remedys
           • Toothbelt - Service intervall overview
       • Toothed Belt › Technical Service Bulletins › Noise, Vibration, Rattle › Bearing noise due to vibration of toothed belt guide roller when idling, Astra G only
     • Cylinder Block65 pages

       • Repair Instructions8 pages

         • Engine bleed flange, Remove and Install (X 14 XE, Z 14 XE, X 16 XEL, Z 16 XE, Z 16 YNG)
         • Cylinder Block, Check for Plane Surface
         • Oil Dipstick Guide Tube, Remove and Install
         • Cylinder Block, Check for Plane Surface
         • Oil Baffle Plate, Remove and Install
         • Oil Dipstick Guide Tube, Remove and Install
         • Special Service Tools
         • Crankshaft drive, cylinder block
         • Recommended Torque Values
         • Cylinder Block, Check for Plane Surface
         • Engine Vent Flange, Remove and Install
       • Description and Operation2 pages

         • Engine, engine attaching parts Crank drive, cylinder block, X 12 XE
         • Engine, engine attaching parts Crank drive, cylinder block, X 18 XE1
       • Component Locator › Engine Identification Code / Engine Number
       • Specifications3 pages

         • Crank Drive, Cylinder Block
         • Recommended Torque Values
         • Crankshaft drive, cylinder block
         • Recommended Torque Values
         • Crankshaft drive, cylinder block
       • Special Tools and Equipment › Special Service Tools
       • Guide Bearing in Crankshaft › Repair Instructions2 pages

         • Crankshaft Bearing Play, Check (Determine Bearing Play Using Plastigage)
         • Crankshaft Bearing Clearance, Check (with Micrometer and Inside Micrometer)
       • Crankshaft Bearing Shell › Repair Instructions5 pages

         • Crankshaft, Remove and Install
         • Crankshaft Bearing Play, Check (Determine Bearing Play Using Plastigage)
         • Crankshaft Bearing Clearance, Check (with Micrometer and Inside Micrometer)
         • Crankshaft, Remove and Install
         • Crankshaft Bearing Play, Check (with Plastigage)
         • Crankshaft Bearing Play, Check (Determine Bearing Play with Micrometer and Internal Micrometer)
       • Piston7 pages

         • Repair Instructions5 pages

           • Piston with Con-rod, Remove and Install
           • Piston Rings, Remove and Install
           • Piston, Replace
           • Piston with Con-rod, Remove and Install
           • Piston Rings, Remove and Install
           • Piston, Replace (X 20 XEV)
           • Piston with Con-rod, Remove and Install
           • Piston, Replace
           • Piston Rings, Replace
         • Description and Operation2 pages

           • Engine, engine attaching parts Pistons with con-rod, X 12 XE
           • Engine, engine attaching parts Pistons with con-rod, X 18 XE1
       • Crankshaft23 pages

         • Repair Instructions21 pages

           • Seal Ring - Rear Crankshaft, Replace
           • Con-rod Bearing, Replace
           • Crankshaft, Remove and Install
           • Crankshaft, Check; Crankshaft Longitudinal Play, Check; Crankshaft Radial Run-out, Check
           • Crankshaft Bearing Play, Check (Determine Bearing Play Using Plastigage)
           • Crankshaft Bearing Clearance, Check (with Micrometer and Inside Micrometer)
           • Seal Ring - Oil Pump, Replace
           • Crankshaft Pick-up, Remove and Install (X 14 XE, X 16 XEL)
           • Reference Gap between Crankshaft Pulse Pick-up and Increment Disc, Check
           • Crankshaft Pulse Pick-up, Remove and Install (X 18 XE1)
           • Seal Ring - Rear Crankshaft, Replace
           • Con-rod Bearing, Replace
           • Crankshaft, Remove and Install
           • Crankshaft, Check; Crankshaft Longitudinal Play, Check
           • Crankshaft Bearing Play, Check (Determine Bearing Play with Plastigage)
           • Crankshaft Bearing Play, Check (Determine Bearing Play with Micrometer and Inside Micrometer)
           • Seal Ring - Oil Pump, Replace; Front Seal Ring - Crankshaft, Replace
           • Crankshaft Pulse Pick-up, Remove and Install
           • Timing Case Seal Ring, Replace
           • Rear Seal Ring - Crankshaft, Replace
           • Crankshaft, Remove and Install
           • Crankshaft End Play, Check
           • Crankshaft Out-of-round, Check
           • Crankshaft Bearing Play, Check (with Plastigage)
           • Crankshaft Bearing Play, Check (Determine Bearing Play with Micrometer and Internal Micrometer)
           • Crankshaft End Play, Check
           • Crankshaft Out-of-round, Check
           • Crankshaft Out-of-round, Check
         • Description and Operation2 pages

           • Engine, engine attaching parts Crankshaft, X 12 XE
           • Engine, engine attaching parts Crankshaft, X 18 XE1
       • Con Rod Bearing › Repair Instructions5 pages

         • Con-rod Bearing, Replace
         • Con-rod Bearing Play, Check (Determine Bearing Play with Plastigage)
         • Con-rod Bearing Play, Check (Determine Bearing Play with Micrometer and Inside Micrometer)
         • Con-rod Bearing, Replace
         • Con-rod Bearing Play, Check (Determine Bearing Play with Plastigage)
         • Con-rod Bearing Play, Check (Determine Bearing Play with Micrometer and Inside Micrometer)
         • Con-rod Bearing, Replace
         • Con-rod Bearing Play, Check (with Plastigage)
         • Con-rod Bearing Play, Check (with Micrometer and Internal Micrometer)
       • Con Rod6 pages

         • Repair Instructions4 pages

           • Piston with Con-rod, Remove and Install
           • Con-rod Bearing, Replace
           • Piston, Replace
           • Piston with Con-rod, Remove and Install
           • Con-rod Bearing, Replace
           • Piston, Replace (X 20 XEV)
           • Piston with Con-rod, Remove and Install
           • Piston, Replace
         • Description and Operation2 pages

           • Engine, engine attaching parts Pistons with con-rod, X 12 XE
           • Engine, engine attaching parts Pistons with con-rod, X 18 XE1
       • Flywheel › Repair Instructions2 pages

         • Flywheel, Remove and Install
         • Drive Disc, Remove and Install
         • Flywheel, Remove and Install
         • Drive Disc, Remove and Install
         • Flywheel, Remove and Install
     • Cylinder Head88 pages

       • Repair Instructions34 pages

         • Cylinder head and attaching parts, check and measure - Survey
         • Cylinder head height, check
         • Cylinder head, check for plane surface
         • Valve, measure
         • Inner diameter of valve guide, check
         • Valve stem play, determine
         • Installation height of valves, check
         • Installation height of valve guide, check
         • Cylinder head, overhaul
         • Cylinder head, attach to assembly tool set KM-6215
         • Cylinder head, disassemble
         • Valves, remove
         • Valve seat, cut (in cylinder head)
         • Valve guide, ream
         • Valve, grind
         • Valve, grind in
         • Valve stem seals, replace
         • Cylinder head, assemble
         • Cylinder head machining table of contents
         • Exhaust Manifold, Remove and Install (X 14 XE, X 16 XEL)
         • Exhaust Manifold, Remove and Install (X 18 XE1)
         • Intake Manifold, Remove and Install (X 14 XE, X 16 XEL)
         • Intake Manifold Flange, Remove and Install (X 14 XE, Z 14 XE, X 16 XEL, Z 16 XE)
         • Intake Manifold, Remove and Install (X 18 XE1)
         • Exhaust Manifold, Remove and Install (X 20 XEV)
         • Intake Manifold, Remove and Install (X 20 XEV, X 20 XER)
         • Special Service Tools
         • Cylinder head
         • Recommended Torque Values
         • Exhaust Manifold, Remove and Install (X 12 XE)
         • Intake Manifold, Remove and Install (X 12 XE)
         • Attaching Parts - Cylinder Head, Remove and Install
         • Attaching Parts - Cylinder Head, Remove and install
         • EGR Valve, Replace (X 12 XE, Z 12 XE up to MY 2003, Z 14 XEP)
         • Exhaust Gas Recirculation Pipe, Replace (X 12 XE, Z 12 XE to MY 2003, Z 14 XEP)
       • Description and Operation3 pages

         • Engine, engine attaching parts Cylinder head, X 12 XE
         • Engine, engine attaching parts Cylinder head, X 18 XE1
         • Engine, engine attaching parts Cylinder head cover, X 18 XE1
       • Specifications3 pages

         • Cylinder head
         • Engine Management
         • Recommended Torque Values
         • Cylinder head
         • Recommended Torque Values
         • Cylinder head
       • Special Tools and Equipment2 pages

         • Cylinder head machining special tools
         • Special Service Tools
       • Technical Service Bulletins4 pages

         • Loose, Missing, Broken › Loosening of Retaining Bolt on Camshaft Sensor
         • No Start › Engine - Stalling or worse Engine run
         • Cold Driveability › Engine - Stalling or worse Engine run
         • Stalls › Engine - Stalling or worse Engine run
       • Hydraulic Valve Lifter › Repair Instructions1 page

         • Hydraulic Valve Lifter, Remove and Install
         • Hydraulic Valve Lifter, Remove and Install
       • Camshaft8 pages

         • Repair Instructions7 pages

           • Camshaft Sprockets, Remove and Install
           • Seal Ring - Camshaft, Replace
           • Camshafts, Remove and Install
           • Camshaft sensor, Remove and Install (X 14 XE, Z 14 XE, X 16 XEL, Z 16 XE, Z 16 YNG)
           • Camshaft Sensor, Remove and Install (X 18 XE1, Z 18 XE, Z 18 XEL)
           • Camshaft Pulleys, Remove and Install
           • Seal Ring - Camshaft, Replace
           • Camshafts, Remove and Install
           • Camshaft Sensor, Remove and Install
           • Camshafts, Remove and Install
           • Camshaft Sprockets, Remove and Install
         • Description and Operation › Engine, engine attaching parts Camshaft sprockets, X 20 XEV
       • Valves5 pages

         • Repair Instructions2 pages

           • All Valve Stem Seals, Replace (Cylinder Head Installed)
           • Replace all valve stem seals (cylinder head installed)
           • All Valve Stem Seals, Replace (Cylinder Head Installed)
         • Technical Service Bulletins3 pages

           • No Start › Engine - Stalling or worse Engine run
           • Cold Driveability › Engine - Stalling or worse Engine run
           • Stalls › Engine - Stalling or worse Engine run
       • Spark Plug20 pages

         • Repair Instructions4 pages

           • Spark Plugs, Remove and Install (X 14 XE, Z 14 XE, X 16 XEL, Z 16 XE, Z 16 YNG)
           • Spark Plugs, Remove and Install (X 18 XE1, Z 18 XE, Z 18 XEL)
           • Spark Plugs, Remove and Install
           • Spark Plugs, Remove and Install X 20 XEV
         • Technical Service Bulletins16 pages

           • Noise, Vibration, Rattle › Spark plug damages - possible causes and failure modes
           • Inoperative - Totally, Partially › Engine - Spark plugs wet
           • Excessive, Indifferent Play › Engine - Spark plugs wet
           • Loose, Missing, Broken › Spark plug damages - possible causes and failure modes
           • Shudder › Spark plug damages - possible causes and failure modes
           • No Start2 pages

             • Engine - Spark plugs wet
             • Spark plug damages - possible causes and failure modes
           • Cold Driveability2 pages

             • Engine - Spark plugs wet
             • Spark plug damages - possible causes and failure modes
           • Backfires, Misfires › Spark plug damages - possible causes and failure modes
           • Hesitation › Spark plug damages - possible causes and failure modes
           • Poor Fuel Economy › Spark plug damages - possible causes and failure modes
           • Poor Start2 pages

             • Engine - Spark plugs wet
             • Spark plug damages - possible causes and failure modes
           • Rough Idle › Spark plug damages - possible causes and failure modes
           • Surge, Miss, Chuggle › Spark plug damages - possible causes and failure modes
       • Cylinder Head Housing8 pages

         • Repair Instructions7 pages

           • Cylinder Head Cover, Remove and Install
           • Cylinder Head, Remove and Install (X 14 XE, Z 14 XE, X 16 XEL, Z 16 XE, Z 16 YNG)
           • Cylinder Head, Remove and Install (X 18 XE1)
           • Cylinder Head, Check for Plane Surface
           • Cylinder Head Cover, Remove and Install
           • Cylinder Head, Remove and Install
           • Cylinder Head, Check for Plane Surface
           • Engine Management
           • Cylinder Head Cover, Remove and Install
           • Cylinder Head, Remove and Install
           • Cylinder Head, Check for Plane Surface
           • Attaching Parts - Cylinder Head, Remove and Install
         • Specifications › Engine Management
   • Diesel Engine352 pages

     • Repair Instructions5 pages

       • Flywheel, Remove and Install
       • Drive Disc, Remove and Install
       • Special Service Tools
       • Recommended Torque Values
       • Repair an engine using a part-engine
     • Description and Operation4 pages

       • Engine, engine attaching parts X 17 DTL OHC-II turbodiesel engine
       • Engine, engine attaching parts Torque and performance curve, X 17 DTL
       • Engine, engine attaching parts Timing, X 17 DTL
       • Engine, engine attaching parts Intake module/intake manifold, X 17 DTL
     • Specifications › Recommended Torque Values
     • Special Tools and Equipment › Special Service Tools
     • Technical Service Bulletins › Sluggish, Power Loss › Loss of power, jerky power fluctuations
     • Schematic and Routing Diagrams › Circuit Diagram › Engine X17DTL
     • General98 pages

       • Repair Instructions80 pages

         • Measuring oil consumption
         • OHC Diesel engine (X 20 DTL, Y 20 DTL, Y 20 DTH, Y 22 DTR) - engine identification / engine number
         • Vacuum routing in engine compartment (X 20 DTL, Y 20 DTL, Y 20 DTH up to MY 2003)
         • Ribbed V-belt Tensioner, Check
         • Test compression pressure (X 20 DTL, Y 20 DTL, Y 20 DTH up to MY 2003)
         • Pressure Loss, Check
         • Oil Temperature, Measure
         • Oil Pressure, Check
         • Oil Consumption, Measure
         • Engine, Lock at 1st Cylinder TDC (Timing, Check)
         • Timing, Adjust
         • Low Pressure System, Check for Leaks
         • Illustration: Air Ducts, X 20 DTL, Y 20 DTL
         • Timing Case, Remove and Install
         • Cylinder Head Cover, Remove and Install
         • Vacuum Pump, Remove and Install
         • Removing and installing inlet manifold upper section (X 20 DTL, Y 20 DTL, Y 20 DTH up to MY 2003)
         • Intake Manifold - Lower Part, Remove and Install
         • Exhaust Manifold with Turbocharger, Remove and Install
         • Cylinder Head, Remove and Install
         • Engine Oil with Oil Filter Change
         • Oil Intake Pipe, Remove and Install
         • Dynamic Oil Level Control, Remove and Install
         • Oil Temperature Sensor, Remove and Install
         • Oil Pressure Regulating Valve, Remove and Install
         • Safety Valve, Remove and Install
         • Oil Pump, Remove and Install
         • Cooling System, Charge and Bleed
         • Cooling System, Check for Leaks
         • Engine, Check for Leaks, (CO Content in Cooling System)
         • Thermostat/Thermostat Housing (Radiator), Remove and Install
         • Coolant Pump, Remove and Install
         • Coolant Pipe, Remove and Install
         • Removing and installing engine (X 20 DTL, Y 20 DTL, Y 20 DTH up to MY 2003)
         • Injection Nozzle Traverse, Remove and Install
         • Crankshaft Pulse Pick-up, Remove and Install
         • Coolant Temperature Sensor, Remove and Install
         • Engine Control Unit, Remove and Install
         • Charge Pressure Control Solenoid Valve, Remove and Install
         • Switchover Valves Solenoid Valve, Remove and Install
         • Switchover Valves Vacuum Unit, Remove and Install
         • Return Manifold, Remove and Install
         • Accelerator Pedal Module with Pedal Position Sensor, Remove and Install
         • Immobiliser Control Unit, Remove and Install
         • Special Service Tools
         • Specifications
         • Checking and Adjustment Values
         • Engine Timing
         • Cooling system
         • Oil circuit
         • Cylinder head
         • Crank drive, cylinder block
         • Engine Management
         • Sealants, Lubricants and Locking Agents
         • Recommended Torque Values
         • OHC II Turbo-Diesel-Engine (X 17 DTL) Number
         • Compression, Check
         • Pressure Loss, Check
         • Oil Temperature, Measure
         • Oil Pressure, Check
         • Oil Consumption, Measure - General
         • Air Cleaner Housing, Air Duct Ducts
         • Cylinder Head, Remove and Install
         • Seal Ring - Rear Crankshaft, Replace
         • Front Seal Ring - Crankshaft, Replace, Seal Ring - Oil Pump, Replace
         • Cooling System, Charge and Bleed system
         • Cooling System, Check for Leaks
         • Engine, Check for Leaks, (CO Content in Cooling System)
         • Fan Motor, Remove and Install
         • Auxiliary Fan Motor, Remove and Install motor
         • Radiator, Remove and Install (Without Air Conditioning)
         • Radiator (With Air Conditioning), Remove and Install
         • Control Unit - Cooling module, Remove and Install
         • Engine Damping Block, Front, Remove and Install Remove and Install
         • Rear Engine Damping Block, Remove and Install
         • Engine Damping Block, Left, Remove and Install
         • Engine Damping Block, Right, Remove and Install
         • Engine, Remove and Install
         • Engine, Repair Using Short-block
         • Fuel Injection Pump, Remove and Install
         • Turbocharger, Remove and Install Remove and Install
         • Intercooler, Remove and Install
         • Immobiliser Control Unit, Remove and Install Install
         • Accelerator Pedal, Remove and Install accelerator
         • Starter, Remove and Install
         • Sealants, Lubricants and Locking Agents Compounds
         • Control Unit - Cooling module, Remove and Install
       • Description and Operation8 pages

         • Engine, engine attaching parts Electronic immobiliser with transponder
         • Engine, engine attaching parts Layout in the vehicle
         • Engine, engine attaching parts Function
         • Engine, engine attaching parts Functional diagram
         • Engine, engine attaching parts Car pass
         • Engine, engine attaching parts Description of individual components Transponder
         • Engine, engine attaching parts Immobiliser control unit
         • Engine, engine attaching parts System programming
       • Component Locator5 pages

         • OHC Diesel engine (X 20 DTL, Y 20 DTL, Y 20 DTH, Y 22 DTR) - engine identification / engine number
         • Vacuum routing in engine compartment (X 20 DTL, Y 20 DTL, Y 20 DTH up to MY 2003)
         • Illustration: Air Ducts, X 20 DTL, Y 20 DTL
         • OHC II Turbo-Diesel-Engine (X 17 DTL) Number
         • Air Cleaner Housing, Air Duct Ducts
       • Specifications
       • Special Tools and Equipment1 page

         • Special Service Tools
         • Special Service Tools
       • Other Information4 pages

         • OHC Diesel engine (X 20 DTL, Y 20 DTL, Y 20 DTH, Y 22 DTR) - engine identification / engine number
         • Vacuum routing in engine compartment (X 20 DTL, Y 20 DTL, Y 20 DTH up to MY 2003)
         • Sealants, Lubricants and Locking Agents
         • OHC II Turbo-Diesel-Engine (X 17 DTL) Number
     • Seals and Seal Rings › Repair Instructions26 pages

       • Timing Case Cover, Remove and Install
       • Seal Ring - Timing Case, Replace / Front Seal Ring - Crankshaft, Replace
       • Rear Seal Ring - Crankshaft, Replace
       • Oil Filter Housing (Heat Exchanger), Remove and Install
       • Oil Pan, Remove and Install
       • Injection Nozzles, Remove and Install
       • Removing and installing charge pressure sensor (X 20 DTL, Y 20 DTL, Y 20 DTH up to MY 2003)
       • Turbocharger, Remove and Install
       • Seal Ring - Camshaft, Replace Replace
       • Vacuum Pump, Remove and Install
       • Cylinder Head, Remove and Install
       • Seal Ring - Rear Crankshaft, Replace
       • Front Seal Ring - Crankshaft, Replace, Seal Ring - Oil Pump, Replace
       • Lower Part of Oil Pan, Remove and Install
       • Upper Part of Oil Pan, Remove and Install
       • Oil Pump, Remove and Install
       • Thermostat, Remove and Install
       • Thermostat Housing, Remove and Install
       • Coolant Pump, Remove and Install
       • Injector Nozzle, Remove and Install Injection System, Remove and Install
       • Crankshaft Pulse Pick-up - EDC 15 M Engine Management System, Remove and Install
       • Charge Pressure Sensor, Remove and Install
       • Oil Temperature Sensor, Remove and Install
       • Coolant Temperature Sensor, Remove and Install
       • Turbocharger, Remove and Install Remove and Install
       • Return Manifold, Remove and Install
     • Ribbed V-Belt13 pages

       • Repair Instructions7 pages

         • Ribbed V-belt Tensioner, Check
         • Ribbed V-belt, Remove and Install
         • Ribbed V-belt Tensioner Assembly, Remove and Install
         • V-belt Tension, Check and Adjust belt Tension, Check and Adjust
         • Ribbed V-belt, Remove and Install Remove and Install
         • V-belt, Remove and Install
         • Ribbed V-belt Tensioner, Remove and Install
       • Description and Operation2 pages

         • Engine, engine attaching parts V-belt / ribbed V-belt, X 17 DTL
         • Engine, engine attaching parts X 20 DTL 16 V OHC turbodiesel engine Ribbed V-belt return roller, X 20 DTL
       • Specifications2 pages

         • Ribbed V-belt
         • V-belt - Ribbed V-belt, Toothed Belt Belt
       • Technical Service Bulletins2 pages

         • Abrasion, Wear › Ribbed belt - Premature wear
         • Noise, Vibration, Rattle › Ribbed V belt makes squeaking noises
     • Engine Damping Block › Repair Instructions5 pages

       • Front Engine Damping Block, Remove and Install
       • Rear Engine Damping Block, Remove and Install
       • Engine Damping Block, Left, Remove and Install
       • Engine Damping Block, Right, Remove and Install
       • Engine Damping Block, Front, Remove and Install Remove and Install
       • Rear Engine Damping Block, Remove and Install
       • Engine Damping Block, Left, Remove and Install
       • Engine Damping Block, Right, Remove and Install
     • Oil Circulating34 pages

       • Repair Instructions30 pages

         • Oil Temperature, Measure
         • Oil Pressure, Check
         • Oil Consumption, Measure
         • Engine Oil with Oil Filter Change
         • Oil Pressure Switch, Remove and Install
         • Oil Filter Housing (Heat Exchanger), Remove and Install
         • Heat Exchanger, Remove and Install
         • Oil Pan, Remove and Install
         • Oil Intake Pipe, Remove and Install
         • Dynamic Oil Level Control, Remove and Install
         • Oil Temperature Sensor, Remove and Install
         • Oil Pressure Regulating Valve, Remove and Install
         • Safety Valve, Remove and Install
         • Oil Pump, Remove and Install
         • Oil Spray Nozzle, Remove and Install
         • Turbocharger Oil Feed Line, Remove and Install
         • Oil Return Line - Turbocharger, Remove and Install
         • Oil circuit
         • Oil Temperature, Measure
         • Oil Pressure, Check
         • Oil Consumption, Measure - General
         • Oil Filter, Replace
         • Bypass Valve, Replace
         • Lower Part of Oil Pan, Remove and Install
         • Upper Part of Oil Pan, Remove and Install
         • Oil Pump, Remove and Install
         • Oil Pump, Check
         • Safety Valve, Remove and Install
         • Oil Pressure Regulating Valve, Replace
         • Oil Cooler, Remove and Install
         • Thermostat (Engine Oil Cooling), Remove and Install
         • Thermostat Housing (Engine Oil Cooling) , Remove and Install
         • Turbocharger Oil Feed Line, Remove and Install
         • Oil Return Line - Turbocharger, Remove and Install
         • Oil Spray Nozzles, Remove and Install
         • Oil Pressure Switch, Remove and Install
         • Oil Dipstick Guide Tube, Remove and Install
         • Oil Intake Pipe, Remove and Install
         • Oil Temperature Sensor, Remove and Install
         • Oil Dipstick Guide Tube, Remove and Install
       • Description and Operation2 pages

         • Engine, engine attaching parts Oil pan, X 17 DTL
         • Engine, engine attaching parts Oil filter housing / heat exchanger
       • Specifications1 page

         • Oil circuit
         • Oil Circuit
       • Technical Service Bulletins › Inoperative - Totally, Partially › Engine - oil dipsticks difficult to read
     • Timing Gear Case33 pages

       • Repair Instructions21 pages

         • Engine, Lock at 1st Cylinder TDC (Timing, Check)
         • Timing, Adjust
         • Timing Case Cover, Remove and Install
         • Simplex Timing Chain Guide Rail, Remove and Install
         • Simplex Injection Pump Pulley, Remove and Install / Simplex Timing Chain, Remove and Install
         • Simplex Chain Tensioner, Remove and Install
         • Duplex Chain Tensioner, Remove and Install
         • Seal Ring - Timing Case, Replace / Front Seal Ring - Crankshaft, Replace
         • Timing Case, Remove and Install
         • Oil Pump, Remove and Install
         • Engine Timing
         • Toothed Belt Tension, Check
         • Toothed Belt Tension, Adjust
         • Air Cleaner Housing, Air Duct Ducts
         • Toothed Belt Cover, Upper Part, Remove and Install
         • Toothed Belt Cover, Lower Part, Remove and Install
         • Toothed Belt, Remove and Install
         • Toothed Belt Tension Roller, Remove and Install
         • Toothed Belt Guide Roller, Remove and Install
         • Rear Toothed Belt Cover, Remove and Install
         • Safety Valve, Remove and Install
       • Component Locator › Air Cleaner Housing, Air Duct Ducts
       • Specifications3 pages

         • Engine Timing
         • V-belt - Ribbed V-belt, Toothed Belt Belt
         • Recommended Torque Values
       • Technical Service Bulletins8 pages

         • Abrasion, Wear2 pages

           • Toothed belt diagnosis - Possible causes and remedys
           • Toothbelt - Service intervall overview
         • Noise, Vibration, Rattle › Toothed belt diagnosis - Possible causes and remedys
         • Inoperative - Totally, Partially › Toothed belt diagnosis - Possible causes and remedys
         • Loose, Missing, Broken2 pages

           • Toothed belt diagnosis - Possible causes and remedys
           • Toothbelt - Service intervall overview
         • Chip, Crack2 pages

           • Toothed belt diagnosis - Possible causes and remedys
           • Toothbelt - Service intervall overview
     • Cylinder Block55 pages

       • Repair Instructions15 pages

         • Alternator, Remove and Install
         • Starter, Remove and Install
         • OHC Diesel engine (X 20 DTL, Y 20 DTL, Y 20 DTH, Y 22 DTR) - engine identification / engine number
         • Cylinder Block, Check for Plane Surface
         • Specifications
         • OHC II Turbo-Diesel-Engine (X 17 DTL) Number
         • Cylinder Block, Check for Plane Surface
         • Piston Projection, Check
         • Oil Spray Nozzles, Remove and Install
         • Coolant Pipe, Remove and Install
         • Engine Damping Block, Left, Remove and Install
         • Engine Damping Block, Right, Remove and Install
         • Engine, Remove and Install
         • Fuel Injection Pump, Remove and Install
         • Alternator, Remove and Install Install
         • Repair an engine using a part-engine
       • Description and Operation › Engine, engine attaching parts cylinder block, crank drive, X 17 DTL
       • Component Locator2 pages

         • OHC Diesel engine (X 20 DTL, Y 20 DTL, Y 20 DTH, Y 22 DTR) - engine identification / engine number
         • OHC II Turbo-Diesel-Engine (X 17 DTL) Number
       • Specifications
       • Other Information2 pages

         • OHC Diesel engine (X 20 DTL, Y 20 DTL, Y 20 DTH, Y 22 DTR) - engine identification / engine number
         • OHC II Turbo-Diesel-Engine (X 17 DTL) Number
       • Crankshaft Bearing Shell4 pages

         • Repair Instructions3 pages

           • Crankshaft Bearing Play, Check (Determine Bearing Play with Plastigage)
           • Crankshaft Bearing Play, Check (Determine Bearing Play with Micrometer and Inside Micrometer)
           • Crank drive, cylinder block
         • Specifications › Crank drive, cylinder block
       • Piston › Repair Instructions4 pages

         • Piston with Con-rod, Remove and Install
         • Piston Rings, Remove and Install
         • Piston, Replace
         • Piston with Con-rod, Remove and Install
         • Piston Rings, Remove and Install
         • Piston, Replace
         • Piston Projection, Check
       • Crankshaft13 pages

         • Repair Instructions11 pages

           • Rear Seal Ring - Crankshaft, Replace
           • Crankshaft, Remove and Install
           • Crankshaft, Check
           • Crankshaft Bearing Play, Check (Determine Bearing Play with Plastigage)
           • Crankshaft Bearing Play, Check (Determine Bearing Play with Micrometer and Inside Micrometer)
           • Crank drive, cylinder block
           • Seal Ring - Rear Crankshaft, Replace
           • Front Seal Ring - Crankshaft, Replace, Seal Ring - Oil Pump, Replace
           • Con-rod Bearing, Remove and Install
           • Crankshaft, Remove and Install
           • Crankshaft, Check; Crankshaft Longitudinal Play, Check; Crankshaft Radial Run-out, Check
           • Crankshaft Bearing Play, Check (Determine Bearing Play with Plastigage)
           • Crankshaft Bearing Play, Check (Determine Bearing Play with Micrometer and Inside Micrometer)
           • Crankshaft Pulse Pick-up - EDC 15 M Engine Management System, Remove and Install
         • Description and Operation › Engine, engine attaching parts Crankshaft, X 17 DTL
         • Specifications › Crank drive, cylinder block
       • Con Rod Bearing › Repair Instructions5 pages

         • Con-rod Bearing, Replace
         • Con-rod Bearing Play, Check (Determine Bearing Play with Plastigage)
         • Con-rod Bearing Play, Check (Determine Bearing Play with Micrometer and Inside Micrometer)
         • Con-rod Bearing, Remove and Install
         • Con-rod Bearing Play, Check (Determine Bearing Play with Plastigage) plastigage)
         • Con-rod Bearing Play, Check (Determine Bearing Play with Micrometer and Inside Micrometer)
       • Con Rod6 pages

         • Repair Instructions5 pages

           • Piston with Con-rod, Remove and Install
           • Piston, Replace
           • Crank drive, cylinder block
           • Piston with Con-rod, Remove and Install
           • Piston, Replace
           • Con-rod Bearing, Remove and Install
           • Crankshaft, Remove and Install
         • Specifications › Crank drive, cylinder block
       • Flywheel › Repair Instructions3 pages

         • Flywheel, Remove and Install
         • Drive Disc, Remove and Install
         • Flywheel, Remove and Install Remove and Install
     • Cylinder Head69 pages

       • Repair Instructions48 pages

         • Cylinder head and attaching parts, check and measure - Survey
         • Cylinder head height, check
         • Cylinder head, check for plane surface
         • Valve, measure
         • Inner diameter of valve guide, check
         • Valve stem play, determine
         • Installation height of valves, check
         • Installation height of valve guide, check
         • Swirl chamber projection, check - 17D, 17DT, X17DT, X17DTL
         • Cylinder head, overhaul
         • Cylinder head, attach to assembly tool set KM-6215
         • Cylinder head, disassemble
         • Valves, remove
         • Valve seat, cut (in cylinder head)
         • Valve guide, ream
         • Valve, grind
         • Valve, grind in
         • Valve stem seals, replace
         • Cylinder head, assemble
         • Cylinder head machining table of contents
         • Cylinder Head Cover, Remove and Install
         • Vacuum Pump, Remove and Install
         • Removing and installing inlet manifold upper section (X 20 DTL, Y 20 DTL, Y 20 DTH up to MY 2003)
         • Intake Manifold - Lower Part, Remove and Install
         • Exhaust Manifold with Turbocharger, Remove and Install
         • Alternator Bracket (Coolant Flange), Remove and Install
         • Removing and installing injection lines (X 20 DTL, Y 20 DTL, Y 20 DTH up to MY 2003)
         • Injection Nozzle Traverse, Remove and Install
         • Injection Nozzles, Remove and Install
         • Glow Plugs, Remove and Install
         • Cylinder head
         • Compression, Check
         • Pressure Loss, Check
         • Timing, Check
         • Timing, Adjust
         • Vacuum Pump, Remove and Install
         • Cylinder Head, Remove and Install
         • Cylinder Head, Check for Plane Surface
         • Oil Pressure Regulating Valve, Replace
         • Engine, Remove and Install
         • Injector Nozzle, Remove and Install Injection System, Remove and Install
         • Injector Nozzle, Disassemble and Assemble
         • Injector Nozzle, Check
         • Injection Lines, Remove and Install Install
         • Charge Pressure Sensor, Remove and Install
         • Turbocharger, Remove and Install Remove and Install
         • Return Manifold, Remove and Install
         • Glow Plugs, Remove and Install and Install
         • Attaching Parts - Cylinder Head, Remove and Install
         • Attaching Parts - Cylinder Head, Remove and Install
         • Check and measure cylinder head and attaching parts - overhaul cylinder head
         • Check and measure cylinder head and attaching parts - overhaul cylinder head
       • Specifications2 pages

         • Cylinder head
         • Cylinder head
         • Recommended Torque Values
       • Special Tools and Equipment › Cylinder head machining special tools
       • Hydraulic Valve Lifter › Repair Instructions2 pages

         • Hydraulic Valve Lifter, Remove and Install
         • Rocker Arm, Replace (Cylinder Head Installed), Hydraulic Valve Lifter, Replace (Cylinder Head, Installed)
       • Rocker Arm › Repair Instructions › Rocker Arm, Replace (Cylinder Head Installed), Hydraulic Valve Lifter, Replace (Cylinder Head, Installed)
       • Camshaft › Repair Instructions2 pages

         • Camshaft, Remove and Install
         • Camshaft, Remove and Install (Cylinder Head Installed)
       • Camshaft Bearing › Repair Instructions2 pages

         • Seal Ring - Camshaft, Replace Replace
         • Rocker Arm, Replace (Cylinder Head Installed), Hydraulic Valve Lifter, Replace (Cylinder Head, Installed)
       • Valves › Repair Instructions2 pages

         • Valve Bridges, Remove and Install
         • Replace valve shaft seals
       • Glow Plug › Repair Instructions4 pages

         • Pressure Loss, Check
         • Glow Plugs, Remove and Install
         • Glow Plugs, Remove and Install and Install
         • Attaching Parts - Cylinder Head, Remove and Install
       • Cylinder Head Housing › Repair Instructions5 pages

         • Cylinder Head, Remove and Install
         • Exhaust Manifold with Turbocharger, Remove and Install
         • Intake Manifold, Remove and Install
         • Attaching Parts - Cylinder Head, Remove and Install
         • Check and measure cylinder head and attaching parts - overhaul cylinder head
         • Check and measure cylinder head and attaching parts - overhaul cylinder head
     • Vacuum Pump4 pages

       • Repair Instructions2 pages

         • Vacuum routing in engine compartment (X 20 DTL, Y 20 DTL, Y 20 DTH up to MY 2003)
         • Vacuum Pump, Remove and Install
         • Vacuum Pump, Remove and Install
       • Component Locator › Vacuum routing in engine compartment (X 20 DTL, Y 20 DTL, Y 20 DTH up to MY 2003)
       • Other Information › Vacuum routing in engine compartment (X 20 DTL, Y 20 DTL, Y 20 DTH up to MY 2003)
     • Auxiliary aggregate drive › Repair Instructions2 pages

       • Ribbed V-belt Tensioner, Check
       • Ribbed V-belt, Remove and Install
   • Fuel Injection Systems301 pages

     • Repair Instructions20 pages

       • Hot Film Mass Air FlowMeter, Remove and Install
       • Fuel Pressure Regulator, Remove and Install
       • Knock Sensor, Remove and Install
       • Engine Control Unit, Remove and Install
       • Solenoid Valve for Intake Manifold Switchover Valve, Remove and Install
       • Throttle Body Potentiometer, Remove and Install (X 16 SZR)
       • Pressure Sensor - Intake Pipe, Remove and Install (X 16 SZR)
       • Crankshaft Pulse Pick-up, Remove and Install (X 16 SZR)
       • Reference Gap Between Crankshaft Pulse Pickup and Increment Disc, Check (X 16 SZR)
       • Knock Sensor, Remove and Install
       • Fuel Pressure Regulator, Fuel Pressure Regulator Diaphragm, Remove and Install (X 16 SZR)
       • Fuel Pressure, Check (X 16 SZR)
       • Idle Speed Stepper Motor, Remove and Install (X 16 SZR)
       • Engine Control Unit, Remove and Install (X 16 SZR)
       • Accelerator Pedal, Remove and Install
       • Engine Management
       • Throttle Body, Remove and Install (Z 16 SE)
       • Pressure Sensor - Intake Pipe, Remove and Install (Z 16 SE)
       • Injectors, Remove and Install (Z 16 SE)
       • Crankshaft Pulse Pick-up, Remove and Install (Z 16 SE)
       • Engine Control Unit, Remove and Install (Z 16 SE)
     • Description and Operation3 pages

       • Engine, engine attaching parts Engine compartment survey, X 16 SZR
       • Engine, engine attaching parts Modular mimic display, X 16 SZR
       • Engine, engine attaching parts Overview of engine control unit instal. sites (all engines)
     • Specifications › Engine Management
     • Multec S84 pages

       • Repair Instructions22 pages

         • Illustration, X 14 XE, Z 14 XE, X 16 XEL, Z 16 XE, Z 16 YNG
         • Intake Manifold, Remove and Install (X 14 XE, X 16 XEL)
         • Intake Manifold Flange, Remove and Install (X 14 XE, Z 14 XE, X 16 XEL, Z 16 XE)
         • Accelerator Pedal, Remove and Install (X 14 XE, X 16 XEL, X 18 XE1)
         • Pressure Sensor - Intake Pipe, Remove and Install (X 16 SZR)
         • Injectors, Remove and Install (X 16 SZR)
         • Crankshaft Pulse Pick-up, Remove and Install (X 16 SZR)
         • Knock Sensor, Remove and Install
         • Fuel Pressure Regulator, Fuel Pressure Regulator Diaphragm, Remove and Install (X 16 SZR)
         • Fuel Pump Relay, Remove and Install
         • Oxygen Sensor, Remove and Install (X 16 SZR)
         • Idle Speed Stepper Motor, Remove and Install (X 16 SZR)
         • Engine Control Unit, Remove and Install (X 16 SZR)
         • Coolant Temperature Sensor, Remove and Install (X 16 SZR)
         • Tank Vent Valve, Remove and Install
         • Immobiliser with Immobiliser Control Unit Transponder, Remove and Install
         • Special Service Tools
         • Checking and Adjustment Values
         • Illustration (Z 16 SE)
         • Pressure Sensor - Intake Pipe, Remove and Install (Z 16 SE)
         • Injectors, Remove and Install (Z 16 SE)
         • Intake Air Temperature Sensor, Remove and Install (Z 16 SE)
       • Description and Operation5 pages

         • Engine, engine attaching parts Multec S, X 14 XE and X 16 XEL
         • Engine, engine attaching parts Engine comp. survey, X 14 XE & X 16 XEL
         • Engine, engine attaching parts Modular mimic disp., X 14 XE & X 16 XEL
         • Engine, engine attaching parts Engine control unit in hybrid design
         • Engine, engine attaching parts Ignition module
       • Component Locator2 pages

         • Illustration, X 14 XE, Z 14 XE, X 16 XEL, Z 16 XE, Z 16 YNG
         • Illustration (Z 16 SE)
       • Specifications
       • Special Tools and Equipment1 page

         • Special Service Tools
         • Special Service Tools
       • Diagnostic Information and Procedures › Diagnostic Procedures › Multec S, X 14 XE, X 16 XEL
       • Schematic and Routing Diagrams › Circuit Diagram2 pages

         • Engine X14XE
         • Engine X16XEL
       • Throttle Valve Housing3 pages

         • Repair Instructions2 pages

           • Throttle Body, Remove and Install (X 14 XE, X 16 XEL)
           • Engine Compartment Survey (Z 16 SE) - Multec S
         • Component Locator › Engine Compartment Survey (Z 16 SE) - Multec S
       • Throttle Valve Potentiometer › Repair Instructions › Throttle Valve Potentiometer, Remove and Install (X 14 XE, X 16 XEL)
       • Intake Pipe Pressure Sensor3 pages

         • Repair Instructions2 pages

           • Pressure Sensor - Intake Manifold, Remove and Install (X 14 XE, X 16 XEL)
           • Engine Compartment Survey (Z 16 SE) - Multec S
         • Component Locator › Engine Compartment Survey (Z 16 SE) - Multec S
       • Pressure Regulator › Repair Instructions3 pages

         • Check fuel pressure (X 14 XE, Z 14 XE, X 16 XEL, Z 16 XE, Z 16 YNG)
         • Fuel Pressure Regulator, Remove and Install (X 14 XE, X 16 XEL)
         • Fuel Pressure, Check (Z 16 SE)
       • Injection Valve3 pages

         • Repair Instructions2 pages

           • Injection valves, Remove and Install (X 14 XE, Z 14 XE, X 16 XEL, Z 16 XE, Z16 YNG)
           • Engine Compartment Survey (Z 16 SE) - Multec S
         • Component Locator › Engine Compartment Survey (Z 16 SE) - Multec S
       • Inductive Impulse Sensor › Repair Instructions5 pages

         • Crankshaft Pick-up, Remove and Install (X 14 XE, X 16 XEL)
         • Reference Gap between Crankshaft Pulse Pick-up and Increment Disc, Check
         • Camshaft sensor, Remove and Install (X 14 XE, Z 14 XE, X 16 XEL, Z 16 XE, Z 16 YNG)
         • Crankshaft Pulse Pick-up, Remove and Install (Z 16 SE)
         • Camshaft Sensor, Remove and Install (Z 16 SE)
       • Knocking Sensor3 pages

         • Repair Instructions2 pages

           • Knock sensor, Remove and Install (X 14 XE, Z 14 XE, X 16 XEL, Z 16 XE, Z 16 YNG)
           • Engine Compartment Survey (Z 16 SE) - Multec S
         • Component Locator › Engine Compartment Survey (Z 16 SE) - Multec S
       • Fuel Pump › Repair Instructions3 pages

         • Check fuel pressure (X 14 XE, Z 14 XE, X 16 XEL, Z 16 XE, Z 16 YNG)
         • Fuel pump relay, Remove and Install (X 14 XE, X 16 XEL)
         • Fuel Pressure, Check (Z 16 SE)
       • Fuel Pump Relay › Repair Instructions › Fuel pump relay, Remove and Install (X 14 XE, X 16 XEL)
       • Oxygen Sensor5 pages

         • Repair Instructions4 pages

           • Oxygen Sensor, Remove and Install (X 14 XE, X 16 XEL)
           • Engine Compartment Survey (Z 16 SE) - Multec S
           • Oxygen Sensor - Mixture Regulation, Remove and Install (Z 16 SE)
           • Oxygen Sensor - Catalytic Converter Control, Remove and Install (Z 16 SE)
         • Component Locator › Engine Compartment Survey (Z 16 SE) - Multec S
       • Idle Air Control Stepper Motor › Repair Instructions › Idle Speed Stepper Motor, Remove and Install (X 14 XE, X 16 XEL)
       • Control Unit6 pages

         • Repair Instructions3 pages

           • Engine Control Unit, Remove and Install (X 14 XE, X 16 XEL)
           • Immobiliser Control Unit, Remove and Install
           • Engine Compartment Survey (Z 16 SE) - Multec S
         • Component Locator › Engine Compartment Survey (Z 16 SE) - Multec S
         • Technical Service Bulletins2 pages

           • Cold Driveability › Engine Driveability - Poor driveability in cold run condition
           • Sluggish, Power Loss › Engine Driveability - Poor driveability in cold run condition
       • Tank Ventilation Valve3 pages

         • Repair Instructions2 pages

           • Tank vent valve, Remove and Install (X 14 XE, Z 14 XE, X 16 XEL, Z 16 XE, Z 16 YNG)
           • Engine Compartment Survey (Z 16 SE) - Multec S
         • Component Locator › Engine Compartment Survey (Z 16 SE) - Multec S
       • Coolant Temperature Sensor9 pages

         • Repair Instructions4 pages

           • Intake air temperature sensor, Remove and Install (X 14 XE, Z 14 XE, X 16 XEL, Z 16 XE, Z 16 YNG)
           • Coolant temperature sensor, Remove and Install (X 14 XE, Z 14 XE, X 16 XEL, Z 16 XE, Z 16 YNG)
           • Engine Compartment Survey (Z 16 SE) - Multec S
           • Intake Air Temperature Sensor, Remove and Install (Z 16 SE)
         • Component Locator › Engine Compartment Survey (Z 16 SE) - Multec S
         • Technical Service Bulletins4 pages

           • No Start › Coolant Temperature Sensor - Wiring harness connector poor contact
           • Cold Driveability › Coolant Temperature Sensor - Wiring harness connector poor contact
           • Rough Idle › Coolant Temperature Sensor - Wiring harness connector poor contact
           • Stalls › Coolant Temperature Sensor - Wiring harness connector poor contact
       • Ignition Module3 pages

         • Repair Instructions2 pages

           • Ignition module, Remove and Install (X 14 XE, Z 14 XE, X 16 XEL, Z 16 XE, Z 16 YNG)
           • Engine Compartment Survey (Z 16 SE) - Multec S
         • Component Locator › Engine Compartment Survey (Z 16 SE) - Multec S
     • Motronic M/ME 1.5.536 pages

       • Repair Instructions4 pages

         • Fuel Pressure, Check
         • Oxygen Sensor - X 12 XE, Remove and Install
         • Accelerator Pedal, Remove and Install (X 12 XE)
         • Specifications
       • Description and Operation5 pages

         • Engine, engine attaching parts Motronic M 1.5.5, X 12 XE
         • Engine, engine attaching parts Engine compartment survey, X 12 XE
         • Engine, engine attaching parts Modular mimic display, X 12 XE
         • Engine, engine attaching parts Engine control unit in hybrid design
         • Engine, engine attaching parts Ignition module
       • Specifications2 pages

         • Checking and Adjustment Values
         • Engine Management
       • Diagnostic Information and Procedures › Diagnostic Procedures › Motronic M1.5.5, X 12 XE
       • Technical Service Bulletins4 pages

         • Poor Operation, Incorrect Operation › X/Z10XE, X/Z12 XE-Engines - Oil non-return-valve in cylinderblock removed
         • Loose, Missing, Broken › X/Z10XE, X/Z12 XE-Engines - Oil non-return-valve in cylinderblock removed
         • Sluggish, Power Loss › Engine stalls when idling, possibly in conjunction with DTC 0505
         • Stalls › Engine stalls when idling, possibly in conjunction with DTC 0505
       • Schematic and Routing Diagrams › Circuit Diagram › Engine X12XE
       • Throttle Valve Housing › Repair Instructions › Throttle Body, Remove and Install (X 12 XE)
       • Throttle Valve Adjuster › Repair Instructions › Throttle Valve Adjuster, Remove and Install (X 12 XE)
       • Throttle Valve Potentiometer › Repair Instructions › Throttle Valve Potentiometer, Remove and Install (X 12 XE)
       • Injection Valve › Repair Instructions › Injectors, Remove and Install (X 12) Fuel Distributor Pipe, Remove and Install (X 12 XE)
       • Inductive Impulse Sensor › Repair Instructions2 pages

         • Crankshaft Pulse Pick-up, Remove and Install
         • Camshaft Sensor, Remove and Install
       • Knocking Sensor › Repair Instructions › Knock Sensor, Remove and Install
       • Fuel Pump › Repair Instructions › Fuel Pump Relay, Remove and Install
       • Fuel Pump Relay › Repair Instructions › Fuel Pump Relay, Remove and Install
       • Idle Speed Adjuster › Technical Service Bulletins3 pages

         • Rough Idle › Throttle Valve Adjuster Voltage high
         • Stalls › Throttle Valve Adjuster Voltage high
         • Warning Lights, Telltale › Throttle Valve Adjuster Voltage high
       • Air Flow Meter › Repair Instructions › Hot Film Mass Air Flow Meter, Remove and Install
       • Control Unit3 pages

         • Repair Instructions2 pages

           • Engine Control Unit, Remove and Install
           • Immobiliser Control Unit, Remove and Install
         • Technical Service Bulletins › Inoperative - Totally, Partially › Battery - Discharged
       • Coolant Temperature Sensor › Repair Instructions › Coolant Temperature Sensor, Remove and Install
       • Air Filter Housing2 pages

         • Repair Instructions › Illustration X 12 XE
         • Component Locator › Illustration X 12 XE
       • Ignition Module › Repair Instructions › Ignition Module, Remove and Install
     • EDC MSA 15 M56 pages

       • Repair Instructions7 pages

         • Fuel Injection Pump, Remove and Install
         • Charge Pressure Control Solenoid Valve, Remove and Install
         • Switchover Valves Solenoid Valve, Remove and Install
         • Switchover Valves Vacuum Unit, Remove and Install
         • Exhaust Gas Recirculation Solenoid Valve, Remove and Install
         • Engine Management
         • Accelerator Pedal, Remove and Install accelerator
       • Description and Operation10 pages

         • Engine, engine attaching parts Fuel injection system EDC 15 M, X 17 DTL
         • Engine, engine attaching parts Engine compartment survey, X 17 DTL
         • Engine, engine attaching parts Brake signal switch, X 17 DTL
         • Engine, engine attaching parts Clutch control switch, X 17 DTL
         • Engine, engine attaching parts Modular mimic display, X 17 DTL
         • Engine, engine attaching parts Preheat system, X 17 DTL
         • Engine, engine attaching parts Sheathed glow plug control unit, X 17 DTL
         • Engine, engine attaching parts Fuel injection system EDC 15 M, X 20 DTL
         • Engine, engine attaching parts Engine compartment survey, X 20 DTL
         • Engine, engine attaching parts Modular mimic display, X 20 DTL
       • Specifications
       • Special Tools and Equipment › Special Service Tools
       • Diagnostic Information and Procedures › Diagnostic Procedures0 pages

         • Electronic Diesel Injection System EDC 15M, X 17 DTL
         • Electronic Diesel Injection System EDC 15M, X 20 DTL
       • Schematic and Routing Diagrams › Circuit Diagram › Engine X20DTL
       • Fuel Injection Nozzles › Repair Instructions5 pages

         • Injection Nozzle Traverse, Remove and Install
         • Injection Nozzles, Remove and Install
         • Injector Nozzle, Remove and Install Injection System, Remove and Install
         • Injector Nozzle, Disassemble and Assemble
         • Injector Nozzle, Check
       • Fuel Injection Lines › Repair Instructions3 pages

         • Removing and installing injection lines (X 20 DTL, Y 20 DTL, Y 20 DTH up to MY 2003)
         • Injection Nozzle Traverse, Remove and Install
         • Injection Lines, Remove and Install Install
       • Crankshaft Pulse Pickup3 pages

         • Repair Instructions2 pages

           • Crankshaft Pulse Pick-up, Remove and Install
           • Crankshaft Pulse Pick-up - EDC 15 M Engine Management System, Remove and Install
         • Description and Operation › Engine, engine attaching parts Crankshaft impulse sensor, X 17 DTL
       • Accelerator Pedal Position Sensor2 pages

         • Repair Instructions › Accelerator Pedal Module with Pedal Position Sensor, Remove and Install
         • Description and Operation › Engine, engine attaching parts Acc. ped. module with pedal value sensor X 17 DTL
       • Fuel Injection Pump3 pages

         • Repair Instructions2 pages

           • Simplex Injection Pump Pulley, Remove and Install / Simplex Timing Chain, Remove and Install
           • Fuel Injection Pump, Remove and Install
           • Fuel Injection Pump, Remove and Install
         • Description and Operation › Engine, engine attaching parts Injection pump VP 29, X 17 DTL
       • Hot Film Mass Air Flow Meter4 pages

         • Repair Instructions2 pages

           • Illustration: Air Ducts, X 20 DTL, Y 20 DTL
           • Hot Film Mass Air Flow Meter, Remove and Install
           • Hot Film Mass Air Flow Meter, Remove and Install
         • Description and Operation › Engine, engine attaching parts Hot film mass air flow meter, X 17 DTL (with integrated intake air temperature sensor)
         • Component Locator › Illustration: Air Ducts, X 20 DTL, Y 20 DTL
       • Control Unit7 pages

         • Repair Instructions3 pages

           • Engine Control Unit, Remove and Install
           • Engine Control Unit, Remove and Install
           • Control Unit - Pre-heater System, Remove and Install
           • Immobiliser Control Unit, Remove and Install Install
         • Description and Operation2 pages

           • Engine, engine attaching parts Engine control unit, X 17 DTL
           • Engine, engine attaching parts AC operating unit (AC switch) X 17 DTL
         • Technical Service Bulletins › Warning Lights, Telltale2 pages

           • Engine - telltale illuminates, fault code P0400
           • Check Control - Engine telltale lights up
       • Charge Pressure Sensor3 pages

         • Repair Instructions2 pages

           • Removing and installing charge pressure sensor (X 20 DTL, Y 20 DTL, Y 20 DTH up to MY 2003)
           • Charge Pressure Sensor, Remove and Install
         • Description and Operation › Engine, engine attaching parts Charge pressure sensor, X 17 DTL
       • Coolant Temperature Sensor2 pages

         • Repair Instructions1 page

           • Coolant Temperature Sensor, Remove and Install
           • Coolant Temperature Sensor, Remove and Install
         • Description and Operation › Engine, engine attaching parts Coolant temperature sensor, X 17 DTL
       • Oil Temperature Sensor2 pages

         • Repair Instructions › Oil Temperature Sensor, Remove and Install
         • Description and Operation › Engine, engine attaching parts Oil temperature sensor, X 17 DTL
       • Intake Air Temperature Sensor › Description and Operation › Engine, engine attaching parts Hot film mass air flow meter, X 17 DTL (with integrated intake air temperature sensor)
       • Air Cleaner Housing2 pages

         • Repair Instructions › Illustration: Air Ducts, X 20 DTL, Y 20 DTL
         • Component Locator › Illustration: Air Ducts, X 20 DTL, Y 20 DTL
     • Multec (F)8 pages

       • Description and Operation › Engine, engine attaching parts Multec (F), X 16 SZR
       • Diagnostic Information and Procedures › Diagnostic Procedures › Multec (F), X 16 SZR
       • Technical Service Bulletins5 pages

         • Noise, Vibration, Rattle › Non-return valve - vibration noises
         • Inoperative - Totally, Partially › Engine cuts out; does not start Engine - faulty control unit
         • No Start › Engine cuts out; does not start Engine - faulty control unit
         • Hesitation › Engine cuts out; does not start Engine - faulty control unit
         • Corrosion, Rust, Dirt › Engine cuts out; does not start Engine - faulty control unit
       • Schematic and Routing Diagrams › Circuit Diagram › Engine X16SZR
       • Control Unit › Description and Operation › Engine, engine attaching parts Engine control unit, X 16 SZR
     • Simtec 7093 pages

       • Repair Instructions16 pages

         • Intake Manifold, Remove and Install (X 18 XE1)
         • Accelerator Pedal, Remove and Install (X 14 XE, X 16 XEL, X 18 XE1)
         • Solenoid Valve - Switchover Valve, Remove and Install (X 18 XE1, Z 18 XE, Z 18 XEL)
         • Vacuum Unit - Switchover Valve, Remove and Install (X 18 XE1, Z 18 XE, Z 18 XEL)
         • Intake Manifold, Remove and Install (X 20 XEV, X 20 XER)
         • Engine Compartment Survey
         • Fuel Pressure, Check
         • Solenoid Valve for Intake Manifold Switchover Valve, Remove and Install
         • Switchover Valve Vacuum Cell, Remove and Install
         • Cruise Control Bowden Cable, Remove and Install
         • Accelerator Pedal, Remove and Install
         • Special Service Tools
         • Specifications
         • Checking and Adjustment Values
         • Engine Management
         • Recommended Torque Values
       • Description and Operation7 pages

         • Engine, engine attaching parts Simtec 70, X 18 XE1 and X 20 XEV Engine compartment survey, X 18 XE1
         • Engine, engine attaching parts Engine compartment survey, X 20 XEV
         • Engine, engine attaching parts Camshaft sensor, X 18 XE1 and X 20 XEV
         • Engine, engine attaching parts Hot film mass air flow meter, X 18 XE1 and X 20 XEV
         • Engine, engine attaching parts Modular mimic display, X 18 XE1 and X 20 XEV
         • Engine, engine attaching parts Engine control unit in hybrid design
         • Engine, engine attaching parts Ignition module
       • Component Locator › Engine Compartment Survey
       • Specifications
       • Special Tools and Equipment1 page

         • Special Service Tools
         • Special Service Tools
       • Diagnostic Information and Procedures › Diagnostic Procedures0 pages

         • Simtec 70, X 18 XE1
         • Simtec 70, X 20 XEV
       • Technical Service Bulletins6 pages

         • Poor Operation, Incorrect Operation › Engine X18XE1 - Engine stalls, trouble code P0100 and/or P0110 set
         • Backfires, Misfires › Engine X18XE1 - Engine stalls, trouble code P0100 and/or P0110 set
         • Hesitation › Engine X18XE1 - Engine stalls, trouble code P0100 and/or P0110 set
         • Sluggish, Power Loss › Engine X18XE1 - Engine stalls, trouble code P0100 and/or P0110 set
         • Stalls › Throttle Body - Idle fluctuations due to dirt contamination
         • Surge, Miss, Chuggle › Throttle Body - Idle fluctuations due to dirt contamination
       • Schematic and Routing Diagrams › Circuit Diagram2 pages

         • Engine X18XE1
         • Engine X20XEV
       • Throttle Valve Housing › Repair Instructions2 pages

         • Throttle Body (Throttle Valve Adjuster), Remove and Install (X 18 XE1)
         • Throttle Body, Remove and Install (X 20 XEV, X 20 XER)
       • Throttle Valve Potentiometer2 pages

         • Repair Instructions › Throttle Valve Potentiometer, Remove and Install (X 20 XEV, X 20 XER)
         • Description and Operation › Engine, engine attaching parts Throttle valve potentiometer, X 20 XEV
       • Throttle Valve Adjuster › Description and Operation › Engine, engine attaching parts Throttle valve adjuster, X 18 XE1
       • Pressure Regulator › Repair Instructions2 pages

         • Fuel Pressure, Check (X 18 XE1, Z 18 XE, Z 18 XEL)
         • Fuel Pressure, Check
       • Injection Valve4 pages

         • Repair Instructions2 pages

           • Injectors, Remove and Install (X 18 XE1, Z 18 XE, Z 18 XEL)
           • Injectors, Remove and Install
         • Description and Operation2 pages

           • Engine, engine attaching parts Injection valves X 18 XE1
           • Engine, engine attaching parts Injection valves X 20 XEV
       • Hall Sensor for Cylinder Recognition › Repair Instructions › Camshaft Sensor, Remove and Install
       • Inductive Impulse Sensor5 pages

         • Repair Instructions3 pages

           • Crankshaft Pulse Pick-up, Remove and Install (X 18 XE1)
           • Camshaft Sensor, Remove and Install (X 18 XE1, Z 18 XE, Z 18 XEL)
           • Crankshaft Pulse Pick-up, Remove and Install
         • Description and Operation2 pages

           • Engine, engine attaching parts Crankshaft impulse sensor, X 18 XE1 and X 20 XEV
           • Engine, engine attaching parts Crankshaft imp. sensor signal allocation and camshaft sensor, X 18 XE1 and X 20 XEV
       • Knocking Sensor2 pages

         • Repair Instructions › Knock Sensor, Remove and Install (X 18 XE1, Z 18 XE, Z 18 XEL)
         • Description and Operation › Engine, engine attaching parts Knock sensor, X 18 XE1 and X 20 XEV
       • Fuel Pump › Repair Instructions3 pages

         • Fuel Pressure, Check (X 18 XE1, Z 18 XE, Z 18 XEL)
         • Fuel Pressure, Check
         • Fuel Pump Relay, Remove and Install
       • Fuel Pump Relay › Repair Instructions2 pages

         • Fuel Pump Relay, Remove and Install (X 18 XE1, Z 18 XE, Z 18 XEL)
         • Fuel Pump Relay, Remove and Install
       • Oxygen Sensor5 pages

         • Repair Instructions4 pages

           • Oxygen Sensor, Remove and Install (X 18 XE1)
           • Coolant Flange (DIS Ignition Module Adapter), Remove and Install
           • DIS-Ignition Module, Remove and Install (X 20 XEV, X 20 XER)
           • Oxygen Sensor, Remove and Install (X 20 XEV, X 20 XER)
         • Description and Operation › Engine, engine attaching parts Oxygen sensor, X 18 XE1 and X 20 XEV
       • Idle Air Control Stepper Motor › Description and Operation › Engine, engine attaching parts Idle speed charge controller, X 20 XEV
       • Control Unit6 pages

         • Repair Instructions3 pages

           • Immobiliser Control Unit, Remove and Install
           • Engine Control Unit, Remove and Install (X 18 XE1)
           • Control Unit / Actuator, Remove and Install
           • Immobiliser Control Unit, Remove and Install
         • Description and Operation › Engine, engine attaching parts Engine cont. unit, X 18 XE1 and X 20 XEV
         • Technical Service Bulletins2 pages

           • Noise, Vibration, Rattle › Engine runs poorly, vibrates or stalls when driving off
           • Stalls › Engine runs poorly, vibrates or stalls when driving off
       • Tank Ventilation Valve › Repair Instructions3 pages

         • Tank Vent Valve, Remove and Install (X 18 XE1, Z 18 XE, Z 18 XEL)
         • Idle Air Control, Remove and Install (X 20 XEV, X 20 XER)
         • Tank Vent Valve, Remove and Install
       • Coolant Temperature Sensor8 pages

         • Repair Instructions2 pages

           • Coolant Temperature Sensor, Remove and Install (X 18 XE1, Z 18 XE, Z 18 XEL)
           • Coolant Temperature Sensor, Remove and Install
         • Description and Operation › Engine, engine attaching parts Coolant temperature sensor, X 18 XE1 and X 20 XEV
         • Technical Service Bulletins5 pages

           • No Start › Coolant Temperature Sensor - Wiring harness connector poor contact
           • Cold Driveability › Coolant Temperature Sensor - Wiring harness connector poor contact
           • Poor Start › Coolant Temperature Sensor - Wiring harness connector poor contact
           • Rough Idle1 page

             • Coolant Temperature Sensor - Wiring harness connector poor contact
             • Coolant Temperature Sensor - Wiring harness connector poor contact
           • Stalls1 page

             • Coolant Temperature Sensor - Wiring harness connector poor contact
             • Coolant Temperature Sensor - Wiring harness connector poor contact
       • Wiring Harness › Technical Service Bulletins5 pages

         • Poor Operation, Incorrect Operation › Wiring Harness Connector Air Mass Meter - Marten bite attacks
         • Backfires, Misfires › Wiring Harness Connector Air Mass Meter - Marten bite attacks
         • Rough Idle › Wiring Harness Connector Air Mass Meter - Marten bite attacks
         • Sluggish, Power Loss › Wiring Harness Connector Air Mass Meter - Marten bite attacks
         • Warning Lights, Telltale › Wiring Harness Connector Air Mass Meter - Marten bite attacks
       • Air Filter Housing5 pages

         • Repair Instructions3 pages

           • Illustration: X 18 XE1, Z 18 XE, Z 18 XEL
           • Hot Film Mass Air Flow Meter, Remove and Install (X 18 XE1, Z 18 XE, Z 18 XEL)
           • Illustration: Air Cleaner Housing, Air Ducts (X 20 XEV, X 20 XER)
         • Component Locator2 pages

           • Illustration: X 18 XE1, Z 18 XE, Z 18 XEL
           • Illustration: Air Cleaner Housing, Air Ducts (X 20 XEV, X 20 XER)
       • Ignition Module3 pages

         • Repair Instructions › Ignition Module, Remove and Install (X 18 XE1, Z 18 XE, Z 18 XEL)
         • Description and Operation2 pages

           • Engine, engine attaching parts Ignition module, X 18 XE1
           • Engine, engine attaching parts Ignition module, X 20 XEV
   • Engine Electrics22 pages

     • Repair Instructions5 pages

       • Check alternator
       • DIS Ignition Module, Remove and Install
       • Starter, Remove and Install
       • Alternator, Remove and Install
       • Engine Management
     • Specifications › Engine Management
     • Schematic and Routing Diagrams › Circuit Diagram › Start & Charging
     • Starter › Repair Instructions1 page

       • Starter, Remove and Install
       • Starter, Remove and Install
       • Starter, Remove and Install
       • Starter, Remove and Install
       • Starter, Remove and Install
     • Alternator11 pages

       • Repair Instructions10 pages

         • Alternator, Remove and Install
         • Alternator Bracket (Coolant Flange), Remove and Install
         • Alternator, Remove and Install
         • Special Service Tools
         • Recommended Torque Values
         • Alternator, Remove and Install
         • Alternator, Remove and Install Install
         • Alternator, Remove and Install
         • Alternator - Remove and Install (with Air Conditioning)
         • Alternator - Remove and Install (without Air Conditioning)
         • Alternator, Check
         • Components of the Alternator, Check
         • Bosch Compact Alternator, Disassemble and Reassemble
       • Specifications1 page

         • Recommended Torque Values
         • Recommended Torque Values
         • Recommended Torque Values
       • Special Tools and Equipment
       • Technical Service Bulletins
     • Pre-Glow System (Diesel Engine) › Repair Instructions3 pages

       • Glow Plugs, Remove and Install
       • Glow Plugs, Remove and Install and Install
       • Control Unit - Pre-heater System, Remove and Install
   • Cooling System62 pages

     • Repair Instructions14 pages

       • Cooling System, Charge and Bleed
       • Cooling System, Check for Leaks
       • Engine, Check for Leaks, (CO Content in Cooling System)
       • Alternator Bracket (Coolant Flange), Remove and Install
       • Coolant Pipe, Remove and Install
       • Coolant Temperature Sensor, Remove and Install
       • Cooling system
       • Cooling System, Charge and Bleed
       • Cooling System, Check for Leaks
       • Engine, Check for Leaks, (CO Content in Cooling System)
       • Coolant Pipe, Remove and Install
       • Cooling System, Charge and Bleed
       • Cooling System, Check for Leaks
       • Engine, Check for Leaks, (CO Content in Cooling System)
       • Coolant Flange (DIS Ignition Module Adapter), Remove and Install
       • Coolant Pipe, Remove and Install
       • Special Service Tools
       • Coolant Circuit
       • Recommended Torque Values
       • Cooling System, Charge and Bleed
       • Cooling System, Check for Leaks
       • Engine, Check for Leaks, (CO Content in Cooling System)
       • Coolant Pipe, Remove and Install
       • Coolant Temperature Sensor, Remove and Install (X 16 SZR)
       • Special Service Tools
       • Coolant Circuit
       • Cooling System, Charge and Bleed system
       • Cooling System, Check for Leaks
       • Engine, Check for Leaks, (CO Content in Cooling System)
       • Coolant Pipe, Remove and Install
       • Coolant Temperature Sensor, Remove and Install
       • Cooling System, Charge and Bleed
       • Cooling System, Check for Leaks
       • Engine, Check for Leaks, (CO Content in Cooling System)
       • Coolant Temperature Sensor, Remove and Install (Z 16 SE)
     • Description and Operation3 pages

       • Engine, engine attaching parts Engine cooling module
       • Engine, engine attaching parts Functional overview eng. cooling module
       • Engine, engine attaching parts Mod. mimic display eng. cooling module
     • Specifications3 pages

       • Cooling system
       • Coolant Circuit
       • Recommended Torque Values
       • Coolant Circuit
       • Recommended Torque Values
       • Coolant Circuit
       • Coolant Circuit
       • Recommended Torque Values
       • Cooling system
     • Special Tools and Equipment1 page

       • Special Service Tools
       • Special Service Tools
       • Special Service Tools
       • Special Service Tools
     • Schematic and Routing Diagrams › Circuit Diagram2 pages

       • Engine cooling (Petrol)
       • Engine cooling module (Diesel)
     • Seal Thermostat Housing › Repair Instructions7 pages

       • Thermostat, Remove and Install (X 14 XE, Z 14 XE, X 16 XEL, Z 16 XE, Z 16 YNG)
       • Thermostat Housing, Remove and Install (X 14 XE, Z 14 XE, X 16 XEL, Z 16 XE)
       • Thermostat, Remove and Install (X 18 XE1, Z 18 XE, Z 18 XEL)
       • Coolant Pump, Remove and Install
       • Thermostat, Remove and Install
       • Coolant Flange (DIS Ignition Module Adapter), Remove and Install
       • Coolant Pump, Remove and Install
       • Coolant Pipe, Remove and Install
       • Thermostat, Remove and Install
       • Coolant Pump, Remove and Install
       • Thermostat, Remove and Install
       • Coolant Pump, Remove and Install
     • Radiator7 pages

       • Repair Instructions4 pages

         • Radiator (With Air Conditioning), Remove and Install
         • Radiator, Remove and Install (Without Air Conditioning)
         • Radiator (With Air Conditioning), Remove and Install
         • Radiator (With Air Conditioning), Remove and Install
         • Radiator (With Air Conditioning), Remove and Install
         • Radiator, Remove and Install (Without Air Conditioning)
         • Radiator (With Air Conditioning), Remove and Install
         • Intercooler, Remove and Install
         • Radiator, Remove and Install (Without Air Conditioning)
         • Radiator (With Air Conditioning), Remove and Install
         • Radiator, Remove and Install (Without Air Conditioning)
         • Fan Motor, Remove and Install (without Air Conditioning)
         • Radiator, Remove and Install (Without Air Conditioning)
       • Technical Service Bulletins3 pages

         • Chip, Crack › Oil/Water Heat Exchanger - Leaky
         • Corrosion, Rust, Dirt › Oil/Water Heat Exchanger - Leaky
         • Leaks › Oil/Water Heat Exchanger - Leaky
     • Fan Motor › Repair Instructions4 pages

       • Fan Motor, Remove and Install
       • Fan Motor, Remove and Install (without Air Conditioning)
       • Fan Motor, Remove and Install (with Air Conditioning)
       • Fan Motor, Remove and Install (with Air Conditioning)
       • Fan Motor, Remove and Install (with Air Conditioning)
       • Fan Motor, Remove and Install
       • Fan Motor, Remove and Install (without Air Conditioning)
       • Fan Motor, Remove and Install (with Air Conditioning)
       • Fan Motor, Remove and Install (without Air Conditioning)
       • Radiator, Remove and Install (Without Air Conditioning)
     • Oil Cooler › Repair Instructions2 pages

       • Oil Filter Housing (Heat Exchanger), Remove and Install
       • Heat Exchanger, Remove and Install
     • Thermostat › Repair Instructions10 pages

       • Thermostat/Thermostat Housing (Radiator), Remove and Install
       • Thermostat, Remove and Install (X 14 XE, Z 14 XE, X 16 XEL, Z 16 XE, Z 16 YNG)
       • Thermostat Housing, Remove and Install (X 14 XE, Z 14 XE, X 16 XEL, Z 16 XE)
       • Thermostat, Remove and Install (X 18 XE1, Z 18 XE, Z 18 XEL)
       • Coolant temperature sensor, Remove and Install (X 14 XE, Z 14 XE, X 16 XEL, Z 16 XE, Z 16 YNG)
       • Coolant Temperature Sensor, Remove and Install (X 18 XE1, Z 18 XE, Z 18 XEL)
       • Thermostat, Remove and Install
       • Coolant Temperature Sensor, Remove and Install
       • Thermostat, Remove and Install
       • Thermostat, Remove and Install
       • Thermostat Housing, Remove and Install
       • Thermostat (Thermostat Housing), Remove and Install
       • Coolant Temperature Sensor, Remove and Install
     • Water Pump2 pages

       • Repair Instructions1 page

         • Coolant Pump, Remove and Install
         • Coolant Pump, Remove and Install
         • Coolant Pump, Remove and Install
         • Coolant Pump, Remove and Install
         • Coolant Pump, Remove and Install
         • Coolant Pump, Remove and Install
       • Technical Service Bulletins › Leaks › Leak in coolant pump
     • Auxiliary Air Fan › Repair Instructions2 pages

       • Auxiliary Fan Motor, Remove and Install
       • Auxiliary Fan Motor, Remove and Install
       • Auxiliary Fan Motor, Remove and Install
       • Auxiliary Fan Motor, Remove and Install motor
       • Auxiliary Fan Motor, Remove and Install
     • Control Unit Cooling5 pages

       • Repair Instructions1 page

         • Control Unit - Cooling module, Remove and Install
         • Control Unit - Cooling module, Remove and Install
         • Control Unit - Cooling module, Remove and Install
         • Control Unit - Cooling module, Remove and Install
         • Control Unit - Cooling module, Remove and Install
         • Control Unit - Cooling module, Remove and Install
       • Description and Operation › Engine, engine attaching parts Engine cooling module control unit
       • Schematic and Routing Diagrams › Circuit Diagram3 pages

         • Engine cooling module (Diesel)
         • Engine cooling module (Petrol & Air conditioning)
         • Engine cooling module (X20XEV & Air conditioning)
   • Turbo-Charging14 pages

     • Repair Instructions5 pages

       • Exhaust Manifold with Turbocharger, Remove and Install
       • Return Manifold, Remove and Install
       • Turbocharger, Remove and Install
       • Turbocharger, Remove and Install Remove and Install
       • Return Manifold, Remove and Install
       • Intercooler, Remove and Install
     • Technical Service Bulletins5 pages

       • Noise, Vibration, Rattle2 pages

         • Turbocharger - Whistling noise from turbocharger
         • Turbocharger - Trouble-Shooting Procedure
       • Sluggish, Power Loss › Turbocharger - Trouble-Shooting Procedure
       • Leaks › Turbocharger - Trouble-Shooting Procedure
       • Smoke, Odour, Fumes › Turbocharger - Trouble-Shooting Procedure
     • Gaskets › Repair Instructions2 pages

       • Turbocharger, Remove and Install Remove and Install
       • Return Manifold, Remove and Install
     • Oil Lines › Repair Instructions2 pages

       • Turbocharger Oil Feed Line, Remove and Install
       • Oil Return Line - Turbocharger, Remove and Install
       • Turbocharger Oil Feed Line, Remove and Install
10. 10Clutch and TransmissionClutch and Transmission: Sections
11. 11Fuel and Exhaust SystemFuel and Exhaust System: Sections
12. 12SteeringSteering: Sections
13. 13Electrical Equipment and InstrumentsElectrical Equipment and Instruments: Sections
14. 14AccessoriesAccessories: Sections