SAFETY PRECAUTIONS
If special testing equipment is required during road test, note the following
| WARNING | Distraction and improperly secured test equipment can lead to accidents. There is a risk that the passenger airbag could deploy in a collision. Operating testing and measuring equipment while driving creates a distraction. There is an increased risk of injury due to unsecured testing and measuring equipment. Always secure testers on the rear seat with a strap and have a second person on the rear seat operate them. |
To reduce the risk of personal injury and/or damage to the fuel injection and ignition system, always observe the following
- Do not touch or remove ignition wires when engine is running or turning at starter speed.
- Always switch ignition off before disconnecting or reconnecting wires for the ignition system, including high voltage wiring and test leads.
- If engine is to be cranked at starting RPM without starting, disconnect the connectors from the ignition coils and fuel injectors. After performing work, check and erase DTC memory.
- Cleaning the engine should only be performed with ignition switched off.
- The battery must only be disconnected and connected with the ignition is switched off, since the Engine Control Module (ECM) can otherwise be damaged.
IGNITION SYSTEM
- The engine control module is equipped with On Board Diagnostics (OBD).
- For the electric components to work properly, a voltage of at least 11.5 Volts is required.
- It is possible that the control module will recognize a malfunction and store a DTC during some tests. Therefore after completing all checks and repairs the DTC memory must be checked and if necessary erased.
- If the engine only starts briefly and then turns off again after troubleshooting, repair or checking of the components, it may be that the immobilizer is blocking the Engine Control Module (ECM). DTC memory must then be checked and if necessary, control module must be adapted.
Scheme 7
- Ignition coil connector 4-pin
- Bolt 10 Nm
- 3-pin harness connector
- Camshaft Position (CMP) sensor Camshaft Position Sensor -G40- cylinder bank 1 Camshaft Position Sensor 3 -G300- cylinder bank 1 Camshaft Position Sensor 2 -G163- cylinder bank 2 Camshaft Position Sensor 4 -G301- cylinder bank 2
- O-ring Replace if damaged Coat with engine oil
- Bolt 20 Nm Tightening specifications affect function of Knock Sensor (KS)
- Knock sensors Contact surfaces between knock sensor and cylinder block must be free of corrosion, dirt and grease Knock Sensor (KS) 1 -G61- cylinder bank 1 Knock Sensor (KS) 2 -G66- cylinder bank 1 Knock Sensor (KS) 3 -G198- cylinder bank 2 Knock Sensor (KS) 4 -G199- cylinder bank 2 Removing and installing, refer to «KNOCK SENSORS»(ref-520193-S11157897532012123100000) .
- Spark plug Removing and installing with the Spark Plug Removal Tool 3122 B 30 Nm
- Ignition coil Ignition Coil 1 with Power Output Stage -N70- Ignition Coil 2 with Power Output Stage -N127- Ignition Coil 3 with Power Output Stage -N291- Ignition Coil 4 with Power Output Stage -N292- Ignition Coil 5 with Power Output Stage -N323- Ignition Coil 6 with Power Output Stage -N324- Ignition Coil 7 with Power Output Stage -N325- Ignition Coil 8 with Power Output Stage -N326- Removing and installing, refer to «IGNITION COILS»(ref-520193-S23850162282012123100000) To remove, use the Ignition Coil Puller T40039
IGNITION COILS
Special tools and workshop equipment required
- Ignition Coil Puller T40039
INSTALLING
Insert all ignition coils loosely into spark plug shaft.
Align the ignition coils to the connectors and then connect all of the connectors simultaneously onto the ignition coils.
Press the ignition coils uniformly onto the spark plugs by hand (do not use an impact tool under any circumstances).
Further installation is performed in reverse order.
REMOVING
| WARNING | Fuel system is under high pressure! Before opening high pressure components of the fuel injection system, pressure must be relieved to residual pressure. Refer to BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM . Then wrap a clean rag around the connection and relieve residual pressure by carefully loosening the connection. Observe safety precautions when disconnecting the battery. Refer to Removal and Installation . |
Remove intake manifold. Refer to INTAKE MANIFOLD .
Scheme 8
2 - Knock Sensor (KS) 1 -G61
9 - Knock Sensor (KS) 2 -G66
Scheme 9
8 - Knock Sensor (KS) 3 -G198
1 - Knock Sensor (KS) 4 -G199
Install the removed knock sensor.
Note. Tightening specifications affects function of Knock Sensor (KS).
Knock sensor tightening specification. Refer to IGNITION ASSEMBLY OVERVIEW .
Reinstall intake manifold. Refer to INTAKE MANIFOLD .
CAMSHAFT POSITION SENSOR
For the locations of the four camshaft position sensors. Refer to COMPONENT LOCATION OVERVIEW .
Disconnect the electrical connector on the respective camshaft position sensor.
Note. The following camshaft position sensors are installed in cylinder bank 1 (right): Camshaft Position (CMP) Sensor -G40- and Camshaft Position (CMP) Sensor 3 -G300- The following camshaft position sensors are installed in cylinder bank 2 (left): Camshaft Position (CMP) Sensor 2 -G163- and Camshaft Position (CMP) Sensor 4 -G301
Remove the air filter housing to remove the Camshaft Position (CMP) Sensor 3 -G300- on cylinder bank 1.
Remove the coolant reservoir to remove the Camshaft Position (CMP) Sensor 4 -G301- on cylinder bank 2.
Installing
Note. Replace the O-ring if damaged
Coat the O-ring with engine oil and carefully press the camshaft position sensor in by hand.
Tighten the camshaft position sensor and connect the electrical connector.
- Camshaft position sensor tightening specification. Refer to «IGNITION ASSEMBLY OVERVIEW»(ref-520193-S15547669222012123100000) .
Further installation is performed in reverse order.
Remove the noise insulation, to do this loosen the mounting parts -1, 2, 3-.
Scheme 10
Disconnect electrical connector -2-.
Scheme 11
Remove the bolt -1- and the Engine Speed (RPM) Sensor -G28
Installation is in reverse order of removal.