Mg5 ap32 principle and functions manual p1

Tài liệu sửa chữa xe MG5 model A32, cung cấp các thông tin cần thiết cho việc sửa chữa được nhanh chóng, hiệu quả, chính xác.

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For relevant information about product brands, part number or special tools mentioned in this manual, we recommendyou to contact with SAIC Motor Passenger Vehicle Co.

SAIC Motor Passenger Vehicle Co

Information is due in June 2021

Without prior written approval from SAIC Motor Passenger Vehicle Co., no part of the manual shall be reproduced,stored in retrieval system or transmitted in any form or by any means (including but not limited to electronic, mechanical,photocopy and recording) The statement above applies to all texts, illustrations and tables

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1 all AP32 Mexico & Peru

project release

New project release 2021.07

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Engine 1

Engine mechanical system-NF1 1.5T 1

Specifications 1

Parameters 1

Description and Operation 6

System Layout 6

Description 21

Operation 23

Engine mechanical system-NSE 1.5L 25

Specifications 25

Parameters 25

System Layout 33

Description 47

Operation 49

Engine Control System-NF1 1.5T 51

Specifications 51

Parameters 51

System Layout 53

System Control Diagram 56

Description 57

Detailed Information List of Component Pins 65

Engine Control System-NSE 1.5L 69

Specifications 69

Parameters 69

System Layout 71

Description 73

Engine Electrical System-NF1 1.5T 83

System Layout 83

Description 83

Operation 84

Engine Electrical System-NSE 1.5L 86

System Layout 86

Description 86

Operation 88

Engine Intake&Exhaust-NF1 1.5T 89

Operation 91

Engine Intake&Exhaust-NSE 1.5L 92

System Layout 92

Description 93

Operation 94

Engine Cooling System 95

Specifications 95

Parameters 95

System Layout 97

Description 103

Operation 105

Engine Fuel & Management System 108

System Layout 108

Description 109

Transmission 111

Shift Lock Control-MT 111

System Layout 111

Shift Lock Control-CVT 112

System Layout 112

Description 113

Shift Lock Control-DCT 115

System Layout 115

Description 117

Transmission-CVT 120

Specifications 120

Parameters 120

System Layout 121

Description 129

Operation 139

Transmission-DCT 152

Specifications 152

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Description 168

Operation 175

Transmission-MT 177

Specifications 177

Parameters 177

System Layout 179

Description 187

Operation 188

Cluth-MT 196

Specifications 196

Parameters 196

System Layout 197

Description 198

Operation 200

HVAC System 201

Specifications 201

Parameters 201

System Layout 203

Description 207

HVAC System-ETC 212

System Layout 212

Description 215

Operation 216

HVAC System-ATC 219

System Layout 219

Description 222

Operation 223

Steering System 227

System Layout 228

Description 232

Operation 233

Electric Steering Colum Lock 235

Description 237

Operation 238

Suspension System 241

Wheel Alignment 241

Specifications 241

Parameter 241

Description 242

Front Suspension 245

Specifications 245

Parameter 245

System Layout 246

Description 249

Rear Suspension 251

Specifications 251

Parameter 251

System Layout 252

Description 254

Type Pressure Monitoring System 255

System Layout 255

Description 256

Operation 257

Brake System 259

Brake 259

Specifications 259

Parameters 259

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Operation 262

Park Brake 265

System Layout 265

Description 268

Operation 269

Brake Module 270

System Layout 270

Description 273

Operation 274

Driveline/Axle 279

Driveline Axle 279

System Layout 279

Description 282

Interior Fitting 283

Seat 283

System Layout 283

Description 285

Operation 286

Exterior Fitting 287

Mirrors 287

System Layout 287

Description 289

Operation 290

Roof 291

System Layout 291

Description 293

Operation 294

Wipers and Washer 295

Description 298

Operation 299

Lighting Systems 301

Lighting 301

System Layout 301

Description 304

Operation 306

Lamps 309

System Layout 309

Description 312

Operation 313

Door System 315

Power Window 315

System Layout 315

Description 317

Operation 319

Body System 323

Body Control Module 323

System Layout 323

Description 326

Operation 327

Horn 332

System Layout 332

Safety and Restraints 335

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Description 338

Operation 339

Gateway 342

System Layout 342

Description 343

Operation 344

Seat Belts 346

System Layout 346

Description 350

Operation 351

Supplementary Restraint Systems 352

System Layout 352

Description 356

Operation 359

Park Assistant System 361

System Layout 361

Description 366

Operation 367

Rear Drive Assist System 372

System Layout 372

Description 374

Operation 375

Passive Entry and Passive Start 377

Operation 381

Driving Assistant System 384

System Layout 384

Description 386

Information and Entertainment 387

Entertainment and Navigation 387

System Layout 387

Description 390

Operation 392

Displays and Gauges 397

System Layout 397

Description 400

Operation 403

Power and Signal 405

Battery 405

Description 405

Glossary List 409

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Engine mechanical system-NF1 1.5T

Specifications

Parameters

1.5T Main Block

Type 1.5 turbocharged gasoline engine, 16-valve, DOHC, variable

intake and exhaust cam timing

Direction of Rotation Clockwise (view from the front of the engine)

Weight (including oil, without A/C, generator, etc.) 110kg (including oil, without A/C, generator, etc.)

1.5T Cylinder Block

Cylinder Block

Cylinder Liner Type Pre-cast mushroom head cylinder liner

Cylinder Liner Diameter Primary: Φ74±0.008mm

Other: Φ74±0.011mmCylinder Bore Out-of-roundness 0.013mm

Surface Flatness - Top Surface of Cylinder Block - Length up

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1.5T Crankshaft

Crankshaft

Connecting Rod Journal Diameter Φ44±0.008mm

Crankshaft Axial Clearance 0.15-0.38mm

Crankshaft Main Bearing Bore Diameter

Primary: Φ51.875±0.007mmOther: Φ51.875±0.011mmCrankshaft Main Bearing Clearance - #1 Bearing 0.017-0.053mm

Crankshaft Main Bearing Clearance - #2, 3, 4 and 5 Bearings 0.017-0.053mm

Crankshaft Main Journal Diameter Φ47±0.008mm

Crankshaft Main Journal Out-of-roundness 0.005mm

Runout of Main Journal 2, 3 and 4 Relative to Main Journal 1

Thrust Plate There is no separate thrust plate, it is integrated with the No.

4 upper main bearing shell to form a flanged bearing shell

1.5T Cylinder Head

Cylinder Head

Valve Seat Angle - Pressure Relief Surface 50° for exhaust and 56° for intake

Valve Seat Angle - Base Surface 90°

Valve Seat Angle - Bottom Section 120° for exhaust and 140° for intake

Hydraulic Tappet Type Hydraulic tappet, directly driven by camshaft

Hydraulic Tappet Outer Diameter Φ11.993±0.007mm

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1.5T Camshaft

Camshaft

Bearing 7-speed bearing for intake and 6-speed bearing for exhaust

Camshaft Journal Diameter - Journal 1 Φ30.935-Φ30.960mm

Camshaft Journal Diameter - Journal 2-6 Φ23.935-Φ23.960mm

Camshaft Journal Clearance 0.040-0.085mm

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1.5T Piston Connecting Rod

Piston and Pin

Piston Pin Clearance - Connecting Rod Bore 0.007-0.020mm

Piston Pin Clearance - Piston Pin Hole 0.0055-0.0135mm

Piston Diameter (38mm below the top of piston) Φ73.923-Φ73.937mm

Fit Clearance between Piston and Cylinder 0.055-0.085mm

Piston Pin Hole Diameter Φ19.005mm-Φ19.0105mm

Piston Ring Groove Width - Top Surface 1.23-1.25mm

Piston Ring Groove Width - Secondary Surface 1.22-1.24mm

Piston Ring Groove Width - Oil Control Surface 2.01-2.03mm

Piston Ring

Top Compression Ring Steel band ring, with ring height of 1.2 (-0.03, -0.01) mmSecond Compression Ring Cast iron ring, with ring height of 1.2 (-0.03, -0.01) mmOil Ring Three-piece oil ring, 2.0 (-0.13, -0.02) mm in height

Tolerance of Piston Ring to Ring Groove:

Top Compression Ring

Second Compression Ring

Oil Ring

0.04-0.08mm0.03-0.07mm0.03-0.16mmClearance of Piston Ring Assembly Notch:

Oil Ring

0.2-0.3mm0.3-0.5mm0.2-0.7mmConnecting Rod

Connecting Rod Bearing to Crankshaft Pin Clearance 0.002-0.042mm

Connecting Rod Bore Diameter - Bearing End Φ47.186-Φ47.202mm

Connecting Rod Bore Diameter - Piston Pin End (with bushing) Φ19.007-Φ19.017mm

Connecting Rod Side Clearance 0.09-0.57mm

1.5T Lubrication

Lubrication System

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Clearance between Valve Stem and Valve Guide:

Intake Valve

Exhaust Valve

0.025-0.065mm0.035-0.075mmValve Stem Mating Height:

New Intake Valve

New Exhaust Valve

104.64±0.13mm103.67±0.13mmValve Head Diameter:

Intake Valve

Exhaust Valve

Φ28±0.13mmΦ23.3±0.13mmValve Thickness:

Intake Valve

Exhaust Valve

1.79±0.18mm1.97±0.18mm

Distance between Valve Seal Lip and Spring Seat Bottom (a) 16.9mm

Valve Stem Diameter (Intake Valve)

Valve Stem Diameter (Exhaust Valve)

Φ4.965±0.01mmΦ4.955±0.01mmAngle of Valve Surface - Intake and Exhaust Valves 46°±0.25°

Valve Spring:

Free Length

Installation Length

Assembly Load

Intake Valve Opening Load

Exhaust Valve Opening Load

45.3mm35mm250N462N462N

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Description and Operation

System Layout

Engine Layout - 1.5T

1 1.5T Engine

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Exploded ViewViewView ofofof CylinderCylinderCylinder BlockBlock Block - 1.5T1.5T

1 Piston Ring

2 Connecting Rod Bearing Shell

3 Bolt - Engine Connecting Rod

4 Crankshaft Bearing Assembly

5 Piston Cooling Nozzle Assembly

6 Bolt - Lower Crankcase

7 Bolt - Main Bearing Cover

11 Lower Crankcase Locating Pin

12 Cylinder Block Water Jacket Plug

13 Engine Cylinder Block Oil Passage Hole Pug

14 Crankshaft Assembly

15 Crankshaft Torsional Vibration Shock Absorber Button

16 Piston Assembly (with pin)

17 Piston Pin Retaining Ring

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21 Locating Pin - Transaxle

22 Crankshaft Signal Wheel

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Exploded ViewViewView ofofof CamshaftCamshaftCamshaft CoverCover Cover - 1.5T1.5T

1 Oil Filler Cap Assembly

2 Sealing Ring for Oil Filler Cap

3 Camshaft Cover Assembly

4 Crankcase Pressure Regulating Valve Assembly

5 Crankcase Pressure Regulating Valve Assembly

6 Bolt - Camshaft Position Sensor

7 Camshaft Position Sensor

8 Bolt - Camshaft Cover

9 Fixing Sleeve - Camshaft Cover Bolt

10 Stud - Camshaft Cover

11 Bolt - Camshaft Position Actuator Solenoid Valve

12 Camshaft Position Actuator Solenoid Valve Assembly

13 Stud - Camshaft Cover

17 Camshaft Cover Gasket

18 Gasket - Camshaft Position Actuator Solenoid Valve

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Exploded ViewViewView ofofof CylinderCylinderCylinder HeadHead Head - 1.5T1.5T

1 Engine Cylinder Head Assembly

2 Camshaft Cover Check Valve

3 Cylinder Head Oil Passage Plug

4 Bolt - Camshaft Bearing Cover

8 Cylinder Head Plug

9 Exhaust Valve

10 Intake Valve

11 Valve Spring Cap

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15 Valve Stem Oil Seal

16 Exhaust Camshaft Assembly

17 Intake Camshaft Assembly

18 Front Engine Hoisting Bracket

19 Rear Engine Hoisting Bracket

20 Rear Engine Hoisting Bracket

21 Screw - Rear Engine Hoisting Bracket

22 Screw - Front Engine Hoisting Bracket

23 Engine Rocker Assembly

24 Valve Tappet Assembly

25 Cylinder Head Liner

26 Cylinder Head Bolt

27 Cylinder Head Locating Pin

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Exploded ViewView ofView ofof OilOilOil PumpPump andPump andand OilOilOil FilterFilter Filter - 1.5T1.5T

1 Oil Pump Assembly

2 Oil Control Valve

3 Bolt - Oil Pump

4 Gasket - Oil Pump Suction Pipe

8 Oil Pump Gasket

9 Fixing Sleeve - Oil Pump Bolt

10 Locating Pin - Oil Pump

11 Bolt - Oil Pump Suction Pipe

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Exploded ViewViewView ofof Oilof OilOil PanPanPan - 1.5T1.5T

1 Oil Level Indicator Assembly

2 O-ring - Engine Oil Dipstick

3 Lower Crankcase Oil Baffle Assembly

4 Bolt - Lower Crankcase Oil Baffle

5 Fixing Sleeve - Crankcase Oil Return Pipe Bolt

6 Oil Pan Assembly

7 Oil Control Valve Harness Assembly

8 Locating Pin - Oil Pan

9 Bolt - Oil Pan

13 Oil Pan Assembly

14 Bolt - Oil Pan

15 Oil Pan Drain Plug Assembly

16 O-ring - Oil Pan Drain Plug

17 Crankcase Oil Return Pipe Assembly

18 Bolt - Crankcase Oil Return Pipe

19 O-ring - Crankcase Oil Return Pipe

20 Bolt - Engine Harness

21 Fixing Sleeve - Lower Crankcase Oil Baffle Bolt

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Exploded ViewViewView ofof Timingof Timing ChainTiming ChainChain SystemSystem System - 1.5T1.5T

1 Timing Chain Assembly

2 Timing Chain Guide Rail

3 Bolt - Timing Chain Guide Rail

11 Washer - Timing Chain Tensioner

12 Crankshaft Sprocket

13 Stud - Timing Chain Cover

14 Front Crankshaft Oil Seal

15 Locating Pin - Timing Chain Cover

16 Bolt - Timing Chain Cover

17 Bolt - Timing Chain Cover

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21 Oil Pump Chain Tensioner

22 Crankshaft Torsional Vibration Shock Absorber

23 Bolt - Crankshaft Sensor

24 Timing Chain Fuel Injector Assembly

25 Fixing Sleeve - Timing Chain Guide Rail Bolt

26 Bolt - Phase Modulator

27 Fixing Sleeve - Timing Chain Cover Bolt

28 Bolt - Oil Pump Chain Tensioner

29 Chain - Oil Pump

30 Camshaft Position Actuator Assembly

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Exploded ViewViewView ofof Intakeof Intake ManifoldIntake Manifold

1 Pipeline - Canister Solenoid Valve to Intake Pipe

2 Clamp - Canister Control Valve Pipeline

5 Canister Desorption Pipe

6 Canister Desorption Control Valve Assembly

7 Canister Solenoid Valve Pipeline Bracket

8 Bolt - Canister Desorption Control Valve Bracket

9 Intake Manifold Assembly

10 Intake Manifold Acoustic Enclosure Assembly

11 Intake Manifold Gasket

12 Clip - Intake Manifold Acoustic Enclosure

13 Pipeline Assembly - Canister Control Valve to Manifold

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Exploded ViewView ofView of Turbochargerof Turbocharger

1 Bolt - Turbocharger Water Outlet Pipe Bracket

2 Turbocharger Water Outlet Pipe Assembly

3 Pipe Clamp - Turbocharger Water Outlet Pipe

4 Turbocharger Water Outlet to Engine Water Outlet

Pipeline

5 Pipe Clamp - Turbocharger Water Outlet Pipe

6 Gasket - Turbocharger Coolant Pipe

7 Bolt - Turbocharger Coolant Pipe

8 Turbocharger Oil Return Pipe Assembly

9 Liner - Turbocharger Oil Return Pipe

10 Fixing Sleeve - Turbocharger Oil Return Pipe Bolt

11 Bolt - Turbocharger Oil Return Pipe

12 Liner - Turbocharger Oil Return Pipe

16 Bolt - Turbocharger Oil Inlet Pipe

17 Liner - Turbocharger Oil Inlet Pipe

18 Pipe Clamp - Turbocharger Oil Inlet Pipe

19 Fitting - Turbocharger Oil Inlet Pipe

20 Liner - Turbocharger Oil Inlet Pipe

21 Bolt - Turbocharger Heat Shield

22 Turbocharger Heat Shield

23 Stud - Turbocharger

24 Nut - Turbocharger

25 Turbocharger Assembly

26 Nut - Turbocharger Vent Valve Actuator

27 Turbocharger Vent Valve Actuator

28 Turbocharger Relief Valve

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Exploded ViewView ofView ofof WaterWater PumpWater PumpPump andandand ThermostatThermostat Thermostat

-1.5T

1 Locating Pin - Coolant Pump

2 Front Water Pump Cover Assembly

3 Oil Cooler Assembly

4 Gasket - Oil Cooler

5 Bolt - Coolant Pump

6 Bolt - Water Pump Housing

7 Bolt - Water Pump Housing

8 Bolt - Engine Water Outlet

9 Screw - Oil Cooler

10 Liner - Engine Water Outlet Pipe

11 Water Temperature Sensor Assembly

12 Bolt - Thermostat Housing

16 Thermostat and Housing Assembly

17 Liner - Engine Water Pump

18 Liner - Engine Water Pump

19 Liner - Turbocharger Cooling Pipe Connector

20 Turbocharger Cooling Pipe Connector

21 Engine Water Outlet

22 Fixing Sleeve - Engine Water Outlet Pipeline Bolt

23 Bolt - Engine Water Outlet Pipeline

24 Pipeline Assembly - Engine Water Outlet Pipe to WaterPump

25 Pipeline - Engine Water Outlet Pipe to Water Pump

26 Pipe Clamp - Engine Water Outlet Pipeline

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30 Engine Harness Bracket

31 Engine Water Pump Assembly

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Exploded ViewViewView ofof Accessoryof AccessoryAccessory BeltBelt SystemBelt SystemSystem - 1.5T1.5T

1 Auxiliary Drive Tensioner Assembly

2 Bolt - Tensioner

3 Front Engine Belt

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General

The engine is an in-line 4-cylinder, 16-valve, DOHC, timing

chain drive and electronically-controlled multi-point direct fuel

injection system

It mainly consists of cylinder block, cylinder head, crankshaft,

connecting rod, camshaft, etc The cylinder head is made of

cast aluminum and is connected to the cylinder block with 10

high-strength bolts passing through multiple cylinder gaskets

Cylinder Block

The cylinder block consists of an upper cylinder block and a

lower crankcase, which improves the rigidity of the cylinder

block and reduces the manufacture cost and vibration

The upper cylinder block is made of aluminum alloy precision

sand castings, and the four cast-in-place iron cylinder liners are

arranged in a straight line, so that the overall strength is high

and not easy to deform

The lower crankcase assembly includes a lower crankcase and

an oil pump The oil pump is assembled to the bottom of

the lower crankcase The oil passes through an oil filter with

a screen, and is pressurized by the oil pump, so that clean

oil without impurities is distributed to the main bearing and

cylinder head through the main oil passage of the engine body

for lubricating the crankshaft, connecting rod, camshaft and

other parts The joint surface of the lower crankcase and the

engine body is sealed with sealant and fixed with bolts

Cylinder Head

The cylinder head adopts a four-valve structure for each

cylinder, and the spark plug is arranged in the center of the

combustion chamber Due to the overhead valve structure,

a strong vortex is formed in the combustion chamber, so

that the mixed gas is evenly distributed, flame propagation

is facilitated, and the combustion condition is improved,

thereby improving the dynamic performance, fuel economy

and emission performance of the engine

The camshaft drives the roller rocker arm, one end of which

is supported by the hydraulic tappet and the other end is

supported by the valve stem The valve is driven by the torque

of the rocker arm The valve clearance can be automatically

compensated by the hydraulic tappet The valve stem oil seal

is press-fitted on the oil seal base of the cylinder head and can

be used as a valve spring base to support the valve spring

The exhaust valve is carbon deposit-free The valve stem with

processed side can remove carbon deposit at the end of valve

guide and in the combustion chamber, thus preventing the valve

The multi-layer metal cylinder gasket has a press ring structure

at the cylinder port, which strengthens the sealing at thecylinder port

There are four oil passages, one oil inlet passage, one oil returnpassage and two working oil passages at the camshaft frontbearing The oil enters the oil control solenoid valve via theoil passage A camshaft signal wheel is fitted at the tail end

of the camshaft to provide signals for the camshaft positionsensor The exhaust camshaft is provided with a tail groovefor assembling a mechanical vacuum pump

A phase modulator is fitted at the drive ends of the intake andexhaust camshafts and fixed by bolts

Two phase modulator control valves are installed on thecamshaft cover control valve housing, sealed with an O-ringand fixed with a bolt respectively The control valve is afour-way proportional valve, including an oil inlet port, an oilreturn port and two oil passages connected with the workingchamber

Crankshaft

The crankshaft is a forged steel crankshaft equipped with 8balance weights and supported by 5 bearing shells The endfloat is controlled by the thrust washer on the top of No 4main bearing shell The crankshaft shock absorber is used tocontrol torsional vibration

The main bearing journal adopts a bored design, the upperbearing adopts a groove design, and the oil groove provided inthe upper half of the main bearing shell supplies oil to the bigend bearing shell of connecting rod through the oil hole in thecrankshaft

Connecting Rod and Piston

The aluminum alloy thermal expansion piston is equipped with

a floating piston pin, which is in clearance fit with the small end

of connecting rod, and both ends of the piston pin are fixed andlimited by circlips Each piston is fitted with two compressionrings and one oil ring

The powder metallurgy connecting rod has a structure of "H"section The big end of the connecting rod moves on thebearing shell of the crankshaft journal Forging and crackingtechnology are adopted for the connecting rod

Oil Pan

The oil pan is composed of aluminum die casting (upper part

of oil pan) and iron die casting (lower part of oil pan) Theupper part of the oil pan is provided with an oil pump controlvalve connector, fixed on the lower crankcase, and connectedand fixed with the transmission to provide additional structural

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Engine Accessory

The accessory is a single 5-wedge belt drive system driven by

the crankshaft pulley to drive the water pump, alternator and

A/C compressor, and the belt is tensioned via the mechanical

damping tensioner

High Pressure Common Rail and Direct Injection

System

Compared with PFI engine, the direct injection gasoline engine

avoids wet wall of the intake passage, facilitates accurate

measurement of the fuel, reduces the emission of HC during

cold start accordingly, and improves its own transient response

speed

The fuel injection system mainly includes high-pressure fuel

pump, high-pressure fuel pipe, fuel rail, rail pressure sensor

and fuel injector

The high-pressure fuel pump is driven by the overhead cam to

pump high-pressure fuel into the fuel rail through the fuel pipe

The fuel injector injects fuel in the rail into the cylinder at a

certain pulse width The rail pressure sensor returns a signal of

pressure in the rail to ECU, and ECU controls the pressure in

the fuel rail through the high-pressure fuel pump The pressure

of the engine fuel injection system is 35MPa ECUThe spray

shape and fuel injection volume are controlled by controlling

the rail pressure and fuel injection pulse width to meet the

requirements of different conditions for injection

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The lubrication system is a full-flow filtration, forced oil supply

system Oil is drawn from the oil pan through the oil strainer

by the oil pump, and the strainer is equipped with a screen

which can prevent impurities from entering the oil pump

The oil pump with an oil pump control valve is driven by the

crankshaft by using the chain When the oil pressure achieves

maintaining the oil pressure within a certain operating rangeand ensuring the normal operation of the engine

The pressurized oil flows out from the oil pump outlet, thenenters into the oil filter through the lower crankcase oilgallery, then into the main oil gallery of engine block, oil isdistributed to the crankshaft, piston cooling nozzle and timingchain cooling nozzle The grooves around each upper main

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cylinder head, then enters into each oil supply hole of the

camshaft The cast channel supplies oil to each hydraulic

component adjuster, and the drilled channel supplies oil to

the surface of each camshaft bearing The oil flows back to

the oil pan through the cast channel in the cylinder head The

timing chain lubricant is discharged into the oil pan directly All

other moving parts can be lubricated through gravity flow or

splash-down The engine oil switch is installed at the tail end

Turbocharger

It is high temperature and high pressure exhaust gas exhausted

from the engine, and the exhaust gas has a certain energy

In a naturally aspirated engine, this part of energy is often

wasted with exhaust emissions The turbocharger is an

exhaust-driven component, which provides compressed air

(pressurized air) to the engine block, so as to increase its

volumetric efficiency, and the power source of exhaust gas

turbocharger is mainly the exhaust gas The turbine impeller

and the compressor impeller are in rigid connection through

the turbocharger shaft, and this part is called the turbocharger

rotor The turbocharger rotor is fixed in the turbocharger

through the floating bearing (which can guarantee a smaller

friction resistance torque in rotor high-speed rotation)

When the engine operates, the exhausted gas impacts on the

turbocharger impeller at a certain angle at a high speed, so

that the turbocharger rotor rotates at a high speed (up to tens

of thousands of revolutions per minute) Through high-speed

rotation of the compressor impeller, the compressor draws

air from the air filter and forces compressed air into the

intake manifold through the intercooler, and the air pressure

in the intake manifold rises to achieve the pressurization

effect So air will be exposed to greater pressure in the intake

process, so that more, denser air enters the cylinder In this

way, fuel can be combusted more adequately, and the engine

performance is improved

High-pressure oil supplied from the engine provides lubrication

for the bearings, and returns to the oil pan through the oil

return pipe The exhaust gas from the turbocharger goes

into the three-way catalyst converter The boost pressure

is controlled by the exhaust valve The exhaust valve in the

turbocharger provides a bypass for the gas driven by the

turbine, to limit the pressure into the engine when the output

of the turbocharger exceeds the engine volume flow The

pneumatic actuator controls the exhaust valve and responds

to the signals sent by the boost control solenoid valve by

by-pass regulation of the boost pressure of turbocharger

Because of high temperature of the gasoline engine

turbocharger, the turbocharger is cooled by water-cooling

is called gas blow-by Such gases mainly contain unburned

hydrocarbon (HC), which will pollute engine oil and form

overlarge crankcase pressure at high engine speed, causingoil leakage from seals and gaskets The crankcase breathersystem is just used to bring such gases into the air intakesystem from the crankcase

The main channel PCV valve (check valve 1), installed in

the camshaft cover at the engine intake side, has the cut-offfunction, when the turbocharger starts operating, the valvebody closes the channel to prevent gas backflow When theturbocharger does not operate, the gas in the crankcaseenters the intake manifold through the valve

Secondary PCV valve (check valve 2) is installed at the lateral

part of the camshaft cover at the engine intake side and

connected to the turbocharger air inlet pipe and fresh air PCV valve through PCV pipes When the crankcase pressure is greater than 1KPa, the secondary PCV valve starts operating,

the valve body opens the channel and supplies excessiveabnormal piston blow-by in the crankcase into the air inletpipe through the PCV pipe to ensure crankcase pressurebalance

Fresh air PCV valve (check valve 3) is installed at the top of

the camshaft cover at the engine exhaust side, and connected

to the turbocharger air inlet pipe and Secondary PCV valve

through PCV pipes When the crankcase pressure is less than-1KPa, the fresh air PCV valve starts operating, the valve bodyopens the channel for introducing filtered fresh air into thecrankcase to ensure crankcase pressure balance

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Engine mechanical system-NSE 1.5L

Specifications

Parameters

1.5DVCT - Main Block

Model 1.5 L gasoline engine, with 16 valves, dual overhead camshaft,

variable intake/exhaust cam timingCylinder Arrangement 4-cylinder, in-line, transverse, 1st cylinder at the front of engine

Direction of Rotation Clockwise when viewed from engine front end

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Grade A

Grade B

53.690-53.700mm53.680-53.690mmMain Journal Tolerance:

Main Bearing Shell:

Model Steel backed, alloy steel and top half bearing shell has oil

passages

Thrust Washer Two halves of thrust washer on the left and right at the third

main bearing shell, sticks to the thrust surface

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1.5DVCT - Cylinder Block and Piston

Cylinder Block:

Material

Type of Cylinder Liner

Cylinder Liner Diameter

Distance Between Centres

Fractured Connecting Rod, Material C70S6143.7 ± 0.05mm

Piston Pin Model

Fitted Connecting Rod

Length

Full-floating typeClearance44.8-45mmConnecting Rod Bearing Shell:

Clearance

Axial Endplay

0.020-0.071mm0.100-0.246mmPiston:

0.005-0.013mm0.002mmPiston Ring:

Model:

Oil Ring

2 compression rings, 1 oil ringHalf-barrel faced excircle, PVD treated surfaceNose shaped, phosphate coated surfaceThree-piece oil ring, PVD treated bladeTolerance Between Piston Ring and Ring Groove:

Oil Ring

0.030-0.070mm0.03-0.16mm

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Piston Ring Assembly Clearance in Bore (measured at 20mm

from cylinder liner bore):

Oil Ring

0.20-0.30mm0.40-0.60mm0.20-0.70mm

Width of Piston Ring:

Oil Ring

0.970-0.990mm0.970-0.990mm1.870-1.980mm

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1.5DVCT Cylinder Head and Valve

Cylinder head:

Cylinder Head Height:

New

Flatness

118.95-119.05mm0.08mm

Camshaft:

Model Double overhead camshaft directly acted on mechanical tappet

Camshaft Axial Clearance:

Service Limit

0.06-0.19mm0.30mmBearing Clearance:

54.5°BBDC21°ATDC8.1mmValve:

Valve Stem Diameter:

Intake Valve

Exhaust Valve

f4.967-f4.981mmf4.957-f4.971mm

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Valve Stem Fit Height:

New Intake Valve

New Exhaust Valve

Service Limit

50.033-50.893mm49.948-50.808mm0.26mm

Valve Head Diameter:

Intake Valve

Exhaust Valve

f30.02-f30.18mmf25.6-f25.8mm

Valve Seat Width

Intake Valve

Exhaust Valve

Valve Seat Surface Angle - Intake Valve & Exhaust Valve

1.1mm-1.3mm1.369mm-1.828mmIntake 150°, 90°, 65°

Exhaust 90°, 60°

Valve Surface Angle - Intake Valve & Exhaust Valve 45°

Intake Valve: 0.17-0.23mmValve Clearance

Exhaust Valve: 0.27-0.33mmValve Spring:

Exhaust Valve Open Load (L2=28mm) 291±14.6Nm

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Lubrication:

Oil Pump Model:

Outer and Inner Rotor Mesh Clearance

Rotor to Pump Cover End Clearance

Driven by belt0.03-0.11mm0.05-0.086mmFree Length of Pressure Relief Valve Spring 67.95 ± 1mm

Cutoff Pressure of Pressure Relief Valve at 3500rev/min 540-660 kPa

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Usage Times of Bolt

Bolt - Main Bearing CoverScrew - Crankshaft Sensor Signal Wheel

Bolt - Connecting RodBolt - Oil Pump to Oil PanStud - Intake Manifold to Cylinder Head

Cylinder Head BoltBolt - Cylinder Head to Engine Block

Bolt - Crankshaft Shock Absorber

Bolt - Front Cover to Cylinder Head

Bolt - Lower Front Cover to Engine Block

Bolt - FlywheelBolt - TensionerHexagonal Flange Bolt - Exhaust Manifold

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Description and Operation

System Layout

NSE Engine Layout

1 1.5DVCT Engine

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4 Main Bearing (Upper)

5 Main Bearing (Lower)

6 Connecting Rod Big End Bearing

7 Main Bearing Thrust Plate

8 Cylinder Block Rear End Surface Cover Plate

9 Crankshaft Sensor Signal Plate

10 Crankshaft Rear Oil Seal

11 Screw - Crankshaft Sensor Signal Plate

12 Bolt - Crankshaft Rear Oil Seal

13 Location Pin - Crankshaft Sensor Signal Plate

14 Location Pin - Between Crankshaft and Flywheel

15 Location Pin - Cylinder Block to Transmission Case

16 Location Pin - Front Cover to Cylinder Block

17 O-ring - Lower Crank Case to Cylinder Block (Oil

Passage)

18 Plug - Oil Passage

22 Location Pin - Main Bearing Cap

23 Bolt - Main Bearing Cap

30 Main Bearing Cap

31 Main Bearing Cap

Tiêu đề	principle and functions manual mg gt
Trường học	saic motor passenger vehicle co.
Thể loại	manual
Năm xuất bản	2021

Định dạng
Số trang	415
Dung lượng	22,08 MB