4.2L V8 5V Engine Mechanical, Engine Code(S): Bat, BNK

• 00 - General, Technical Data
  • Engine Number
    • Engine Number
    • Engine data
  • Engine Data
    • Engine Data
    • Fuel supply system, checking for leaks
  • Safety Precautions
    • Safety Precautions
  • General repair notes
    • Rules of cleanliness for performing work on fuel injection system
    • Fuel supply system, checking for leaks
    • Contact corrosion!
• 10 - Engine - Assembly
  • Engine, removing and installing
    • Engine, removing
    • Engine and transmission, separating
    • Engine, securing to assembly stand
    • Engine, installing
• 13 - Engine - Crankshaft, Cylinder Block
  • Engine, disassembling and assembling
    • Ribbed belt drive for generator
    • Ribbed belt, removing and installing
    • Vibration damper, removing and installing
    • Seal for crankshaft (ribbed belt side), replacing
  • Drive plate, removing and installing
    • Drive plate, component overview
    • Drive plate, removing and installing
    • Crankshaft seal (timing chain side), replacing
  • Timing chain covers
    • Timing chain covers, component overview
    • Timing chain covers, removing and installing
      • Notes
      • Removing
      • Installing
        • Notes
        • Left Timing Chain Cover, Tightening Sequence
        • Right Timing Chain Cover, Tightening Sequence
        • Lower Timing Chain Cover, Tightening Sequence
  • Camshaft drive
    • Camshaft drive
    • Camshaft timing chain, component overview
      • Left Camshaft Timing Chain, Component Overview
      • Right Camshaft Timing Chain, Component Overview
    • Camshaft timing chain, removing and installing
    • Camshaft timing chains, removing from camshafts
      • Notes
      • Installing
    • Drive chain for timing mechanism, component overview
    • Drive chain for timing mechanism, removing and installing
  • Power take-off
    • Chain for power take-off, component overview
    • Chain for power take-off, removing and installing
    • Power take-off, component overview
    • Seals for power take-off, replacing
    • Spur gear unit, removing and installing
  • Crankshaft, removing and installing
    • Crankshaft, component overview
      • Notes
      • Sealant applied on cylinder block (for guide frame)
      • Installation position of alignment bushings
      • Crankshaft Guide Frame, Torque Sequence
    • Allocation of main bearing shells for new crankshafts
    • Allocation of main bearing shells for used and reworked crankshafts
    • Crankshaft dimensions
    • Axial clearance, measuring
    • Radial clearance, measuring
  • Piston and connecting rod, disassembling and assembling
    • Piston and connecting rod, component overview
      • Notes
      • Piston ring end gap, measuring
      • Measuring piston ring side clearance
      • Checking piston
      • Measuring cylinder bore
      • Piston installation position
      • Mark connecting rod
      • Connecting rod, installed location
      • Oil spray jet for piston cooling
    • Oil spray jet for piston cooling
    • Connecting rod radial clearance, measuring
• 15 - Engine - Cylinder head, Valvetrain
  • Cylinder head, removing and installing
    • Cylinder head, removing and installing
      • Overview
      • Notes
      • Cylinder Head. Tightening Sequence
    • Cylinder head, component overview
      • Notes
      • Checking cylinder head for distortion
      • Reworking dimension, cylinder head
    • Left cylinder head cover, removing and installing
      • Notes
      • Installing
    • Right cylinder head cover, removing and installing
      • Removing
      • Installing
    • Compression pressures, checking
  • Intake manifold, removing and installing
    • Intake manifold, component overview
    • Intake manifold, removing and installing
  • Valvetrain, servicing
    • Valvetrain, servicing
    • Valvetrain, component overview
    • Camshafts, removing and installing
    • Camshafts, checking axial clearance
    • Roller rocker lever, removing and installing
    • Valve stem seals, replacing
    • Valve guides, checking
    • Valves, checking
    • Valve dimensions
    • Valve seats, reworking
• 17 - Engine - Lubrication
  • Lubrication system components, removing and installing
    • Lubrication system components, removing and installing
    • Oil pump, lower section of oil pan, component overview
      • Notes
      • Oil Level Thermal Sensor G266, removing and installing
    • Oil pan (lower part), removing and installing
    • Oil pump, removing and installing
    • Upper section of oil pan, component overview
    • Oil pan (upper part), removing and installing
    • Oil check valves and spray nozzle valve, component overview
    • Oil check valves and spray nozzle valve, removing and installing
    • Oil filter housing, component overview
    • Oil filter housing, removing and installing
    • Oil cooler, removing and installing
    • Oil pressure and oil pressure switch, checking
    • Engine oil
    • Oil level, checking
      • Notes
      • Range of markings on dipstick:
• 19 - Engine - Cooling system
  • Cooling system components, removing and installing
    • Cooling system components, removing and installing
    • Coolant hose connection diagram
    • Cooling system, draining and filling
    • Coolant pump and coolant regulator, component overview
      • Notes
      • Coolant thermostat installation location
    • Coolant pump, removing and installing
    • Coolant thermostat, removing and installing
    • Thermostat, checking
    • Coolant pipes, component overview
    • Front coolant line, removing and installing
    • Rear coolant line, removing and installing
    • Left coolant pipe, removing and installing
    • Radiator and coolant fan, component overview
    • Radiator, removing and installing
    • Fan shroud, removing and installing
    • Cooling system, checking for leaks
      • Notes
      • Pressure relief valve in cap, checking
    • Coolant fan, removing and installing
• 26 - Exhaust system, Emission controls
  • Exhaust system components, removing and installing
    • Exhaust system components, removing and installing
    • Exhaust system, assembly overview
      • Notes
      • Installed position of front double clamps
      • Installed position of rear double clamps
      • Individual suspension components, left side
      • Individual components of suspension, right side
      • Individual components of center bracket mounting for front exhaust pipe
    • Center muffler and rear muffler, separating
    • End pipe, replacing
    • Left front exhaust pipe (with catalytic converter), removing and installing
    • Right exhaust pipe (with catalytic converter), removing and installing
    • Left exhaust manifold, removing and installing
    • Right exhaust manifold, removing and installing
    • Exhaust system, installing free of tension
    • Tail pipes, aligning
    • Exhaust system, checking for leaks
  • Secondary Air Injection (AIR), servicing
    • Secondary Air Injection (AIR), servicing
    • Secondary air injection (AIR) system, overview
      • Notes
      • Installation location of Secondary Air Injection (AIR) Solenoid Valve N112
      • Component location of Secondary Air Injection (AIR) Pump Motor V101
      • Component location for Secondary Air Injection (AIR) Pump Relay J299
      • Combination valve for Secondary Air Injection (AIR)
    • Secondary Air Injection (AIR) Pump Motor V101, removing and installing
    • Combination valve for Secondary Air Injection (AIR), checking for function and leaks
    • Left combination valve for Secondary Air Injection (AIR), removing and installing
    • Right combination valve for Secondary Air Injection (AIR), removing and installing