Work when refueling with unsuitable fuel Note: The fuel lines are connected with quick couplings. Fuel hoses may only be secured with spring clips. It is recommended to use clamp pliers to install spring clamps. Observe safety regulations. Follow the rules for...
Ground connection for fuel filler neck Lay the earth cable as shown in the figure. Check the security of the connector. Connector -2- of earth cable on threaded ring -3- of filler neck. Insert contact tongue -1- of earth cable into fixing hole of fuel tank...
Mounting position of the fuel supply module The arrow -3- on the fuel tank must point to the mark -2- on the ring nut -1-. Fuel lines on the fuel supply module 1. Fuel supply line 2. Fuel return line 3. Fuel line to metering pump -V54-
Fuel filter parts and assemblies 1. Fuel filter bottom with built-in bracket; follow the instructions for the fuel hoses in the engine compartment 2. Filter element; observe replacement intervals 3. Fuel filter top: with fittings; follow the...
Removing water from the fuel filter Note: Do not spill diesel fuel on the coolant hoses. In case of contact, the hoses must be cleaned immediately! The water removal valve is not available on all versions. Connect the transparent hose with the water...
Removal and installation of the fuel filter Switch off the ignition. If the fuel filter needs to be removed only because of tightness Disconnect fuel supply lines -1- and -2-. Unlock and disconnect the quick coupler. Remove fuel lines -1- and -2- from bracket...
Fuel hoses in the engine compartment Note: The fuel hose fittings on the fuel filter -1-, on the fuel temperature sender -2- and the quick-release couplings are equipped with a two-wave profile -arrows- and a crease lip. This improves the tightness of the...
Removing and installing fuel level sender -G- Remove the fuel supply unit. Disconnect connector -2- from the connecting flange, while releasing the connector locks. Detach cable holder from bracket -arrows A- and set aside. Unlock catches -1-, -3- -arrows B- and...
Removal and installation of the fuel tank, a / m with front-wheel drive Note: Empty the fuel tank. Move the front seats all the way forward. Switch off the ignition and remove the ignition key from the lock. Remove rear seat. Unlock cover clips -1- with wedge -3409- -arrows-. Remove sealing...
Removing and installing fuel pump control unit -J538- Move the front seats all the way forward. Switch off the ignition. Remove rear seat. Use the wedge -3409- -arrows- to release the fasteners of the cover -1- from the mounting. Remove sealing sleeve -1- from cover -2-...
Checking the fuel level sender -G- Move the front seats all the way forward. Switch off the ignition. Remove rear seat. Unlock cover clips -1- from retainer using wedge -3409- -arrows-. Disconnect connector -2- from the connecting flange, while releasing...
Parts and assemblies of a turbocharger with attachments 1. Hollow screw, 30 Nm 2. Oil supply line: check the patency; before installation, fill the turbocharger with engine oil through the oil pressure pipe fitting; consider catalog number 3. 12 Nm 4. Union nut, 22 Nm 5....
Removal and installation of a turbocharger For vehicles with engine code CRVC Carefully! In the event of mechanical damage to the turbocharger, such as a broken compressor impeller, it is not enough to simply replace the turbocharger. To avoid subsequent damage,...
Vacuum hose connection diagram 1. Vacuum pipeline 2. Check valve: install in the correct position; the light side is facing the cylinder head cover 3. Cylinder head cover: with vacuum drive 4. Vacuum drive: on the turbocharger; With turbocharger...
Parts and components of the intercooler 1. O-ring: replace after disassembly 2. Landing pin 3. 8 Nm 4. Sealing gasket: replace after disassembly 5. Bolt 6. Bracket: intake manifold 7. Bolt 8. Bolt: replace after disassembly 9. Landing pin 10.8 Nm 11. Intake...
Accelerator position sender -G79- and accelerator position sender 2 -G185- In the accelerator pedal module. 2. Electric connector of the accelerator pedal module Note: Accelerator position sender -G79- and accelerator position sender 2 -G185- are integrated in the accelerator pedal module and...
Electric connectors of the injection system 1. Charge pressure control solenoid valve -N75- 2. Exhaust gas temperature sender 4 -G648- 3. Exhaust gas temperature sender 3 -G495- 4. Exhaust gas temperature sender 2 -G448- for vehicles with engine code CRKB 5....
Details and components of the fuel system (general scheme) Note: Red color = fuel supply line. Blue color = fuel return line. Arrows point in the direction of fuel flow. 1. Fuel filter 2. High pressure fuel pump 3. Fuel metering valve -N290- 4. Fuel temperature sender -G81- 5....
Filling the fuel system with fuel / removing air from the system Carefully! To prevent the operation of the injection pump (precision, precisely matched parts) in dry friction mode and quickly start the engine after replacing parts, be sure to do the following. If any...
Parts and assemblies of nozzles (injectors) 1. O-ring: in the cylinder head cover; replace after removal 2. Copper washer: replace after disassembly 3. O-ring: replace after disassembly 4. Injector: re-installable injectors and high pressure fuel lines may only...
Details and components of the fuel rail 1. Fuel pressure sender -G247-, 100 Nm: Can be reused 2. Pressure line, 28 Nm: between the fuel rail (pressure accumulator) and nozzles; observe all instructions for the installation of high-pressure piping 3. Fuel rail...
Adapting the corrective values of the injectors Function "Correction of the amount of injected fuel (IMA) " designed to individually adjust the amount of fuel injected by the Common Rail system into each cylinder within the control range. 7-digit adaptation codes are...
Installation of fuel return lines Carefully insert the return line unions into the nozzles. The fitting should lock into place with a distinctly audible click. After that, you need to gently press the latches down. Check fuel system for leaks. Checking...
Removal and installation of nozzles Remove the top engine cover. Remove soundproofing. Pull the fuel return connector out of the injector by pulling the catches upwards -arrows-. Disconnect electrical connectors -arrows- from injectors. Note: One pressure...
High pressure pipe installation Note: Before removing, clean with cleaner "Kalireiniger" fuel line on the tip and dry them with compressed air. When reinstalling the high-pressure lines, observe the cylinder markings. The high pressure pipes can be...
Removal and installation of the fuel rail Removal of high pressure pipelines between the fuel rail and injection pump. Release fuel return hose -1-. Open retaining clips -arrows-, detach and remove guide well -2-. Disconnect electrical connectors. 1. Fuel...
Details and knots of the fuel pump of a high pressure 1. Attachment bracket 2. Bolt, 3 pcs: different lengths; replace after disassembly; tightening torque: short screw, 20 Nm and tighten by 45° (⅛ vol.), long screw, 20 Nm and tighten by 180° (½ vol.) 3. Toothed pulley...
Removal and installation of the high pressure fuel pump Remove toothed belt from camshaft. Removal of high pressure pipelines between the fuel rail and injection pump. Place stop -T10051- on sprocket of injection pump. Tighten nut -arrow- hand-tight. Pull out retainer...
Removing and installing fuel temperature sender -G81- Remove engine cover. Disconnect connector -1-. Unscrew fuel temperature sender -C81- -arrow-. Installation Installation in reverse order. Check fuel system for leaks.
Removing and installing air mass meter -G70- Remove engine cover. Unclip vacuum hoses -arrows- at breather pipe. Loosen clamps -1 and 2- and remove intake hose. Remove screw -1-. Turn air mass meter -G70- -pos 2- in -direction of arrow B- and remove. Installation...
Checking and replacing fuel pressure regulator -N276- Remove the top engine cover. Loosen clamp -arrow- and detach fuel return hose from fuel rail. Close the hole in the fuel return pipe with a plug. Connect the auxiliary hose -3- to the fuel return line of the fuel rail...
Removing and installing fuel pressure sender -G247- Remove the top engine cover. Attention! Before removing, clean threaded area around fuel pressure sender -G247- with lubricant solvent (ingress of dirt into the hole of the fuel rail is unacceptable). Work carefully -...
Details and components of the intake manifold 1. O-ring: replace after disassembly 2. Landing pin 3. 8 Nm 4. Sealing gasket: replace after disassembly 5. Bolt 6. Bracket: intake manifold 7. Bolt 8. Bolt: replace after disassembly 9. Landing pin 10.8 Nm 11. Intake...
Removing and installing throttle valve control unit -J338- Remove the top engine cover. Remove the air filter housing. Unscrew left and right screws -arrow-. Unhook and remove bottom part -1- of air duct. Remove screws -arrows-. Loosen clamp -2- and remove air duct -1-. For...
Removal and installation of an inlet collector Note: The intake manifold with the intercooler form a single piece. Remove the front upper coolant pipe. Remove the high pressure line. Remove air filter. Remove screws -arrows-. Loosen clamp -2- and remove air duct...
Air filter parts and assemblies 1. Airflow guide: at the bottom of the air filter 2. 2 Nm 3. Air intake bottom: on the front carrier 4. Air intake top: on the front carrier 5. Cover: air duct 6. 2 Nm 7. 1.5 Nm 8. The upper part of the air filter...
Removal and installation of the air filter Unscrew bolts -1, 3-. Release catch -arrow- and remove cover -2-. Release coolant hose -2-. Unlock catches -arrows-, remove top section of air duct -1-. Disconnect electrical connector -2- from mass air flow meter...
Front, middle and rear parts of the exhaust system, vehicles Euro 4 For vehicles with engine code CRVC 1. Gasket: replace after disassembly; position 2. Clamp, 7 Nm: replacement 3. Downpipe: adjusting the position of the elements of the exhaust system (stress-free installation) 4. 23 Nm...
Removal and installation of a reception pipe Remove the bottom cover of the tunnel. For vehicles with engine code CLHA, CLHB, CRKB, CKFB, CKFC, CUPA Disconnect connector -1-. All Release clutch -2- and push back. Remove bolts -1- Loosen screw -2- and remove...
Replacing the middle or rear muffler Note: On vehicles with torsion beam rear suspension, a split point for the exhaust pipe is provided to facilitate the removal of the exhaust system. The location of the connector is marked on the exhaust pipe by...
Adjusting Exhaust Parts to Relieve Stress When adjusting the position, the components of the exhaust system must not be hot. Loosen the screw connections of the coupling -2-. Press the parts of the exhaust system forward so that the displacement of the exhaust...
Parts and assemblies of the exhaust gas temperature control system Carefully! Loose flue gas temperature sensors lead to functional interference. The threads of the exhaust gas temperature sender -O495- and -G648- are coated. It is forbidden to cover them with additional refractory...
Removal and installation of exhaust gas temperature sensors Removing and installing exhaust gas temperature sensor 1-G235- Note: Install cable ties in the appropriate places. When removing, it is forbidden to cut the electrical wires, because. in this case it will no longer be...
Exhaust gas recirculation control motor -V338- — parts and assemblies For vehicles with engine codes CRKB, CRVC 1. coolant hose 2. Spring clamp 3. Exhaust gas recirculation control motor -V338-; with exhaust gas recirculation potentiometer -G212- 4. Gasket: Replace after removed 5....
Removing and installing exhaust gas recirculation control motor -V338- For vehicles with engine code CRVC, CRKB Remove throttle valve control unit -J338-. Disconnect connector -3-. Pinch the coolant supply hose with clamp -MP7-602 (3094) -. Loosen clamp -2- and remove coolant hose. Remove...
Removal and installation of a radiator of system recirculation OG For vehicles with engine code CRVC Remove the neutralizer. Drain coolant. Loosen clamp -1- and detach hose. Loosen the nuts - see arrows-. Secure the coolant pipe at the top, eg with cable clamps. Unscrew bolts -1-...
Pre-glow system — design description 1. Hall sender -G40- 2. 9 Nm 3. O-ring: not a spare part, if damaged, replace together with Hall sender -G40- 4. Glow plug: Glow plug 1 -Q10-. Glow plug 2 -Q11-, Glow plug 3 -Q12-. Glow plug 4 -Q13-; only for engines...
Removal and installation of glow plugs Note: This engine uses metal glow plugs. Glow plug versions 1. Glow Plug with Combustion Chamber Pressure Sensor - Cylinder 3 Engine Code CRKB Only 2. Glow plug without combustion chamber pressure sensor Switch off the...
Removing and installing Hall sender -G40- Remove the top engine cover. Unscrew bolts -arrows-, push fuel lines slightly forward. Disconnect connector -2-. Remove screw -1- and remove Hall sender -G40-. Installation in reverse order.
Removing and installing engine speed sender -G28- Remove soundproofing. Disconnect connector -1- using assembly tool -T10118-. Note: To remove the connector without the tool -T10118-, press the connector of the engine speed sensor with a screwdriver and at the same...