500 Factory Service Manual (2007-2024): Engine
General
Maintenance
Diagnostics
Engine
Transmission
Brakes
Steering & suspension
Heating & A/C
Electrical
Body & interior
Choose Sections to see everything in a chapter, or a chapter title to start at its first page.
General2 pages
Engine and power unit6 pages
- Power unit with manual gearbox - r+r for versions with A/C
- Power unit (manual gearbox), removed, dismantle and reassemble
- Engine - position on stand and remove
- Engine, removed - remove cylinder head and oil sump for inspection - includes positioning on stand and removal
- Engine - dismantle and reassemble following operation 1004e10 - wash and check dismantled parts - refit cylinder head an
- Engine, removed - general overhaul
Power unit supports8 pages
- Introduction - power unit supports
- Introduction - power unit mounts
- Power unit rigid support - gearbox side - r.r.
- Power unit rigid support - timing side - r.r.
- Power unit front support flexible mounting (timing side) - replace
- Gearbox side support flexible mounting(s) - replace
- Power unit lower reaction link - r.r.
- Bracket on gearbox for lower reaction rod - r.r.
- Engine block › Introduction - engine crankcase
Cylinder head/s10 pages
- Introduction - cylinder head(s)
- Cylinder head/s - various operations
- Single tappet cover - r.r. and replace gasket
- Single cylinder head - r.r. and replace gasket on versions with air conditioning
- Single camshaft housing - replace gasket
- Single camshaft housing - r.r. with timing belt removed - replace gasket
- Single cylinder head, removed - overhaul
- Valve guides in single cylinder head - replace during op. 1016e10
- Single cylinder head, removed - r .r parts for grinding
- Single cylinder head or (one) left or right, removed - grinding
Crankcase sump and covers12 pages
- Crankcase oil sump
- Oil seals on crankshaft
- Introduction - crankcase sump and covers
- Crankcase oil sump - r.r clean surfaces for sealant application
- Crankcase oil sump - r.r clean surfaces for sealant application with engine or interfering components removed
- Engine oil drain plug - replace
- Chain-drive valve gear cover - r.r. and gasket replacement for models with air-conditioner
- Timing cover oil seal - replace
- Front crankshaft oil seal cover - r+r and replace gaskets for versions with air conditioning
- Front crankshaft cover oil seal - replace for versions with air conditioning
- Flywheel side oil seal cover - r.r and replace gaskets
- Flywheel side oil seal cover - r.r. and replace gaskets with flywheel removed
Crankshaft and flywheel8 pages
- Crankshaft
- Flywheel
- Crankshaft - r.r with engine removed - check and, if necessary, replace main journals and crankpins
- Engine flywheel - r + r for versions with manual gearbox
- Engine flywheel - r.r with clutch removed for versions with manual gearbox
- Engine flywheel cover - r.r.
- Engine flywheel protection - r.r
- Phonic wheel on flywheel for RPM and timing sensor - r.r with timing sensor removed
Pistons and connecting rods5 pages
- Introduction - pistons and connecting rods
- Pistons and connecting rods
- Piston with connecting rod - r.r. for version with air conditioning
- Piston with connecting rod - dismantling at the bench
- Set of pistons, gudgeon pins and seals - replace pistons and connecting rods at the bench - includes alignment and balan
Timing system27 pages
- Chain timing system
- Timing system tensioners
- Toothed timing belt - r + r for timing adjustment or replacement versions with air conditioner
- Toothed driven pulley (one) - r + r with timing belt removed
- Toothed drive pulley - r + r with timing belt removed
- Toothed drive pulley - r.r. for versions with air conditioning
- Timing belt toothed pulley - r.r. for versions with air conditioning
- Timing system drive chain - r.r
- Camshaft gear - r.r. with shaft assembly removed
- Timing system moving tensioner - r.r with timing belt/chain removed
- Moving timing belt tensioner - r.r. for versions with air conditioning
- Timing system chain tensioner pad - r.r.
- Timing system fixed chain tensioner pad r r
- Timing system front protective cover (upper part) - r.r.
- Timing system front protective cover (lower part) - r.r.
- Introduction - timing system
- Camshaft (1) in camshaft housings (2)
- Overhead camshaft in cylinder head - r.r on vehicle
- Front camshaft oil seal - r.r with timing belt removed
- Phase transformer on camshaft in cylinder head - r.r.
- Overhead camshaft rear cover - r + r and replace seals
- Hydraulic tappet (one) - r.r.
- Valve tappets - check clearance
- Valve tappets - adjustment following clearance check
- Camshafts in camshaft housing - r.r. - includes camshaft housing replacement if necessary
- Camshafts in camshaft housing - r.r. with camshaft housing removed - includes possible replacement. of camshaft housing
- Camshaft seal support in camshaft housing - r.r.
Fuel tank and pipes17 pages
- Introduction - fuel tank and pipes
- Fuel tank and components
- Check on supply voltage and current uptake
- Submerged fuel pump check
- Fuel supply operation restoration following fuel cut-off intervention
- Check fuel pump relay functions
- Fuel supply circuit check
- Fuel tank - r + r and decant fuel
- Fuel filler pipe assembly- r + r
- Plug for fuel filler pipe - r + r
- Submerged pump assembly complete with level gauge control - r + r
- Submerged pump assembly complete with fuel gauge - r.r. with tank removed
- Front fuel delivery line - r.r.
- Rear fuel delivery line - r.r
- Rear fuel return pipe - r.r.
- Fuel filler pipe protection - arrange
- Fuel pipe protection - r.r
Fuel circuit pump/s and devices2 pages
Engine air supply circuit14 pages
- Introduction - engine air supply circuit
- Vacuum air circuit
- Air intake/vacuum circuit check
- Air filter assembly - r.r.
- Air cleaner filter element - replace.
- Cold air intake for air filter - r.r
- Hose from air filter to intake manifold - r + r
- Turbocharger air intake pipe - r.r.
- Rigid supply pipe (one) between turbocharger and heat exchanger -r.r.
- Air delivery hose between turbocharger and heat exchanger - replace
- Intermediate air supply pipe from turbocharger to heat exchanger - r.r.
- Air supply hose from heat exchanger to rigid pipe - replace
- Rigid air supply pipe between heat exchanger and intake manifold - r.r.
- Turbocharger intercooler - r + r
Petrol injection system23 pages
- Introduction - petrol fuel injection system
- Injector operation check
- Engine coolant temperature sensor operation check
- Fuel system supply pressure check
- Aspirated air temperature sensor operation check
- Throttle body actuator operation check
- Injector seal check
- Variable valve timing check
- Variable valve timing control solenoid operation check
- Throttle body intergral with mds - r.r.
- Air pressure sensor - r + r
- Phase transformer electromagnet - r.r.
- Intake air pressure/temperature sensor - r.r.
- Single fuel manifold pipe, with injectors - r.r.
- Set of injectors - r + r with fuel manifold pipe removed - includes seal replacement
- Set of injectors - r.r. - comp. gasket replacement
- Injector (one) - r + r with fuel manifold pipe removed - includes seal replacemnt
- Injector (one) - r.r. including replacing seal
- Switch on clutch pedal - r.r (petrol engines)
- Injection/ignition system e.c.u. (one) - r + r
- Ignition/injection system control unit support - r.r
- System cable loom - r.r.
- Injector cable loom - r.r.
Diesel injection system48 pages
- Introduction - diesel fuel injection system
- Diesel pressure pump and control
- Injectors and pipes
- Diesel injection pressure pump electronic control
- Diesel temperature check
- Injector operation check
- Injector noise / knocking check
- Rpm sensor efficiency check
- Timing sensor operation check
- Atmospheric pressure check
- Supercharging pressure check
- Check measured air mass
- Air temperature check
- Engine speed check
- Check operation of main engine control unit relay
- Check engine control unit connections
- Check engine control unit connections
- Check engine control unit connections
- Check operation of sensor detecting presence of water in diesel filter
- Fuel pressure sensor on rail operation check
- Flow meter operation check
- Clutch pedal switch operation check
- Fuel pressure regulator on single manifold operation check
- Low fuel return pressure circuit check
- Low fuel delivery pressure circuit check
- Injector seal test
- High pressure fuel circuit check
- Engine coolant temperature sensor operation check
- Pressure delta at the fuel filter check
- Diesel injection pressure pump - r.r.
- Injector one r r
- Pipe from pressure pump to fuel manifold - r.r.
- Single fuel manifold pipe - r.r.
- Pipe from fuel manifold to injector - r.r.
- Pipes (all) from fuel manifold to injector - r.r.
- Fuel return manifold - r.r.
- Fuel return pipe from injectors - r.r.
- Air flow meter - r.r.
- Engine coolant temperature sensor - r.r.
- Excess pressure sensor - r.r.
- Fuel temperature sensor - r.r.
- Engine RPM sensor - r.r.
- Cam angle sensor - r.r
- Fuel pressure sensor on fuel manifold to injectors - r.r
- Fuel pressure regulator on single manifold to injectors - r r
- Switch on clutch pedal - r.r. (JTD engines)
- Diesel electronic injection control unit - r.r
- System cable loom - r.r.
Engine supercharging system6 pages
Accelerator controls2 pages
Exhaust pipes and silencers11 pages
- Introduction - exhaust pipes and silencers
- Introduction - exhaust pipes and silencers - for versions without dpf
- Introduction - exhaust pipes and silencers - for versions with dpf
- Heat shield for intermediate exhaust silencer - r.r.
- Heat shield for exhaust pipe on fuel tank - r.r
- Exhaust pipe rear heat shield(s) - r.r
- Catalytic converter heat shield - r.r
- Rear exhaust silencer - r + r
- Intermediate exhaust silencer - r + r
- Centre exhaust pipe - r.r.
- Intermediate exhaust pipe with hose section - r+r
Emission control system40 pages
- Introduction - emission control system
- Introduction - exhaust emission control system
- Introduction - exhaust emission control system - for versions without dpf
- Introduction - exhaust emission control system - for versions with dpf
- Exhaust gas recirculation system (e.g.r.)
- Crankcase vapour/gas recirculation system
- Introduction - crankcase vapour/gas recirculation system
- Evaporation control system
- Upstream lambda sensor operation check
- Downstream lambda sensor operation check
- Differential pressure sensor operation check
- Dpf input temperature sensor operation check
- Check the operation of the lambda sensor heater
- Egr solenoid operation check
- Idling c.o. level - check with special equipment
- Exhaust fumes - check with opacimeter
- Front lambda sensor to with catalytic converter - r.r
- Rear lambda sensor to catalytic converter - r.r
- Catalytic converter - r + r
- Particulate filter (d.p.f.) - r.r.
- Particulate filter differential pressure (d.p.f.) sensor - r.r.
- Exhaust gas temperature sensor on particulate filter (d.p.f.) - r.r.
- Flexible pipe for particle filter differential pressure sensor - r.r.
- Electric pump for exhaust air injection system - r.r.
- Lambda sensor - r.r.
- Exhaust gas diffuser on e.g.r. system intake manifold - r.r.
- E.g.r. system solenoid - r + r
- Exhaust gas/water heat exchanger for EGR system - r.r
- E.g.r. - valve heat exchanger assembly - connector pipes - r.r.
- Engine oil vapour recirculation spark out - replace
- Engine oil vapour pipe from intake to separator - r.r.
- Oil vapour recovery pipe between separator and turbo - r.r.
- Oil vapour pipe from tappet cover to intake - r.r
- Engine oil vapour separator - r + r
- Active carbon filter for fuel vapours - r + r
- Enablement solenoid for flow of fuel vapour to inlet - r+r
- Fuel vapour separator fuel vapour inlet pipe - r.r.
- Intermediate fuel vapour pipe r r
- Air intake chamber fuel vapour intake pipe - r.r.
- Guard for activated carbon filter for fuel vapours - r.r
Engine lubrication13 pages
- Introduction - engine lubrication
- Engine oil lubrication circuit
- Engine oil pressure switch
- Oil dipstick pipe - r.r
- Engine oil pressure warning light switch - r + r
- Engine oil pump - r+r vehicles with A/C
- Engine oil pump, removed - check at bench
- Engine oil intake duct - r.r
- Engine oil filter - r.r
- Engine oil delivery pipe to turbocharger - r + r
- Engine oil return pipe from turbo - r + r
- Engine oil heat exchanger, complete with engine oil filler and filter - r.r.
- Heat shield on engine oil heat exchanger - r.r.
Engine cooling23 pages
- Introduction - engine cooling system
- Engine cooling radiator
- Water pump and thermostat
- Coolant temperature control devices
- Check engine cooling fan operation
- Engine coolant supply reservoir - r.r.
- Engine cooling radiator - r.r. for air conditioned versions
- Upper pin supporting engine cooling radiator (one), lh or rh - r&r
- Water pump - r+r for versions with air conditioning
- Water pump - r + r with timing belt(s) removed
- Thermostat unit - r+r
- Degassing pipe from thermostat to engine coolant reservoir - r.r
- Radiator coolant outlet hose - r.r.
- Upper radiator coolant inlet hose - r.r.
- Water pump rigid coolant inlet pipe - r.r.
- Engine coolant return pipe to supply reservoir - r.r.
- Flexible pipe between coolant reservoir and multiway connector - r.r.
- Engine oil heat exchanger rigid supply or return pipes - r.r.
- Coolant supply pipe to engine oil heat exchanger - r.r.
- Radiator cooling fan - r.r with air conditioner
- Radiator cooling fan - r + r
- Resistor for radiator cooling fan - r + r
- Switch for water temperature warning light - r.r.
Engine component miscellaneous drives5 pages