Astra H: Engine and Engine Aggregates

Also for this vehicle: Astra, Astra F, Astra G, 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 Instructions2 pages

     • Boost Pressure Sensor, Replace (Z 20 LEH)
     • Reprogrammable Electronic Control Units all Petrol Vaariants
   • Component Locator › DOHC petrol engine engine number
   • Other Information › Reprogrammable Electronic Control Units all Petrol Vaariants
   • Technical Service Bulletins89 pages

     • Abrasion, Wear › Surge Tank Hose - Chafing
     • Noise, Vibration, Rattle10 pages

       • Engine Z20LE/T/L/R/H - Whistling noise during deceleration
       • Engine Z17DTR, charging, intake system - Hissing noise during let off
       • Engine Z16XE1/LET/LER/XEP/XER/Z18XER - Whistling noise
       • Engine Z13DT/J/H - Smoke and/or sizzling noise from cylinder head
       • Engine Z18XER - Rattling noise from poly-v-belt
       • Turbocharger - Trouble-Shooting Procedure
       • Z20LEH Engine - Flow noise out of the engine when engine is hot and decelerating with 1500 - 2200 rpm.
       • Engine A/Z/16/18XER - Rattling noise sometimes P0011 or P0014 stored, SVS on
       • Engine A/Z16/18XER - Booming Noise between 2500 - 3500 rpm
       • Engine A/Z13DTx, Poly-V belt - Chirping noise
     • Inoperative - Totally, Partially6 pages

       • Engine or drivetrain - Damaged due to Tuning
       • Petrol engines - Refuelled with diesel fuel
       • Diesel Engines - Usage of Gasoline instead of Diesel Fuel
       • Engine Z13DTJ / Z13DTH - Stalls unintentionally
       • Two-mass flywheel - Diagnosis
       • Engine A/Z/16/18XER - Rattling noise sometimes P0011 or P0014 stored, SVS on
     • Won't Maintain Adjustment2 pages

       • Diesel Fuel - Contains up to 7% Bio Diesel (FAME)
       • Engine Z19DTx, oil level sensor - "Check oil level" message shows up too early
     • Poor Operation, Incorrect Operation14 pages

       • Engine or drivetrain - Damaged due to Tuning
       • All Z engines - Overrun fuel cutoff device temporarily not active
       • Petrol engines - Refuelled with diesel fuel
       • New P&A engines with ECU - TC P0602 (44)
       • Engines (all) - Usage of engine oil additives
       • Oil filter - Wrong oil filter in vehicles with ECO Service-Flex
       • Diesel Engines - Usage of Gasoline instead of Diesel Fuel
       • Engine Z19DTH/ J - Intake manifold, swirl flaps, actuator out of order, DTC: P1109, P2075 set
       • Engine Z17DT/R/J - SPS programming does not work on service ECU
       • Engine Z19DT/H/J/L, DPF - Flashing glow indicator after battery disconnection
       • Engine Z13DTJ/DTH - Oil dilution, Trouble Codes P253F/?53F8/C13F8 set
       • Engine Z16XE1/LET/LER/XEP/XER/Z18XER - Whistling noise
       • Engine Z18XER - Knocking noise as of 2500 1/min
       • Engine Z19DT/L, AGR valve - Trouble code P0400 (5A) is set
     • Excessive Effort, Hard Work › Diesel Engines - Usage of Gasoline instead of Diesel Fuel
     • Loose, Missing, Broken6 pages

       • Oil filter - Wrong oil filter in vehicles with ECO Service-Flex
       • Engine Y/Z17DT/L/H - Idler or tensioner broken after replacement
       • Engine Z13DTJ/DTH - Oil dilution, Trouble Codes P253F/?53F8/C13F8 set
       • Engine Z16XE1/LET/LER/XEP/XER/Z18XER - Whistling noise
       • Engine Z20LEH, Z20LER - Exhaust manifold leaky
       • Diesel engines, AC condenser, charge air cooler - Get loose
     • No Start3 pages

       • Engine Z19DT/L - Failure code P0340(28), wrong camshaft signal
       • Z13DTH Engine - P0190(07) set, stalls, crank,but no start, unstable idle
       • Engine Z/A16LET/L/R - Does not start or unstable idle, 0 mileage defects only
     • Cold Driveability2 pages

       • Petrol engines - Refuelled with diesel fuel
       • Engine Z18XER - Bad throttle response after cold start
     • Detonation, Knock2 pages

       • Petrol engines - Refuelled with diesel fuel
       • Engine Z18XER - Knocking noise as of 2500 1/min
     • Hesitation › Engine Z16/18XER - No start, somtimes TC P0340 or P0365 set
     • Poor Fuel Economy2 pages

       • Engines (all) - Usage of engine oil additives
       • Engine Z13DTJ/DTH - Oil dilution, Trouble Codes P253F/?53F8/C13F8 set
     • Poor Start5 pages

       • Battery - Cable at terminal loose
       • Engine Z19DT/L/H/J - Rough idle after cold start
       • Engine Z18XER - Bad throttle response after cold start
       • Z13DTH Engine - P0190(07) set, stalls, crank,but no start, unstable idle
       • Engine Z/A16LET/L/R - Does not start or unstable idle, 0 mileage defects only
     • Rough Idle2 pages

       • Engine Z19DT/L/H/J - Rough idle after cold start
       • Z13DTH Engine - P0190(07) set, stalls, crank,but no start, unstable idle
     • Sluggish, Power Loss8 pages

       • Engine Z19DT/L/H/J and Z13DTJ/H - Diesel particulate filter clogged, Trouble Code P1901(75) set
       • Engine Z19DTH/ J - Intake manifold, swirl flaps, actuator out of order, DTC: P1109, P2075 set
       • Engine Z20LEL/R/H - Lack of power, SVS on, DTC P1106 (11) stored
       • Engine Z18XER - Bad throttle response after cold start
       • Engine Z19DT/L - Failure code P0340(28), wrong camshaft signal
       • Engine Z16/18XER - No start, somtimes TC P0340 or P0365 set
       • Turbocharger - Trouble-Shooting Procedure
       • Engine A/Z/18/16XER - Low torque between 2000 RPM and 4000 RPM
     • Stalls3 pages

       • Engine Z19DT/L - Failure code P0340(28), wrong camshaft signal
       • Engine Z13DTJ / Z13DTH - Stalls unintentionally
       • Z13DTH Engine - P0190(07) set, stalls, crank,but no start, unstable idle
     • Surge, Miss, Chuggle2 pages

       • Engine Z16XE1 - High idle
       • Engine Z/A16LET/L/R - Does not start or unstable idle, 0 mileage defects only
     • Warning Lights, Telltale9 pages

       • New P&A engines with ECU - TC P0602 (44)
       • Engine Z19DT/L/H/J and Z13DTJ/H - Diesel particulate filter clogged, Trouble Code P1901(75) set
       • Engine Z19DTH/ J - Intake manifold, swirl flaps, actuator out of order, DTC: P1109, P2075 set
       • Engine Z20LEL/R/H - Lack of power, SVS on, DTC P1106 (11) stored
       • Engine Z19DT/H/J/L, DPF - Flashing glow indicator after battery disconnection
       • Z13DTH Engine - P0190(07) set, stalls, crank,but no start, unstable idle
       • Engine Z16/18XE1/P/R, thermostat - Mil on, trouble code P0115 is stored
       • Engine Z19DT/L, AGR valve - Trouble code P0400 (5A) is set
       • Engine A/Z/16/18XER - Rattling noise sometimes P0011 or P0014 stored, SVS on
     • Chip, Crack › Engine Y/Z17DT/L/H - Idler or tensioner broken after replacement
     • Corrosion, Rust, Dirt › Engine Z13DTJ/DTH - Oil dilution, Trouble Codes P253F/?53F8/C13F8 set
     • Leaks5 pages

       • Surge Tank Hose - Chafing
       • Engine Y/Z17DT/L/H - water pump - Leakages visible
       • Engine Z20LEH, Z20LER - Exhaust manifold leaky
       • Engine Z16XE1/XEP/XER/LEL/LET/LER, Z18XER - Oil leakage crankshaft sealing ring
       • Turbocharger - Trouble-Shooting Procedure
     • Misaligned › Engine Y/Z17DT/L/H - Idler or tensioner broken after replacement
     • Smoke, Odour, Fumes2 pages

       • Engine Z13DT/J/H - Smoke and/or sizzling noise from cylinder head
       • Turbocharger - Trouble-Shooting Procedure
   • Inspections › Exhaust Emissions Test18 pages

     • Foreword to exhaust emissions test
     • Arrangement of diagnostic plug
     • Adjustment data for Astra-H Z 14 XEP (1.4 16V TWINPORT ECOTEC) 66 kW
     • Adjustment data for Astra-H Z 14 XEL (1.4 16V TWINPORT ECOTEC) 55 kW
     • Adjustment data for Astra-H Z 16 XEP (1.6 16V TWINPORT ECOTEC) 77 kW
     • Adjustment data for Astra-H Z 20 LER (2.0 Turbo ECOTEC) 147 kW
     • Adjustment data for Astra-H Z 17 DTH (1.7 CDTI ECOTEC) 74 kW
     • Adjustment data for Astra-H Z 19 DTH (1.9 CDTI 16V ECOTEC) 110 kW
     • Adjustment data for Astra-H Z 13 DTH (1.3 CDTI ECOTEC) 66 kW
     • Adjustment data for Astra-H Z 19 DT (1.9 CDTI ECOTEC) 88 kW
     • Adjustment data for Astra-H Z 19 DTL (1.9 CDTI ECOTEC) 74kW
     • Adjustment data for Astra-H Z 18 XER (1.8 16V ECOTEC) 103 kW
     • Adjustment data for Astra-H Z 20 LEH (2.0 Turbo ECOTEC) 177 kW
     • Adjustment data for Astra-H Z 16 XE1 (1.6 16V TWINPORT ECOTEC) 77 kW
     • Adjustment data for Astra-H Z 16 XER (1.6 16V ECOTEC) 85 kW
     • Adjustment data for Astra-H Z 16 LET (1.6 Turbo ECOTEC) 132 kW
     • Adjustment data for Astra-H Z 17 DTJ (1.7 CDTI ECOTEC) 81 kW
     • Adjustment data for Astra-H Z 17 DTR (1.7 CDTI ECOTEC) 92 kW
   • Technical Information › 1998 › Reprogrammable Electronic Control Units all Petrol Vaariants
   • DOHC Petrol Engine331 pages

     • Specifications › Recommended Torque Values
     • Technical Service Bulletins3 pages

       • Loose, Missing, Broken › Engine A10XEP, Z12/14XE/P/L - Crankcase ventilation hoses cracked
       • Leaks › Engine Z16XER, Z18XER - Camshaft bearing bridge leaky
       • Smoke, Odour, Fumes › Engine A10XEP, Z12/14XE/P/L - Crankcase ventilation hoses cracked
     • General49 pages

       • Repair Instructions39 pages

         • Measuring oil consumption
         • Engine Identification Code / Engine Number
         • Compression, Check
         • Check engine pressure loss
         • Fuel Pressure, Check
         • Engine, Check for Leaks, (CO Content in Cooling System)
         • Replacing the air cleaner housing
         • Resonator, Replace
         • Engine, Remove and Install
         • Engine Identification Code / Engine Number
         • Compression, Check
         • Check engine pressure loss
         • Engine, Check for Leaks, (CO Content in Cooling System)
         • Fuel Pressure, Check
         • Engine, Remove and Install (Without Air Conditioning, MTA)
         • MTA Transmission from/to Engine, Detach and Attach (Engine Removed)
         • Engine Compartment Overview
         • Engine compartment vacuum routing
         • Ribbed V-belt Tension, Check
         • Compression, Check
         • Check engine pressure loss
         • Engine, Check for Leaks, (CO Content in Cooling System)
         • Oil Temperature, Measure
         • Engine Oil Pressure, Check
         • Replacing the air cleaner housing
         • Replace air intake pipe
         • Replacing resonator
         • Removing and installing charge air pipe
         • Replace front toothed belt cover (upper)
         • Replace front toothed belt cover (lower)
         • Replace rear toothed belt cover
         • Toothed Belt Tension, Adjust
         • Timing, Check
         • Timing, Adjust
         • Flywheel, Remove and Install
         • Engine, Remove and Install
         • Manual Transmission, Remove from Engine and Install
         • MTA-Manual Transmission, Remove from Engine and Install
         • Repair engine using a short block
         • MTA Manual Transmission from/to Engine Detach and Attach (Engine Removed)
         • Repair Engine Using An Engine Short Block (Z16XEP)
         • Illustration - Coolant Hoses (Z 20 LEH)
         • Compression, Check
         • Check engine pressure loss
         • Engine Oil Pressure, Check
         • Engine, Check for Leaks, (CO Content in Cooling System)
         • Fuel Pressure, Check
         • Engine maintenance using a section engine
         • Engine, Remove and Install
         • Manual Transmission, Remove from Engine and Install
         • Remove and install automatic transmission with torque converter from engine
         • Repair Engine Using An Engine Short Block (Z16XE1)
         • Check engine pressure loss
         • Engine, Check for Leaks, (CO Content in Cooling System)
         • Fuel Pressure, Check
         • Removing and installing air cleaner housing
         • Fuel Pressure, Check
         • Check for engine leaks (CO content in coolant)
         • Engine, Remove and Install
         • Manual Transmission, Remove from Engine and Install
         • Remove and install automatic transmission with torque converter from engine
         • Engine maintenance using a section engine
         • Engine, Remove and Install
         • MTA Manual Transmission from/to Engine Detach and Attach (Engine Removed)
         • Attach engine to engine overhaul stand and remove
         • Resonator, Replace
         • Replace exhaust gas recirculation valve
         • Repair engine using a short block
       • Component Locator8 pages

         • Engine Identification Code / Engine Number
         • Engine Compartment Overview
         • Engine compartment vacuum routing
         • Illustration - Coolant Hoses (Z 20 LEH)
         • Illustration of Air Duct
         • Illustration of engine compartment vacuum routing
         • Engine Identification Code / Engine Number
         • DOHC petrol engine engine number
         • Overview of Engine Compartment
         • Illustration of Air Duct
         • Illustration of Air Duct
       • Specifications
       • Special Tools and Equipment1 page

         • Special Service Tools
         • Special Service Tools
         • Special Service Tools
         • Special Service Tools
         • Special Service Tools
         • Special Service Tools
       • Other Information › DOHC II petrol engine Z 20 LEL / Z 20 LER engine code/engine number
     • Seals and Seal Rings12 pages

       • Repair Instructions11 pages

         • Timing Case Seal Ring, Replace
         • Seal Ring - Front Crankshaft, Replace
         • Seal Ring - Rear Crankshaft, Replace
         • Seal Ring - Camshaft, Replace
         • Seal Ring - Crankshaft (Front), Replace
         • Seal Ring - Camshaft, Replace
         • Replace all valve stem seals (cylinder head installed)
         • Seal Ring - Rear Crankshaft, Replace
         • Seal Ring - Front Crankshaft, Replace
         • Replace oil pump seal ring - replace front crankshaft seal ring
         • Seal Ring (Rear), Replace (New Design from MY 2005)
         • Seal Ring - Camshaft, Replace
         • Seal Ring - Crankshaft (Front), Replace
         • Crankshaft Seal Ring (Rear), Replace
         • Replace all valve stem seals (cylinder head installed)
         • Seal Ring - Crankshaft (Front), Replace
         • Replace crankshaft seal ring (rear)
         • Seal Ring - Crankshaft (Front), Replace
         • Seal Ring - Rear Crankshaft, Replace (AT)
         • Seal Ring - Camshaft, Replace
       • Technical Service Bulletins › Leaks › Engine Z10/12/14XEP - Loss of oil between oil filter modul and engine block
     • Ribbed V-Belt12 pages

       • Repair Instructions9 pages

         • Ribbed V-Belt (Without Air Conditioning), Replace
         • Ribbed V-Belt Tensioner, Replace (Without Air-Conditioning)
         • Testing ribbed V-belt tensioner
         • Replace ribbed V-belt
         • Replace ribbed V-belt tensioner
         • Ribbed V-belt Tension, Check
         • Replace ribbed V-belt
         • Replace ribbed V-belt tensioner
         • Replace ribbed V-belt
         • Replace ribbed V-belt tensioner
         • Replace ribbed V-belt
         • Replace ribbed V-belt tensioner
         • Accessory Drive, Replace
         • Check ribbed V-belt tension
         • Replace ribbed V-belt
         • Replace ribbed V-belt tensioner
         • Accessory Drive, Replace
         • Ribbed V-Belt (With Air Conditioning), Replace
       • Specifications2 pages

         • Ribbed V-Belt - Engine Timing
         • Ribbed V-belt
         • Ribbed V-belt
         • Ribbed V-belt
         • Ribbed V-belt
         • Ribbed V-belt
       • Technical Service Bulletins › Noise, Vibration, Rattle › Engine Z18XER - Rattling noise from poly-v-belt
     • Fuel Pump › Repair Instructions2 pages

       • Fuel Pressure, Check
       • Replace high-pressure fuel pump
     • Engine Damping Block14 pages

       • Repair Instructions13 pages

         • Replace engine damping block (front)
         • Replace engine damping block (rear)
         • Replace left engine damping block
         • Replace right-hand engine damping block
         • Replace engine damping block (front)
         • Replace engine damping block (rear)
         • Replace left engine damping block
         • Replace right-hand engine damping block
         • Replace right-hand engine damping block
         • Replace left engine damping block
         • Replace front engine damper block
         • Replace rear engine damper block
         • Manual Transmission, Remove from Engine and Install
         • Replace engine damping block (rear)
         • Replace engine damping block (front)
         • Replace left engine damping block
         • Replace right engine damping block
         • Remove and install automatic transmission with torque converter from engine
         • Replace engine damping blocks
         • Replace engine damping block (rear)
         • Replace (rear) engine damping block bracket
         • Replace engine damping block (front)
         • Replace left engine damping block
         • Replace right engine damping block
         • Engine, Remove and Install
         • Repair engine using a short block
       • Component Locator › Engine Identification Code / Engine Number
     • Oil Circulating52 pages

       • Repair Instructions49 pages

         • Oil Temperature, Measure
         • Oil Pressure, Check
         • Engine oil with oil filter change
         • Oil Pressure Switch, Remove and Install
         • Oil Pan, Remove and Install
         • Oil Intake Pipe, Remove and Install
         • Replace oil pressure regulating valve
         • Oil Pump, Remove and Install
         • Oil Pump, Check
         • Oil Temperature, Measure
         • Oil Pressure, Check
         • Engine oil with oil filter change
         • Oil Pump, Remove and Install
         • Oil Pump, Check
         • Replace oil pressure regulating valve
         • Cylinder Head Oil Pressure Switch, Replace
         • Cylinder Block Oil Pressure Switch, Replace
         • Oil Temperature, Measure
         • Engine Oil Pressure, Check
         • Replace engine oil with oil filter
         • Removing and installing temperature regulator housing (heat exchanger)
         • Removing and installing temperature regulator (heat exchanger)
         • Replace engine oil cooler oil lines / heat exchanger
         • Replace engine oil cooler / heat exchanger
         • Replace oil pump seal ring - replace front crankshaft seal ring
         • Lower Part of Oil Pan, Remove and Install
         • Upper Part of Oil Pan, Remove and Install
         • Oil Intake Pipe, Remove and Install
         • Removing and installing engine oil level sensor
         • Oil Pump, Check
         • Pressure Relief Valve in Oil Circuit, Replace
         • Oil Baffle Plates, Remove and Install (Z 20 LEL, Z 20 LER)
         • Replace oil pressure switch
         • Replace oil dipstick guide tube
         • Removing and installing turbocharger oil feed line (cylinder block)
         • Oil Feed Line - Turbocharger (Turbocharger), Remove and Install
         • Oil Return Line - Turbocharger, Remove and Install
         • Oil Baffle Plate, Remove and Install (Z 20 LEH)
         • Oil Pan, Remove and Install (New Design)
         • Engine Oil Level Sensor, Replace (New Design)
         • Oil Filter Housing, Remove and Install (From MY 2005.5)
         • Engine oil with oil filter change
         • Oil Pan, Remove and Install
         • Oil Dipstick Guide Tube, remove and Install
         • Oil Pump, Remove and Install
         • Oil Pump, Check
         • Oil Filter Housing, Remove and Install
         • Replace oil pressure switch
         • Replace oil pressure regulating valve
         • Replace overpressure valve
         • Oil Dipstick Guide Tube, Replace (New Design)
         • Engine Oil Pressure, Check
         • Oil Pump, Remove and Install
         • Replace oil pressure switch
         • Replace engine oil level sensor
         • Replace turbocharger oil return line
         • Compression, Check
         • Check engine pressure loss
         • Engine Oil Pressure, Check
         • Oil Temperature, Measure
         • Replace oil pump
         • Overhaul oil pump
         • Engine oil with filter change
         • Oil Pan, Remove and Install
         • Additional work for replacement of oil pan
         • Replace oil dipstick guide tube
         • Replace oil pressure switch
         • Replace oil pump pressure regulating valve
         • Replace oil filter short circuit valve
         • Replace oil spray nozzle (timing chain)
         • Oil Dipstick Guide Tube, remove and Install
         • Oil Pan, Remove and Install
         • Replace turbocharger oil feed line
         • Removing and installing oil baffle plate
         • Replace oil pressure regulating valve
         • Oil Filter Housing, Remove and Install
         • Replace oil dipstick guide tube
         • Replace engine oil level sensor
       • Component Locator › Oil Pump, Remove and Install
       • Specifications1 page

         • Oil circulation
         • Oil circulation
         • Oil circulation
         • Oil circulation
         • Oil circulation
       • Other Information › Replace engine oil with oil filter
     • Timing Gear Case38 pages

       • Repair Instructions11 pages

         • Timing Case, Remove and Install
         • Timing Case Seal Ring, Replace
         • Timing, Check
         • Timing, Adjust
         • Timing, Check
         • Timing, Adjust
         • Timing, Check
         • Timing, Adjust
         • Replace front toothed belt cover (upper)
         • Replace front toothed belt cover (lower)
         • Replace rear toothed belt cover
         • Timing, Check
         • Timing, Adjust
         • Camshaft Sprockets, Remove and Install
         • Timing, Check
         • Timing, Adjust
         • Timing, Check
         • Timing Gear, Replace
         • Timing, Check
         • Timing, Adjust
         • Replace guide rail (primary chain)
         • Replace chain tensioner of balance shaft timing chain
         • Timing, Adjust
       • Technical Service Bulletins5 pages

         • Abrasion, Wear › Toothed belt diagnosis - Possible causes and remedys
         • Noise, Vibration, Rattle › Toothed belt diagnosis - Possible causes and remedys
         • Inoperative - Totally, Partially › Toothed belt diagnosis - Possible causes and remedys
         • Loose, Missing, Broken › Toothed belt diagnosis - Possible causes and remedys
         • Chip, Crack › Toothed belt diagnosis - Possible causes and remedys
       • Cover, timing case › Repair Instructions5 pages

         • Replace front toothed belt cover (top)
         • Replace front toothed belt cover (lower)
         • Front Toothed Belt Cover, Centre, Replace
         • Replace rear toothed belt cover
         • Replace timing case cover
       • Hydraulic chain tensioner › Repair Instructions › Hydraulic Chain Tensioner, Replace (Primary)
       • Timing chain4 pages

         • Repair Instructions2 pages

           • Replace timing chain (primary)
           • Replace timing chain (secondary)
         • Technical Service Bulletins2 pages

           • Abrasion, Wear › Engine Z22SE/Z22YH, tensioner timing chain - Rattling noise from timing chain
           • Noise, Vibration, Rattle › Engine Z22SE/Z22YH, tensioner timing chain - Rattling noise from timing chain
       • Toothed Belt12 pages

         • Repair Instructions11 pages

           • Replace front toothed belt cover (top)
           • Replace front toothed belt cover (lower)
           • Replace toothed belt
           • Replace toothed belt tensioner
           • Toothed Belt Guide Roller. Replace
           • Replace rear toothed belt cover
           • Replace toothed belt
           • Replace toothed belt tensioner
           • Replace toothed belt guide rollers
           • Replace toothed belt drivewheel
           • Toothed Belt Tension, Check
           • Toothed Belt Tension, Adjust
           • Replace toothed belt
           • Replace toothed belt tensioner
           • Toothed Belt Guide Roller. Replace
           • Replace front toothed belt cover (top)
           • Replace front toothed belt cover (lower)
           • Front Toothed Belt Cover, Centre, Replace
           • Replace rear toothed belt cover
           • Replace front toothed belt cover (top)
           • Replace front toothed belt cover (lower)
           • Replace rear toothed belt cover
           • Replace toothed belt
           • Replace toothed belt tensioner
           • Toothed Belt Guide Roller. Replace
           • Replace toothed belt drivewheel
         • Specifications1 page

           • Toothed belt
           • Toothed belt
           • Toothed belt
           • Toothed belt
     • Cylinder Block66 pages

       • Repair Instructions12 pages

         • Engine Identification Code / Engine Number
         • Cylinder Block, Check for Plane Surface
         • Cylinder Block, Check for Plane Surface
         • Make bores for adapter KM-412-31
         • Compression, Check
         • Check engine pressure loss
         • Removing and installing engine vent pipe
         • Check and adjust balancer shaft unit/crankshaft tooth backlash
         • Balancer Shaft Unit, Remove and Install
         • Cylinder Block, Check for Plane Surface
         • Lower Part of Oil Pan, Remove and Install
         • Upper Part of Oil Pan, Remove and Install
         • Engine Identification Code / Engine Number
         • Drive Disc, Remove and Install
         • Compression, Check
         • Crank drive bearing
         • Cylinder Block, Check for Plane Surface
       • Component Locator › Engine Identification Code / Engine Number
       • Specifications3 pages

         • Crankshaft drive, cylinder block
         • Crank drive, cylinder block Z16XEP, Z16XE1
         • Crankshaft drive, cylinder block
         • Crankshaft drive, cylinder block
         • Crankshaft drive, cylinder block
         • Crankshaft drive, cylinder block
         • Crank drive, cylinder block A16XER, Z16XER
       • Starter Ring Gear › Repair Instructions › Replace drive disc
       • Guide Bearing in Crankshaft › Repair Instructions3 pages

         • Crankshaft End Play, Check
         • Check crankshaft bearing clearance (with plastigage)
         • Check crankshaft bearing clearance (with micrometer gauge internal measuring device)
       • Crankshaft Bearing Shell › Repair Instructions2 pages

         • Crankshaft Bearing Play, Check (with Plastigage)
         • Check crankshaft bearing play (with micrometer gauge internal measuring device)
       • Piston › Repair Instructions7 pages

         • Piston with Con-rod, Remove and Install
         • Replacing one piston / con-rod
         • Piston Rings, Replace
         • Replace one piston/con-rod
         • Piston with Con-rod, Remove and Install
         • Piston Rings, Replace
         • Replacing one piston / con-rod
         • Piston Rings, Replace
         • Piston with Con-rod, Remove and Install
         • Piston Rings, Replace
         • Piston, Replace
         • Piston with Con-rod, Remove and Install
         • Piston Rings, Replace
         • Piston, Replace
         • All Pistons with Con-rod, Remove and Install
         • Replace one piston and/or con-rod (piston removed with con-rod)
         • Piston Rings, Replace
       • Crankshaft › Repair Instructions24 pages

         • Seal Ring - Front Crankshaft, Replace
         • Seal Ring - Rear Crankshaft, Replace
         • Crankshaft, Remove and Install
         • Crankshaft End Play, Check
         • Radial Run-out of Crankshaft, Check
         • Replace toothed belt drivewheel
         • Seal Ring - Crankshaft (Front), Replace
         • Crankshaft, Remove and Install
         • Crankshaft End Play, Check
         • Crankshaft Out-of-round, Check
         • Check crankshaft bearing clearance (with plastigage)
         • Check crankshaft bearing clearance (with micrometer gauge internal measuring device)
         • Seal Ring - Rear Crankshaft, Replace
         • Seal Ring - Front Crankshaft, Replace
         • Adjust balancer shaft unit/crankshaft tooth backlash
         • Crankshaft, Remove and Install
         • Check crankshaft end play
         • Crankshaft Out-of-round, Check
         • Check crankshaft bearing clearance with plastigage
         • Check crankshaft bearing clearance with micrometer gauge and internal measuring device
         • Seal Ring (Rear), Replace (New Design from MY 2005)
         • Seal Ring - Crankshaft (Front), Replace
         • Crankshaft Seal Ring (Rear), Replace
         • Con-rod Bearing, Replace
         • Check con-rod bearing clearance (with plastigage)
         • Check con-rod bearing clearance (with micrometer gauge and internal measuring device)
         • Crankshaft, Remove and Install
         • Crankshaft End Play, Check
         • Crankshaft Out-of-round, Check
         • Check crankshaft bearing clearance (with plastigage)
         • Check crankshaft bearing clearance (with micrometer gauge internal measuring device)
         • Seal Ring - Crankshaft (Front), Replace
         • Replace crankshaft seal ring (rear)
         • Crankshaft End Play, Check
         • Crankshaft Out-of-round, Check
         • Check crankshaft bearing clearance (with micrometer gauge internal measuring device)
         • Check crankshaft bearing play (with plastigage) -
         • Seal Ring - Crankshaft (Front), Replace
         • Seal Ring - Rear Crankshaft, Replace (AT)
         • Crankshaft, Remove and Install
         • Replace the crankshaft gear
         • Measuring crankshaft
         • Check crankshaft bearing clearance (with plastigage)
         • Check crankshaft bearing clearance (with micrometer gauge internal measuring device)
         • Crankshaft Out-of-round, Check
         • Crankshaft End Play, Check
         • Crankshaft, Remove and Install
       • Con Rod Bearing › Repair Instructions8 pages

         • Con-rod Bearing, Replace
         • Con-rod Bearing Play, Check (with Plastigage)
         • Check con-rod bearing play (with micrometer gauge and internal measuring device)
         • Con-rod Bearing, Replace
         • Check con-rod bearing clearance (with plastigage)
         • Check con-rod bearing clearance (with micrometer gauge and internal measuring device)
         • Con-rod Bearing, Replace
         • Checking con-rod bearing play (with plastigage)
         • Check con-rod bearing play with micrometer gauge and internal measuring device
         • Check con-rod bearing clearance (with plastigage)
         • Con-rod Bearing, Replace
         • Check con-rod bearing clearance (with micrometer gauge and internal measuring device)
         • Replace one con-rod bearing
         • Check con-rod bearing clearance (with micrometer gauge and internal measuring device)
         • Check con-rod bearing clearance (with plastigage)
       • Con Rod › Repair Instructions3 pages

         • Piston with Con-rod, Remove and Install
         • Replacing one piston / con-rod
         • Replace one piston/con-rod
         • Piston with Con-rod, Remove and Install
         • Replacing one piston / con-rod
         • Piston with Con-rod, Remove and Install
       • Flywheel › Repair Instructions2 pages

         • Flywheel, Remove and Install
         • Flywheel, Remove and Install
         • Flywheel, Remove and Install
         • Flywheel, Remove and Install
         • Replace torsional vibration damper
     • Cylinder Head80 pages

       • Repair Instructions35 pages

         • Cylinder Head Cover, Remove and Install
         • Cylinder Head, Remove and Install
         • Attaching Parts - Cylinder Head, Remove and Install
         • Replace EGR valve
         • Exhaust Gas Recirculation Pipe, Replace
         • Cylinder Head Cover, Remove and Install
         • Cylinder Head, Remove and Install (Z16XEP)
         • Attaching Parts - Cylinder Head, Remove and Install (Z16XEP)
         • Replace engine venting pipe
         • Engine, Check for Leaks, (CO Content in Cooling System)
         • Cylinder Head Cover, Remove and Install
         • Camshaft Sprockets, Remove and Install
         • Cylinder Head, Remove and Install
         • Attaching Parts - Cylinder Head, Remove and Install
         • Valve Lash - Petrol Engine, Check and Adjust
         • Cylinder Head Cover, Remove and Install
         • Replace engine venting pipe
         • Cylinder Head, Remove and Install
         • Attach and detach attaching parts
         • Cylinder Head, Remove and Install (Z16XE1)
         • Attaching Parts - Cylinder Head, Remove and Install (Z16XE1)
         • Cylinder Head Cover, Remove and Install
         • Replace engine venting pipe
         • Replace cylinder head cover
         • Cylinder Head, Remove and Install
         • Detach and reattach attaching parts of cylinder head (cylinder head removed)
         • Cylinder Head, Remove and Install
         • 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
       • Specifications1 page

         • cylinder head
         • cylinder head
         • cylinder head
         • cylinder head
         • cylinder head
         • cylinder head
       • Special Tools and Equipment › Cylinder head machining special tools
       • Hydraulic Valve Lifter › Repair Instructions3 pages

         • Hydraulic Valve Lifter, Remove and Install
         • Cup tappet, install and remove
         • Hydraulic Valve Lifter, Remove and Install
         • Cup tappet, install and remove
         • Cup tappet, install and remove
         • Replace hydraulic valve lifter
       • Rocker Arm › Repair Instructions2 pages

         • Removing and installing roller cam followers
         • Replace roller cam follower
       • Camshaft10 pages

         • Repair Instructions9 pages

           • Camshaft Sprockets, Remove and Install
           • Removing and installing both camshafts
           • Camshaft Sprockets, Replace
           • Removing and installing both camshafts
           • Seal Ring - Camshaft, Replace
           • Seal Ring - Camshaft, Replace
           • Removing and installing both camshafts
           • Replace camshaft sensor
           • Camshafts, Remove and Install
           • Seal Ring - Camshaft, Replace
           • Removing and installing both camshafts
           • Camshaft Sprockets, Replace
           • Seal Ring - Camshaft, Replace
           • Replace camshaft sensor
           • Camshaft Sprocket, Replace
           • Both Camshafts, Replace
           • Replace camshaft sensor
           • Removing and installing both camshafts
           • Replace engine venting pipe
           • Seal Ring - Camshaft, Replace
         • Technical Service Bulletins › Leaks › Engine Z16/18XER, cylinderhead - Oil leakage between camshaft bearing bridge and camshaft cover
       • Camshaft adjuster › Repair Instructions2 pages

         • Camshaft Adjustment Valves, Replace
         • Camshaft Adjuster, Replace
       • Valves › Repair Instructions3 pages

         • Replace all valve stem seals (cylinder head installed)
         • Check and adjust valve play
         • Replace all valve stem seals (cylinder head installed)
         • Replace all valve stem seals (cylinder head installed)
         • Replace all valve stem seals (cylinder head installed)
         • Replace all valve stem seals (cylinder head installed)
         • Check and adjust valve play
         • All Valve Stem Seals, Replace
       • Intake manifold › Repair Instructions5 pages

         • Intake Manifold, Remove and Install
         • Intake Manifold, Replace (Z16XEP)
         • Intake Manifold Flange, Replace
         • Replace intake manifold
         • Replace intake manifold
         • Replace intake manifold
         • Intake Manifold, Replace - Petrol Engines
         • Replace intake manifold
       • Exhaust manifold5 pages

         • Repair Instructions3 pages

           • Replacing exhaust manifold
           • Removing and installing exhaust manifold with turbocharger
           • Exhaust Manifold, Replace (from MY 2005.5)
           • Replacing exhaust manifold
           • Replacing exhaust manifold
           • Removing and installing exhaust manifold with turbocharger
         • Technical Service Bulletins2 pages

           • Loose, Missing, Broken › Engine Z20LEH, Z20LER - Exhaust manifold leaky
           • Leaks › Engine Z20LEH, Z20LER - Exhaust manifold leaky
       • Spark Plug12 pages

         • Repair Instructions1 page

           • Replace spark plugs
           • Replace spark plugs
         • Technical Service Bulletins11 pages

           • Noise, Vibration, Rattle › Spark plug damages - possible causes and failure modes
           • Loose, Missing, Broken › Spark plug damages - possible causes and failure modes
           • Shudder › Spark plug damages - possible causes and failure modes
           • No Start › Spark plug damages - possible causes and failure modes
           • Cold Driveability › 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 Start › 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 Housing › Repair Instructions › Cylinder Head, Remove and Install
     • Pre-volume Chamber › Repair Instructions2 pages

       • Replacing resonator
       • Replacing resonator
       • Resonator, Replace
   • Diesel Engine116 pages

     • Schematic and Routing Diagrams › Circuit Diagram › Pedal position sensor (not Z16XER/ Z18XER)
     • General12 pages

       • Repair Instructions10 pages

         • Measuring oil consumption
         • Check engine pressure loss
         • Compression, Check
         • Engine Oil Pressure, Check
         • Check engine for leaks
         • Engine, Remove and Install
         • Remove and install automatic transmission with torque converter from engine
         • Manual Transmission, Remove from Engine and Install
         • Repair engine using a short block
         • Pressure Loss Test, Charge Air System
       • Component Locator › OHC diesel engine Z 19 DT - engine number/engine code
       • Specifications
       • Special Tools and Equipment › Special Service Tools
     • Seals and Seal Rings › Repair Instructions4 pages

       • Camshaft seals, remove and install
       • Replace crankshaft seal ring (rear)
       • Replace crankshaft seal ring (front)
       • Replace oil pump seal ring
     • Ribbed V-Belt8 pages

       • Repair Instructions2 pages

         • Replace ribbed V-belt
         • Replace torsional vibration damper
       • Specifications › Ribbed V-belt
       • Tension Roller › Repair Instructions2 pages

         • Replace ribbed V-belt tensioner
         • Replace toothed belt tension roller
       • Guide Roller › Repair Instructions3 pages

         • Replace upper ribbed V-belt guide roller
         • Replace toothed belt guide roller
         • Replace lower ribbed V-belt guide roller
     • Engine Damping Block › Repair Instructions6 pages

       • Replace engine damping block adapter
       • Replace right engine damping block
       • Replace engine damping block (front)
       • Replace engine damping block (rear)
       • Replace left engine damping block
       • Replace (right) engine damping block adapter
     • Oil Circulating18 pages

       • Repair Instructions17 pages

         • Engine Oil Pressure, Check
         • Engine Oil with Oil Filter Change
         • Replace oil pressure switch
         • Oil Filter Housing, Remove and Install
         • Replace engine oil cooler / heat exchanger
         • Oil Intake Pipe, Remove and Install
         • Oil Pump, Remove and Install
         • Replace oil pump seal ring
         • Oil Pump, Check
         • Oil Pump Pressure-Regulating Valve, Remove and Install
         • Replace residual oil quantity sensor
         • Replace oil dipstick guide tube
         • Replace turbocharger oil feed line (manual transmission)
         • Replace turbocharger oil feed line (automatic transmission)
         • Replace turbocharger oil return line
         • Remove and install oil pan (with F40-6 transmission or AF40-6 transmission from MY 07)
         • Oil Spray Nozzles, Remove and Install
       • Specifications › Oil circulation
     • Timing Gear Case › Technical Service Bulletins5 pages

       • Abrasion, Wear › Toothed belt diagnosis - Possible causes and remedys
       • Noise, Vibration, Rattle › Toothed belt diagnosis - Possible causes and remedys
       • Inoperative - Totally, Partially › Toothed belt diagnosis - Possible causes and remedys
       • Loose, Missing, Broken › Toothed belt diagnosis - Possible causes and remedys
       • Chip, Crack › Toothed belt diagnosis - Possible causes and remedys
     • Cylinder Block16 pages

       • Repair Instructions › Cylinder Block, Check for Plane Surface
       • Specifications › Crankshaft drive, cylinder block
       • Piston › Repair Instructions3 pages

         • Replacing one piston / con-rod
         • Piston Rings, Replace
         • Remove and install all pistons with con-rods (with F40-6 transmission or AF40-6 transmission from MY 07)
       • Crankshaft › Repair Instructions6 pages

         • Replace crankshaft seal ring (rear)
         • Replace crankshaft seal ring (front)
         • Crankshaft, Remove and Install
         • Check crankshaft end play
         • Check crankshaft bearing clearance (with plastigage)
         • Check crankshaft bearing clearance (with micrometer gauge and internal measuring device)
       • Con Rod Bearing › Repair Instructions3 pages

         • Con-rod Bearing, Replace
         • Check con-rod bearing clearance (with plastigage)
         • Check con-rod bearing clearance (with micrometer)
       • Flywheel › Repair Instructions2 pages

         • Flywheel, Remove and Install
         • Drive Disc, Remove and Install
     • Cylinder Head38 pages

       • Repair Instructions28 pages

         • Engine cover, remove and install
         • Replace cylinder head cover
         • Replace toothed belt drivewheel
         • Cylinder Head, Remove and Install
         • Attach and detach attaching parts
         • Replace exhaust gas recirculation valve
         • Replace metal pipe exhaust gas recirculation
         • Replace metal pipe exhaust gas recirculation, centre
         • Replace metal pipe exhaust gas recirculation, lower
         • 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
       • Specifications › cylinder head
       • Special Tools and Equipment › Cylinder head machining special tools
       • Camshaft › Repair Instructions3 pages

         • Camshaft Sprocket, Replace
         • Camshaft seals, remove and install
         • Removing and installing camshaft
       • Valves › Repair Instructions › Check and adjust valve play
       • Intake manifold › Repair Instructions › Replace intake manifold
       • Exhaust manifold › Repair Instructions2 pages

         • Exhaust manifold with turbocharger, remove and install (with manual transmission)
         • Exhaust manifold with turbocharger, remove and install (with automatic transmission)
       • Cup Tappets › Repair Instructions › Cup tappet, install and remove
     • Vacuum Pump › Repair Instructions › Vacuum Pump, Remove and Install
     • Toothed Belt7 pages

       • Repair Instructions6 pages

         • Toothed Belt Tension, Check and Adjust
         • Timing, Check
         • Timing, Adjust
         • Replace toothed belt cover
         • Replace toothed belt
         • Replace toothed belt drivewheel
       • Specifications › Toothed belt
   • Fuel Injection Systems1,420 pages

     • Repair Instructions › Boost Pressure Sensor, Replace (Z 20 LEH)
     • Multec S105 pages

       • Repair Instructions5 pages

         • Air Cleaner Housing, Replace (Z16XEP)
         • Replace throttle valve module
         • Air Cleaner Housing, Replace (Z16XE1 / A16XER / Z16XER)
         • Twinport Solenoid Valve, Replace
         • Twinport Vacuum Unit, Replace
       • Component Locator2 pages

         • Illustration engine management Z16XEP
         • Illustration engine management Z16XE1
       • Specifications › Engine Management
       • Diagnostic Information and Procedures › Diagnostic Procedures › Multec S (F), Z 16 XEP, Z 16 XE171 pages

         • Additional Information3 pages

           • General Information
           • Safety Measures
           • Electronic System Specific Information
         • A Diagnostic System Check
         • B-xx Functional Group Tests32 pages

           • B-001 DIAGNOSTIC TROUBLE CODE
           • B-002 DATA LIST
           • B-003 Diagnostic System Check
           • B-004 Symptom Chart/Customer Complaints
           • B-005 No Matching Customer Complaint
           • B-006 Complaint: Engine Start
           • B-007 Complaint: Engine Operation
           • B-008 Check: Intake-Air System
           • B-009 Check: Exhaust System
           • B-010 Fuel System
           • B-011 Mechanical Function Check
           • B-012 ACTUATOR TEST
           • B-013 ADDITIONAL FUNCTIONS
           • B-014 PROGRAMMING
           • B-015 CONTROL TEST
           • B-016 Trouble Codes: Check 1
           • B-017 Trouble Codes: Check 2
           • B-018 Trouble Codes: Check 3
           • B-019 Check: Air/Fuel Ratio
           • B-020 Check: Knock Sensor
           • B-021 Check: Throttle Valve
           • B-022 Check: Coolant Circuit
           • B-023 Check: Ignition Coil
           • B-024 Check: Injection Valves (Petrol)
           • B-025 Check: Misfire
           • B-026 Check: Torque Control
           • B-027 Mechanical Function Check (Twinport)
           • B-028 Fuse Check 1
           • B-029 Fuse Check 2
           • B-030 Fuse Check 3
           • B-031 Fuse Check 4
           • B-032 Fuse Check 5
         • C-xx Fault Isolation Procedures35 pages

           • C-001 5V Circuit 1
           • C-002 5V Circuit 2
           • C-003 Crankshaft Sensor Circuit
           • C-004 Fuel Pump Relay Circuit
           • C-005 Pedal Position Sensor Circuit
           • C-006 Throttle Position Sensor Circuit
           • C-007 Manifold Absolute Pressure Sensor Circuit
           • C-008 Intake Air Temperature Sensor Circuit
           • C-009 Camshaft Position Sensor Circuit
           • C-010 Ignition Coil Cylinder 1 Circuit
           • C-011 Ignition Coil Cylinder 2 Circuit
           • C-012 Ignition Coil Cylinder 3 Circuit
           • C-013 Ignition Coil Cylinder 4 Circuit
           • C-014 Cylinder 1 Injector Circuit
           • C-015 Cylinder 2 Injector Circuit
           • C-016 Cylinder 3 Injector Circuit
           • C-017 Cylinder 4 Injector Circuit
           • C-018 Knock Sensor Signal Circuit
           • C-019 Exhaust Gas Recirculation Valve Circuit
           • C-020 Port Deactivation Position Sensor Circuit
           • C-021 Port Deactivation Solenoid Valve Circuit
           • C-022 Evaporative Emission Control System Circuit
           • C-023 O2 Sensor Heater Circuit (Before Catalyst)
           • C-024 O2 Sensor Circuit (Before Catalyst)
           • C-025 O2 Sensor Heater Circuit (Behind Catalyst)
           • C-026 O2 Sensor Circuit (Behind Catalyst)
           • C-027 Throttle Valve Positioner Circuit
           • C-028 Engine-Compression
           • C-029 Exhaust Control System
           • C-030 Mechanical Function
           • C-031 Ignition Status Circuit
           • C-032 Control Unit Hard- and Software
           • C-033 Idle Speed Actuator Circuit
           • C-034 Control Unit Hard- and Software 1
           • C-035 Engine Oil Status
       • Technical Service Bulletins4 pages

         • Inoperative - Totally, Partially › Engine Z16XE1 - Cruise control cannot be deactivated by stalk switch
         • Poor Operation, Incorrect Operation › Engine Z16XE1 - Cruise control cannot be deactivated by stalk switch
         • Warning Lights, Telltale › Engine Z16/18XE1/P/R, thermostat - Mil on, trouble code P0115 is stored
         • Leaks › Engine Z16XE1/XEP/XER/LEL/LET/LER, Z18XER - Oil leakage crankshaft sealing ring
       • Schematic and Routing Diagrams4 pages

         • Circuit Diagram2 pages

           • Engine Z16XE1, Multec S (F) - 1
           • Engine Z16XE1, Multec S (F) - 2
         • Block Diagram2 pages

           • Engine Z16XE1, Multec S (F) (Not rear electronic module)
           • Engine Z16XE1, Multec S (F) (Rear electronic module)
       • Throttle Valve Housing › Repair Instructions › Replace throttle valve module
       • Intake Pipe Pressure Sensor › Repair Instructions2 pages

         • Intake Pipe Pressure Sensor, Replace (Z16XEP)
         • Replace intake pipe pressure sensor
       • Injection Valve › Repair Instructions1 page

         • Injectors, Remove and Install
         • Injectors, Remove and Install
       • Inductive Impulse Sensor › Repair Instructions2 pages

         • Replace crankshaft pulse generator
         • Replace camshaft sensor
       • Knocking Sensor › Repair Instructions › Replace knock sensor
       • Oxygen Sensor › Repair Instructions2 pages

         • Replace mixture regulator lambda sensor
         • Replace catalytic converter control oxygen sensor
         • Replace catalytic converter control oxygen sensor
       • Air Mass Meter › Repair Instructions2 pages

         • Intake Air Temperature Sensor, Replace (Z16XEP)
         • Replace intake air temperature sensor
       • Control Unit › Repair Instructions2 pages

         • Engine Control Unit, Remove and Install (Z16XEP)
         • Engine Control Unit, Remove and Install
       • Tank Ventilation Valve › Repair Instructions › Tank Vent Valve, Remove and Install
       • Coolant Temperature Sensor › Repair Instructions › Replace coolant temperature sensor
       • DIS-Ignition Module › Repair Instructions › Replace ignition module
       • Ignition Module › Repair Instructions › Spark Plugs, Remove and Install
       • Accelerator Pedal Position Sensor › Repair Instructions › Accelerator Pedal Module, Remove and Install
     • Simtec 71 › Diagnostic Information and Procedures › Diagnostic Procedures › Simtec 71.6, Z 18 XE82 pages

       • Additional Information3 pages

         • General Information
         • Safety Measures
         • Electronic System Specific Information
       • A Diagnostic System Check
       • B-xx Functional Group Tests44 pages

         • B-001 DIAGNOSTIC TROUBLE CODE
         • B-002 DATA LIST
         • B-003 Diagnostic System Check
         • B-004 Symptom Chart/Customer Complaints
         • B-005 No Matching Customer Complaint
         • B-006 Complaint: Engine Start
         • B-007 Check: Start Release
         • B-008 Mechanical Function Check
         • B-009 ACTUATOR TEST
         • B-010 ADDITIONAL FUNCTIONS
         • B-011 CONTROL TEST
         • B-012 Accelerator Pedal Position Check
         • B-013 Fuse Check 1
         • B-014 Fuse Check 2
         • B-015 Fuse Check 3
         • B-016 Fuse Check 4
         • B-017 Fuse Check 5
         • B-018 Fuse Check 6
         • B-019 Fuse Check 7
         • B-020 Fuse Check 8
         • B-021 Fuse Check 9
         • B-022 Fuse Check 10
         • B-023 Fuse Check 11
         • B-024 Fuse Check 12
         • B-025 Fuse Check 13
         • B-026 Fuse Check 14
         • B-027 Fuse Check 15
         • B-028 Fuse Check 16
         • B-029 Fuse Check 17
         • B-030 Fuse Check 18
         • B-031 Fuse Check 19
         • B-032 Fuse Check 20
         • B-033 Complaint: Indicating Devices/Telltales
         • B-034 Complaint: Exhaust Gas
         • B-035 Electrical Function Check
         • B-036 Check: Ignition Coil
         • B-037 Check: ABS Anti-Lock Brake System
         • B-038 Check: Knock Control
         • B-039 Complaint: Warning Telltales
         • B-040 Trouble Codes
         • B-041 Check: Misfire
         • B-042 Check: Intake-Air System
         • B-043 Check: Exhaust System
         • B-044 Fuel System
       • C-xx Fault Isolation Procedures34 pages

         • C-001 Control Unit Main Relay Circuit
         • C-002 Crankshaft Sensor Circuit
         • C-003 Fuel Pump Relay Circuit
         • C-004 Pedal Position Sensor Circuit
         • C-005 Throttle Valve Positioner Circuit
         • C-006 Mass Air Flow Circuit
         • C-007 Intake Air Temperature Sensor Circuit
         • C-008 Engine Oil Level Circuit
         • C-009 Ignition Coil Cylinder 1 Circuit
         • C-010 Ignition Coil Cylinder 2 Circuit
         • C-011 Ignition Coil Cylinder 3 Circuit
         • C-012 Ignition Coil Cylinder 4 Circuit
         • C-013 Cylinder 1 Injector Circuit
         • C-014 Cylinder 2 Injector Circuit
         • C-015 Cylinder 3 Injector Circuit
         • C-016 Cylinder 4 Injector Circuit
         • C-017 Knock Sensor Signal Circuit
         • C-018 Charcoal Canister Purge Valve Circuit
         • C-019 O2 Sensor Heater Circuit (Before Catalyst)
         • C-020 O2 Sensor Circuit (Before Catalyst)
         • C-021 O2 Sensor Heater Circuit (Behind Catalyst)
         • C-022 O2 Sensor Circuit (Behind Catalyst)
         • C-023 Camshaft Position Sensor Circuit
         • C-024 Intake Manifold Valve Circuit
         • C-025 Fan Relay (Stage 4) Circuit
         • C-026 System Status Information
         • C-027 Transmission Communication Circuit
         • C-028 ABS Communication Circuit
         • C-029 Mechanical Function
         • C-030 Malfunction Indication Lamp (MI) Circuit
         • C-031 Service Telltale Circuit
         • C-032 Air/Fuel Ratio Adaption
         • C-033 Control Unit Hard- and Software
         • C-034 Misfire Detection
     • Simtec 81113 pages

       • Repair Instructions6 pages

         • Fuel Pressure, Check
         • Replace spark plugs
         • Replace intake pipe pressure sensor
         • Coolant Temperature Sensor, Replace (Z 22 YH, RHD)
         • Replace camshaft sensor
         • Replace intake manifold switchover valve control motor
       • Specifications › Engine Management
       • Diagnostic Information and Procedures › Diagnostic Procedures › Simtec 81, Z 22 YH87 pages

         • Additional Information3 pages

           • General Information
           • Safety Measures
           • Electronic System Specific Information
         • A Diagnostic System Check
         • B-xx Functional Group Tests46 pages

           • B-001 DIAGNOSTIC TROUBLE CODE
           • B-002 DATA LIST
           • B-003 Diagnostic System Check
           • B-004 ACTUATOR TEST
           • B-005 CONTROL TEST
           • B-006 Symptom Chart/Customer Complaints
           • B-007 No Matching Customer Complaint
           • B-008 Complaint: Engine Start
           • B-009 Trouble Codes
           • B-010 Trouble Codes: Check 1
           • B-011 Trouble Codes: Check 2
           • B-012 Trouble Codes: Check 3
           • B-013 Trouble Codes: Check 4
           • B-014 Trouble Codes: Check 5
           • B-015 Trouble Codes: Check 6
           • B-016 Fuse Check 1
           • B-017 Fuse Check 2
           • B-018 Fuse Check 3
           • B-019 Fuse Check 4
           • B-020 Fuse Check 5
           • B-021 Fuse Check 6
           • B-022 Fuse Check 7
           • B-023 Fuse Check 8
           • B-024 Fuse Check 9
           • B-025 Fuse Check 10
           • B-026 Fuse Check 11
           • B-027 Fuse Check 12
           • B-028 Fuse Check 13
           • B-029 Fuse Check 14
           • B-030 Fuse Check 15
           • B-031 Fuse Check 16
           • B-032 Fuse Check 17
           • B-033 Fuse Check 18
           • B-034 Fuse Check 19
           • B-035 Fuse Check 20
           • B-036 Fuse Check 21
           • B-037 Fuse Check 22
           • B-038 Check: Intake-Air System
           • B-039 Check: Exhaust System
           • B-040 Check: TCM
           • B-041 Complaint: Exhaust Gas
           • B-042 Check: Start Release
           • B-043 Mechanical Function Check
           • B-044 Fuel System
           • B-045 Check: ABS Anti-Lock Brake System
           • B-046 Complaint: Indicating Devices/Telltales
         • C-xx Fault Isolation Procedures37 pages

           • C-001 Engine Start Signal Circuit
           • C-002 Control Unit Main Relay Circuit
           • C-003 Pedal Position Sensor Circuit
           • C-004 Throttle Valve Positioner Circuit
           • C-005 Mass Air Flow Circuit
           • C-006 Intake Air Temperature Sensor Circuit
           • C-007 Manifold Absolute Pressure Sensor Circuit
           • C-008 Ignition Coil Cylinder 1 Circuit
           • C-009 Ignition Coil Cylinder 2 Circuit
           • C-010 Ignition Coil Cylinder 3 Circuit
           • C-011 Ignition Coil Cylinder 4 Circuit
           • C-012 Cylinder 1 Injector Circuit
           • C-013 Cylinder 2 Injector Circuit
           • C-014 Cylinder 3 Injector Circuit
           • C-015 Cylinder 4 Injector Circuit
           • C-016 Knock Sensor Signal Circuit
           • C-017 Linear Exhaust Gas Recirculation Valve Circuit
           • C-018 Charcoal Canister Purge Valve Circuit
           • C-019 O2 Sensor Heater Circuit (Before Catalyst)
           • C-020 O2 Sensor Circuit (Before Catalyst)
           • C-021 O2 Sensor Heater Circuit (Behind Catalyst)
           • C-022 O2 Sensor Circuit (Behind Catalyst)
           • C-023 Exhaust Control System
           • C-024 Crankshaft Sensor Circuit
           • C-025 Camshaft Position Sensor Circuit
           • C-026 Swirl Level Control Circuit
           • C-027 Fuel High Pressure Sensor Circuit
           • C-028 Fuel Rail Pressure Control Valve Circuit
           • C-029 Fuel Pump Relay Circuit
           • C-030 Transmission Communication Circuit
           • C-031 Vehicle Speed Information Circuit
           • C-032 System Status Information
           • C-033 Engine Speed Output Signal Circuit
           • C-034 Misfire Detection
           • C-035 Injector Circuit
           • C-036 Malfunction Indication Lamp (MI) Circuit
           • C-037 Hardware Failure
       • Schematic and Routing Diagrams4 pages

         • Circuit Diagram3 pages

           • Engine Z22YH, Simtec 81 - 1
           • Engine Z22YH, Simtec 81 - 2
           • Pedal position sensor (not Z16XER/ Z18XER)
         • Block Diagram › Engine Z22YH, Simtec 81
       • Throttle valve module › Repair Instructions › Replace throttle valve module
       • Accelerator Pedal Position Sensor › Repair Instructions › Pedal Travel Sensor, Replace
       • Pressure Regulator › Repair Instructions2 pages

         • Replace fuel pressure sensor (high pressure)
         • Fuel Pressure Sensor (High Pressure), Replace (Z 22 YH, RHD)
       • Injection Valve › Repair Instructions2 pages

         • Replacing injection valves
         • Remove injectors from cylinder head
       • Crankshaft Pulse Pickup › Repair Instructions › Replace crankshaft pulse generator
       • Knocking Sensor › Repair Instructions › Replace knock sensor
       • Fuel Pump › Repair Instructions › Replace high-pressure fuel pump
       • Oxygen Sensor › Repair Instructions2 pages

         • Replace mixture regulator oxygen sensor
         • Replace catalytic converter control oxygen sensor
       • Control Unit › Repair Instructions › Engine Control Unit, Remove and Install
       • Air Filter Housing › Repair Instructions2 pages

         • Replacing the air cleaner housing
         • Replace hot film mass air flow meter
       • Ignition Module › Repair Instructions › Replace DIS ignition module
     • Denso DEC141 pages

       • Repair Instructions32 pages

         • Replacing the air cleaner housing
         • Replace air intake pipe
         • Removing and installing charge air pipe
         • High-Pressure Pump Drive Gear, Remove and Install
         • Replace exhaust gas recirculation valve
         • Oil Pressure Sensor, Replace
         • Replace residual oil quantity sensor
         • High-Pressure Lines, Replace
         • High-Pressure Fuel Lines, High-Pressure Pump to Pressure Chamber, Replace
         • One Injector, Remove and Install
         • Pressure Chamber, Replace
         • High-Pressure Pump, Remove and Install
         • Replace fuel return line
         • Replace crankshaft pulse generator
         • Replace camshaft sensor
         • Replace coolant temperature sensor
         • Replace charge pressure sensor
         • Replace charge pressure control solenoid valve
         • Replace solenoid valve for intake manifold switchover valve
         • Replace solenoid valve for exhaust manifold bypass
         • Replace throttle valve potentiometer
         • Replace hot film mass air flow meter
         • Engine Control Unit, Remove and Install
         • Replace pre-heating system control unit
         • Sheathed Glow Plugs, Remove and Install
         • Replace oxygen sensor
         • Replace differential pressure sensor
         • Particle filter temperature sensor 1
         • Replace pre-catalytic converter temperature sensor
         • Particle filter temperature sensor 2
         • Replace accelerator pedal module
         • Metering Unit, Replace
       • Component Locator3 pages

         • Illustration of Common Rail System
         • Illustration of Air Duct
         • Illustration of engine management system
       • Specifications › Engine Management
       • Diagnostic Information and Procedures › Diagnostic Procedures › Electronic Diesel Injection System DECE1C, A 17 DTJ, A 17 DTR, Z 17 DTJ, Z 17 DTR77 pages

         • Additional Information3 pages

           • General Information
           • Safety Measures
           • Electronic System Specific Information
         • A Diagnostic System Check
         • B-xx Functional Group Tests39 pages

           • B-001 DIAGNOSTIC TROUBLE CODE
           • B-002 DATA LIST
           • B-003 Diagnostic System Check
           • B-004 Symptom Chart/Customer Complaints
           • B-005 No Matching Customer Complaint
           • B-006 ACTUATOR TEST
           • B-007 Complaint: Engine Start
           • B-008 Complaint: Engine Idling
           • B-009 Complaint: Engine Behaviour Under Normal Driving Conditions
           • B-010 Complaint: Engine Performance
           • B-011 Complaint: Exhaust Gas
           • B-012 Complaint: Oil / Coolant / Fuel-System
           • B-013 Check: Functionality of Adjacent Systems
           • B-014 Check: Outside Temperature Sensor Signal
           • B-015 Check: Engine Speed Signal
           • B-016 Fuse Check 1
           • B-017 Fuse Check 2
           • B-018 Fuse Check 3
           • B-019 Fuse Check 4
           • B-020 Fuse Check 5
           • B-021 Fuse Check 6
           • B-022 Fuse Check 7
           • B-023 Fuse Check 8
           • B-024 Fuse Check 9
           • B-025 Trouble Codes: Check 1
           • B-026 Trouble Codes: Check 2
           • B-027 Trouble Codes: Check 3
           • B-028 Trouble Codes: Check 4
           • B-029 Trouble Codes: Check 5
           • B-030 Trouble Codes: Check 6
           • B-031 Intake-Air System
           • B-032 Check: Intake-Air System
           • B-033 Intake Air / Vacuum System
           • B-034 Intake-Air System: Check 1
           • B-035 Fuel System
           • B-036 Check: Low and High Pressure Section
           • B-037 Check: Charge-Air System
           • B-038 Check: Diesel Particulate Filter
           • B-039 Check: Pressure Loss
         • C-xx Fault Isolation Procedures34 pages

           • C-001 Control Unit Hard- and Software 2
           • C-002 Control Unit Main Relay Circuit
           • C-003 5V Circuit 1
           • C-004 5V Circuit 2
           • C-005 Pedal Position Sensor Circuit
           • C-006 Rail Pressure Sensor Circuit
           • C-007 Crankshaft Sensor Circuit
           • C-008 Camshaft Position Sensor Circuit
           • C-009 Boost Pressure Sensor Circuit
           • C-010 Mass Air Flow Circuit
           • C-011 Intake Air Temperature Sensor Circuit
           • C-012 Charge Air Temperature Sensor Circuit
           • C-013 Fuel Temperature Sensor Circuit
           • C-014 Boost Pressure Control Valve Circuit
           • C-015 Exhaust Gas Recirculation Valve Circuit
           • C-016 Swirl Level Control Circuit
           • C-017 Throttle Valve Positioner Circuit
           • C-018 Fuel Metering Solenoid Valve Circuit
           • C-019 Cylinder 1 Injector Circuit
           • C-020 Cylinder 2 Injector Circuit
           • C-021 Cylinder 3 Injector Circuit
           • C-022 Cylinder 4 Injector Circuit
           • C-023 Injector Circuit
           • C-024 Exhaust Gas Recirculation Cooler Bypass Solenoid Valve Circuit
           • C-025 Exhaust Gas Temperature Sensor 1 Circuit
           • C-026 Exhaust Gas Temperature Sensor 2 Circuit
           • C-027 Exhaust Gas Temperature Sensor 3 Circuit
           • C-028 Differential Pressure Sensor Circuit
           • C-029 O2 Sensor Circuit
           • C-030 O2 Sensor Heater Circuit
           • C-031 Glow Time Relay Circuit
           • C-032 Function-Group Intake Air System
           • C-033 Function-Group Low and High Pressure Section
           • C-034 System Condition
       • Technical Service Bulletins17 pages

         • Inoperative - Totally, Partially › Engine Z/A17DTx, Engine Control Unit: - Hang up during programming with MDI
         • Poor Operation, Incorrect Operation › Engine Z/A17DTx, Engine Control Unit: - Hang up during programming with MDI
         • No Start › A/Z17DTx Engine, Suction control valve - Engine stalls, DTC P0093 set.
         • Poor Start › Engine A/Z17DTJ/R - Fuel filter heater not activated
         • Rough Idle › Engine A/Z17DTJ/R - Fuel filter heater not activated
         • Sluggish, Power Loss4 pages

           • Engine A/Z17DT/J/R, turbocharger - Lack of power, DTC P0234(52) set
           • Engine A/Z17DTJ/R - Fuel filter heater not activated
           • Engine A/Z17DTx, Turbocharger - Loss of power, trouble code P0234, P0299 set
           • Engine Z/A17DTx - Lack of power and DPF glogged, SVS on, DTC: P242F and/or P2003 might be locked
         • Stalls › A/Z17DTx Engine, Suction control valve - Engine stalls, DTC P0093 set.
         • Warning Lights, Telltale5 pages

           • Engine A/Z17DT/J/R, turbocharger - Lack of power, DTC P0234(52) set
           • A/Z17DTx Engine, Suction control valve - Engine stalls, DTC P0093 set.
           • Engine A/Z17DTx: EGR Valve - Trouble code P0400, P0403, P0409 set
           • Engine A/Z17DTx, Turbocharger - Loss of power, trouble code P0234, P0299 set
           • Engine Z/A17DTx - Lack of power and DPF glogged, SVS on, DTC: P242F and/or P2003 might be locked
         • Corrosion, Rust, Dirt › Engine A/Z17DTx, Turbocharger - Loss of power, trouble code P0234, P0299 set
         • Leaks › Turbo charger - Connection Turbo charger to intercooler hose leaky, oil mist.
       • Schematic and Routing Diagrams11 pages

         • Circuit Diagram9 pages

           • Coolant temperature sensor
           • Engine A17DTJ, DECE1 - 1
           • Engine A17DTJ, DECE1 - 2
           • Engine A17DTR, DECE1 - 1
           • Engine A17DTR, DECE1 - 2
           • Engine Z17DTJ, DECE1 - 1
           • Engine Z17DTJ, DECE1 - 2
           • Engine Z17DTR, DECE1 - 1
           • Engine Z17DTR, DECE1 - 2
         • Block Diagram2 pages

           • Engine Z17DTR/Z17DTJ, DECE1 (Not rear electronic module)
           • Engine Z17DTR/Z17DTJ, DECE1 (Rear electronic module)
     • Electronic Diesel Control EDC 16 C3, EDC 16 CP33, EDC 16 C36, EDC 17 C115 pages

       • Repair Instructions › Measuring the diesel fuel return quantity of Bosch solenoid valve injectors
       • Technical Service Bulletins2 pages

         • Poor Operation, Incorrect Operation › Engine Z19DT/L, AGR valve - Trouble code P0400 (5A) is set
         • Warning Lights, Telltale › Engine Z19DT/L, AGR valve - Trouble code P0400 (5A) is set
       • Schematic and Routing Diagrams › Block Diagram2 pages

         • Engine Z17DTL / Z17DTH, EDC 16 (Not rear electronic module)
         • Engine Z17DTL / Z17DTH, EDC 16 (Rear electronic module)
     • Motronic ME 7.6.1/ME 7.6.2/ME 7.6.3/ME 7.6.4/ME 7.9.9271 pages

       • Repair Instructions13 pages

         • Replace mixture regulator lambda sensor
         • Replace catalytic converter control oxygen sensor
         • Engine Compartment Overview
         • Fuel Pressure, Check
         • Replace ignition module
         • Spark Plugs, Remove and Install
         • Boost Pressure Sensor, Replace (Z 20 LEL, Z 20 LER)
         • Replace mixture regulator lambda sensor
         • Replace catalytic converter control oxygen sensor
         • Replace camshaft sensor
         • Replace atmospheric pressure sensor
         • Fuel Pressure, Check
         • Replace throttle valve module
         • Remove and install fuel rail
         • Replace mixture regulator lambda sensor
         • Replace spark plugs
         • Replace camshaft sensor
         • Replace catalytic converter control oxygen sensor
         • Replace fuel rail
       • Component Locator2 pages

         • Engine Compartment Overview
         • Illustration of engine management system
       • Specifications1 page

         • Engine Management
         • Engine Management
         • Engine Management
       • Diagnostic Information and Procedures › Diagnostic Procedures213 pages

         • Motronic 7.6.1, Z 12 XEP, Z 14 XEP, Z 14 XEL68 pages

           • Additional Information3 pages

             • General Information
             • Safety Measures
             • Electronic System Specific Information
           • A Diagnostic System Check
           • B-xx Functional Group Tests32 pages

             • B-001 DIAGNOSTIC TROUBLE CODE
             • B-002 DATA LIST
             • B-003 Diagnostic System Check
             • B-004 Symptom Chart/Customer Complaints
             • B-005 No Matching Customer Complaint
             • B-006 Complaint: Engine Start
             • B-007 ACTUATOR TEST
             • B-008 CONTROL TEST
             • B-009 ADDITIONAL FUNCTIONS
             • B-010 Fuse Check 1
             • B-011 Fuse Check 2
             • B-012 Fuse Check 3
             • B-013 Fuse Check 4
             • B-014 Fuse Check 5
             • B-015 Fuse Check 6
             • B-016 Fuse Check 7
             • B-017 Fuse Check 8
             • B-018 Trouble Codes: Check 1
             • B-019 Trouble Codes: Check 2
             • B-020 Check: Start Release
             • B-021 Fuel System
             • B-022 Mechanical Function Check
             • B-023 Complaint: Exhaust Gas
             • B-024 Check: Fuel Tank Content
             • B-025 Check: Knock Control
             • B-026 Check: Engine
             • B-027 Check: Outside Temperature Sensor
             • B-028 Check: O2 Sensor Heater Circuit (Bank 1 Sensor 1)
             • B-029 Check: O2 Sensor Heater Circuit (Bank 1 Sensor 2)
             • B-030 Check: Functionality of Adjacent Systems
             • B-031 Check: O2 Sensor (Bank 1 Sensor 1)
             • B-032 Check: O2 Sensor (Bank 1 Sensor 2)
           • C-xx Fault Isolation Procedures32 pages

             • C-001 Hardware Failure
             • C-002 Crankshaft Sensor Circuit
             • C-003 Fuel Pump Relay Circuit
             • C-004 Pedal Position Sensor Circuit
             • C-005 Throttle Position Sensor Circuit
             • C-006 Throttle Position Motor Control Circuit
             • C-007 Mass Air Flow Circuit
             • C-008 Intake Air Temperature Sensor Circuit
             • C-009 Camshaft Position Sensor Circuit
             • C-010 Port Deactivation Position Sensor Circuit
             • C-011 Port Deactivation Solenoid Valve Circuit
             • C-012 Cylinder 1 Injector Circuit
             • C-013 Cylinder 2 Injector Circuit
             • C-014 Cylinder 3 Injector Circuit
             • C-015 Cylinder 4 Injector Circuit
             • C-016 Ignition Coil Primary/Secondary Circuit
             • C-017 Knock Sensor Signal Circuit
             • C-018 Linear Exhaust Gas Recirculation System Circuit
             • C-019 Charcoal Canister Purge Valve Circuit
             • C-020 O2 Sensor Heater Circuit (Bank 1, Sensor 1)
             • C-021 O2 Sensor Heater Circuit (Before Catalyst)
             • C-022 O2 Sensor Circuit (Bank 1, Sensor 1)
             • C-023 O2 Sensor Circuit (Before Catalyst)
             • C-024 O2 Sensor Heater Circuit (Bank 1, Sensor 2)
             • C-025 O2 Sensor Heater Circuit (Behind Catalyst)
             • C-026 O2 Sensor Circuit (Bank 1, Sensor 2)
             • C-027 O2 Sensor Circuit (Behind Catalyst)
             • C-028 Engine Speed Input Signal Circuit
             • C-029 Misfire Detection
             • C-030 Catalyst System
             • C-031 Air/Fuel Ratio Adaption
             • C-032 Engine Oil Status
         • Motronic 7.6.1, Z 20 LEH, Z 20 LEL, Z 20 LER70 pages

           • Additional Information3 pages

             • General Information
             • Safety Measures
             • Electronic System Specific Information
           • A Diagnostic System Check
           • B-xx Functional Group Tests31 pages

             • B-001 DIAGNOSTIC TROUBLE CODE
             • B-002 DATA LIST
             • B-003 Diagnostic System Check
             • B-004 Symptom Chart/Customer Complaints
             • B-005 No Matching Customer Complaint
             • B-006 Complaint: Engine Start
             • B-007 ACTUATOR TEST
             • B-008 ADDITIONAL FUNCTIONS
             • B-009 CONTROL TEST
             • B-010 Fuse Check 1
             • B-011 Fuse Check 2
             • B-012 Fuse Check 3
             • B-013 Fuse Check 4
             • B-014 Fuse Check 5
             • B-015 Fuse Check 6
             • B-016 Check: Air/Fuel Ratio
             • B-017 Trouble Codes: Check 1
             • B-018 Trouble Codes: Check 2
             • B-019 Fuel System
             • B-020 Mechanical Function Check
             • B-021 Complaint: Exhaust Gas
             • B-022 Check: Fuel Tank Content
             • B-023 Check: Knock Control
             • B-024 Check: Engine
             • B-025 Check: Outside Temperature Sensor
             • B-026 Check: O2 Sensor Heater Circuit (Bank 1 Sensor 1)
             • B-027 Check: O2 Sensor Heater Circuit (Bank 1 Sensor 2)
             • B-028 Check: Functionality of Adjacent Systems
             • B-029 Check: O2 Sensor (Bank 1 Sensor 1)
             • B-030 Check: O2 Sensor (Bank 1 Sensor 2)
             • B-031 Check: Component
           • C-xx Fault Isolation Procedures35 pages

             • C-001 Hardware Failure
             • C-002 Crankshaft Sensor Circuit
             • C-003 Fuel Pump Relay Circuit
             • C-004 Pedal Position Sensor Circuit
             • C-005 Throttle Position Sensor Circuit
             • C-006 Throttle Position Motor Control Circuit
             • C-007 Mass Air Flow Circuit
             • C-008 Intake Air Temperature Sensor Circuit
             • C-009 Camshaft Position Sensor Circuit
             • C-010 Cylinder 1 Injector Circuit
             • C-011 Cylinder 2 Injector Circuit
             • C-012 Cylinder 3 Injector Circuit
             • C-013 Cylinder 4 Injector Circuit
             • C-014 Ignition Coil Primary/Secondary Circuit
             • C-015 Knock Sensor Signal Circuit
             • C-016 Charcoal Canister Purge Valve Circuit
             • C-017 O2 Sensor Heater Circuit (Bank 1, Sensor 1)
             • C-018 O2 Sensor Heater Circuit (Behind Catalyst)
             • C-019 O2 Sensor Circuit (Bank 1, Sensor 1)
             • C-020 O2 Sensor Circuit (Before Catalyst)
             • C-021 O2 Sensor Heater Circuit (Bank 1, Sensor 2)
             • C-022 O2 Sensor Heater Circuit (Before Catalyst)
             • C-023 O2 Sensor Circuit (Bank 1, Sensor 2)
             • C-024 O2 Sensor Circuit (Behind Catalyst)
             • C-025 Engine Speed Input Signal Circuit
             • C-026 Misfire Detection
             • C-027 Catalyst System
             • C-028 Air/Fuel Ratio Adaption
             • C-029 Engine Oil Status
             • C-030 Barometer Sensor Circuit
             • C-031 Boost Pressure Sensor Circuit
             • C-032 Waste Gate Valve Circuit
             • C-033 Turbocharger Bypass Solenoid Valve Circuit
             • C-034 Auxiliary Coolant Pump Circuit
             • C-035 Vehicle Speed Input Signal Circuit
         • Motronic 7.6.2, A 16 LET, Z 16 LET75 pages

           • Additional Information3 pages

             • General Information
             • Safety Measures
             • Electronic System Specific Information
           • A Diagnostic System Check
           • B-xx Functional Group Tests41 pages

             • B-001 DIAGNOSTIC TROUBLE CODE
             • B-002 DATA LIST
             • B-003 Diagnostic System Check
             • B-004 Symptom Chart/Customer Complaints
             • B-005 No Matching Customer Complaint
             • B-006 Complaint: Engine Start
             • B-007 Check: Intermittent Faults
             • B-008 ACTUATOR TEST
             • B-009 ADDITIONAL FUNCTIONS
             • B-010 CONTROL TEST
             • B-011 Fuse Check 1
             • B-012 Fuse Check 2
             • B-013 Fuse Check 3
             • B-014 Fuse Check 4
             • B-015 Fuse Check 5
             • B-016 Fuse Check 6
             • B-017 Fuse Check 7
             • B-018 Fuse Check 8
             • B-019 Fuse Check 9
             • B-020 Fuse Check 10
             • B-021 Fuse Check 11
             • B-022 Check: Air/Fuel Ratio
             • B-023 Trouble Codes: Check 1
             • B-024 Trouble Codes: Check 2
             • B-025 Trouble Codes: Check 3
             • B-026 Trouble Codes: Check 4
             • B-027 Trouble Codes: Check 5
             • B-028 Trouble Codes: Check 6
             • B-029 Trouble Codes: Check 7
             • B-030 Fuel System
             • B-031 Check: Intake-Air System
             • B-032 Mechanical Function Check
             • B-033 Check: Fuel Tank Content
             • B-034 Check: Knock Control
             • B-035 Check: Engine
             • B-036 Check: Outside Temperature Sensor
             • B-037 Complaint: Exhaust Gas
             • B-038 Check: O2 Sensor (Bank 1 Sensor 1)
             • B-039 Check: O2 Sensor (Bank 1 Sensor 2)
             • B-040 Check: Functionality of Adjacent Systems
             • B-041 Check: Component
           • C-xx Fault Isolation Procedures30 pages

             • C-001 Hardware Failure
             • C-002 Crankshaft Sensor Circuit
             • C-003 Fuel Pump Relay Circuit
             • C-004 Pedal Position Sensor Circuit
             • C-005 Throttle Position Sensor Circuit
             • C-006 Throttle Position Motor Control Circuit
             • C-007 Mass Air Flow Circuit
             • C-008 Intake Air Temperature Sensor Circuit
             • C-009 Camshaft Position Sensor Circuit
             • C-010 Cylinder 1 Injector Circuit
             • C-011 Cylinder 2 Injector Circuit
             • C-012 Cylinder 3 Injector Circuit
             • C-013 Cylinder 4 Injector Circuit
             • C-014 Ignition Coil Primary/Secondary Circuit
             • C-015 Knock Sensor Signal Circuit
             • C-016 Charcoal Canister Purge Valve Circuit
             • C-017 O2 Sensor Heater Circuit (Bank 1, Sensor 1)
             • C-018 O2 Sensor Circuit (Bank 1, Sensor 1)
             • C-019 O2 Sensor Heater Circuit (Bank 1, Sensor 2)
             • C-020 O2 Sensor Circuit (Bank 1, Sensor 2)
             • C-021 Engine Speed Input Signal Circuit
             • C-022 Misfire Detection
             • C-023 Catalyst System
             • C-024 Air/Fuel Ratio Adaption
             • C-025 Engine Oil Status
             • C-026 Barometer Sensor Circuit
             • C-027 Boost Pressure Sensor Circuit
             • C-028 Waste Gate Valve Circuit
             • C-029 Turbocharger Bypass Solenoid Valve Circuit
             • C-030 Vehicle Speed Input Signal Circuit
       • Technical Service Bulletins6 pages

         • Noise, Vibration, Rattle › Z20LEH Engine - Flow noise out of the engine when engine is hot and decelerating with 1500 - 2200 rpm.
         • Poor Operation, Incorrect Operation › Engine Z14XEP - Trouble Code P1602 (4C) stored in ECU after SPS programming
         • No Start › Engine Z/A16LET/L/R - Does not start or unstable idle, 0 mileage defects only
         • Poor Start › Engine Z/A16LET/L/R - Does not start or unstable idle, 0 mileage defects only
         • Surge, Miss, Chuggle › Engine Z/A16LET/L/R - Does not start or unstable idle, 0 mileage defects only
         • Leaks › Engine Z16XE1/XEP/XER/LEL/LET/LER, Z18XER - Oil leakage crankshaft sealing ring
       • Schematic and Routing Diagrams20 pages

         • Circuit Diagram16 pages

           • Coolant temperature sensor
           • Engine Z12XEP, Motronic 7.6.1 - 1
           • Engine Z12XEP, Motronic 7.6.1 - 2
           • Engine Z14XEL, Motronic 7.6.1 - 1
           • Engine Z14XEL, Motronic 7.6.1 - 2
           • Engine Z14XEP, Motronic 7.6.1 - 1
           • Engine Z14XEP, Motronic 7.6.1 - 2
           • Engine Z16LET, Motronic 7.6.2 - 1
           • Engine Z16LET, Motronic 7.6.2 - 2
           • Engine Z20LEH, Motronic 7.6.1 - 1
           • Engine Z20LEH, Motronic 7.6.1 - 2
           • Engine Z20LEL, Motronic 7.6.1 - 1
           • Engine Z20LEL, Motronic 7.6.1 - 2
           • Engine Z20LER, Motronic 7.6.1 - 1
           • Engine Z20LER, Motronic 7.6.1 - 2
           • Pedal position sensor (not Z16XER/ Z18XER)
         • Block Diagram4 pages

           • Engine Z12XEP/Z14XEL/Z14XEP, Motronic 7.6.1 (Not rear electronic module)
           • Engine Z12XEP/Z14XEL/Z14XEP, Motronic 7.6.1 (Rear electronic module)
           • Engine Z16LET, Motronic 7.6.2
           • Engine Z20LEL/Z20LEH/Z20LER, Motronic 7.6.1
       • Throttle Valve Housing › Repair Instructions2 pages

         • Replace throttle valve module
         • Removing and installing throttle valve module
       • Accelerator Position Sensor › Repair Instructions1 page

         • Accelerator Pedal Module, Remove and Install
         • Accelerator Pedal Module, Remove and Install
         • Accelerator Pedal Module, Remove and Install
       • Injector › Repair Instructions1 page

         • Replacing injection valves
         • Replacing injection valves
         • Replacing injection valves
       • Pulse Pick-Up › Repair Instructions2 pages

         • Replace camshaft sensor
         • Replace crankshaft pulse pick-up
         • Replace crankshaft pulse pick-up
       • Knock Sensor › Repair Instructions1 page

         • Replace knock sensor
         • Replace knock sensor
       • Fuel Pump › Repair Instructions › Replace fuel pressure regulator
       • Air Mass Meter › Repair Instructions1 page

         • Replace hot film mass air flow meter
         • Replace hot film mass air flow meter
         • Replace hot film mass air flow meter
       • Control Unit › Repair Instructions1 page

         • Engine Control Unit, Remove and Install
         • Engine Control Unit, Remove and Install
         • Engine Control Unit, Remove and Install
       • Tank Vent Valve › Repair Instructions › Replace tank vent valve
       • Temperature Sensor › Repair Instructions1 page

         • Replace coolant temperature sensor
         • Replace coolant temperature sensor
       • Ignition module › Repair Instructions2 pages

         • Replace ignition module
         • Spark Plugs, Remove and Install
         • Replace ignition module
       • Twin Port Sensor › Repair Instructions › Twinport Sensor, Replace
       • Twin Port Valve › Repair Instructions › Twinport Vacuum Unit, Replace
     • Electronic Diesel Control EDC 16 C9256 pages

       • Repair Instructions39 pages

         • Measuring the diesel fuel return quantity of Bosch solenoid valve injectors
         • Heat Protection Sleeve, Remove and Install
         • Replace EGR valve
         • Vacuum Unit Change-Over Valves, Remove and Install
         • Replace throttle valve module
         • Replacing the air cleaner housing
         • Replace air intake pipe
         • High-Pressure Pump Drive Gear, Remove and Install
         • Replace high-pressure pump
         • Replace crankshaft pulse generator
         • Replace camshaft sensor
         • Replace coolant temperature sensor
         • Replace charge pressure sensor
         • Replace turbocharger solenoid valve
         • Replace throttle valve module
         • Replace hot film mass air flow meter
         • Engine Control Unit, Remove and Install
         • Replace pre-heating system control unit
         • Replace oxygen sensor
         • Replace accelerator pedal module
         • High Pressure Fuel Lines, Pressure Chamber to Injectors, Replace
         • High Pressure Fuel Lines, High Pressure Pump to Pressure Chamber, Replace
         • Replace oil leak line
         • Accumulator, Remove and Install
         • One Injector, Replace
         • Oil Regulating Valve, Remove and Install
         • Rail Pressure Sensor, Replace
         • Actuating Drive, Change-Over Valves, Remove and Install
         • Replace air intake pipe
         • Replace high-pressure pump drive gear
         • Injector, Remove and Install
         • Replace accumulator sensor
         • Replace particle filter temperature sensor
         • Replace pre-catalytic converter temperature sensor
         • Replace throttle valve module
         • Replace differential pressure sensor
         • Replace fuel return damping case
         • Replace differential pressure sensor
         • Replace particle filter temperature sensor
         • Replace pre-catalytic converter temperature sensor
         • Replace vacuum reservoir
         • Metering Unit, Replace
         • Removing and installing charge air pipe
         • Accumulator, Remove and Install
         • Replace pressure regulator
         • Replace fuel return damping case
         • Replace vacuum reservoir
         • Oxygen Sensor, Mixture Regulation, Replace
       • Component Locator3 pages

         • Illustration of Common Rail
         • Illustration of Air Duct
         • Illustration of Common Rail
         • Illustration of Air Duct
         • Illustration of Common Rail System
       • Specifications1 page

         • Engine Management
         • Engine Management
         • Engine Management
       • Diagnostic Information and Procedures › Diagnostic Procedures170 pages

         • Electronic Diesel Injection System EDC 16C9, Z 17 DTL, Z 17 DTH73 pages

           • Additional Information3 pages

             • General Information
             • Safety Measures
             • Electronic System Specific Information
           • A Diagnostic System Check
           • B-xx Functional Group Tests38 pages

             • B-001 DIAGNOSTIC TROUBLE CODE
             • B-002 DATA LIST
             • B-003 Diagnostic System Check
             • B-004 Symptom Chart/Customer Complaints
             • B-005 No Matching Customer Complaint
             • B-006 Complaint: Engine Start
             • B-007 Complaint: Engine Idling
             • B-008 Complaint: Engine Behaviour Under Normal Driving Conditions
             • B-009 Complaint: Engine Performance
             • B-010 Complaint: Exhaust Gas
             • B-011 Complaint: Oil / Coolant / Fuel-System
             • B-012 Complaint: Engine Mechanic
             • B-013 Complaint: Engine Temperature
             • B-014 ACTUATOR TEST
             • B-015 Programming ECM
             • B-016 Check: System Voltage
             • B-017 Check: Outside Temperature Sensor Signal
             • B-018 Fuel System
             • B-019 Intake-Air System
             • B-020 Check: Intake-Air System
             • B-021 Check: Intake-Air System/Charge-Air System
             • B-022 Check: Charge-Air System
             • B-023 Check: Vacuum Supply System
             • B-024 Check: Distance Signal
             • B-025 Check: Pressure Sensor Signal
             • B-026 Check: High Pressure Area
             • B-027 Check: Low and High Pressure Section
             • B-028 Check: Low Pressure Section
             • B-029 Trouble Codes: Check 1
             • B-030 Trouble Codes: Check 2
             • B-031 Trouble Codes: Check 3
             • B-032 Check: Engine Speed Signal
             • B-033 Check: Engine
             • B-034 Fuse Check 1
             • B-035 Fuse Check 2
             • B-036 Fuse Check 3
             • B-037 Fuse Check 4
             • B-038 ADDITIONAL FUNCTIONS
           • C-xx Fault Isolation Procedures31 pages

             • C-001 Control Unit Hard- and Software
             • C-002 Control Unit Hard- and Software 2
             • C-003 Control Unit Main Relay Circuit
             • C-004 5V Circuit 1
             • C-005 5V Circuit 2
             • C-006 5V Circuit 3
             • C-007 Crankshaft Sensor Circuit
             • C-008 Camshaft Position Sensor Circuit
             • C-009 Pedal Position Sensor Circuit
             • C-010 Intake Air Temperature Sensor Circuit
             • C-011 Mass or Volume Air Flow Circuit
             • C-012 Boost Pressure Sensor Circuit
             • C-013 Boost Pressure Control Valve Circuit
             • C-014 Throttle Valve Positioner Circuit
             • C-015 Swirl Level Control Circuit
             • C-016 Rail Oil Pressure Sensor Circuit
             • C-017 Fuel Metering Solenoid Valve Circuit
             • C-018 Injector Circuit
             • C-019 Cylinder 1 Injector Circuit
             • C-020 Cylinder 2 Injector Circuit
             • C-021 Cylinder 3 Injector Circuit
             • C-022 Cylinder 4 Injector Circuit
             • C-023 Exhaust Gas Recirculation Valve Circuit
             • C-024 Exhaust Gas Recirculation Sensor Circuit
             • C-025 Glow Time Relay Circuit
             • C-026 Filterheating Circuit
             • C-027 Function-Group High Pressure Area
             • C-028 System Status Information
             • C-029 Mechanical Function
             • C-030 System Voltage Circuit
             • C-031 Engine-Compression
         • Electronic Diesel Injection System EDC 16C9/16C39, Z 19 DT, Z 19 DTH, Z 19 DTL97 pages

           • Additional Information3 pages

             • General Information
             • Safety Measures
             • Electronic System Specific Information
           • A Diagnostic System Check
           • B-xx Functional Group Tests52 pages

             • B-001 DIAGNOSTIC TROUBLE CODE
             • B-002 DATA LIST
             • B-003 Diagnostic System Check
             • B-004 Symptom Chart/Customer Complaints
             • B-005 No Matching Customer Complaint
             • B-006 Complaint: Engine Start
             • B-007 Complaint: Engine Idling
             • B-008 Complaint: Engine Behaviour Under Normal Driving Conditions
             • B-009 Complaint: Engine Performance
             • B-010 Complaint: Exhaust Gas
             • B-011 Complaint: Oil / Coolant / Fuel-System
             • B-012 Check: Functionality of Adjacent Systems
             • B-013 ACTUATOR TEST
             • B-014 ADDITIONAL FUNCTIONS
             • B-015 Check: Start Release
             • B-016 Check: Outside Temperature Sensor Signal
             • B-017 Check: Fuel Filter Water Level Switch Circuit
             • B-018 Check: Engine Speed Signal
             • B-019 Fuse Check 1
             • B-020 Fuse Check 2
             • B-021 Fuse Check 3
             • B-022 Fuse Check 4
             • B-023 Fuse Check 5
             • B-024 Fuse Check 6
             • B-025 Fuse Check 7
             • B-026 Fuse Check 8
             • B-027 Fuse Check 9
             • B-028 Fuse Check 10
             • B-029 Trouble Codes: Check 1
             • B-030 Trouble Codes: Check 2
             • B-031 Trouble Codes: Check 3
             • B-032 Trouble Codes: Check 4
             • B-033 Trouble Codes: Check 5
             • B-034 Trouble Codes: Check 6
             • B-035 System Selection
             • B-036 Intake-Air System
             • B-037 Check: Intake-Air System
             • B-038 Intake Air / Vacuum System
             • B-039 Intake-Air System: Check 1
             • B-040 Fuel System
             • B-041 Check: Low Pressure Section
             • B-042 Check: Low and High Pressure Section
             • B-043 Check: High Pressure Area
             • B-044 Check: Intake-Air System/Charge-Air System
             • B-045 Check: Charge-Air System
             • B-046 Check: Diesel Particulate Filter
             • B-047 Check: Pressure Sensor Signal
             • B-048 Check: System Voltage
             • B-049 Complaint: Engine Temperature
             • B-050 Check: Distance/Consumption Signal
             • B-051 Check: Engine
             • B-052 Check: Vehicle Speed Signal
           • C-xx Fault Isolation Procedures41 pages

             • C-001 Control Unit Hard- and Software 1
             • C-002 Control Unit Hard- and Software 2
             • C-003 Control Unit Main Relay Circuit
             • C-004 Fuel Pump Relay Circuit
             • C-005 5V Circuit 1
             • C-006 5V Circuit 2
             • C-007 5V Circuit 3
             • C-008 Pedal Position Sensor Circuit
             • C-009 Crankshaft Sensor Circuit
             • C-010 Camshaft Position Sensor Circuit
             • C-011 Boost Pressure Sensor Circuit
             • C-012 Mass Air Flow Circuit
             • C-013 Intake Air Temperature Sensor Circuit
             • C-014 Charge Air Temperature Sensor Circuit
             • C-015 Fuel Temperature Sensor Circuit
             • C-016 Boost Pressure Control Valve Circuit
             • C-017 Exhaust Gas Recirculation Valve Circuit
             • C-018 Swirl Level Control Circuit
             • C-019 Throttle Valve Positioner Circuit
             • C-020 Fuel Rail Pressure Sensor Circuit
             • C-021 Fuel Metering Solenoid Valve Circuit
             • C-022 Fuel Rail Pressure Control Valve Circuit
             • C-023 Cylinder 1 Injector Circuit
             • C-024 Cylinder 2 Injector Circuit
             • C-025 Cylinder 3 Injector Circuit
             • C-026 Cylinder 4 Injector Circuit
             • C-027 Injector Circuit
             • C-028 O2 Sensor Circuit
             • C-029 O2 Sensor Heater Circuit
             • C-030 Exhaust Gas Temperature Sensor 1 Circuit
             • C-031 Exhaust Gas Temperature Sensor 2 Circuit
             • C-032 Differential Pressure Sensor Circuit
             • C-033 Glow Time Relay Circuit
             • C-034 Fuel Filter Water Level Switch Circuit
             • C-035 Filterheating Circuit
             • C-036 Function-Group Intake Air System
             • C-037 Function-Group Low and High Pressure Section
             • C-038 Function-Group High Pressure Area
             • C-039 Function-Group Fuel System
             • C-040 System Condition
             • C-041 Engine-Compression
       • Technical Service Bulletins12 pages

         • Noise, Vibration, Rattle2 pages

           • Diesel Engine - Booming Noise
           • Engine Z17/19DTx, cylinder balance test - Rugh idle, engine cuts out
         • Poor Operation, Incorrect Operation3 pages

           • Engine Z17DTL/H - Jerking at steady state
           • Engine Z19DT/L/H - SVS on, Trouble code P2452(58), DPF sensor hose malfunction set
           • Engine Z19DT/L, AGR valve - Trouble code P0400 (5A) is set
         • Hesitation › Engine Z17DTL/H - Jerking at steady state
         • Rough Idle › Engine Z17/19DTx, cylinder balance test - Rugh idle, engine cuts out
         • Sluggish, Power Loss3 pages

           • Engine Z17DTL/H - Jerking at steady state
           • Engine Z19DT/H/L - Changed characteristic after SPS programming with TIS 2000-DVD, version 83
           • Engine Z17/19DTx, cylinder balance test - Rugh idle, engine cuts out
         • Warning Lights, Telltale2 pages

           • Engine Z19DT/L/H - SVS on, Trouble code P2452(58), DPF sensor hose malfunction set
           • Engine Z19DT/L, AGR valve - Trouble code P0400 (5A) is set
       • Schematic and Routing Diagrams › Circuit Diagram2 pages

         • Engine Z17DTH, EDC 16 - 1
         • Engine Z17DTH, EDC 16 - 2
       • Injector Nozzles › Repair Instructions › One Injector, Remove and Install
       • Pressure Line › Repair Instructions2 pages

         • High Pressure Fuel Lines, Pressure Chamber to Injectors, Replace
         • Replace high pressure fuel lines from high pressure pump to accumulator
         • High Pressure Fuel Lines, Pressure Chamber to Injectors, Replace
         • Replace high pressure fuel lines from high pressure pump to accumulator
       • Pulse Pick-up, Crankshaft › Repair Instructions2 pages

         • Replace crankshaft pulse pick-up
         • Replace crankshaft pulse generator
       • Accelerator Position Sensor › Repair Instructions1 page

         • Replace accelerator pedal module
         • Replace accelerator pedal module
       • High Pressure Pump7 pages

         • Repair Instructions3 pages

           • High-Pressure Pump Drive Gear, Remove and Install
           • High-Pressure Pump, Remove and Install
           • Replace high-pressure pump
         • Technical Service Bulletins4 pages

           • No Start › Engine Z17DTL/H, high pressure pump - Engine does not start or stalls during driving
           • Sluggish, Power Loss › Engine Z17DTL/H, high pressure pump - Engine does not start or stalls during driving
           • Stalls › Engine Z17DTL/H, high pressure pump - Engine does not start or stalls during driving
           • Surge, Miss, Chuggle › Engine Z17DTL/H, high pressure pump - Engine does not start or stalls during driving
       • Hot Film Mass Air Flow Meter › Repair Instructions1 page

         • Replace hot film mass air flow meter
         • Replace hot film mass air flow meter
       • Control Unit › Repair Instructions2 pages

         • Engine Control Unit, Remove and Install
         • Replace pre-heating system control unit
         • Engine Control Unit, Remove and Install
       • Coolant Temperature Sensor › Repair Instructions1 page

         • Replace coolant temperature sensor
         • Replace coolant temperature sensor
       • Air Cleaner Housing › Repair Instructions2 pages

         • Replacing the air cleaner housing
         • Replace air intake pipe
         • Replacing the air cleaner housing
       • Camshaft Pulse Pick-up › Repair Instructions1 page

         • Replace camshaft sensor
         • Replace camshaft sensor
       • Charge Pressure Sensor › Repair Instructions1 page

         • Replace charge pressure sensor
         • Replace charge pressure sensor
       • Solenoid Valve › Repair Instructions3 pages

         • Solenoid Valve - Turbocharger, Remove and Install
         • Replace switchover valve solenoid valve
         • Replace turbocharger solenoid valve
       • Pressure Reservoir › Repair Instructions3 pages

         • Accumulator, Remove and Install
         • Replace pressure regulator
         • Pressure Chamber Pressure Sensor, Replace
       • Oil Leak Lines › Repair Instructions2 pages

         • Replace fuel return line
         • Replace oil leak line
     • Multijet 6JO155 pages

       • Repair Instructions8 pages

         • Measuring the diesel fuel return quantity of Bosch solenoid valve injectors
         • Oil Pressure Sensor, Replace
         • Replace engine oil level sensor
         • Oxygen Sensor, Mixture Regulation, Replace
         • Vacuum Reservoir, Replace
         • Replace differential pressure sensor
         • Replace particle filter temperature sensor
         • Replace pre-catalytic converter temperature sensor
       • Specifications › Engine Management
       • Diagnostic Information and Procedures › Diagnostic Procedures › Electronic Diesel Injection System Multijet 6JO, Z 13 DTH101 pages

         • Additional Information3 pages

           • General Information
           • Safety Measures
           • Electronic System Specific Information
         • A Diagnostic System Check
         • B-xx Functional Group Tests57 pages

           • B-001 DIAGNOSTIC TROUBLE CODE
           • B-002 DATA LIST
           • B-003 Diagnostic System Check
           • B-004 Symptom Chart/Customer Complaints
           • B-005 No Matching Customer Complaint
           • B-006 Complaint: Engine Start
           • B-007 Complaint: Engine Idling
           • B-008 Complaint: Engine Behaviour Under Normal Driving Conditions
           • B-009 Complaint: Engine Performance
           • B-010 Complaint: Exhaust Gas
           • B-011 Complaint: Oil / Coolant / Fuel-System
           • B-012 Complaint: Engine Mechanic
           • B-013 Check: Functionality of Adjacent Systems
           • B-014 ACTUATOR TEST
           • B-015 ADDITIONAL FUNCTIONS
           • B-016 ECU Control
           • B-017 Check: System Voltage
           • B-018 Programming ECM
           • B-019 Check: Start Release
           • B-020 Check: Outside Temperature Sensor Signal
           • B-021 Check: Fuel Filter Water Level Switch Circuit
           • B-022 Fuel System
           • B-023 Fuel System: Check 1
           • B-024 Intake-Air System
           • B-025 Check: Intake-Air System
           • B-026 Check: Vacuum System
           • B-027 Check: Intake-Air System/Charge-Air System
           • B-028 Check: Charge-Air System
           • B-029 Check: Exhaust System
           • B-030 Check: Distance Signal
           • B-031 Check: Pressure Sensor Signal
           • B-032 Complaint: Engine Temperature
           • B-033 Check: Low and High Pressure Section
           • B-034 Check: Low Pressure Section
           • B-035 Check: High Pressure Area
           • B-036 Check: Injectors
           • B-037 Fuse Check 1
           • B-038 Fuse Check 2
           • B-039 Fuse Check 3
           • B-040 Fuse Check 4
           • B-041 Fuse Check 5
           • B-042 Fuse Check 6
           • B-043 Fuse Check 7
           • B-044 Fuse Check 9
           • B-045 Fuse Check 10
           • B-046 Check: Diesel Particulate Filter
           • B-047 Trouble Codes: Check 1
           • B-048 Trouble Codes: Check 2
           • B-049 Trouble Codes: Check 3
           • B-050 Trouble Codes: Check 4
           • B-051 Trouble Codes: Check 5
           • B-052 Trouble Codes: Check 6
           • B-053 Trouble Codes: Check 7
           • B-054 Trouble Codes: Check 8
           • B-055 Trouble Codes: Check 9
           • B-056 Trouble Codes: Check 10
           • B-057 Trouble Codes
         • C-xx Fault Isolation Procedures40 pages

           • C-001 Control Unit Hard- and Software
           • C-002 Control Unit Hard- and Software 1
           • C-003 Control Unit Main Relay Circuit
           • C-004 Fuel Pump Relay Circuit
           • C-005 5V Circuit 1
           • C-006 5V Circuit 2
           • C-007 5V Circuit 3
           • C-008 Crankshaft Sensor Circuit
           • C-009 Camshaft Position Sensor Circuit
           • C-010 Pedal Position Sensor Circuit
           • C-011 Barometer Sensor Circuit
           • C-012 Boost Pressure Sensor Circuit
           • C-013 Mass or Volume Air Flow Circuit
           • C-014 Intake Air Temperature Sensor Circuit
           • C-015 Boost Air Temperature Sensor Circuit
           • C-016 Fuel Temperature Sensor Circuit
           • C-017 Boost Pressure Control Valve Circuit
           • C-018 Exhaust Gas Recirculation Valve Circuit
           • C-019 Throttle Valve Positioner Circuit
           • C-020 Rail Pressure Sensor Circuit
           • C-021 Fuel Metering Solenoid Valve Circuit
           • C-022 Rail Pressure Solenoid Valve Circuit
           • C-023 Cylinder 1 Injector Circuit
           • C-024 Cylinder 2 Injector Circuit
           • C-025 Cylinder 3 Injector Circuit
           • C-026 Cylinder 4 Injector Circuit
           • C-027 O2 Sensor Heater Circuit
           • C-028 O2 Sensor Circuit
           • C-029 Exhaust Gas Temperature Sensor Circuit
           • C-030 Differential Pressure Sensor Circuit
           • C-031 Mechanical Function
           • C-032 Glow Time Relay Circuit
           • C-033 Fuel Filter Water Level Switch Circuit
           • C-034 Filterheating Circuit
           • C-035 Function-Group Low Pressure Section
           • C-036 Function-Group Low and High Pressure Section
           • C-037 Function-Group High Pressure Area
           • C-038 Function-Group Diesel Particulate Filter
           • C-039 System Status Information
           • C-040 Engine-Compression
       • Technical Service Bulletins15 pages

         • Noise, Vibration, Rattle2 pages

           • Engine Y/Z13DT/H/J - Bad cold start behavior at low ambient temperatures
           • Engine Z13DT/J/H - Smoke and/or sizzling noise from cylinder head
         • Poor Operation, Incorrect Operation › Engine Z13DTH, ECU - Trouble code U2105 set, crank no start
         • No Start3 pages

           • Engine Y/Z13DT/H/J - Bad cold start behavior at low ambient temperatures
           • Engine Z13DTH, ECU - Trouble code U2105 set, crank no start
           • Z13DTH Engine - P0190(07) set, stalls, crank,but no start, unstable idle
         • Poor Start2 pages

           • Engine Y/Z13DT/H/J - Bad cold start behavior at low ambient temperatures
           • Z13DTH Engine - P0190(07) set, stalls, crank,but no start, unstable idle
         • Rough Idle › Z13DTH Engine - P0190(07) set, stalls, crank,but no start, unstable idle
         • Sluggish, Power Loss › Engine Z13DTH, Electro Pneumatic Valve (EPV) - Lack of power DTC's P0108, P0243 set
         • Stalls › Z13DTH Engine - P0190(07) set, stalls, crank,but no start, unstable idle
         • Warning Lights, Telltale3 pages

           • Engine Z13DTH, ECU - Trouble code U2105 set, crank no start
           • Z13DTH Engine - P0190(07) set, stalls, crank,but no start, unstable idle
           • Engine Z13DTH, Electro Pneumatic Valve (EPV) - Lack of power DTC's P0108, P0243 set
         • Smoke, Odour, Fumes › Engine Z13DT/J/H - Smoke and/or sizzling noise from cylinder head
       • Schematic and Routing Diagrams4 pages

         • Circuit Diagram2 pages

           • Engine Z13DTH, Multijet 6O2 - 1
           • Engine Z13DTH, Multijet 6O2 - 2
         • Block Diagram2 pages

           • Engine Z13DTH, Multijet 6O2 (Not rear electronic module)
           • Engine Z13DTH, Multijet 6O2 (Rear electronic module)
       • Injector Nozzles › Repair Instructions › Replace injectors
       • Pressure Line › Repair Instructions2 pages

         • One Fuel High Pressure Line, Replace - Pressure Reservoir - Injector
         • Fuel High Pressure Line, Replace (High Pressure Pump - Accumulator)
       • Pulse Pick-up, Crankshaft3 pages

         • Repair Instructions › Crankshaft Pulse Pick-Up, Remove and Install
         • Technical Service Bulletins2 pages

           • Inoperative - Totally, Partially › Engine Z13DT/J/H - Lack of power after rework 08-R-014 was done
           • Hesitation › Engine Z13DT/J/H - Lack of power after rework 08-R-014 was done
       • Accelerator Position Sensor › Repair Instructions › Accelerator Pedal with Pedal Sensor, Remove and Install
       • High Pressure Pump › Repair Instructions › High Pressure Pump, Remove and Install
       • Hot Film Mass Air Flow Meter › Repair Instructions › Air Mass Flow Meter, Remove and Install
       • Control Unit › Repair Instructions2 pages

         • Engine Control Unit, Remove and Install
         • Control Unit for Pre-Heating System, Replace
       • Coolant Temperature Sensor › Repair Instructions › Replace coolant temperature sensor
       • Air Cleaner Housing › Repair Instructions3 pages

         • Replacing the air cleaner housing
         • Air Intake Pipe, Remove and Install
         • Air Intake Hose for Intercooler, Replace (with Air Conditioning)
       • Camshaft Pulse Pick-up › Repair Instructions › Camshaft Sensor, Remove and Install
       • Charge Pressure Sensor › Repair Instructions › Charge Pressure Sensor, Remove and Install
       • Solenoid Valve › Repair Instructions2 pages

         • Replace turbocharger solenoid valve
         • Throttle Valve Solenoid Valve, Replace
       • Pressure Reservoir › Repair Instructions3 pages

         • Accumulator, Remove and Install
         • Accumulator Pressure Sensor, Replace
         • Fuel Pressure Regulator (High Pressure), Replace
       • Oil Leak Lines › Repair Instructions2 pages

         • Oil leak line, remove and install
         • Replace fuel return damping case
       • Throttle Valve › Repair Instructions2 pages

         • Throttle Valve Body, Remove and Install
         • Throttle Valve Solenoid Valve, Replace
     • Simtec 75239 pages

       • Repair Instructions11 pages

         • Replace throttle valve module
         • Spark Plugs, Remove and Install
         • Camshaft Sensors, Replace
         • Replace coolant temperature sensor
         • Replace switchover valve solenoid valve
         • Air Cleaner Housing, Replace (Z16XE1 / A16XER / Z16XER)
         • Replace intake pipe pressure sensor
         • Twinport Solenoid Valve, Replace
         • Twinport Vacuum Unit, Replace
         • Replace intake pipe pressure sensor
         • Replace intake air temperature sensor
         • Replace throttle valve module Z18XER (conversion from old version to modified version)
       • Component Locator › Illustration engine management A16XER, Z16XER
       • Specifications › Engine Management
       • Diagnostic Information and Procedures › Diagnostic Procedures193 pages

         • Simtec 75, Z 16 XER92 pages

           • Additional Information3 pages

             • General Information
             • Safety Measures
             • Electronic System Specific Information
           • A Diagnostic System Check
           • B-xx Functional Group Tests49 pages

             • B-001 DIAGNOSTIC TROUBLE CODE
             • B-002 DATA LIST
             • B-003 Diagnostic System Check
             • B-004 Symptom Chart/Customer Complaints
             • B-005 No Matching Customer Complaint
             • B-006 Complaint: Engine Start
             • B-007 Complaint: Engine Operation
             • B-008 Mechanical Function Check
             • B-009 ACTUATOR TEST
             • B-010 ADDITIONAL FUNCTIONS
             • B-011 CONTROL TEST
             • B-012 Accelerator Pedal Position Check
             • B-013 Fuse Check 2
             • B-014 Fuse Check 3
             • B-015 Fuse Check 4
             • B-016 Fuse Check 5
             • B-017 Fuse Check 6
             • B-018 Fuse Check 7
             • B-019 Fuse Check 8
             • B-020 Fuse Check 9
             • B-021 Fuse Check 10
             • B-022 Fuse Check 11
             • B-023 Fuse Check 12
             • B-024 Fuse Check 13
             • B-025 Fuse Check 14
             • B-026 Fuse Check 15
             • B-027 Fuse Check 16
             • B-028 Fuse Check 17
             • B-029 Fuse Check 18
             • B-030 Fuse Check 19
             • B-031 Fuse Check 20
             • B-032 Fuse Check 21
             • B-033 Fuse Check 22
             • B-034 Fuse Check 23
             • B-035 Trouble Codes: Check 1
             • B-036 Trouble Codes: Check 2
             • B-037 Trouble Codes: Check 3
             • B-038 Trouble Codes: Check 4
             • B-039 Trouble Codes: Check 5
             • B-040 Trouble Codes: Check 6
             • B-041 Complaint: Indicating Devices/Telltales
             • B-042 Complaint: Exhaust Gas
             • B-043 Check: ABS Anti-Lock Brake System
             • B-044 Check: Knock Control
             • B-045 Check: Misfire
             • B-046 Check: Intake-Air System
             • B-047 Check: Exhaust System
             • B-048 Fuel System
             • B-049 Check: TCM
           • C-xx Fault Isolation Procedures39 pages

             • C-001 Control Unit Main Relay Circuit
             • C-002 Engine Start Signal Circuit
             • C-003 Crankshaft Sensor Circuit
             • C-004 Intake Camshaft Position Sensor Circuit
             • C-005 Exhaust Camshaft Position Sensor Circuit
             • C-006 Intake Camshaft Phasing Solenoid Valve Circuit
             • C-007 Exhaust Camshaft Phasing Solenoid Valve Circuit
             • C-008 Fuel Pump Relay Circuit
             • C-009 Pedal Position Sensor Circuit
             • C-010 Throttle Valve Positioner Circuit
             • C-011 Manifold Absolute Pressure Sensor Circuit
             • C-012 Intake Air Temperature Sensor Circuit
             • C-013 Engine Oil Level Circuit
             • C-014 Ignition Coil Cylinder 1 Circuit
             • C-015 Ignition Coil Cylinder 2 Circuit
             • C-016 Ignition Coil Cylinder 3 Circuit
             • C-017 Ignition Coil Cylinder 4 Circuit
             • C-018 Cylinder 1 Injector Circuit
             • C-019 Cylinder 2 Injector Circuit
             • C-020 Cylinder 3 Injector Circuit
             • C-021 Cylinder 4 Injector Circuit
             • C-022 Knock Sensor Signal Circuit
             • C-023 Charcoal Canister Purge Valve Circuit
             • C-024 O2 Sensor Heater Circuit (Before Catalyst)
             • C-025 O2 Sensor Circuit (Before Catalyst)
             • C-026 O2 Sensor Heater Circuit (Behind Catalyst)
             • C-027 O2 Sensor Circuit (Behind Catalyst)
             • C-028 Intake Manifold Valve Circuit
             • C-029 Thermostat Heater Circuit
             • C-030 System Status Information
             • C-031 ABS Communication Circuit
             • C-032 Mechanical Function
             • C-033 Malfunction Indication Lamp (MI) Circuit
             • C-034 Service Telltale Circuit
             • C-035 Air/Fuel Ratio Adaption
             • C-036 Control Unit Hard- and Software
             • C-037 Misfire Detection
             • C-038 Transmission Communication Circuit
             • C-039 Fan Relay (Stage 3) Circuit
         • Simtec 75, Z 18 XER101 pages

           • Additional Information3 pages

             • General Information
             • Safety Measures
             • Electronic System Specific Information
           • A Diagnostic System Check
           • B-xx Functional Group Tests56 pages

             • B-001 DIAGNOSTIC TROUBLE CODE
             • B-002 DATA LIST
             • B-003 Diagnostic System Check
             • B-004 Symptom Chart/Customer Complaints
             • B-005 No Matching Customer Complaint
             • B-006 Complaint: Engine Start
             • B-007 Complaint: Engine Behaviour Under Normal Driving Conditions
             • B-008 Check: Start Release
             • B-009 Mechanical Function Check
             • B-010 ACTUATOR TEST
             • B-011 ADDITIONAL FUNCTIONS
             • B-012 CONTROL TEST
             • B-013 Accelerator Pedal Position Check
             • B-014 Fuse Check 1
             • B-015 Fuse Check 2
             • B-016 Fuse Check 3
             • B-017 Fuse Check 4
             • B-018 Fuse Check 5
             • B-019 Fuse Check 6
             • B-020 Fuse Check 7
             • B-021 Fuse Check 8
             • B-022 Fuse Check 9
             • B-023 Fuse Check 10
             • B-024 Fuse Check 11
             • B-025 Fuse Check 12
             • B-026 Fuse Check 13
             • B-027 Fuse Check 14
             • B-028 Fuse Check 15
             • B-029 Fuse Check 16
             • B-030 Fuse Check 17
             • B-031 Fuse Check 18
             • B-032 Fuse Check 19
             • B-033 Fuse Check 20
             • B-034 Fuse Check 21
             • B-035 Fuse Check 22
             • B-036 Fuse Check 23
             • B-037 Trouble Codes: Check 1
             • B-038 Trouble Codes: Check 2
             • B-039 Trouble Codes: Check 3
             • B-040 Trouble Codes: Check 4
             • B-041 Trouble Codes: Check 5
             • B-042 Trouble Codes: Check 6
             • B-043 Trouble Codes: Check 7
             • B-044 Check: Temperature-Sensors
             • B-045 Complaint: Indicating Devices/Telltales
             • B-046 Complaint: Exhaust Gas
             • B-047 Electrical Function Check
             • B-048 Check: ABS Anti-Lock Brake System
             • B-049 Check: Knock Control
             • B-050 Complaint: Warning Telltales
             • B-051 Check: Misfire
             • B-052 Check: Intake-Air System
             • B-053 Check: Exhaust System
             • B-054 Fuel System
             • B-055 Check: TCM
             • B-056 Check: Ignition Coil
           • C-xx Fault Isolation Procedures41 pages

             • C-001 Control Unit Main Relay Circuit
             • C-002 Engine Start Signal Circuit
             • C-003 Crankshaft Sensor Circuit
             • C-004 Intake Camshaft Position Sensor Circuit
             • C-005 Exhaust Camshaft Position Sensor Circuit
             • C-006 Intake Camshaft Phasing Solenoid Valve Circuit
             • C-007 Exhaust Camshaft Phasing Solenoid Valve Circuit
             • C-008 Fuel Pump Relay Circuit
             • C-009 Pedal Position Sensor Circuit
             • C-010 Throttle Valve Positioner Circuit
             • C-011 Mass Air Flow Circuit
             • C-012 Intake Air Temperature Sensor Circuit
             • C-013 Manifold Absolute Pressure Sensor Circuit
             • C-014 Temperature Sensor Circuit
             • C-015 Engine Oil Level Circuit
             • C-016 Ignition Coil Cylinder 1 Circuit
             • C-017 Ignition Coil Cylinder 2 Circuit
             • C-018 Ignition Coil Cylinder 3 Circuit
             • C-019 Ignition Coil Cylinder 4 Circuit
             • C-020 Cylinder 1 Injector Circuit
             • C-021 Cylinder 2 Injector Circuit
             • C-022 Cylinder 3 Injector Circuit
             • C-023 Cylinder 4 Injector Circuit
             • C-024 Knock Sensor Signal Circuit
             • C-025 Charcoal Canister Purge Valve Circuit
             • C-026 O2 Sensor Heater Circuit (Before Catalyst)
             • C-027 O2 Sensor Circuit (Before Catalyst)
             • C-028 O2 Sensor Heater Circuit (Behind Catalyst)
             • C-029 O2 Sensor Circuit (Behind Catalyst)
             • C-030 Intake Manifold Valve Circuit
             • C-031 System Status Information
             • C-032 Transmission Communication Circuit
             • C-033 ABS Communication Circuit
             • C-034 Mechanical Function
             • C-035 Malfunction Indication Lamp (MI) Circuit
             • C-036 Service Telltale Circuit
             • C-037 Air/Fuel Ratio Adaption
             • C-038 Control Unit Hard- and Software
             • C-039 Misfire Detection
             • C-040 Thermostat Heater Circuit
             • C-041 Fan Relay (Stage 3) Circuit
       • Technical Service Bulletins8 pages

         • Noise, Vibration, Rattle › Engine A/Z/16/18XER - Rattling noise sometimes P0011 or P0014 stored, SVS on
         • Inoperative - Totally, Partially › Engine A/Z/16/18XER - Rattling noise sometimes P0011 or P0014 stored, SVS on
         • Poor Operation, Incorrect Operation › Engine Z18XER: Airflow Meter - Driveability complaints, MIL on, Trouble Code P0100 set, deactivation of ESP
         • Warning Lights, Telltale4 pages

           • Engine Z18XER: Airflow Meter - Driveability complaints, MIL on, Trouble Code P0100 set, deactivation of ESP
           • Engine Z16/18XE1/P/R, thermostat - Mil on, trouble code P0115 is stored
           • Engine A/Z/16/18XER - Rattling noise sometimes P0011 or P0014 stored, SVS on
           • Engine Z16XER, Coolant Temperatur Sensor - SVS on , P2182(17) set
         • Corrosion, Rust, Dirt › Engine Z16XER, Coolant Temperatur Sensor - SVS on , P2182(17) set
       • Schematic and Routing Diagrams10 pages

         • Circuit Diagram5 pages

           • Engine Z16XER, Simtec 75 - 1
           • Engine Z16XER, Simtec 75 - 2
           • Engine Z18XER, Simtec 75 - 1
           • Engine Z18XER, Simtec 75 - 2
           • Pedal position sensor (Z16XER/Z18XER)
         • Block Diagram5 pages

           • Engine Z16XER, Simtec 75 (Not rear electronic module)
           • Engine Z16XER, Simtec 75 (Rear electronic module)
           • Engine Z18XER, Simtec 75
           • Engine Z18XER, Simtec 75 (Not rear electronic module)
           • Engine Z18XER, Simtec 75 (Rear electronic module)
       • Injector › Repair Instructions › Injectors, Remove and Install
       • Pulse Pick-Up3 pages

         • Repair Instructions › Replace crankshaft pulse pick-up
         • Technical Service Bulletins2 pages

           • Hesitation › Engine Z16/18XER - No start, somtimes TC P0340 or P0365 set
           • Sluggish, Power Loss › Engine Z16/18XER - No start, somtimes TC P0340 or P0365 set
       • Knock Sensor › Repair Instructions › Replace knock sensor
       • Oxygen Sensor › Repair Instructions2 pages

         • Mixture Regulator Oxygen Sensor, Replace
         • Replace catalytic converter control oxygen sensor
       • Air Mass Meter › Repair Instructions2 pages

         • Replace mass air flow sensor
         • Replace intake air temperature sensor
       • Control Unit3 pages

         • Repair Instructions1 page

           • Engine Control Unit, Remove and Install
           • Engine Control Unit, Remove and Install
         • Technical Service Bulletins2 pages

           • Hesitation › Engine Z16XER - Low torque below 2000 rpm
           • Sluggish, Power Loss › Engine Z16XER - Low torque below 2000 rpm
       • DIS-Ignition Module › Repair Instructions › Replace ignition module
       • Air Cleaner Housing › Repair Instructions › Removing and installing air cleaner housing
       • Pedal Position Sensor › Repair Instructions › Accelerator Pedal Module, Remove and Install
     • Electronic Diesel Control EDC 16 C3952 pages

       • Repair Instructions36 pages

         • Measuring the diesel fuel return quantity of Bosch solenoid valve injectors
         • Replacing the air cleaner housing
         • Replace air intake pipe
         • High-Pressure Pump Drive Gear, Remove and Install
         • Replace high-pressure pump
         • Replace crankshaft pulse generator
         • Replace camshaft sensor
         • Replace coolant temperature sensor
         • Replace charge pressure sensor
         • Replace turbocharger solenoid valve
         • Replace throttle valve module
         • Replace hot film mass air flow meter
         • Engine Control Unit, Remove and Install
         • Replace pre-heating system control unit
         • Replace oxygen sensor
         • Replace accelerator pedal module
         • High Pressure Fuel Lines, Pressure Chamber to Injectors, Replace
         • High Pressure Fuel Lines, High Pressure Pump to Pressure Chamber, Replace
         • Replace oil leak line
         • Accumulator, Remove and Install
         • One Injector, Replace
         • Oil Regulating Valve, Remove and Install
         • Rail Pressure Sensor, Replace
         • Actuating Drive, Change-Over Valves, Remove and Install
         • Replacing the air cleaner housing
         • Replace air intake pipe
         • Replace high-pressure pump drive gear
         • Injector, Remove and Install
         • Replace high-pressure pump
         • Replace accumulator sensor
         • Replace oil leak line
         • Replace particle filter temperature sensor
         • Replace pre-catalytic converter temperature sensor
         • Replace coolant temperature sensor
         • Replace charge pressure sensor
         • Replace throttle valve module
         • Replace crankshaft pulse generator
         • Replace camshaft sensor
         • Replace turbocharger solenoid valve
         • Replace differential pressure sensor
         • Replace hot film mass air flow meter
         • Replace pre-heating system control unit
         • Engine Control Unit, Remove and Install
         • Replace accelerator pedal module
         • Replace fuel return damping case
         • Replace differential pressure sensor
         • Replace particle filter temperature sensor
         • Replace pre-catalytic converter temperature sensor
         • Replace vacuum reservoir
         • Removing and installing charge air pipe
         • High Pressure Fuel Lines, Pressure Chamber to Injectors, Replace
         • Replace high pressure fuel lines from high pressure pump to accumulator
         • Accumulator, Remove and Install
         • Replace pressure regulator
         • Replace fuel return damping case
         • Replace vacuum reservoir
         • Oxygen Sensor, Mixture Regulation, Replace
       • Component Locator2 pages

         • Illustration of Common Rail
         • Illustration of Air Duct
         • Illustration of Common Rail
         • Illustration of Air Duct
       • Specifications1 page

         • Engine Management
         • Engine Management
       • Technical Service Bulletins5 pages

         • Poor Operation, Incorrect Operation2 pages

           • Engine Z19DT/L/H - SVS on, Trouble code P2452(58), DPF sensor hose malfunction set
           • Engine Z19DT/L, AGR valve - Trouble code P0400 (5A) is set
         • Sluggish, Power Loss › Engine Z19DT/H/L - Changed characteristic after SPS programming with TIS 2000-DVD, version 83
         • Warning Lights, Telltale2 pages

           • Engine Z19DT/L/H - SVS on, Trouble code P2452(58), DPF sensor hose malfunction set
           • Engine Z19DT/L, AGR valve - Trouble code P0400 (5A) is set
       • Schematic and Routing Diagrams8 pages

         • Circuit Diagram6 pages

           • Engine Z19DT, EDC 16 C39 - 1
           • Engine Z19DT, EDC 16 C39 - 2
           • Engine Z19DTH, EDC 16 C39 - 1
           • Engine Z19DTH, EDC 16 C39 - 2
           • Engine Z19DTL, EDC 16 C39 - 1
           • Engine Z19DTL, EDC 16 C39 - 2
         • Block Diagram2 pages

           • Engine Z19DTL/Z19DT, EDC 16 C39 (Not rear electronic module)
           • Engine Z19DTL/Z19DT, EDC 16 C39 (Rear electronic module)
   • Engine Electrics24 pages

     • Repair Instructions › Check alternator
     • Schematic and Routing Diagrams › Circuit Diagram › Start & Charging
     • Starter › Repair Instructions3 pages

       • Starter, Remove and Install
       • Starter, Remove and Install
       • Starter, Remove and Install
       • Remove and install starter (M20-6 MTA)
       • Replace starter
     • Alternator15 pages

       • Repair Instructions9 pages

         • Test battery/alternator
         • Alternator, Remove and Install
         • Alternator, Remove and Install
         • Alternator, Remove and Install
         • Alternator with Vacuum Pump, Remove and Install
         • Alternator, Remove and Install
         • Alternator Support, Remove and Install
         • Alternator, Remove and Install
         • Regulator for Alternator, Replace
         • Alternator, Remove and Install
         • Replace alternator drive disc
         • Replace alternator support
         • Alternator, Remove and Install
         • Alternator, Remove and Install
         • Alternator Bracket, Remove and Install
         • Alternator, Remove and Install
         • Replace alternator
         • Regulator for Alternator, Replace
         • Replace alternator support
       • Technical Service Bulletins6 pages

         • Noise, Vibration, Rattle2 pages

           • Engine Y/Z13DT/J/H, Alternator pulley - High frequent squeaking noise out of engine compartment
           • Engine Z19DT/H/J/L, Alternator pulley - Battery discharged or noises (only Bosch alternator)
         • Inoperative - Totally, Partially2 pages

           • Engine Z19DT/H/J/L, Alternator pulley - Battery discharged or noises (only Bosch alternator)
           • Alternator - Defect
         • Poor Operation, Incorrect Operation2 pages

           • Engine Y/Z13DT/J/H, Alternator pulley - High frequent squeaking noise out of engine compartment
           • Alternator - Defect
     • Pre-Glow System (Diesel Engine) › Repair Instructions4 pages

       • Sheathed Glow Plugs, Remove and Install
       • Replace pre-heating system control unit
       • Replace pre-heating system control unit
       • Sheathed Glow Plugs, Replace
       • Control Unit for Pre-Heating System, Replace
       • Sheathed Glow Plugs, Replace
       • Replace pre-heating system control unit
       • Sheathed Glow Plugs, Remove and Install
       • Replace pre-heating system control unit
       • Sheathed Glow Plugs, Remove and Install
   • Cooling System91 pages

     • Repair Instructions16 pages

       • Cooling System, Check for Leaks
       • Cooling System, Charge and Bleed
       • Cooling System, Charge and Bleed
       • Coolant flange, remove and install
       • Coolant Pipe, Remove and Install
       • Illustration - Coolant Hoses (Z 20 LEL, Z 20 LER)
       • Cooling System, Charge and Bleed
       • Intercooler, Replace (Z 20 LEL, Z 20 LER)
       • Coolant flange, remove and install
       • Replace EGR cooler
       • Cooling System, Charge and Bleed
       • Coolant Pipe, Remove and Install
       • Coolant flange, remove and install
       • Replace coolant temperature sensor
       • Cooling System, Charge and Bleed
       • Coolant Pipe, Remove and Install
       • Cooling System, Charge and Bleed
       • Coolant Expansion Tank, Remove and Install
       • Intercooler, Replace (Z 20 LEH)
       • Cooling System, Charge and Bleed
       • Replace EGR cooler
       • Replace coolant temperature sensor
       • Cooling System, Charge and Bleed
       • Coolant Pipe, Replace
       • Heat Exchanger, Replace
       • Replace coolant hose
       • Check engine for leaks
       • Replace EGR cooler
       • Coolant Pipe, Remove and Install
       • Coolant flange, remove and install
       • Cooling System, Charge and Bleed
       • Coolant Pipe, Replace
       • Coolant flange, remove and install
       • Cooling System, Charge and Bleed
       • Coolant Pipe, Replace
       • Replace coolant compensation tank
       • Coolant Temperature Sensor, Replace (Z 22 YH, RHD)
       • Heat Exchanger, Replace
     • Component Locator3 pages

       • Illustration of coolant hoses
       • Illustration of coolant hoses
       • Illustration - Coolant Hoses (Z 20 LEL, Z 20 LER)
       • Illustration of coolant hoses
       • Illustration of coolant hoses
       • Illustration of coolant hoses
       • Illustration of coolant hoses
       • Illustration of coolant hoses
       • Illustration of coolant hoses
       • Illustration of Air Duct
     • Specifications2 pages

       • Cooling system
       • Coolant Circuit
       • Coolant Circuit
       • Coolant Circuit
       • Coolant Circuit
       • Cooling system
       • Cooling system
       • Coolant Circuit
       • Coolant Circuit
       • Cooling system
       • Coolant Circuit
     • Diagnostic Information and Procedures › Diagnostic Procedures › Engine Cooling18 pages

       • Additional Information3 pages

         • General Information
         • Safety Measures
         • Electronic System Specific Information
       • A Diagnostic System Check
       • B-xx Functional Group Tests8 pages

         • B-002 Diagnostic System Check
         • B-003 Symptom Chart/Customer Complaints
         • B-004 Fuse Check 1
         • B-005 Fuse Check 2
         • B-006 Complaint: Engine Temperature
         • B-007 Check: Engine
         • B-008 Check: Coolant Circuit
         • B-009 No Matching Customer Complaint
       • C-xx Fault Isolation Procedures6 pages

         • C-001 Engine Coolant Temperature Sensor Circuit
         • C-002 Radiator Coolant Temperature Sensor Circuit
         • C-003 Fan Circuit
         • C-004 Thermostat Heater Circuit
         • C-005 Coolant Circulation
         • C-006 Fan Relay (Stage 3) Circuit
     • Schematic and Routing Diagrams › Circuit Diagram15 pages

       • Engine cooling (A17DTJ/A17DTR & not air conditioning)
       • Engine cooling (Diesel & air conditioning)
       • Engine cooling (Z12XEP/Z14XEL/Z14XEP & not air conditioning)
       • Engine cooling (Z12XEP/Z14XEL/Z14XEP/Z16XE1/Z16XER & air conditioning)
       • Engine cooling (Z16LET & air conditioning)
       • Engine cooling (Z16XE1/Z16XER/Z16LET/Z18XER/Z13DTH & not air conditioning)
       • Engine cooling (Z17DTL/Z17DTH/Z17DTR/Z17DTJ & not air conditioning)
       • Engine cooling (Z18XER & Automatic transmission & air conditioning)
       • Engine cooling (Z18XER & Manual transmission & air conditioning)
       • Engine cooling (Z19DT & Automatic transmission & not air conditioning)
       • Engine cooling (Z19DTH & not air conditioning)
       • Engine cooling (Z19DTL/Z19DT & Manual transmission & not air conditioning)
       • Engine cooling (Z20LEL/Z20LER/Z20LEH)
       • Engine cooling (Z22YH & Air conditioning)
       • Engine cooling (Z22YH & not air conditioning)
     • Radiator14 pages

       • Repair Instructions11 pages

         • Replace radiator (without air conditioning)
         • Radiator, Replace
         • Radiator, Replace (Z 20 LEL, Z 20 LER)
         • Replace EGR cooler
         • Replace radiator (with air conditioning)
         • Replace intercooler
         • Radiator, Remove and Install (with Air Conditioning)
         • Replace intercooler
         • Radiator, Replace (Z 20 LEH)
         • Replace radiator (without air conditioning)
         • Fan Motor, Replace
         • Radiator, Replace
         • Replace radiator (without air conditioning)
         • Replace radiator (with air conditioning)
         • Radiator, Replace (from MY 06)
         • Replace intercooler
         • Radiator, Replace
         • Radiator, Replace
         • Radiator, Replace (from MY 08)
       • 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 Instructions8 pages

       • Replace fan motor (without air conditioning)
       • Replace fan motor (without air conditioning)
       • Fan Motor, Replace (Z 20 LEL, Z 20 LER)
       • Replace fan motor (with air conditioning system)
       • Replace auxiliary fan motor
       • Fan Motor, Replace
       • Fan motor, Replace (Z 20 LEH)
       • Replace fan motor (without air conditioning)
       • Replace fan motor (without air conditioning)
       • Replace fan motor (with air conditioning system)
       • Fan Motor, Replace (from MY 06)
       • Fan Motor, Replace
       • Fan Housing, Replace
       • Fan Motor, Replace
       • Replace auxiliary fan motor
       • Fan Housing, Replace
       • Fan Motor, Replace
     • Oil Cooler › Repair Instructions2 pages

       • Replace engine oil cooler / heat exchanger
       • Replace engine oil cooler / heat exchanger
       • Heat Exchanger, Remove and Install
       • Replace engine oil cooler / heat exchanger
     • Thermostat › Repair Instructions6 pages

       • Thermostat, Remove and Install
       • Thermostat, Remove and Install
       • Removing and installing thermostat with coolant outlet connection
       • Thermostat, Remove and Install
       • Thermostat Housing, Remove and Install
       • Thermostat Housing, Remove and Install
       • Thermostat Housing, Remove and Install
       • Replace thermostat housing
       • Thermostat, Remove and Install
       • Coolant flange, remove and install
       • Thermostat, Remove and Install
       • Thermostat Housing, Remove and Install
       • Thermostat, Remove and Install
       • Replace thermostat
       • Replace thermostat housing
       • Thermostat Housing, Remove and Install
       • Thermostat Housing, Remove and Install
     • Water Pump › Repair Instructions3 pages

       • Coolant Pump, Remove and Install
       • Coolant Pump, Remove and Install
       • Replace coolant pump
       • Coolant Pump Drive Gear, Remove and Install
       • Coolant Pump, Remove and Install
       • Coolant Pump, Remove and Install
       • Coolant Pump, Remove and Install
       • Coolant Pump, Remove and Install
       • Replace coolant pump
       • Coolant Pump, Remove and Install
       • Coolant Pump Drive Gear, Remove and Install
       • Coolant Pump, Remove and Install
       • Replace coolant pump
       • Replace coolant pump
     • Auxiliary Air Fan › Repair Instructions4 pages

       • Auxiliary Fan Motor, Replace (Z 20 LEL, Z 20 LER)
       • Replace auxiliary fan motor
       • Replace auxiliary fan motor
       • Auxiliary Fan Motor, Replace (Z 20 LEH)
       • Replace auxiliary fan motor
       • Additional Fan Motor, Replace (from MY 06)
       • Replace auxiliary fan motor
       • Replace auxiliary fan motor
   • Turbo-Charging49 pages

     • Repair Instructions24 pages

       • Engine compartment vacuum routing
       • Replace air intake pipe
       • Removing and installing charge air pipe
       • Removing and installing exhaust manifold with turbocharger
       • Oil Return Line - Turbocharger, Remove and Install
       • Intercooler, Replace (Z 20 LEL, Z 20 LER)
       • Replace vacuum reservoir solenoid valve
       • Replace turbocharger
       • Removing and installing charge air pipe
       • Exhaust Manifold with Turbocharger, Replace
       • Replace turbocharger
       • Replace charge pressure sensor
       • Solenoid Valve - Turbocharger, Remove and Install
       • Removing and installing charge air pipe
       • Removing and installing exhaust manifold with turbocharger
       • Replace turbocharger
       • Air Intake Pipe, Remove and Install
       • Air Intake Hose for Intercooler, Replace (with Air Conditioning)
       • Replace intercooler
       • Replace turbocharger
       • Vacuum Reservoir, Replace
       • Intercooler, Replace (Z 20 LEH)
       • Replace turbocharger solenoid valve
       • Replace vacuum reservoir
       • Exhaust manifold with turbocharger, remove and install (with manual transmission)
       • Exhaust manifold with turbocharger, remove and install (with automatic transmission)
       • Replace vacuum reservoir
       • Replace turbocharger
       • Removing and installing charge air pipe
       • Exhaust Manifold, Remove and Install
       • Replace turbocharger
       • Replace charge pressure sensor
       • Removing and installing exhaust manifold with turbocharger
       • Replace turbocharger oil feed line
       • Removing and installing oil baffle plate
       • Replace turbocharger
       • Replace charge air pipe to intercooler
     • Component Locator2 pages

       • Engine compartment vacuum routing
       • Illustration of engine compartment vacuum routing
     • Technical Service Bulletins5 pages

       • Noise, Vibration, Rattle2 pages

         • Engine Z20LEL/LEH/LER, Turbocharger - Rattling/knocking noise during load cycle
         • Turbocharger - Trouble-Shooting Procedure
       • Sluggish, Power Loss › Turbocharger - Trouble-Shooting Procedure
       • Leaks › Turbocharger - Trouble-Shooting Procedure
       • Smoke, Odour, Fumes › Turbocharger - Trouble-Shooting Procedure
     • Boost Pressure Regulator › Repair Instructions5 pages

       • Replace turbo control unit solenoid valve
       • Replace charge pressure regulator control unit
       • Replace turbocharger solenoid valve
       • Replace charge pressure sensor
       • Replace charge pressure control solenoid valve
     • Oil Lines › Repair Instructions10 pages

       • Removing and installing turbocharger oil feed line (cylinder block)
       • Oil Feed Line - Turbocharger (Turbocharger), Remove and Install
       • Replace turbocharger oil feed line
       • Turbocharger Oil Return Hose, Replace
       • Replace turbocharger oil feed line
       • Replace turbocharger oil return line
       • Oil Feed Line - Turbocharger, Remove and Install
       • Oil Return Line - Turbocharger, Remove and Install
       • Turbocharger Oil Return Line Flange, Replace
       • Replace turbocharger oil feed line (manual transmission)
       • Replace turbocharger oil feed line (automatic transmission)
       • Replace turbocharger oil return line
       • Replace turbocharger oil feed line
       • Turbocharger Oil Return Hose, Replace
     • Oil Cooler › Repair Instructions › Oil Filter Housing, Remove and Install
     • Charge air cooler › Repair Instructions2 pages

       • Replace intercooler
       • Replace intercooler
       • Intercooler, Replace (from MY 06)
       • Replace intercooler
       • Replace intercooler
   • DOHC diesel engine279 pages

     • Repair Instructions › Remove and install automatic transmission with torque converter from engine
     • General30 pages

       • Repair Instructions20 pages

         • Measuring oil consumption
         • Compression, Check
         • Check engine pressure loss
         • Check engine for leaks
         • Engine cover, remove and install
         • Engine, Remove and Install
         • Manual Transmission, Remove from Engine and Install
         • Engine maintenance using a section engine
         • DOHC Diesel engine (Z 19 DTH / Z 19 DTH (120PS)) - engine number/engine code
         • Check engine for leaks
         • Replacing the air cleaner housing
         • Replace air intake pipe
         • Removing and installing charge air pipe
         • Engine cover, remove and install
         • Cooling System, Charge and Bleed
         • Thermostat Housing, Remove and Install
         • Engine, Remove and Install
         • Compression, Check
         • Check engine pressure loss
         • Check engine for leaks
         • Flywheel, Remove and Install
         • Manual Transmission From/To Engine, Detach and Attach (Z 19 DTH)
         • Compression, Check
         • Check engine pressure loss
         • Engine Oil with Oil Filter Change
         • Cooling System, Charge and Bleed
         • Engine, Remove and Install
         • Manual Transmission, Remove from Engine and Install
         • Engine maintenance using a section engine
         • Repair engine using a short block
         • Pressure Loss Test, Charge Air System
         • Pressure Loss Test, Charge Air System
         • Compression, Check
         • Check engine pressure loss
         • Check engine for leaks
         • Check and adjust valve play
         • Replacing the air cleaner housing
         • Replace air intake pipe
         • Engine, Remove and Install
         • Manual Transmission, Remove from Engine and Install
         • Engine maintenance using a section engine
       • Component Locator9 pages

         • DOHC Diesel engine (Z 17 DTL / Z 17 DTH) - engine number/engine code
         • Illustration of Common Rail
         • Illustration of Air Duct
         • Illustration of Air Duct
         • Illustration of Common Rail System
         • Illustration of coolant hoses
         • Vacuum Routing in the Engine Compartment
         • Engine Number/Engine Code
         • Illustration of coolant hoses
         • Illustration of Common Rail System
         • Illustration of Air Duct
         • Illustration of engine management system
         • DOHC diesel engine Z 17 DTR, Z17DTJ, A 17 DTR and A17DTJ - engine number/engine code
       • Specifications
       • Special Tools and Equipment1 page

         • Special Service Tools
         • Special Service Tools
         • Special Service Tools
         • Special Service Tools
     • Seals and Seal Rings › Repair Instructions9 pages

       • Seal Ring - Camshaft, Replace
       • Replace crankshaft seal ring (rear)
       • Replace crankshaft seal ring (front)
       • Replace oil pump seal ring-
       • Replacing front crankshaft seal ring
       • Seal Ring - Camshaft, Replace
       • Seal Ring - Rear Crankshaft, Replace
       • Replace oil pump seal ring
       • Front Crankshaft Seal Ring, Replace
       • Seal Ring - Rear Crankshaft, Replace
       • Valve Stem Seals, Replace
       • Seal Ring - Camshaft, Replace
       • Replace crankshaft seal ring (rear)
       • Replace crankshaft seal ring (front)
       • Replace oil pump seal ring
     • Ribbed V-Belt14 pages

       • Repair Instructions10 pages

         • Testing ribbed V-belt tensioner
         • Replace ribbed V-belt
         • Check ribbed V-belt
         • Replace ribbed V-belt
         • Ribbed V-Belt, Remove and Install
         • Ribbed V-Belt Tensioner, Remove and Install
         • Torsional Vibration Damper, Remove and Install
         • Testing ribbed V-belt tensioner
         • Replace ribbed V-belt
         • Replace ribbed V-belt tensioner
         • Ribbed V-Belt Guide Roller, Replace
         • Coolant Pump Drive Gear, Remove and Install
         • Replace lower ribbed V-belt guide roller
       • Specifications1 page

         • Ribbed V-belt
         • Ribbed V-belt
         • Ribbed V-belt
         • Ribbed V-belt
       • Tension Roller › Repair Instructions1 page

         • Replace ribbed V-belt tensioner
         • Replace ribbed V-belt tensioner
       • Guide Roller › Repair Instructions2 pages

         • Ribbed V-Belt Guide Roller, Replace
         • Replace upper ribbed V-belt guide roller
     • Engine Damping Block › Repair Instructions11 pages

       • Replace engine damping block (front)
       • Replace engine damping block (rear)
       • Replace left engine damping block
       • Replace (right) engine damping block
       • Manual Transmission, Remove from Engine and Install
       • Engine maintenance using a section engine
       • Replace engine damping block (front)
       • Replace engine damping block (rear)
       • Replace left engine damping block
       • Replace right engine damping block
       • Replace engine damping block (front)
       • Replace engine damping block (rear)
       • Left Engine Damping Block, Remove and Install
       • Right Engine Damping Block, Remove and Install
       • Replace (right) engine damping block adapter
       • Engine, Remove and Install
       • Replace engine damping block (front)
       • Replace engine damping block (rear)
       • Replace right engine damping block
       • Replace left engine damping block
       • Engine maintenance using a section engine
     • Oil Circulating41 pages

       • Repair Instructions40 pages

         • Oil Temperature, Measure
         • Engine Oil Pressure, Check
         • Engine Oil with Oil Filter Change
         • Oil Filter Housing, Remove and Install
         • Oil Intake Pipe, Remove and Install
         • Oil Pump, Remove and Install
         • Replace oil pump seal ring-
         • Oil Pump, Check
         • Excess Pressure Valve, Remove and Install
         • Oil Pressure Regulating Valve, Remove and Install
         • Replace oil pressure switch
         • Replace engine oil level sensor
         • Replace oil dipstick guide tube
         • Replace turbocharger oil feed line
         • Turbocharger Oil Return Hose, Replace
         • Lower Part of Oil Pan, Remove and Install
         • Upper Part of Oil Pan, Remove and Install
         • Oil Temperature, Measure
         • Engine Oil Pressure, Check
         • Engine Oil with Oil Filter Change
         • Replace engine oil cooler / heat exchanger
         • Oil Intake Pipe, Remove and Install
         • Oil Pressure Regulating Valve, Remove and Install
         • Replace oil pressure switch
         • Replace residual oil quantity sensor
         • Replace oil dipstick guide tube
         • Replace turbocharger oil feed line
         • Replace turbocharger oil return line
         • Oil Pan, Remove and Install
         • Replace oil separator
         • Replace oil baffle plate
         • Replace engine oil filling nozzle
         • Oil Filter Housing, Remove and Install
         • Oil Pump, Remove and Install
         • Oil Pump, Check
         • Replace oil pump seal ring
         • Oil Pump Pressure-Regulating Valve, Remove and Install
         • Oil Spray Nozzles, Remove and Install
         • Heat Exchanger, Remove and Install
         • Oil Temperature, Measure
         • Engine Oil Pressure, Check
         • Oil Spray Nozzle (Tube), Timing Chain, Replace
         • Engine Oil with Oil Filter Change
         • Oil Filter Housing, Remove and Install
         • Engine Oil Cooler/Heat Exchanger, Replace
         • Oil Pump, Remove and Install
         • Oil Pump, Check
         • Oil Pump Pressure-Regulating Valve, Remove and Install
         • Oil Dipstick Guide Tube, remove and Install
         • Oil Feed Line - Turbocharger, Remove and Install
         • Oil Return Line - Turbocharger, Remove and Install
         • Turbocharger Oil Return Line Flange, Replace
         • Oil Pan, Remove and Install
         • Replace oil baffle plate
         • Intake Pipe for Oil Pump, Replace
         • Replace engine oil filling nozzle
         • Replace oil separator
         • Oil Pressure Sensor, Replace
         • Replace engine oil level sensor
         • Replace cylinder block ventilation flange
         • Oil Temperature, Measure
         • Engine Oil Pressure, Check
         • Engine oil with oil filter change
         • Oil Filter Housing, Remove and Install
         • Oil Pump Drive Gear, Remove and Install
         • Oil Intake Pipe, Remove and Install
         • Oil Pump, Remove and Install
         • Replace oil pump seal ring
         • Pressure Relief Valve in Oil Circuit, Replace
         • Oil Pump Pressure-Regulating Valve, Remove and Install
         • Oil Pressure Sensor, Replace
         • Replace residual oil quantity sensor
         • Replace oil dipstick guide tube
         • Replace turbocharger oil feed line
         • Turbocharger Oil Return Hose, Replace
         • Lower Part of Oil Pan, Remove and Install
         • Upper Part of Oil Pan, Remove and Install
         • Replace the oil spray nozzle
       • Specifications1 page

         • Oil circulation
         • Oil circulation
         • Oil circulation
         • Oil circulation
     • Timing Gear Case22 pages

       • Repair Instructions7 pages

         • Replace front toothed belt cover (top)
         • Replace front toothed belt cover (lower)
         • Replace rear toothed belt cover
         • Timing, Check
         • Timing, Adjust
         • Ribbed V-Belt Tensioner, Remove and Install
         • Timing Case, Remove and Install
         • Timing, Check
         • Timing, Adjust
       • Technical Service Bulletins5 pages

         • Abrasion, Wear › Toothed belt diagnosis - Possible causes and remedys
         • Noise, Vibration, Rattle › Toothed belt diagnosis - Possible causes and remedys
         • Inoperative - Totally, Partially › Toothed belt diagnosis - Possible causes and remedys
         • Loose, Missing, Broken › Toothed belt diagnosis - Possible causes and remedys
         • Chip, Crack › Toothed belt diagnosis - Possible causes and remedys
       • Cover, timing case › Repair Instructions › Replace front toothed belt cover (top)
       • Hydraulic chain tensioner › Repair Instructions › Hydraulic Chain Tensioner, Replace
       • Timing chain › Repair Instructions6 pages

         • Timing Chain, Replace
         • Camshaft Sprocket, Replace
         • Toothed Belt Drive Gear - Crankshaft Sprocket, Replace
         • Timing Chain Sliding Rail, Replace
         • Replace timing chain tension rail
         • Oil Spray Nozzle (Tube), Timing Chain, Replace
       • Slide rail, timing chain › Repair Instructions › Timing Chain Sliding Rail, Replace
       • Tension rail, timing chain › Repair Instructions › Replace timing chain tension rail
     • Cylinder Block63 pages

       • Repair Instructions25 pages

         • Cylinder Block, Check for Plane Surface
         • DOHC Diesel engine (Z 19 DTH / Z 19 DTH (120PS)) - engine number/engine code
         • Cylinder Block, Check for Plane Surface
         • Alternator Support, Remove and Install
         • Check engine pressure loss
         • Replace oil baffle plate
         • Replace cylinder block ventilation flange
         • Engine maintenance using a section engine
         • Flywheel, Remove and Install
         • Bracket for Crankshaft Seal Ring (Rear), Remove and Install
         • Replace crankshaft seal ring (rear)
         • Replace crankshaft seal ring (front)
         • Con-rod Bearing, Replace
         • Check con-rod bearing clearance (with Plastigage)
         • Coolant Pipe, Remove and Install
         • Coolant flange, remove and install
         • Alternator Bracket, Remove and Install
         • Cylinder Block, Check for Plane Surface
         • Check con-rod bearing clearance (with micrometer)
         • Piston Rings, Replace
         • Replacing one piston / con-rod
         • All pistons with con-rod, remove and install - Diesel engine
         • Crankshaft Out-of-round, Check
         • Crankshaft End Play, Check
         • Determine crankshaft bearing clearance (determine bearing clearance with Plastigage)
         • Check crankshaft bearing clearance (with micrometer gauge internal measuring device)
         • Crankshaft, Remove and Install - Diesel engine
       • Component Locator › Engine Number/Engine Code
       • Specifications1 page

         • Crankshaft drive, cylinder block
         • Crankshaft drive, cylinder block
         • Crankshaft drive, cylinder block
         • Crankshaft drive, cylinder block
       • Crankshaft Bearing Shell › Repair Instructions3 pages

         • Check crankshaft axial play
         • Check crankshaft bearing clearance (with plastigage)
         • Check crankshaft bearing clearance (with micrometer gauge internal measuring device)
       • Piston › Repair Instructions6 pages

         • Piston with Con-rod, Remove and Install
         • Piston Rings, Replace
         • Replacing one piston / con-rod
         • All Pistons with Con-rod, Remove and Install
         • Piston Rings, Replace
         • Replacing one piston / con-rod
         • Oil Spray Nozzles, Remove and Install
         • All Pistons with Con-rod, Remove and Install
         • Replace one piston and/or con-rod
         • Piston Rings, Replace
       • Crankshaft › Repair Instructions18 pages

         • Bracket for Crankshaft Seal Ring (Rear), Remove and Install
         • Replace crankshaft seal ring (rear)
         • Replace crankshaft seal ring (front)
         • Crankshaft, Remove and Install
         • Crankshaft End Play, Check
         • Crankshaft Out-of-round, Check
         • Determine crankshaft bearing clearance (determine bearing clearance with Plastigage)
         • Check crankshaft bearing clearance (with micrometer gauge internal measuring device)
         • Replace crankshaft pulse pick-up
         • Replacing front crankshaft seal ring
         • Seal Ring - Rear Crankshaft, Replace
         • Crankshaft, Remove and Install
         • Longitudinal Play of Crankshaft, Check
         • Determine crankshaft bearing clearance (determine bearing clearance with Plastigage)
         • Toothed Belt Drive Gear - Crankshaft Sprocket, Replace
         • Torsional Vibration Damper, Remove and Install
         • Front Crankshaft Seal Ring, Replace
         • Seal Ring - Rear Crankshaft, Replace
         • Check con-rod bearing clearance (with micrometer gauge and internal measuring device)
         • Crankshaft, Remove and Install
         • Check crankshaft axial play
         • Check crankshaft bearing clearance (with plastigage)
         • Check crankshaft bearing clearance (with micrometer gauge internal measuring device)
         • Check crankshaft bearing clearance (with micrometer gauge internal measuring device)
       • Con Rod Bearing › Repair Instructions5 pages

         • Con-rod Bearing, Replace
         • Check con-rod bearing clearance (with Plastigage)
         • Check con-rod bearing clearance (with micrometer)
         • Con-rod Bearing, Replace
         • Check con-rod bearing clearance (with plastigage)
         • Con-rod Bearing, Replace
         • Con-rod Bearing Play, Check (with Plastigage)
         • Check con-rod bearing clearance (with micrometer gauge and internal measuring device)
         • Check con-rod bearing clearance (with micrometer)
       • Con Rod › Repair Instructions3 pages

         • All Pistons with Con-rod, Remove and Install
         • Replacing one piston / con-rod
         • All Pistons with Con-rod, Remove and Install
         • Replace one piston and/or con-rod
       • Flywheel › Repair Instructions1 page

         • Flywheel, Remove and Install
         • Flywheel, Remove and Install
         • Flywheel, Remove and Install
     • Cylinder Head67 pages

       • Repair Instructions40 pages

         • Change-Over Valve Housing, Remove and Install
         • Cylinder Head, Remove and Install
         • Cylinder Head, Check for Plane Surface
         • Attaching Parts - Cylinder Head, Remove and Install
         • Replace EGR cooler
         • Engine cover, remove and install
         • Replace exhaust gas recirculation valve
         • Replace EGR cooler
         • Cylinder Head, Remove and Install
         • Cylinder Head, Check for Plane Surface
         • Attach and detach attaching parts
         • Compression, Check
         • Check engine pressure loss
         • Cylinder Head, Remove and Install
         • Attaching Parts - Cylinder Head, Remove and Install
         • Cylinder Head, Check for Plane Surface
         • Replace exhaust gas recirculation valve
         • Replace EGR cooler
         • Oil Pressure Sensor, Replace
         • Camshaft Sprocket, Replace
         • Engine cover, remove and install
         • Exhaust Manifold, Remove and Install
         • Replace intake manifold
         • Intake Manifold Intake Pipe, Replace
         • Seal Ring - Camshaft, Replace
         • Removing and installing both camshafts
         • Camshaft Housing Cover, Remove and Install
         • Cup Tappets, Replace
         • Replace exhaust gas recirculation valve
         • Replace EGR cooler
         • Replace turbocharger
         • Camshaft Housing, Replace
         • Check camshaft housing for plane surface
         • Cylinder Head, Remove and Install
         • Cylinder Head, Check for Plane Surface
         • Attaching Parts - Cylinder Head, Remove and Install
         • 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
       • Specifications1 page

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

         • Hydraulic Valve Lifter, Remove and Install
         • All Valve Tappets/Hydraulic Valve Lifters, Replace
       • Rocker Arm › Repair Instructions › Removing and installing roller cam followers
       • Camshaft › Repair Instructions8 pages

         • Seal Ring - Camshaft, Replace
         • Camshaft Sprocket, Remove and Install
         • Removing and installing both camshafts
         • Replace EGR valve
         • Replace camshaft sensor
         • Camshaft Sprocket, Replace
         • Camshafts, Remove and Install
         • Seal Ring - Camshaft, Replace
         • Camshaft Sprocket, Replace
         • Removing and installing both camshafts
         • Valve Stem Seals, Replace
       • Camshaft Housing › Repair Instructions7 pages

         • Camshaft Housing Cover, Remove and Install
         • Camshaft Housing, Replace
         • Check camshaft housing for plane surface
         • Camshaft Housing, Remove and Install
         • Check camshaft housing for plane surface
         • Engine cover, remove and install
         • Seal camshaft housing in respect of cylinder head
         • Removing and installing both camshafts
         • Camshaft Housing, Replace
       • Valves › Repair Instructions2 pages

         • Check and adjust valve play
         • Valve Stem Seals, Replace
         • Valve Stem Seals, Replace
         • Check and adjust valve play
       • Intake manifold › Repair Instructions1 page

         • Replace intake manifold
         • Replace intake manifold
         • Replace intake manifold
       • Exhaust manifold › Repair Instructions3 pages

         • Exhaust Manifold with Turbocharger, Replace
         • Removing and installing exhaust manifold with turbocharger
         • Exhaust Manifold, Remove and Install
       • Glow plugs › Repair Instructions › Sheathed Glow Plugs, Replace
     • Vacuum Pump › Repair Instructions4 pages

       • Vacuum Pump, Remove and Install
       • Vacuum Pump, Remove and Install
       • Replace engine oil filling nozzle
       • Vacuum Pump, Remove and Install
       • Vacuum Reservoir, Replace
       • Vacuum Pump, Replace
     • Toothed Belt17 pages

       • Repair Instructions13 pages

         • Toothed Belt Tension, Adjust
         • Timing, Check
         • Timing, Adjust
         • Replace front toothed belt cover (top)
         • Replace front toothed belt cover (lower)
         • Replace toothed belt
         • Replace toothed belt drivewheel
         • Replace rear toothed belt cover
         • Oil Pump Drive Gear, Remove and Install
         • Replace front toothed belt cover (top)
         • Replace toothed belt
         • Replace toothed belt drivewheel
         • High-Pressure Pump Drive Gear, Remove and Install
         • Toothed Belt Tension, Check and Adjust
         • Timing, Check
         • Timing, Adjust
         • Timing, Check
         • Timing, Adjust
         • Replace front toothed belt cover (top)
         • Replace front toothed belt cover (lower)
         • Replace toothed belt
         • Replace toothed belt drivewheel
         • Toothed Belt Tensioner, Replace
         • Replace toothed belt guide roller
         • Replace rear toothed belt cover
         • High-Pressure Pump Drive Gear, Remove and Install
       • Specifications1 page

         • Toothed belt
         • Toothed belt
         • Toothed belt
       • Tension Roller › Repair Instructions1 page

         • Replace toothed belt tensioner
         • Replace toothed belt tensioner
       • Guide Roller › Repair Instructions2 pages

         • Toothed Belt Guide Roller. Replace
         • Replace toothed belt guide roller
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