Mg5 ap32 refit and remove manual p9

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.

Trang 1

rod to the front horizontal stabilizer bar, t 1 nut (one

on each side) and tighten it to75–90Nm

Caution: To prevent damage to components, use two

spanner s when loosening or tightening unions

3 Fix the steering gear to the subframe , t 3 bolts and

nuts, and tighten them to70Nm+90°

4 Locate the lower tie rod to the subframe , t 1 bolt and

nut, and tighten it to135-165Nm+（（85-95 ））°.）

5 Locate the front subframe assembly to the body, t 4

bolts, and tighten them to90Nm+180º

6 Locate the exhaust pipe bracket to the subframe , t 2

bolts and tighten them to19–25Nm

7 Lower the hydraulic lifter, and move it to the safety

zone

8 Fit the steering gear outer tie rod

SteeringSteering GearGear OuterGear Outer TieOuter TieTie RodRodRod RefitRefit

9 Fit the bottom de ector

BottomBottom DeflectorDeflectorDeflector RefitRefit

10 Locate the intermediate shaft universal joint to the

steering gear input shaft, t 1 bolt and tighten it to

20Nm+120°

11 Check the four-wheel alignment parameters

Four-wheelFour-wheel AlignmentAlignment

12 Perform a self-learning for electric power steering

module For details, refer to Module Self-learning and

Programming Manual, "Electric Power Steering (EPS)"

Steering Gear Outer Tie Rod

Remove

1 Remove the front wheels

WheelsWheels RemoveRemove

2 Remove and discard 1 nut (2) xing the steering gearouter tie rod to the steering knuckle

3 Disconnect the steering gear outer tie rod from thesteering knuckle

4 Mark the location of the locking nut, and loosen thelocking nut (1) xing the steering gear outer tie rod tothe steering gear inner tie rod

5 Unscrew the steering gear outer tie rod from thesteering gear inner tie rod

Re t

1 Screw the steering gear outer tie rod to the markedlocation of the locking nut with the ball joint downward

2 Tighten the outer tie rod locking nut to63–73Nm

3 Locate the steering gear outer tie rod on the steeringknuckle, t a new nut and tighten it to40–50Nm

4 Fit the front wheels

WheelsWheels RefitRefit

5 Check four-wheel alignment

6 Perform a self-learning for electric power steeringmodule For details, refer to Module Self-learning andProgramming Manual, "Electric Power Steering (EPS)"

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Steering Gear Inner Tie Rod

Remove

1 Remove the steering gear boot

SteeringSteering GearGearGear BootBootBoot RemoveRemove

2 Unscrew the steering gear inner tie rod from the

steering gear and disconnect the connection

3 Remove the steering gear inner tie rod

Re t

1 Locate the steering gear inner tie rod to the steering

gear and use a tool to tighten the steering gear inner

tie rod to85–95Nm

2 Fit the steering gear boot

SteeringSteering GearGearGear BootBootBoot RefitRefit

Steering Gear Boot Repair Pack

Remove

1 Remove the steering gear outer tie rod

SteeringSteering GearGearGear OuterOuterOuter TieTieTie RodRodRod RemoveRemove

2 Remove the inner boot clamp (1) of the steering gear,and discard the clamp

3 Remove the outer boot clamp (2) of the steering gear,and discard the clamp

4 Remove the steering gear sleeve from the steering gear

Re t

1 Fit the steering gear boot to the steering gear Ensurethat the steering gear boot is located in the ttinggroove

2 Fit the new inner boot clamp of the steering gear tothe steering gear boot, and secure it

3 Fit the new outer boot clamp of the steering gear tothe steering gear boot, and secure it

4 Fit the steering gear outer tie rod

SteeringSteering GearGearGear OuterOuterOuter TieTieTie RodRodRod RefitRefit

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Upper Steering Column Assembly

Remove

1 Remove the steering wheel combination switch

SteeringSteering WheelWheel CombinationWheel CombinationCombination SwitchSwitchSwitch RemoveRemove

2 Remove the driver side lower trim panel assembly

DriverDriver SideSideSide LowerLower TrimLower TrimTrim PanelPanelPanel AssemblyAssemblyAssembly RemoveRemove

3 Disconnect the harness connector of theEPS module

4 Disconnect the harness connector of the electronic

steering column lock module

5 Remove and discard 1 bolt xing the intermediate shaft

to the upper steering column

6 Remove 3 bolts xing the steering column to the

instrument panel beam assembly

7 Loosen the relevant harness and clip from the steeringcolumn assembly

8 Remove the upper steering column assembly

9 Fix the upper steering column assembly to the drillingmachine , drill a small hole in the screw head of thesteering column lock, choose a broken screw extractorwith an appropriate diameter to rotate the screw out,and do not damage adjacent parts

10 Disconnect the electronic steering column lock fromthe upper steering column

8 Connect the harness connector of theEPS module

9 Fit the driver side lower trim panel assembly

DriverDriver SideSide LowerSide LowerLower TrimTrim PanelTrim PanelPanel AssemblyAssembly RefitAssembly Refit

10 Fit the steering wheel combination switch

SteeringSteering WheelWheelWheel CombinationCombination SwitchCombination Switch RefitSwitch Refit

11 Perform the self-learning for programming and encodingthe electric power steering module Refer to ModuleSelf-learning and Programming Manual, "Electric PowerSteering (EPS)"

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Steering Intermediate Shaft

Remove

1 Keep the wheels facing forward and lock the steering

wheel

DriverDriver SideSide LowerSide Lower TrimLower TrimTrim PanelPanel AssemblyPanel AssemblyAssembly RemoveRemove

to the steering gear

5 Take out the steering intermediate shaft

Re t

1 Locate the intermediate shaft to the steering gear, t 1

new bolt and tighten it to20Nm+120°

2 Locate the intermediate shaft to the upper steering

column, t 1 new bolt, tighten non-bosch bolt

to20Nm+120°（（NOT Bosch））/bosch bolt to）

20Nm+90°（（Bosch））.）

DriverDriver SideSide LowerSide LowerLower TrimTrimTrim PanelPanel AssemblyPanel AssemblyAssembly RefitRefit

Steering Column Shield

Remove

1 Remove the steering wheel assembly

SteeringSteering WheelWheel AssemblyWheel AssemblyAssembly RemoveRemove

2 Pry off the clip between the steering column uppershield and the instrument pack frame upholstery, andremove the steering column upper shield assembly

3 Pry off the clip and separate the steering column uppershield from the lower shield

4 Remove 1 screw xing the steering column lower shield

to the steering column

5 Remove 2 screws xing the steering column lowershield to the combination switch

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6 Release the steering column to an appropriate position,

and remove the steering column lower shield

Re t

1 Locate the steering column lower shield to the steering

column

2 Fit 2 screws xing the steering column lower shield to

the combination switch, and tighten them

3 Fit 1 screw xing the steering column lower shield to

the steering column, and tighten it

4 Align the clip of the instrument pack frame with the

hole on the steering column upper shield, push it hard

to the end and clamp it in place

5 Align the adapter of instrument pack frame and the

upper shield assembly with that of steering column

lower shield, push them hard to the end and clamp

them in place

6 Fit the steering wheel assembly

SteeringSteering WheelWheelWheel AssemblyAssembly RefitAssembly Refit

Steering Wheel Positioning Adjustment

Adjustment

1 If the steering wheel exceeds the locator valueclockwise:

a Loosen the right locking nut

b Turn the right outer tie rod to the left by a hexagonalplane

c Tighten the right locking nut to63–73Nm

d Loosen the left locking nut

e Turn the left outer tie rod to the left by a hexagonalplane

f Tighten the left locking nut to63–73Nm

2 If the steering wheel exceeds the locator valuecounterclockwise:

a Loosen the left locking nut

b Turn the left outer tie rod to the right by a hexagonalplane

c Tighten the left locking nut to63–73Nm

d Loosen the right locking nut

e Turn the right outer tie rod to the right by ahexagonal plane

f Tighten the right locking nut to63–73Nm

3 Repeat 1 or 2 till the wheels are facing forward and thesteering wheel is in the centre

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Steering Wheel Assembly

Remove

1 Remove the steering wheel airbag

SteeringSteering WheelWheelWheel AirbagAirbagAirbag RemoveRemove

2 Disconnect the harness connector of the steering

wheel switch

3 Position the steering wheel in the middle so that the

wheels are in the straight ahead position

4 Lock the steering column to ensure that the steering

wheel does not rotate, and loosen the bolts xing the

steering wheel to the steering column until the steering

wheel is completely loosened from the spline of the

steering column before removing the bolts

Re t

1 Ensure that the steering column does not rotate, and

t the steering wheel to the steering column according

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Steering Wheel Moulding

Remove

2 Use a tool to pry off the steering wheel moulding

carefully

3 Remove the steering wheel moulding

Re t

1 Locate the steering wheel moulding on the steering

wheel, and gently press the moulding by hand

2 Fit the steering wheel airbag

SteeringSteering WheelWheelWheel AirbagAirbagAirbag RefitRefit

Steering Wheel Multifunction Switch

Remove

1 Disconnect the negative battery cable

3 Remove 1 screw (1) xing the harness connector ofthe steering wheel multifunction switch to the steeringwheel, and remove the harness

4 Disconnect the harness connector (2) of the steeringwheel multifunction switch

5 Pry off the clip, disconnect the harness connector onthe back of the left steering wheel multifunction switch,and remove the steering wheel multifunction switch

Re t

1 Connect the harness connector on the back of the leftsteering wheel multifunction switch, and x the steeringwheel multifunction switch to the steering wheel

2 Connect the harness connector of the steering wheelmultifunction switch

3 Fix the harness of the steering wheel multifunctionswitch to the steering wheel body, t 1 screw andtighten it

4 Fit the steering wheel airbag

SteeringSteering WheelWheel AirbagWheel AirbagAirbag RefitRefit

5 Connect the negative battery cable

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Steering Wheel Combination Switch

Remove

2 Remove the steering column shield

SteeringSteering ColumnColumnColumn ShieldShieldShield RemoveRemove

3 Pry off the retaining clip of the stalk switch trim panel

and remove the trim panel

4 Remove 2 screws (3) xing the wiper stalk switch to

the clock spring, remove the wiper stalk switch and

disconnect the harness connector

5 Remove 2 screws (1) xing the light stalk switch to

the clock spring, remove the light stalk switch and

disconnect the harness connector

6 Remove 2 screws (2) xing the cruise control stalk

switch to the clock spring, remove the cruise control

stalk switch and disconnect the harness connector (if

any)

SteeringSteering WheelWheelWheel AssemblyAssemblyAssembly RemoveRemove

8 Fix the angle sensor with tapes, ensure it will not move

left and right (relative to the clock spring) and is always

in the centre

9 Remove 1 screw xing the clock spring to the steering

column, disconnect the harness connector and remove

the clock spring Be careful not to damage the locating

tape

Re t

Caution: If the peg on a new rotary coupler is broken, or

if you suspect that the rotary coupler has been dropped

or mishandled, discard the coupler

1 Before tting, ensure that the red locating pin of the

clock spring is not removed or damaged and the front

wheels face the front

2 Ensure the clock spring to be tted is in the centre, if

Align the connector clip with the Lock Pin position (thislocation is the centre)

3 Connect the harness connector of the clock spring

4 Fix the clock spring to the steering column, t 1 screw,tighten it to5–6Nm, check the torque, and ensure thecombination switch assembly is not loose

5 Fit the steering wheel assembly

SteeringSteering WheelWheel AssemblyWheel AssemblyAssembly RefitRefit

6 Connect the harness connector of the stalk switch

7 Fix the stalk switch to the clock spring, t and tighten

6 screws (4 screws for vehicles without cruise controlfunction)

8 Fit the stalk switch trim panel and press the clip

10 Perform self-learning on the electric power steering(EPS) For details, please refer to Module Self-learningand Programming Manual - Electric Power Steering(EPS)

11 Check the system, rotate each lever of the combinationswitch and check for correct operation

12 Check if the buttons of the entertainment switch onthe steering wheel for correct operation

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Shift Paddle

Remove

2 Remove the steering wheel multifunction switch

SteeringSteering WheelWheel MultifunctionWheel MultifunctionMultifunction SwitchSwitchSwitch RemoveRemove

3 Remove 4 screws xing the shift paddle switch to the

steering wheel

4 Loosen the clip and remove the shift paddle

Re t

1 Fix the shift paddle to the steering wheel, t 4 screws

and tighten them

2 Fit the steering wheel multifunction switch

SteeringSteering WheelWheel MultifunctionWheel MultifunctionMultifunction SwitchSwitchSwitch RefitRefit

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Electronic Steering Column Lock

Speci cations

Torque

Bolt-Steering column lock to steering column 13–15Nm

Bolt- Steering column intermediate shaft to Steering column 20Nm+120°（NOT Bosch）

Bolt- Steering column intermediate shaft to Steering column 20Nm+90°（Bosch）

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Service Procedures

Electronic Steering Column Lock Module

Remove

1 Remove the steering wheel combination switch

SteeringSteering WheelWheel CombinationWheel CombinationCombination SwitchSwitchSwitch RemoveRemove

DriverDriver SideSideSide LowerLower TrimLower TrimTrim PanelPanelPanel AssemblyAssemblyAssembly RemoveRemove

3 Disconnect the harness connector of theEPS module

4 Disconnect the harness connector of the electronic

steering column lock module

6 Remove 3 bolts xing the steering column to the

instrument panel beam assembly

7 Loosen the relevant harness and clip from the steeringcolumn assembly

8 Remove the upper steering column assembly

9 Fix the upper steering column assembly to the drillingmachine , drill a small hole in the screw head of thesteering column lock, choose a broken screw extractorwith an appropriate diameter to rotate the screw out,and do not damage adjacent parts

10 Disconnect the electronic steering column lock fromthe upper steering column

8 Connect the harness connector of theEPS module

DriverDriver SideSide LowerSide LowerLower TrimTrim PanelTrim PanelPanel AssemblyAssembly RefitAssembly Refit

10 Fit the steering wheel combination switch

SteeringSteering WheelWheelWheel CombinationCombination SwitchCombination Switch RefitSwitch Refit

11 Perform the self-learning for programming and encodingthe electronic steering column lock Refer to ModuleSelf-learning and Programming Manual, "ElectronicSteering Column Lock (ESCL)"

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Service Procedures

Four-wheel Alignment

Check

Steering and vibration complaints are not always the result of

improper alignment One possible cause is wheel and tire

imbalance, and another possibility is vehicle off-track due to

worn or improperly manufactured tyres

De nition of vehicle off-track: Vehicle off-track refers to the

phenomenon that the vehicle turns to one side in the process

of straight running on a at road, resulting in the inconsistency

between the axis of front and rear shaft centres and the

centreline of the traveling track

Before performing any adjustment affecting wheel alignment,

perform the following inspections and adjustments in order to

ensure correct alignment readings:

• Check tyres for proper pressure or irregular wear

• Check the radial runout of wheels and tyres

• Check wheel bearings for excessive clearance or gap

• Check ball joints and steering tie rod ends for looseness

or wear

• Check control arms and stabilizer bar for looseness or

wear

• Check the steering gear on the frame for looseness

• Check struts/shock absorbers for wear, leakage or any

noticeable noises

• Check the vehicle trim height

• Check the steering wheel for excessive drag or poor

returnability due to stiffness or corrosion of linkage

mechanism or suspension components

Give consideration also to the cond ition of the equipment

being used for the alignment, and follow the equipment

manufacturer's instructions

Satisfactory vehicle operation may occur over a wide range of

alignment setting value However, if the setting value exceeds

the ser vice allowable speci cations, correct the alignment to

the ser vice recommend ed speci cations

Perform the following steps when measuring front and rear

wheel alignment angles:

1 Fit the alignment equipment according to the

manufacturer's instructions

2 Conduct up and down vibration for the front and rear

bumpers 3 times prior to checking the wheel alignment

3 Measure the alignment angles and record the readings

4 Adjust alignment angles to the speci ed value, if necessar y

Adjustment

the requirements

2 Front wheel toe angle adjustm ent:

a Loosen the locking nut (1) of the steering gear outertie rod

b Adjust the steering gear outer tie rod to set the frontwheel toe angle to the speci ed value

c Tighten the locking nut to63–73Nm

d For the other side , repeat the above steps

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Front Suspension

Speci cations

Torque

Bolt-Front lower control arm front bushing to front subframe （81–99）Nm+ （85–95）°

Nut-Front lower control arm rear bushing to front subframe （81–99）Nm+ （85–95）°

Bolt-Front lower control arm ball joint to steering knuckle 90–110Nm

Nuts-Front lower control arm ball joint to front lower

Nut-Front shock absorber assembly top nut 65–75Nm

Nuts-Front shock absorber assembly to body 60–80Nm

Nuts-Front shock absorber assembly to steering knuckle 140–170Nm

Nut-Front anti-roll bar links to front shock absorber assembly 75–90Nm

Bolt-Front brake hose pipe bracket to damper 10–15Nm

Bolt-Lower Tie Bar to Subframe 135-165Nm+85-95°

Bolts-Front anti-roll bar bushing bracket to front subframe 55–65Nm

Bolts-front subframe to body （63–77）Nm+ （175–185）°

Nut-Front anti-roll bar to front anti-roll bar links 75–90Nm

Nut-Steering outer tie rod to steering arm 40–50Nm

Bolt-Lower Tie Bar to Lower Tie Bar Bracket （81-99 ）Nm+ （85-95 ）°

Bolt- Steering column intermediate shaft to Steering 20Nm+120°

Bolts-Front wheel hub bearing assembly to steering knuckle （63–77）Nm+ （85–95）º

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Service Procedures

Front Lower Swing Arm Assembly

Remove

2 Remove the bottom de ector

3 Support the steering knuckle assembly with the

hydraulic lifter

4 Remove 1 bolt and nut (3) xing the outer ball joint of

front lower swing arm to the front steering knuckle,

and discard them Disconnect the outer ball joint of

front lower swing arm from the front steering knuckle

5 Remove 1 bolt and nut (2) xing the rear bushing of

front lower swing arm to the front subframe , and

discard them

6 Remove 1 bolt (4) xing the front bushing of front

lower swing arm to the front subframe , and discard it

7 Remove the front lower swing arm assembly

Re t

1 Locate the front bushing of front lower swing arm to

the front subframe , t 1 new bolt, and tighten it to

（

（81–99））Nm+（）（（85–95））°.）

2 Locate the rear bushing of front lower swing arm to

the front subframe, t 1 new bolt and nut, and tighten

to（（81–99）））Nm+（（（85–95）））°

3 Locate the outer ball joint of front lower swing arm to

the front steering knuckle, t 1 new bolt and nut, and

tighten to90–110Nm

4 Lower the hydraulic lifter, and push it to the safety zone

Front Lower Swing Arm Rear Bushing

Remove

FrontFront LowerLowerLower SwingSwing ArmSwing ArmArm AssemblyAssemblyAssembly RemoveRemove

2 Press the rear bushing of front lower swing arm out ofthe front lower swing arm assembly with a press andspecial toolTCH00109

3 Remove the rear bushing of front lower swing arm

3 Fit the front lower swing arm assembly

FrontFront LowerLowerLower SwingSwing ArmSwing ArmArm AssemblyAssemblyAssembly RefitRefit

Trang 17

Front Lower Swing Arm Outer Ball Joint

Remove

Caution: This ball joint boot kit should only be used if the

boot is damaged during a service It must not be used if

the vehicle has been driven with a damaged boot

2 Support the steering knuckle assembly with the

hydraulic lifter

3 Remove 1 bolt and nut (3) xing the outer ball joint

of front lower swing arm to the steering knuckle, and

discard them

4 Remove 3 bolts and nuts (1) xing the outer ball joint to

the front lower swing arm assembly, and discard them

5 Disconnect the outer ball joint from the front lower

swing arm assembly

6 Knock down the outer ball joint of front lower swing

arm with a tool

Re t

1 Clean the junction of the outer ball joint of front lower

swing arm and the front steering knuckle

2 Locate the outer ball joint to the front lower swing arm

assembly, t 3 new bolts and nuts, and tighten them to

（

（55–65））Nm+（）（（40–50）））°

3 Locate the outer ball joint of front lower swing arm to

the steering knuckle, t 1 new bolt and nut, and tighten

them to90–110Nm

Front Shock Absorber Assembly

Remove

2 Release the wheel speed sensor harness from the frontshock absorber and remove the retaining bolt of thebrake hose

3 Remove 1 nut (1) xing the front horizontal stabilizerbar connecting rod to the front shock absorber, discard

it and disconnect the connection

4 Remove 2 bolts and nuts (2) xing the front shockabsorber assembly to the steering knuckle, discardthem and disconnect the front shock absorber fromthe steering knuckle

5 Lower the vehicle to an appropriate height

6 Remove the side corner, assembly and accessories ofA/C air inlet grille

SideSide Corner,Corner,Corner, AssemblyAssemblyAssembly andandand AccessoriesAccessories ofAccessories ofof A/CA/CAirAir InletInlet GrilleInlet GrilleGrille RemoveRemove

7 Remove 1 nut xing the front shock absorber assembly

to the body, and discard it

8 Remove the front shock absorber assembly from thevehicle

9 Fix the spring compressorT32016 and T32017 to the

Trang 18

front shock absorber spring.

10 Ensure the adapter of the spring compressor is properly

tted, and compress the spring

11 Clamp the top of the front shock absorber with a tool,

remove the nut and discard it

12 Remove the upper mounting support assembly of front

shock absorber

13 Remove the spring vibration isolator

14 Remove the coil spring of front shock absorber

15 Remove the bumper block and the dust shield of the

front shock absorber

16 Release the pressure of coil spring, loosen the adapter

from the spring compressor and remove the coil spring

Re t

1 Check the front shock absorber strut bearing for any

signs of crack and damage

2 Check the front shock absorber dust shield and front

bumper block for any sign of aging or damage

3 Clean the front shock absorber strut and front bumper

block

4 Fit the front bumper block and the front shock absorber

strut dust shield to the front shock absorber strut

5 Fit the coil spring of the front shock absorber to the

front shock absorber strut

6 Locate the spring com pressor to the front shock

absorber, applyT32016 and T32017 to compress the

spring

7 Ensure proper re t relative position, and locate the

vibration isolator of the front shock absorber spring to

the front shock absorber shaft

8 Locate the upper mounting bearing assembly on the

shock absorber strut Fit the nut on the top of the

front shock absorber

9 Lock the front shock absorber strut with a tool and

of the spring compressor and take out the springcompressor

11 Clean the junction of the front shock absorber assemblyand the body

12 Locate the front shock absorber assembly to the body,

t and tighten the new nuts to60–80Nm

13 Fit the anti-rust cap of the front shock absorber

14 Fit the side corner, assembly and accessories of A/Cair inlet grille

SideSide Corner,Corner,Corner, AssemblyAssemblyAssembly andandand AccessoriesAccessoriesAccessories ofofof A/CA/CAirAir InletInletInlet GrilleGrilleGrille RefitRefit

15 Raise the vehicle

16 Locate the lower part of the front shock absorberassembly to the steering knuckle, t 2 new bolts andnuts, and tighten them to140–170Nm

17 Clean the front horizontal stabilizer bar connecting rodand t it to the front shock absorber assembly Use atool to clamp the connecting rod to lock the ball joint,

t 1 new nut and tighten it to75–90Nm

18 Locate the front brake hose clip bracket to the shockabsorber, t 1 bolt and tighten it to10–15Nm

19 Fit the wheel speed sensor harness

21 Check four-wheel alignment

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Front Subframe Assembly

Remove

2 Remove 1 bolt xing the intermediate shaft universal

joint to the steering gear input shaft, and discard it

Disconnect the intermediate shaft universal joint from

the steering gear input shaft

BottomBottom DeflectorDeflectorDeflector RemoveRemove

FrontFront LowerLower SwingLower SwingSwing ArmArm AssemblyArm AssemblyAssembly RemoveRemove

5 Remove 2 bolts (2) xing the exhaust pipe bracket to

the front subframe , and disconnect the connection

6 Support the front subframe assembly and the

transmission assembly with the hydraulic lifter

respectively

7 Remove 1 bolt (2) xing the lower tie rod to the lower

tie rod bracket, and discard it

8 Remove 2 nuts (2) (one on each side) xing the steeringgear outer tie rod to the steering knuckle, and discardthem Disconnect the steering gear outer tie rod fromthe steering knuckle

9 Remove 2 nuts (2) (one on each side) xing thefront horizontal stabilizer bar to the front horizontalstabilizer bar connecting rod, and discard them

10 Remove 4 bolts xing the front subframe assembly tothe body, and discard them

Trang 20

11 Lower the hydraulic lifter and remove the front

subframe assembly

12 Remove 4 bolts xing the bushing bracket of front

horizontal stabilizer bar to the front subframe , and

remove the front horizontal stabilizer bar

13 Remove 3 bolts and nuts xing the steering gear to the

front subframe Remove steering sub-assembly

14 Remove 1 bolt (3) xing the lower tie rod to the front

subframe , discard it and remove the lower tie rod

4 Lift the front subframe and align it to its locating points

on each side) and tighten it to75–90Nm

7 Locate the steering gear outer tie rod on the steeringknuckle, t a new nut and tighten it to40–50Nm

8 Locate the lower tie rod to the lower tie rod bracket,

t 1 new bolt and tighten it to（（81-99 ）））Nm+

（（85-95 ）））°

9 Locate the exhaust pipe bracket to the front subframe ,

t 2 bolts and tighten them to19–25Nm

11 Fit the front lower swing arm assembly

FrontFront LowerLowerLower SwingSwing ArmSwing ArmArm AssemblyAssemblyAssembly RefitRefit

BottomBottom DeflectorDeflector RefitDeflector Refit

14 Locate the intermediate shaft universal joint to thesteering gear input shaft, t 1 bolt and tighten it to20Nm+120°

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Front Horizontal Stabilizer Bar

Remove

2 Remove 1 bolt xing the intermediate shaft universal

joint to the steering gear input shaft, and discard it

Disconnect the intermediate shaft universal joint from

the steering gear input shaft

BottomBottom DeflectorDeflectorDeflector RemoveRemove

4 Support the front subframe assembly and the

transmission assembly with the hydraulic lifter

respectively

front lower swing arm to the front steering knuckle,

and discard them Disconnect the outer ball joint of

front lower swing arm from the front steering knuckle

6 Remove 2 bolts (2) xing the exhaust pipe bracket to

the front subframe , and disconnect the connection

7 Remove 2 nuts (2) (one on each side) xing the steeringgear outer tie rod to the steering knuckle, and discardthem Disconnect the steering gear outer tie rod fromthe steering knuckle

8 Remove 2 nuts (2) (one on each side) xing thefront horizontal stabilizer bar to the front horizontalstabilizer bar connecting rod, and discard them.Disconnect the front horizontal stabilizer bar from thefront horizontal stabilizer bar connecting rod

9 Remove 1 bolt (2) xing the lower tie rod to the lowertie rod bracket, and discard it

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10 Remove 4 bolts xing the front subframe assembly to

the body, and discard them

11 Lower the hydraulic lifter to lower the front subframe

to an appropriate height

12 Remove 4 bolts xing the bushing bracket of front

horizontal stabilizer bar to the front subframe (two on

each side)

13 Carefully remove the front horizontal stabilizer bar

from the vehicle

Re t

1 Fix the bushing and bracket of front horizontal stabilizer

bar to the subframe , t 4 bolts, and tighten them to

55–65Nm

3 Locate the front subframe assembly to the body, t 4bolts, pre-tighten 4 bolts, then tighten them diagonally

to（（63–77））Nm+（）（（175–185）））°

4 Locate the lower tie rod to the lower tie rod bracket,

t 1 new bolt and tighten it to（（81-99 ）））Nm+

（（85-95 ）））°

5 Locate the front horizontal stabilizer bar to the fronthorizontal stabilizer bar connecting rod, t 2 nuts (one

on each side) and tighten them to75–90Nm

6 Locate the steering gear outer tie rod on the steeringknuckle, t 2 new nuts (one on each side) and tightenthem to40–50Nm

7 Locate the exhaust pipe bracket to the subframe , t 2bolts and tighten them to19–25Nm

8 Locate the outer ball joint of front lower swing arm tothe front steering knuckle, t 2 new bolts and nuts (one

on each side), and tighten them to90–110Nm

9 Lower the hydraulic lifter, and move it to the safetyzone

BottomBottom DeflectorDeflector RefitDeflector Refit

11 Locate the intermediate shaft universal joint to thesteering gear input shaft, t 1 bolt and tighten it to20Nm+120°

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Front Horizontal Stabilizer Bar Bushing

Remove

1 Raise the vehicle on a lift to an appropriate height

2 Locate the appropriate point to remove 4 bolts xing

the bushing and bracket of front horizontal stabilizer

bar to the subframe , and discard them

3 Remove the bracket and bushing of the front horizontal

stabilizer bar, and discard the bushing

Re t

1 Locate the new bushing to the front horizontal

stabilizer bar, t the bushing bracket and adjust it to

the appropriate place

Caution: Anti roll bar bushes have a special coating and

must not be lubricated

2 Fit 4 new bolts, pre-tighten them and then tighten them

to55–65Nm in sequence

3 Check whether the tightening force is correct or not

in order

Caution: Failure to carry out this procedure can result in

bolts being incorrectly tightened

4 Lower the vehicle

Front Horizontal Stabilizer Bar Connecting Rod

Remove

2 Remove 1 nut (2) xing the connecting rod of fronthorizontal stabilizer bar to the front horizontal stabilizerbar, discard the nut and disconnect the connection

3 Remove 1 nut (1) xing the connecting rod of fronthorizontal stabilizer bar to the front shock absorber,discard the nut and disconnect the connection.Caution: To prevent damage to components, use twospanner s when loosening or tightening unions

4 Remove the connecting road of front horizontalstabilizer bar

Caution: To prevent damage to components, use twospanner s when loosening or tightening unions

3 Lower the vehicle

Trang 24

Front Wheel Hub Assembly

Remove

1 Remove the wheel center trim cover, Pry up the nut

locking device of the front axle shaft with a tool,

remove and discard the axle shaft nut

3 Remove the front brake caliper and front brake disc

FrontFront BrakeBrakeBrake DiscDiscDisc RemoveRemove

4 Remove 1 nut (2) xing the steering gear outer tie rod

to the steering knuckle Disconnect the steering gear

outer tie rod from the steering knuckle

front lower swing arm to the front steering knuckle

Disconnect the outer ball joint of front lower swing

arm from the front steering knuckle

6 Pull the steering knuckle outward to disconnectthe axle shaft assembly from the wheel hub bearingassembly And x the axle shaft in place

7 Remove and discard 3 bolts xing the front wheel hubbearing assembly to the front steering knuckle Removethe front wheel hub bearing assembly

4 Locate the outer ball joint of front lower swing arm

to the front steering knuckle, t 1 bolt and nut, andtighten to90–110Nm

5 Locate the steering gear outer tie rod on the steeringknuckle, t a nut and tighten it to40–50Nm

6 Fit the brake disc and brake caliper

FrontFront BrakeBrake DiscBrake Disc RefitDisc Refit

Trang 25

tighten it to345–375Nm Press down the locking

device of the nut and install the wheel center trim cover

Trang 26

T32016 compressorCoil spring

T32017 coil springAdaptor

compressor

Trang 27

Rear Suspension

Speci cations

Torque

Nut-Rear shock absorber assembly top nut 22–28Nm

Bolts-Rear shock absorber assembly to body 55–65Nm

Bolt-Rear shock absorber assembly to torsion beam 90–110Nm

Bolt-Rear wheel hub bearing to rear wheel carrier （162-198 ）Nm+（175-185 ）°

Bolt-Rear brake disc retaining to rear torsion beam （27–33）Nm+ （85–95）°

Bolt-Rear torsion beam bracket to rear torsion beam （83–97）Nm+ （175-185 ）°

Bolt-Rear wheel speed sensor to the torsion beam 7–10Nm

Trang 28

Service Procedures

Rear Shock Absorber Assembly

Remove

1 Remove the rear wheels

3 Support the rear torsion beam with the hydraulic lifter

4 Remove 1 bolt and nut xing the rear shock absorber

assembly to the rear torsion beam, and discard them

5 Remove 2 bolts xing the rear shock absorber assembly

to the body, and discard them

6 Remove the rear shock absorber assembly

7 Remove the sound insulation cap of the rear shock

absorber, use a wrench to clamp the rear shock

absorber column to prevent it from turning, and

remove the top nut of the shock absorber

8 Remove the rear shock absorber top support assembly,

rear shock absorber auxiliary spring and dust shield

Re t

1 Fit dust shield, rear shock absorber auxiliary spring and

upper support assembly

2 Fit the top nut of the rear shock absorber and tighten it

3 Locate the rear shock absorber assembly to the body,

t 2 new bolts and tighten them to55–65Nm

4 Locate the rear shock absorber assembly to the reartorsion beam, t 1 new bolt and nut, and tighten thebolt to90–110Nm

6 Lower the vehicle

7 Fit the rear wheels

Trang 29

Rear Suspension Spring Assembly

Remove

3 Remove 1 bolt and nut (one on each side) xing the

rear shock absorber assembly to the rear torsion

beam， and discard them

4 Remove 8 bolts xing the rear torsion beam to the

body（both sides ）

5 Lower the hydraulic lifter to lower the rear torsion

beam to an appropriate height

6 Remove the rear suspension spring assembly

7 Remove the upper vibration isolators (1) and lower

vibration isolators (2) of the rear suspension springassembly

3 Lift the rear torsion beam with the hydraulic lifter

4 Fit 8 bolts xing the rear torsion beam to the body, andtighten them to90–110Nm

5 Locate the rear shock absorber assembly to the reartorsion beam, t the new bolt and nut (one on eachside), and tighten them to90–110Nm

7 Lower the vehicle

Trang 30

Rear Wheel Hub Assembly

Remove

2 Remove the rear brake caliper and rear brake disc

RearRear BrakeBrakeBrake DiscDiscDisc RemoveRemove

3 Remove the rear wheel hub grease cap and discard it

4 Remove the spline bolt xing the rear wheel hub

bearing assembly to the rear wheel bracket, and discard

it

5 Remove the rear wheel hub bearing assembly

Caution: Do not store hub bearings near magnetic elds

or iron lings as damage may occur

Re t

1 Locate the rear wheel hub bearing assembly to the rear

wheel bracket, t 1 new spline bolt and tighten it to

（

（162-198））Nm+（）（（175-185 ））°.）

2 Fit 1 new rear wheel hub grease cap

3 Fit the rear brake disc and the brake caliper

RearRear BrakeBrakeBrake DiscDiscDisc RefitRefit

Rear Wheel Bracket Assembly

Remove

1 Remove the rear wheel hub assembly

RearRear WheelWheelWheel HubHubHub AssemblyAssemblyAssembly RemoveRemove

2 Remove and discard 4 bolts xing the rear wheelbracket assembly to the torsion beam

Caution: Do not store hub bearings near magnetic elds

or iron lings as damage may occur

3 Remove the rear brake disc guard plate and rear wheelbracket assembly

Re t

1 Locate the rear brake disc guard plate and rear wheelbracket assembly to the rear torsion beam, t 4new bolts and tighten them to（（27–33）））Nm+

（（85–95）））°

2 Fit the rear wheel hub assembly

RearRear WheelWheelWheel HubHubHub AssemblyAssemblyAssembly RefitRefit

Trang 31

Rear Torsion Beam Assembly

Remove

2 Remove the rear brake caliper and rear brake disc

RearRear BrakeBrakeBrake DiscDiscDisc RemoveRemove

3 Remove 1 bolt xing the rear wheel speed sensor

to the rear torsion beam Take out the wheel speed

sensor and x it in a proper position Disconnect the

harness of wheel speed sensor from the torsion beam

(one on each side)

5 Remove the bolt and nut (one on each side) xing

the rear shock absorber assembly to the rear torsion

beam, and discard them

6 Remove 8 bolts xing the rear torsion beam to the

body, and discard them

7 Disconnect the relevant harness and pipe clip from therear torsion beam assembly

8 Slowly lower the hydraulic lifter to disconnect the reartorsion beam from the body

9 Remove the rear suspension spring assembly and therear torsion beam assembly

10 Remove 8 bolts (both sides) xing the rear wheelbracket and the rear brake disc guard plate to thetorsion beam Remove the rear brake disc guard plate ,the wheel bracket and the hub bearing

11 Remove the bolts and nuts xing the torsion beambracket to the torsion beam, and discard them Removethe torsion beam bracket

Re t

1 Fix the torsion beam bracket to the torsion beam, tnew bolts and nuts, and tighten them to（（83–97））Nm+（（175-185 ）））°

2 Fix the rear wheel bracket, hub bearing and rear brakedisc guard plate to the torsion beam, t bolts andtighten them to（（27–33）））Nm+（（（85–95）））°

3 Lift the rear suspension spring assembly and reartorsion beam assembly on the hydraulic lifter and alignthem with their locating points on the body

4 Connect the relevant harness and pipe clip to thetorsion beam assembly

Trang 32

5 Locate the rear torsion beam assembly to the body, t

8 bolts and tighten them to90–110Nm

6 Locate the rear shock absorber assembly to the rear

torsion beam, t new bolts and nuts (one on each side),

and tighten them to90–110Nm

8 Locate the rear wheel speed sensor to the torsion

beam, t 1 bolt and tighten it to7–10Nm Locate the

harness of the rear wheel speed sensor to the torsion

beam (one on each side)

9 Fit rear brake calipers and brake discs

RearRear BrakeBrakeBrake DiscDiscDisc RefitRefit

Trang 33

Tyres and Wheels

Speci cations

Torque

Trang 34

2 Loosen 5 wheel bolts counterclockwise for half a turn

with the socket wrench in the vehicle

3 Raise the vehicle to the appropriate height

4 Remove the 5 wheel bolts and place them in the tool

tray

5 Remove the wheel, extract the valve core assembly

(the rubber type assembly needs to be discarded after

being pulled out) and remove the tyre from the trim

with a tyre changer

Warning: Use a tyre changer to remove the tyre Manual

tools or prybar could damage the road wheel or tyre

Caution: Do not place the wheel face down on the ground

to avoid scratching

Re t

Caution: Please remove any corrosion from the surface of

the road wheel, drum and brake disc before re tting If

wheel, disc and drum contact surfaces are not properly

cleaned, the wheel xings could become loose and may

cause thewheel to fall offwhile thevehicle is moving This

will cause the vehicle to go out of control, and could cause

injur y

1 Fit the wheel valve assembly (the rubber type assembly

needs to be tted with a new one)

2 Fit the tyre with a tyre changer and in ate the tyre

until the rim is in place Ensure that the locating ring

at the outside of the tyre bead is around the wheel rim

anges This method can ensure the correct position

of the tyre bead

3 Conduct wheel dynamic balancing with a tyre dynamic

balancer, and t the new and appropriate wheel balance

weights

4 Fit the wheel and tighten the wheel bolts until the

wheel is seated rmly against the wheel hub

5 Lower the vehicle

6 Tighten 5 wheel bolts to120–130Nm For tightening

order, please refer to the picture below (1 to 5)

Warning: If there is oil leakage between the wheel and thebrake disc or drum, it will cause the wheel bolts to becomeloose and result in injur y with the vehicle out of control.Never use heat to remove a seized wheel This will shor tenthe life of the wheel, wheel bolts , hub and bearing Wheelbolts must be tightened in correct sequence and to correcttorque to avoid distor tion of wheel, brake drum or disc

7 Fit the wheel bolt caps

Trang 35

Tyres Pressure Monitoring System

Trang 36

Service Procedures

Tyre Pressure Sensor

Remove

1 Remove the wheels

2 De ate the tyre

3 Press the tyre at the valve core on the tyre changer

until the tyre pressure sensor is exposed

4 Remove the spline locking bolt xing the tyre pressure

sensor and valve core assembly to the wheel

a For metal type valve core assembly, remove the spline

locking bolt xing the tyre pressure sensor and valve

core assembly to the wheel

b For rubber type valve core assembly, pull it out

directly and discard it

5 Remove the tyre pressure sensor and valve core

assembly

Re t

1 Fit the tyre pressure sensor and valve core seat

assembly to the wheel hub

a For metal type valve core assembly, t the locking

bolt and tighten it to4.5– 5.5Nm

b For rubber type valve core assembly, t the new tyre

pressure sensor and valve core seat assembly into

the wheel hub and install in place

Warning: Make sure that the tyre does not touch the Tyre

Pressure Sensor during disassembly and installation

2 In ate the tyre to a suitable tyre pressure value

3 Re-conduct tyre dynamic balancing

4 Fit the wheels

WheelWheel RefitRefit

5 Perform a self-learning for the tyre pressure monitoring

Trang 37

Speci cations

Torque

Bolt-Front brake caliper assembly to knuckle 25–30Nm

Bolt- Brake caliper assembly bracket to knuckle 190–210Nm

Bolt-Front brake disc shield to knuckle 7–10Nm

Bolt-Brake caliper shuck to Brake caliper knuckle 25-30Nm

Bolt-Front brake hose to front brake caliper 28–32Nm

Bolt-Front brake caliper shuck assembly to bracket 25–30Nm

Bolt-Rear brake caliper to rear torsion beam （81–99）Nm+ （85–95）°

Bolt-Rear brake disc retaining to rear torsion beam （27–33）Nm+ （85–95）°

Bolt-Rear brake caliper shuck assembly to bracket 25–30Nm

Bolt-Rear Brake hose to rear brake caliper 28–32Nm

Bolt-Rear brake caliper bracket to rear the torsion beam 90Nm+90°

Bolt-Brake fulid reservoir to brake master cylinder 2.5–4.5Nm

Nut-Brake master cylinder to vacuum houster 21–29Nm

Bolt-Brake lamp signal to brake master cylinder cylinder 7–9Nm

Bolt-acceleration pedal assembly to brake pedal 4–5Nm

Bolt-Front brake hose pipe bracket to damper 10–15Nm

Trang 38

Service Procedures

Front Brake Pad

Remove

2 Remove the guide pin caps of the front brake caliper

3 Remove the stop spring of front brake caliper (1.5T

model)

4 Remove and discard 2 guide pin bolts xing the front

brake caliper housing assembly to the steering knuckle

(1.5L model) or to the front brake caliper bracket (1.5T

model)

5 Remove the front brake caliper housing assembly

from the steering knuckle (1.5L model) or from the

front brake caliper bracket (1.5T model), and nd the

appropriate position to x it

Caution: Do not tie or allow caliper to hang on brake

hose

6 Remove the front brake pad from the front brake

caliper housing assembly (1.5L model) or from the front

brake caliper bracket (1.5T model)

Re t

1 Clean up all dir t and corrosion contents from the edge

of the front brake disc

2 Clean the front brake caliper housing and the steering

knuckle (1.5L model) or the front brake caliper bracket

(1.5T model)

3 Check the front brake caliper and seals for damage,

and replace it if necessar y

4 Locate the front brake pad into the front brake caliper

housing and lock it in place (1.5L model), or locate it to

the front brake caliper bracket (1.5T model)

5 Locate the front brake caliper housing assembly to the

steering knuckle (1.5L model) or to the front brake

6 Fit the stop spring of front brake caliper (1.5T model)

7 Fit the guide pin caps of front brake caliper

9 Depress the brake pedal for several times to t thefront brake pad in place

Tip: Pedal travel may be longer than normal during rstbrake applications

Trang 39

Front Brake Disc

Remove

2 Remove the front brake caliper assembly (1.5L model)

a Remove and discard 2 bolts xing the front brake

caliper assembly to the steering knuckle

3 Remove the front brake caliper assembly (1.5T model)

a Remove and discard 2 bolts xing the front brake

caliper assembly to the steering knuckle

4 Remove the front brake caliper assembly from the

steering knuckle

5 Lift the front brake caliper assembly and nd the

appropriate position to x it

6 Remove 1 countersunk head screw xing the front

brake disc to the front wheel hub

7 Remove the front brake disc

4 Check the front brake pad, and replace it if necessar y

5 Fit the front brake caliper assembly (1.5T model)

a Locate the front brake caliper assembly to thesteering knuckle, t 2 new bolts and tighten them to190–210Nm

6 Fit the front brake caliper assembly (1.5L model)

a Locate the front brake caliper assembly to thesteering knuckle, t 2 new bolts and tighten them

to25–30Nm

Trang 40

Front Brake Disc Guard Plate

Remove

1 Remove the front brake disc

FrontFront BrakeBrakeBrake DiscDiscDisc RemoveRemove

2 Remove and discard 3 bolts xing the front brake disc

guard plate to the front steering knuckle

3 Remove the front brake disc guard plate

Re t

1 Locate the front brake disc guard plate to the front

steering knuckle, t 3 bolts and tighten them to

7–10Nm

2 Fit the front brake disc

FrontFront BrakeBrakeBrake DiscDiscDisc RefitRefit

Front Brake Caliper Housing Assembly

Remove

2 Place an appropriate container under the vehicle tocollect the spilled liquid

3 Remove 1 bolt and gasket xing the front brake hose

to the front brake caliper housing, discard the gasketand disconnect the pipeline

Caution: Before disconnecting or removing components,ensure the immediate area around joint faces andconnections are clean Plug open connections to preventcontamination

4 Remove the front brake caliper assembly (1.5L model)

a Remove 2 guide pin caps of front brake caliper

b Remove and discard 2 guide pin bolts xing the frontbrake caliper assembly to the steering knuckle

5 Remove the front brake caliper assembly (1.5T model)

a Remove 2 guide pin caps of front brake caliper

b Remove the stop spring of the front brake caliper

Tiêu đề	Mg5 Ap32 Refit And Remove Manual
Thể loại	manual

Định dạng
Số trang	200
Dung lượng	13,99 MB