Mg5 ap32 refit and remove manual p8

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Engine Control System-NF1 1.5T Engine

8 Fit 2 nuts xing the high-pressure fuel pipe to the fuel

pump and the fuel rail,, tighten them to28-32Nm, and

check the torque

9 Fit the engine heat shield

10 Fit the bonnet

11 Connect the negative battery cable

Fuel Rail

RemoveCaution:

1 Disconnect the negative battery cable

2 Remove the bonnet

3 Remove the engine trim pad

4 Place absorbent rags around the fuel rail high-pressurefuel pipe to collect any spilled fuel

Warning: Fuel vapour is highly ammable and in con nedspaces is also explosive and toxic Always have a reextinguisher containing foam, CO2, gas or powder closeWarning: The spilling of fuel is unavoidable during thisoperation Ensure that all necessar y precautions aretaken to prevent re and explosion

5 Slowly loosen the high-pressure fuel pipe nut at the end

of the high-pressure fuel rail until fuel ows out When

no fuel ows out, remove the nut

6 Remove the rag from the high-pressure fuel rail andplace it in a permitted container

Caution:

7 Remove the connecting nut of the high-pressure fuelpipe on the high-pressure fuel pump, remove anddiscard the high-pressure fuel pipe

Caution: Always t plugs to open connections to preventcontamination

8 Disconnect the fuel rail harness from the engineharness

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13 Remove 8 bolts (3) xing the fuel rail to the cylinder

head, and remove the fuel rail

Re t

1 Seat the fuel rail assembly, and align the fuel injectors

and the 8 bolts of the fuel rails with their mounting

holes respectively Press down to allow the injector

interfaces on the fuel rail fully engage with the 4

injectors until the mounting surfaces of bolts 8\4\2\6

are in contact with the cylinder head

2 Tighten 8 bolts manually according to the sequence

of 8-4-2-6/7-3-1-5 Circularly tighten 8 bolts in the

sequence of 1-8 Torque shall be applied twice, the

rst tightening shall reach half of the nal torque, and

the second tightening shall reach the nal torque The

torque of 8-4-2-6 bolts shall be8-12Nm, and the

torque of 7-3-1-5 bolts shall be 21–29 Nm Finally,

check the torque

3 Connect the fuel injector connectors

4 Fit the ignition coil

IgnitionIgnition CoilCoilCoil RemoveRemoveRemove &&& RefitRefit

5 Connect the fuel rail harness to the engine harness

6 Fix the new high-pressure fuel pipe to the fuel rail and

the high-pressure fuel pump, t 2 nuts, tighten them to

23–27 Nm and check the torque

7 Connect the fuel rail pressure sensor connector

9 Fit the bonnet

Fuel Injector

Remove

1 Remove the fuel rail assembly

FuelFuel RailRail RemoveRail Remove

2 Remove 4 injectors with the special toolTPT00238and discard 16 injector seal rings

Re t

1 Clean the grooves on fuel injectors and fuel rails

2 Put the special toolTEN00152-04 into the injectorand place it at the bottom

Caution:

3 Hold the injector with the special toolTEN00152-01,and press the seal ring slowly into the injector groovewith ngers

4 Hold the injector with the special toolTEN00152-02,and press the seal ring slowly into the injector groovewith ngers

5 Use the special toolTEN00152-03 to pre-clamp theseal ring of the fuel injector to make it shrink Duringpre-clamping, it needs to rotate 90 degrees and stay for

2 times, each time for 3–5 minutes

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6 Rotate and pull out the special toolTEN00152-04

from the bottom When the seal ring completely enters

the shrinking passage of the special tool, stay for more

than 5 min utes and then pull the special tool out

7 Fix 4 fuel injectors to the fuel rail and insert pins to

t them in place Special tools can be used when

necessaryTPT00238

8 Fix the fuel injectors into the fuel injector seat holes on

the cylinder head and t them in place

9 Fit the fuel rail assembly

FuelFuel RailRailRail RefitRefit

Spark Plug

Remove

1 Remove the ignition coil

IgnitionIgnition CoilCoil RemoveCoil Remove

2 Clean the area around the spark plug Remove the dustaround the spark plug with high-pressure gas

3 Remove 4 spark plugs with the spark plug socket

Re t

1 Identify the model of the original spark plug beforetting a new one Spark plug of the same model shall

be selected for replacement

2 Fit the spark plug, tighten it to20Nm, and check thetorque

IgnitionIgnition CoilCoil RefitCoil Refit

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Engine Control Module (ECM)

Remove

2 Disconnect the connectors (1) and (2) from theECM

Caution: ECM

3 Remove 4 bolts (3) xing theECM to the battery baf e

4 Remove the ECM

Re t

1 Fix theECM to the battery baf e, t 4 bolts, tighten

them to8-10Nm, and check the torque

2 Fix the wire harness and connect it to theECM

connector

Caution: ECM

4 Programme and encodeECM Refer to Module

Self-learning and Programming Manual, "Engine Control

Module (ECM)"

Ignition Coil

Remove

2 Remove the engine cover

3 Remove the engine heat shield

4 Disconnect 4 ignition coil connectors

5 Remove 4 bolts xing the ignition coil to the cylinderhead

6 Hold the rubber bush end of the ignition coil, and pullout the ignition coil from the spark plug (if it is dif cult

to pull out, you can loosen the ignition coil, left andright)

Re t

1 Fit 4 ignition coils to the spark plug, t 4 retaining bolts,tighten them to8–12Nm, and check the torque

2 Connect the ignition coil connector

4 Fit the engine cover

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Crankshaft Position Sensor

Remove

2 Raise the vehicle on a lift

3 Disconnect the connector of the crankshaft position

sensor

4 Remove 1 bolt xing the cranks haft position sensor

to the cylinder block

5 Remove the crankshaft position sensor

Re t

1 Clean the junction surface of the crankshaft position

sensor and the cylinder block

2 Fix the cranks haft position sensor to the cylinder block,

t 1 bolt, and tighten it to8–12Nm

3 Connect the crankshaft position sensor connector

4 Lower the vehicle

6 Place the start switch in "ON" position, and use the

SIPS to perform “ECM Self-learning Value Reset”

7 Wait 2–5 seconds, turn OFF the start switch, and then

restart the vehicle

Engine Coolant Temperature Sensor

Remove

2 Remove the coolant expansion tank cap to release thepressure in the cooling system, and re t the cap.Warning: Since injur y such as scalding could be caused byescaping steam or coolant, do not remove the ller capfrom the coolant expansion tank while the system is hot

3 Disconnect the vacuum hose from the vacuum pumpand remove the vacuum hose

4 Loosen the retaining clip of the coolant temperaturesensor

5 Disconnect the connector of the coolant temperaturesensor

6 Pull up and remove the coolant temperature sensor

7 Place a proper container to collect the over owingcoolant

Re t

1 Clean the coolant temperature sensor

2 Check the sensor seal washer for aging, deformation,crack, etc If any, replace the sensor assembly

3 Fit the coolant temperature sensor and secure withclips

4 Connect the connector of the coolant temperaturesensor

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Manifold Absolute Pressure Sensor

Remove

2 Disconnect the connector of the manifold absolute

pressure sensor

3 Remove 1 bolt xing the manifold absolute pressure

sensor to the intake manifold, and remove the manifold

absolute pressure sensor

Re t

1 Fix the manifold absolute pressure sensor to the intake

manifold, t 1 bolt, and tighten it to4–6Nm

2 Connect the connector of the manifold absolute

pressure sensor

Oil Pump Control Valve Harness

Remove

2 Remove the engine oil lter

EngineEngine OilOil FilterOil FilterFilter RemoveRemove

3 Remove the oil pan

CrankshaftCrankshaft ShockShock AbsorberShock AbsorberAbsorber RemoveRemove

4 Disconnect the harness connector (1) of the engine oilpump control valve

5 Remove 1 bolt (2) xing the engine oil pump controlvalve

6 Disconnect the harness connector of the engine oilpump control valve

7 Remove the engine oil pump control valve

4 Fit the oil pan

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Camshaft Position Sensor

Remove

2 Remove the bonnet

4 Disconnect the connectors of the intake/exhaust

camshaft position sensors respectively

5 Remove 2 bolts xing the intake/exhaust camshaft

position sensors to the cylinder block respectively, and

remove the 2 camshaft position sensors

Re t

1 Clean the two camshaft position sensors and their

junction surfaces

2 Check the sensor seal washer for any aging,

deformation, crack, etc If any, replace the sensor

assembly

3 Fix the intake and exhaust camshaft position sensors

to the camshaft cover, t 2 bolts, tighten them to

8–12Nm

4 Connect two camshaft position sensor connectors

6 Fit the bonnet

8 Place the start switch in "ON" position, and use the

SIPS to perform “ECM Self-learning Value Reset”

Camshaft Phase Adjustment Solenoid Valve

Remove

2 Remove the engine cover

4 Disconnect the connectors of 2 camshaft phaseadjustment solenoid valves

5 Remove 2 bolts xing 2 camshaft phase adjustmentsolenoid valves to the engine

6 Remove 2 camshaft phase adjustment solenoid valves

4 Fit the engine cover

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Oil Pressure Sensor

Remove

2 Remove the starter motor

StarterStarter MotorMotorMotor Refit/RemoveRefit/Remove

3 Disconnect the connector of the oil pressure sensor

4 Place the oil sink under the sensor to collect the

over owing uid

5 Remove the oil pressure sensor with the socket

Re t

1 Clean the threads of the oil pressure sensor

2 Apply new sealant to the oil pressure sensor, t the oil

pressure sensor to the engine, tighten the sensor to

31–39Nm, and check the torque

3 Connect the connector of the oil pressure sensor

4 Fit the starter motor

StarterStarter MotorMotorMotor RefitRefit

6 Check the engine oil level, and re ll as needed

Knock Sensor

Remove

StarterStarter MotorMotorMotor RemoveRemove

3 Disconnect the knock sensor connector

4 Remove 1 bolt xing the knock sensor to the cylinderblock, and remove the knock sensor

3 Connect the knock sensor connector

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Oxygen Sensor

Remove

2 Disconnect the front oxygen sensor connector (1)

3 Remove the front oxygen sensor (2) from the three-way

catalytic converter with the special toolTEN00011

4 Remove 3 bolts xing the turbocharger heat shield to

the turbocharger, and rem ove the turbocharger heat

shield

5 Disconnect the rear oxygen sensor connector (1)

6 Remove the rear oxygen sensor (2) from the front

exhaust pipe with the special toolTEN00011

Re t

1 Fit the rear oxygen sensor on the front exhaust pipewith the special toolTEN00011, tighten them to40–60Nm, and check the torque

2 Fit 1 bolt xing the rear oxygen sensor connectorbracket to the transmission, and tighten it to16–20Nm

3 Connect the rear oxygen sensor connector

4 Fit 3 bolts xing the turbocharger heat shield to theturbocharger, tighten them to8-12Nm, and checkthe torque

5 Fit the front oxygen sensor on the three-way catalyticconverter with the special toolTEN00011, tightenthem to40–60Nm, and check the torque

6 Connect the front oxygen sensor connector

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Canister Solenoid

Remove

2 Disconnect the canister solenoid valve connector (1)

3 Disconnect the vacuum hose (2) from the canister

3 Connect the canister solenoid valve connector

4 Fix the canister solenoid valve to the canister solenoid

valve bracket of the cylinder block

Turbocharger Electrically Controlled BypassValve

Remove

2 Remove 3 bolts xing the turbocharger heat shield tothe engine

3 Remove 2 circlips xing the turbocharger push rod anddiscard them

4 Disconnect the turbocharger relief valve connector (1)

5 Remove 3 bolts (2) xing the relief valve to theturbocharger

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Re t

1 Fix the turbocharger relief valve to the turbocharger, t

3 bolts, tighten them to8Nm, and check the torque

2 Connect the connector of the turbocharger relief valve

3 Fit 2 new springs and the circlips for xing the

turbocharger push rod

4 Fit 3 bolts xing the turbocharger heat shield to the

engine, tighten them to8-12Nm, and check the torque

Turbocharger Relief Valve

Remove

2 Disconnect the turbocharger intake pipe from theturbocharger and remove the pipe

3 Disconnect the interface (1) at the end of turbocharger

- intercooler hose from the turbocharger and removethe pipe

4 Disconnect the connector of turbocharger relief valve

5 Remove 3 bolts xing the turbocharger relief valve tothe turbocharger

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Re t

1 Fix the turbocharger relief valve to the turbocharger,

t 3 bolts, tighten them to8-10Nm, and check the

torque

2 Connect the connector of the turbocharger relief valve

3 Connect the turbocharger - intercooler hose to the

turbocharger

4 Connect the turbocharger intake pipe to the

turbocharger and x it with clamps

Intake Air Temperature/Pressure Sensor

Remove

2 Remove 1 bolt xing the expansion tank to the body,and remove the expansion tank

3 Disconnect the intake air temperature and pressuresensor connector

4 Remove 1 bolt xing the intake air temperature andpressure sensor to the hose from intercooler to engine,and remove the intake air temperature and pressuresensor

Re t

1 Fix the intake air temperature and pressure sensor tothe hose from intercooler to engine, t 1 bolt, andtighten it to3–4Nm

2 Connect the connector of the intake air temperatureand pressure sensor

3 Fix the expansion tank to the body, t 1 bolt and tighten

it to4–6Nm

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Canister Desorption Pressure Sensor

Remove

2 Disconnect the harness connector (1) from the canister

desorption pressure sensor

3 Disconnect the breather pipe (2) from the canister

desorption pressure sensor

4 Remove 1 stud xing the canister desorption pressure

sensor to the bracket

5 Remove the canister desorption pressure sensor

Re t

1 Fit and tighten 1 stud xing the canister desorption

pressure sensor to the bracket

2 Connect the breather pipe to the canister desorption

Engine Harness

Remove

2 Disconnect the harness (1) from the ECM

3 Disconnect the harness (2) from the manifold absolutepressure sensor

4 Disconnect the harness (3) from the electronic throttle

5 Disconnect the harness (4) from the intake cam shaftposition sensor

6 Disconnect the harness (5) from the fuel rail

7 Disconnect the harness from the canister pressurediagnostic sensor

8 Disconnect the harness (1) from the canister solenoidvalve

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10 Disconnect the harness (1) from the starter motor.

11 Disconnect the harness (2) from the knock sensor

12 Disconnect the harness (1) from the high pressure fuel

pump

13 Disconnect the harness (2) from the oil pressure sensor

14 Disconnect the harness (1) from the crankshaft position

sensor

15 Disconnect the harness (2) from the oil pump control

valve

16 Disconnect the harness (1) from the ignition coil

17 Disconnect the harness (2) from the front oxygensensor

18 Disconnect the harness (3) from the exhaust camshaftposition sensor

19 Disconnect the harness (1) from the air ow meter

20 Disconnect the harness (2) from the turbocharger

21 Remove 1 screw (1) xing the grounding wire of theengine harness to the engine

22 Disconnect the harness (2) from the coolanttemperature sensor

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Re t

1 Connect the harness to the coolant temperature

sensor

2 Fit 1 screw xing the grounding wire of the engine

harness to the engine, tighten it to7-10Nm, and check

the torque

3 Connect the harness to the turbocharger

4 Connect the harness to the air ow meter

5 Connect the harness to the exhaust camshaft position

sensor

6 Connect the harness to the front oxygen sensor

7 Connect the harness to the ignition coil

8 Connect the harness to the oil pump control valve

9 Connect the harness to the crankshaft position sensor

10 Connect the harness to the oil pressure sensor

11 Connect the harness to the high pressure fuel pump

12 Connect the harness to the knock sensor

13 Connect the harness to the starter motor

14 Connect the harness to the generator

15 Connect the harness to the canister solenoid valve

16 Connect the harness to the canister pressure diagnostic

sensor

17 Connect the harness to the fuel rail

18 Connect the harness to the intake camshaft position

sensor

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Engine Control System-NSE 1.5L Engine Engine Control System-NSE 1.5L

Bolt - chain guide rail upper to cylinder head front cam

Bolt - timing chain tensioner to cyclinder head 18-22Nm +(22-28°)

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Service Procedures

Spark Plug

Remove

1 Remove the ignition coil

IgnitionIgnition CoilCoilCoil RemoveRemove

2 Clean the area around the spark plug, and clear the

dust around the spark plug with high-pressure gas

3 Remove 4 spark plugs with spark plug socket

Re t

1 Identify the model of original one before tting the

spark plug, and select the one of the same model for

IgnitionIgnition CoilCoilCoil RefitRefit

Ignition Coil

Remove

2 Disconnect the harness (1) from the ignition coil

3 Remove 4 bolts (2) xing the ignition coil to the engine

4 Hold the root of ignition coil rubber sheath, pull outthe ignition coil from the spark plug (if it is tough to pull

it out, you can unscrew it from left to right)

Re t

1 Fit 4 bolts xing the ignition coil to the engine, tightenthem to8-12Nm, and check the torque

2 Connect the harness to the ignition coil

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Engine Control System-NSE 1.5L Engine

Engine Control Module (ECM)

Remove

2 Disconnect the harness (1) from the ECM

Caution: ECM

3 Remove 4 bolts (2) xing the ECM to the battery baf e

Re t

1 Fit 4 bolts xing the ECM to the baf e, tighten them to

7-10Nm, and check the torque

2 Connect the harness to the ECM

Caution: ECM

4 Programme and encode ECM Refer to Module

Self-learning and Programming Manual, "Engine Control

Module (ECM)"

Engine Coolant Temperature Sensor (ECT)

Remove

2 Remove the coolant expansion tank cap to release thepressure in the cooling system, and re t the cap.Warning: Since injur y such as scalding could be caused byescaping steam or coolant, do not remove the ller capfrom the coolant expansion tank while the system is hot

3 Disconnect the harness connector (2)

4 Drain the coolant

CoolantCoolant DrainDrain

5 Remove the circlip (1) xing the engine coolanttemperature sensor

6 Remove the engine coolant temperature sensor

Re t

1 Clean the thread of the coolant temperature sensor

2 Fit the new seal washer to the coolant temperaturesensor

3 Fit the engine coolant temperature sensor and tighten

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Engine Oil Temperature Sensor

Remove

1 Disconnect the battery negative

2 Disconnect the harness connector from the oil

1 Clean the thread of the oil temperature sensor

2 Fit a new sealing washer to the oil temperature sensor

and tighten the switch to14-18Nm

3 Connect the temperature sensor connector

4 Remove the oil sink

5 Connect the battery negative

6 Check the engine oil level, and re ll if necessary

Crankshaft Position Sensor

Remove

2 Remove the bottom de ector

BottomBottom DeflectorDeflector RemoveDeflector Remove

3 Disconnect the harness connector from the crankshaftposition sensor

4 Remove the bolt xing the crankshaft position sensor

to the cylinder block

5 Remove the crankshaft position sensor

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Camshaft Position Sensor

Remove

2 Disconnect the harness connector from the camshaft

position sensor

3 Remove the bolt xing the camshaft position sensor,

remove the camshaft position sensor and discard the

O-ring

Re t

1 Clean the camshaft position sensor and mating surface,

and t an O-ring to the camshaft position sensor

2 Fit the camshaft position sensor to the cylinder head

and tighten the bolts to8-12Nm

3 Connect the camshaft position sensor harness

connector

Camshaft Phase Modulator

Remove

2 Drain the engine oil

EngineEngine OilOil FilterOil FilterFilter RemoveRemove

3 Remove the upper cover plate of the timing chain.Timing

Timing ChainChainChain UpperUpper CoverUpper CoverCover PlatePlatePlate RemoveRemove

4 Remove the lower cover plate of the timing chain.Timing

Timing ChainChainChain LowerLower CoverLower CoverCover PlatePlatePlate RemoveRemove

5 Remove the timing chain tensioner, and discard theseal washer

6 Remove the upper guide rail

7 Remove the oil control valve

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8 Remove and discard the intake/exhaust phase

modulator bolts

9 Remove the intake/exhaust phase modulators, and hang

the chain on the upper guide rail mounting boss

Re t

1 Rotate the ywheel until the ywheel pin hole is aligned

with the engine block pin hole

2 Inser tTEN00002 into the engineblock timing pin hole

and ywheel pin hole to lock the ywheel

3 Rotate the camshaft with the timing hole up, and x the

4 Locate the intake/exhaust camshaft phase modulator tothe camshaft, t the chains to both modulators, andpre-tighten the bolts

5 Fit the oil control valve

OilOil ControlControlControl ValveValve RefitValve Refit

6 Fit the upper guide rail to the front bearing cover ofthe camshaft, x with two bolts and tighten them to8-12Nm

7 Fit a new timing hydraulic tensioner washer, screw thetiming hydraulic tensioner into the cylinder head withthe tightening torque of18-22Nm+(22-28°)

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8 Fix the intake/exhaust phase modulators to the

camshaft and tighten the bolts to70-80Nm

9 Fit the lower cover plate of the timing chain

TimingTiming ChainChain LowerChain LowerLower CoverCoverCover PlatePlate RefitPlate Refit

10 Fit the upper cover plate of the timing chain

TimingTiming ChainChain UpperChain UpperUpper CoverCoverCover PlatePlate RefitPlate Refit

11 Re ll the engine oil

EngineEngine OilOilOil FilterFilterFilter RefitRefit

Oil Pressure Switch

Remove

3 Disconnect the harness connector from the oilpressure switch

4 Place the oil sink under the switch to collect the spilledoil

5 Remove the oil pressure switch

Re t

1 Clean the thread of the oil pressure switch

2 Fit a new seal washer to the oil pressure switch andtighten the switch to14-18Nm

3 Connect the harness connector of the oil pressureswitch

4 Remove the oil sink

5 Fit the bottom de ector

BottomBottom DeflectorDeflector RefitDeflector Refit

7 Check the engine oil level, and re ll as needed

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Knock Sensor

Remove

2 Disconnect the knock sensor harness connector

3 Remove the bolt xing the knock sensor onto the

cylinder block, and take away the sensor

Re t

1 Clean the mating surface of the knock sensor and the

cylinder block

2 Fit the knock sensor, ensure that the harness is properly

placed, and tighten the bolts to15-25Nm

3 Connect the knock sensor harness connector

Fuel Rail

Remove

2 Release the pressure of the fuel system

Warning: Fuel vapour is highly ammable and in con nedspaces is also explosive and toxic Always have a reextinguisher containing foam, CO2, gas or powder close

3 Disconnect the harness connector from the fuel railassembly

4 Release the fuel inlet pipe from the fuel rail

Caution: Always t plugs to open connections to preventcontamination

5 Remove 2 bolts xing the fuel rail to the intake manifold

Re t

1 Clean the fuel injector and the intake manifold groove

2 Locate the fuel rail assembly on the intake manifold, andpush each fuel injector into the corresponding hole ofthe intake manifold

3 Fix the fuel rail assembly to the intake manifold with 2bolts, and tighten the bolts to8-12Nm

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6 Connect the battery negative Fuel Injector

Remove

2 Disconnect the fuel injector harness connector

FuelFuel RailRailRail AssemblyAssemblyAssembly RemoveRemove

4 Release the spring clamp xing the fuel injector to thefuel rail, and remove the fuel injector

5 Remove 2 O-rings from each fuel injector, and discardthem

6 Fit the end cap to the end of each fuel injector

Re t

1 Remove the end cap from each fuel injector

2 Clean the groove of the fuel injector and fuel rail

3 Lubricate new O-rings with oil, and t them to bothends of each fuel injector

4 Fit the fuel injector to the fuel rail

5 Fix the fuel injector to the fuel rail with spring clamps

6 Fit the fuel rail assembly

FuelFuel RailRailRail AssemblyAssemblyAssembly RefitRefit

7 Connect the fuel injector harness connector

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Upstream Oxygen Sensor

Remove

2 Disconnect the harness (1) from the upstream oxygen

sensor

3 Remove the upstream oxygen sensor (2) with the

special toolTEN00011

Re t

1 Fit the upstream oxygen sensor with the special tool

TEN00011, tighten it to 40-60Nm, and check the

torque

Caution:

2 Connect the harness to the upstream oxygen sensor

Downstream Oxygen Sensor

Remove

3 Disconnect the downstream oxygen sensor connector(1)

4 Remove the downstream oxygen sensor (2) with specialtool TEN00011

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Manifold Absolute Pressure/Temperature Sensor

Remove

StarterStarter MotorMotorMotor RemoveRemove

3 Disconnect the harness connector of the manifold

absolute pressure/temperature sensor

4 Remove the bolts xing the manifold absolute

pressure/temperature sensor to the intake manifold,

and remove the sensor

Re t

1 Clean the junction surfaces of the manifold absolute

pressure/temperature sensor and the intake manifold

2 Fit the manifold absolute pressure/temperature sensor,

and tighten the bolts to4-5Nm

3 Connect the harness connector of the manifold

absolute pressure/temperature sensor

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Special Tools

Tool

Number Description Picture

TEN00002 Holding pinywheel timing

TEN00004 Camshaft timinglocking

TEN00011 Wrench O2sensor

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Engine Electrical System-NF1 1.5T Engine Engine Electrical System-NF1 1.5T

Speci cations

Torque

Nut-Battery positive cable to start motor 11–15Nm

Trang 30

Service Procedures

Auxiliary Drive Belt

Remove

BottomBottom DeflectorDeflectorDeflector RemoveRemove

2 Inser t the installer into the square hole in the tensioner,

pull the torque wrench counterclockwise to disengage

the tensioner from the belt

3 Remove the belt

4 Allow the tensioner to return slowly, and remove the

tool

Re t

1 Inser t the installer into the square hole in the tensioner

and counterclockwise pull the torque wrench

2 Fit the auxiliary drive belt into each pulley groove and

onto the tension pulley

3 Release the tensioner slowly, make sure the pulley shall

be basically located in the centre of each pulley after

installation, and a 2mm margin shall be kept on both

sides of the tension pulley

BottomBottom DeflectorDeflectorDeflector RefitRefit

Starter Motor

Remove

2 Disconnect the harness connector from the startermotor

3 Remove 1 nut xing the battery cable to the startermotor

4 Remove 1 bolt and 1 nut xing the starter motor tothe engine

Re t

1 Fit 1 bolt xing the starter motor to the engine, tighten

it to40-50Nm, and check the torque

2 Fit 1 nut xing the starter motor to the engine, tighten

it to40-50Nm, and check the torque

3 Fit 1 nut xing the battery cable to the starter motor,tighten it to11–15Nm, and check the torque

4 Connect the harness connector to the starter motor

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Engine Electrical System-NF1 1.5T Engine

Alternator

Remove

2 Remove the auxiliary drive belt

AuxiliaryAuxiliary DriveDriveDrive BeltBeltBelt RemoveRemove

3 Disconnect the harness connector of the alternator

4 Remove 1 nut xing the power cord to the alternator

5 Remove 3 bolts xing the alternator to the alternator

mounting bracket

6 Remove the alternator

Re t

1 Fit 3 bolts xing the alternator to the alternator

mounting bracket, tighten them to19-25Nm, and

Automatic Tension Pulley - Auxiliary Drive Belt

Remove

AuxiliaryAuxiliary DriveDrive BeltDrive BeltBelt RemoveRemove

2 Remove 1 bolt xing the auxiliary belt tensioner to thefront engine cover

3 Remove the auxiliary belt tensioner

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Engine Electrical System-NSE 1.5L

Trang 33

Engine Electrical System-NSE 1.5L Engine Service Procedures

Alternator

Remove

AuxiliaryAuxiliary DriveDriveDrive BeltBeltBelt RemoveRemove

3 Disconnect the harness (1) from the alternator

4 Remove 1 nut (2) xing the harness to the alternator

5 Remove 3 bolts (3) xing the alternator to the engine

Re t

1 Clean the junction surfaces between alternator, cylinder

head and cylinder block

2 Fit 3 bolts xing the alternator to the engine, tighten

them to40-50Nm, and check the torque

Caution:

3 Fit and tighten 1 nut xing the harness to the alternator

4 Connect the harness to the alternator

5 Fit the auxiliary drive belt

AuxiliaryAuxiliary DriveDriveDrive BeltBeltBelt RefitRefit

Auxiliary Drive Belt

Remove

1 Raise the vehicle to a suitable height for operation.Warning: Do not work on or under a vehicle supportedonlyby a jack.Always support the vehicle on safety stands

4 Inser t the tting tool into the square hole in thetensioner, pull the torque wrench counterclockwise todisengage the tensioner from the belt, the torque shallnot be greater than 82Nm

5 Remove the belt

6 Allow the tensioner to return slowly, and remove the

Trang 34

1 Inser t the tting tool into the square hole in the

tensioner, and counterclockwise pull the torque wrench

with the torque no more than 82Nm

2 Fit the auxiliary drive belt into each pulley groove and

onto the tension pulley and idler in the sequence as

shown

3 Release the tensioner slowly, make sure the pulley is

located in the centre of the tension pulley after re t, a

2mm margin shall be kept on both sides of the tension

pulley

4 Remove the tool

BottomBottom DeflectorDeflectorDeflector RefitRefit

7 Lower the vehicle

Auxiliary Drive Belt Tensioner

Remove

AuxiliaryAuxiliary DriveDrive BeltDrive Belt RemoveBelt Remove

2 Remove the bolt of the auxiliary drive belt tensioner

3 Remove the auxiliary drive belt tensioner

Re t

1 Fit the bolt xing the auxiliary drive belt to the engine,tighten it to62-68Nm, and check the torque

2 Tighten the bolt of the auxiliary drive belt tensioner

3 Fit the auxiliary drive belt

AuxiliaryAuxiliary DriveDrive BeltDrive Belt RefitBelt Refit

Trang 35

Engine Electrical System-NSE 1.5L Engine

Idler

Remove

2 Remove the alternator

AlternatorAlternator RemoveRemove

3 Remove 3 bolts xing the idler to the engine

Re t

1 Fit 3 bolts xing the idler to the engine, tighten them to

62-68Nm, and check the torque

2 Fit the alternator

AlternatorAlternator RefitRefit

Starter Motor

Remove

3 Unscrew the nuts, and disconnect the battery wirefrom the starter motor solenoid coil

4 Remove the retaining bolt (1) of the starter motor

5 Remove the retaining bolt (2) of the starter motorfrom the bottom of the vehicle

6 Remove the starter motor cable

Re t

1 Clean the junction surfaces of the starter motor and

Trang 36

Engine Intake&Exhaust-NF1 1.5T

Speci cations

Torque

Bolt-Air Filter Out Pipe to Air Filter 2.5-3.5Nm

Screw-Air Filter Upper Shell to Air Filter Lower Shell 1.2-1.8Nm

Bolt-Electronic Throttle to The Intake Manifold 8-12Nm

Nut-Three-way Catalyst to Flange Support 19-25Nm

Nut-The Front Exhaust Pipe to Three-way Catalyst 19-25Nm

Bolt-Three-way Catalyst Support to Transmission 19-25Nm

Bolt-Install The Bracket to Three-way Catalyst Support 19-25Nm

Nut-The Front Exhaust Pipe to Medium Exhaust Pipe 19-25Nm

Bolt-Under The Tie-bar Bracket to Under The Tie-bar

Bolt-The Front Exhaust Pipe to The Sub-frame 19-25Nm

Bolt-Rear Muf er Insulation Board to Bod y 1.5-2Nm

Bolt-Exhaust Channel Heat Shield to Bod y 1.5-2Nm

Trang 37

Engine Intake&Exhaust-NF1 1.5T Engine Service Procedures

Air Filter Inlet Pipe

Remove

1 Remove the front bumper

FrontFront BumperBumperBumper RemoveRemove

2 Remove the 2 plastic split pins xing the air lter intake

pipe to the upper radiator beam

3 Remove 1 bolt xing the air lter intake pipe to the

right longitudinal beam

4 Unplug the air lter intake pipe from the air lter

assembly

Re t

1 Fit the air lter intake pipe and insert it into the air

lter assembly

2 Fit 1 bolt xing the air lter intake pipe to the right

longitud inal beam, tighten it to7-10Nm, and check

the torque

3 Fit 2 plastic split pins xing the air lter intake pipe to

the upper radiator beam

4 Fit the front bumper and bracket

FrontFront BumperBumperBumper RefitRefit

Air Filter Assembly

3 Remove 1 bolt xing the air lter assembly to the body

4 Remove the air lter assembly

Trang 38

Air Filter Element

Remove

2 Disconnect the harness connector (1) of the air ow

meter

3 Disconnect the clip (2) xing the harness of the air ow

meter to the upper air lter housing

4 Remove 1 bolt (1) xing the air lter outlet pipe to the

metal clamp of the air lter assembly

5 Remove 4 screws (2) xing the upper air lter housing

to the lower air lter housing

6 Remove the air lter element

Re t

1 Clean the inside of the air lter

2 Fit a new air lter element

3 Fit 4 screws xing the upper air lter housing to the

lower air lter housing, tighten them to1.2-1.8Nm,

and check the torque

4 Fit 1 bolt xing the air lter outlet pipe to the

metal clamp of the air lter assembly, tighten it to

2.5-3.5Nm, and check the torque

5 Fix the harness clip of the air ow meter to the upper

Trang 39

Engine Intake&Exhaust-NF1 1.5T Engine

Electronic Throttle

Remove

2 Disconnect the hose (intercooler to throttle) from the

throttle

3 Disconnect the harness connector (1) from the

electronic throttle

4 Remove 4 bolts xing the electronic throttle to the

intake manifold and discard the electronic throttle

washer (2)

Re t

1 Fit a new electronic throttle gasket and ensure that the

sealing surface is clean

Caution: Never inser t any tool into the throttle hole to

7 Perform the "Electronic Throttle Self-Learning", whichshall refer to Module Self-learning and ProgrammingManual-"Engine Control Module (ECM)" for details

Trang 40

Rear Muf er Assembly

Remove

Warning: Exhaust components get extremely hot during

operation Ensure exhaust components are suf ciently

cooled before handling

1 Raise the vehicle on a lift

2 Remove 2 nuts xing the rear muf er assembly to the

middle muf er, and discard the washers

3 Remove 2 rubber lifting lugs for xing the rear muf er

4 Remove the rear muf er assembly

Re t

1 Fit 2 rubber lugs xing the rear muf er

2 Fit 2 nuts and new gaskets xing the rear muf er to the

middle muf er, tighten them to19-25Nm, and check

the torque

3 Lower the vehicle on the lift

Three-way Catalytic Converter

Remove

2 Remove the upstream oxygen sensor

OxygenOxygen SensorSensor RemoveSensor Remove

3 Remove 3 bolts xing the turbocharger heat shield tothe turbocharger, and remove the turbocharger heatshield

4 Remove the clamp xing the three-way catalyticconverter to the turbocharger air outlet, anddisconnect the three-way catalytic converter from theturbocharger

6 Remove 2 nuts (1) xing the three-way catalyticconverter mounting bracket to the three-way catalyticconverter

7 Remove 1 bolt (2) xing the mounting bracket ofthe three-way catalytic converter to the gearbox andremove the bracket

Tiêu đề	Mg5 Ap32 Refit And Remove Manual
Thể loại	manual

Định dạng
Số trang	200
Dung lượng	22,18 MB