Mg hs as23 refit and remove manual p6

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Remove

1 Remove the rear left wheel

WheelsWheels RemoveRemove

2 Remove the rear wheelhouse liner

RearRear WheelhouseWheelhouseWheelhouse LinerLinerLiner RemoveRemove

3 Disconnect the two breather hoses from the canister

Caution: Always t plugs to open connections to prevent

contamination

4 Remove 2 nuts (1) xing the canister to the body

5 Remove 1 bolt (2) xing the canister to the body

contamination

6 Remove the canister

Re t

1 Make sure that all the hose connections are clean

2 Locate the canister to the body, t 1 bolt and tighten

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Under oor Fuel Pipe - 1.5T

Remove

1 Disconnect the negative battery cable

Warning: Fuel vapour is highly ammable and in con ned

spaces is also explosive and toxic Always have a re

extinguisher containing foam, CO2, gas or powder close

2 Release the pressure in the fuel system

FuelFuel SystemSystem System - PressurePressurePressure ReleaseRelease

3 Disconnect the fuel inlet pipe (1) from the high-pressure

fuel pump

4 Disconnect the canister breather hose (2) from the

canister solenoid

5 Raise the vehicle on a lift to an appropriate height

6 Disconnect the fuel inlet pipe connector

7 Disconnect the breather hose connector

8 Loosen the clip xing the under oor fuel pipe assembly

2 Connect the breather hose connector

3 Connect the fuel inlet pipe connector

4 Lower the vehicle

5 Connect the breather hose connector to the canistersolenoid

6 Connect the fuel inlet pipe connector to thehigh-pressure fuel pump

7 Connect the negative battery cable

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Under oor Fuel Pipe - 2.0T

Remove

2 Release the pressure in the fuel system

FuelFuel SystemSystem System - PressurePressurePressure ReleaseRelease

3 Disconnect the fuel inlet pipe (2) from the high-pressure

fuel pump

4 Disconnect the canister breather hose (1) from the

canister solenoid

5 Raise the vehicle on a lift to an appropriate height

6 Disconnect the fuel inlet pipe connector

7 Disconnect the breather hose connector

8 Loosen the clip xing the under oor fuel pipe assembly

2 Connect the breather hose connector

3 Connect the fuel inlet pipe connector

4 Lower the vehicle

5 Connect the breather hose connector to the canistersolenoid

6 Connect the fuel inlet pipe connector to thehigh-pressure fuel pump

Trang 4

Fuel Filler Pipe

Remove

2 Drain the fuel tank

FuelFuel TankTankTank DrainDrain

3 Remove 3 bolts xing the fuel tank ller onto the body

4 Remove the rear wheelhouse liner

RearRear WheelhouseWheelhouse LinerWheelhouse LinerLiner RemoveRemove

5 Disconnect the fuel breather hose from the canister (1)

6 Remove 2 bolts (2) xing the fuel ller pipe assembly

to the body

7 Disconnect three breather hoses (1)

8 Loosen the clamp (2), disconnect the fuel ller hose

from the fuel tank, and discard the clamp

9 Pull the fuel tank ller pipe assembly out of the vehicle

Re t

1 Locate the fuel ller hose to the fuel tank, t a newclamp and fasten it

2 Connect the breather hose

3 Locate the fuel ller pipe assembly to the body, t 2bolts and tighten them to5–7Nm

4 Connect the breather hose of the canister

5 Fit the rear wheelhouse liner

RearRear WheelhouseWheelhouseWheelhouse LinerLiner RefitLiner Refit

6 Locate the fuel tank ller onto the body, t 3 bolts andtighten them to5–7Nm

7 Re ll the fuel tank

8 Fit the fuel tank ller cap

9 Close the fuel ller door

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Fuel System - Pressure Release

Check

1 Loosen the fuel ller cap to release the steam pressure

in the fuel tank

2 Remove the fuel pump fuse from the engine

compartment fuse box

3 Place the ignition switch in “ON” position and keep the

engine idling until it stops

4 Place the ignition switch in "OFF" position, restart the

engine with the ignition key and keep for 10s to con rm

that the engine has no fuel

5 Fix the fuel ller cap

Fuel System - Pressure Test - SGE 1.5T

Check

1 Place a piece of absorbent cloth around the joint of thehigh-pressure fuel pump low-pressure fuel pipe and theunder oor fuel pipeline to absorb the 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

2 Disconnect the high-pressure fuel pump low-pressurefuel pipe from the fuel supply pipe

3 Respectively connect the connectors of thehigh-pressure fuel pump low-pressure fuel pipe andthe fuel supply pipe to the quick connectors of theTCH00107

4 Fix theTCH00107 to the fuel pressure gauge T18002

5 Start the engine to allow the fuel pump to work,observe the readings on the fuel pressure gauge within

a min ute; if the readings are in the range of 5.3-6 bar, itindicates that the fuel system is normal

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pressure maintaining, so check the pressure regulating

valve of the fuel pump for normal operation

7 Respectively disconnect the high-pressure fuel pump

low-pressure fuel pipe and the fuel supply pipe from

theTCH00107

8 Drain the fuel remaining in the tool to the container

9 Connect the low-pressure fuel pipe of high-pressure

fuel pump to the fuel supply pipe

Fuel System - Pressure Test - 2.0T

Check

1 Place a piece of absorbent cloth around the joint of thehigh-pressure fuel pump low-pressure fuel pipe and theunder oor fuel pipeline to absorb the 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

2 Disconnect the high-pressure fuel pump low-pressurefuel pipe from the fuel supply pipe

3 Respectively connect the connectors of thehigh-pressure fuel pump low-pressure fuel pipe andthe fuel supply pipe to the quick connectors of theTCH00106

4 Fix theTCH00106 to the fuel pressure gauge T18002

5 Start the engine to allow the fuel pump to work,observe the readings on the fuel pressure gauge within

Trang 7

pressure maintaining, so check the pressure regulating

valve of the fuel pump for normal operation

7 Respectively disconnect the high-pressure fuel pump

low-pressure fuel pipe and the fuel supply pipe from

theTCH00106

8 Drain the fuel remaining in the tool to the container

9 Connect the low-pressure fuel pipe of high-pressure

fuel pump to the fuel supply pipe

Fuel Tank Drain and Re ll

DrainWarning: The capacity of containers must be more thanadequate for the amount of fuel to be extracted ordrained The container should be clearly marked with itscontents and placed in a safe storage area which meetsthe requir ements of local authority regulation

Warning: Proper fuel recovery equipment must be used,and make sure the necessar y protective measures havetaken to prevent re and explosion

1 Open the fuel ller cap

2 With the fuel recovery device, drain the fuel into asealed container from the fuel tank

3 Please follow the manufacturer's instructions forconnection and safe use of the fuel recovery device.Warning: The capacity of containers must be more thanadequate for the amount of fuel to be extracted ordrained The container should be clearly marked with itscontents and placed in a safe storage area which meetsthe requir ements of local authority regulation

4 Re ll the fuel tank

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Special Tools

Tool

Number Description Picture

TCH00108 Wrench fueltank lock ring

TCH00107Three-way pipeof fuel pressure

gauge

T18002 test equipmentFuel pressure

TCH00106Three-way pipeof fuel pressure

gauge

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Engine Control System-2.0T

Bolt-CMP sensor to camshaft cover 9–11Nm

Bolt -high fuel bump to camshaft cover 9-11Nm

Nut -low fuel line to high fuel bump 20-24Nm

Nut -high fuel line to high fuel bump 26-34Nm

Nut -high fuel line to fuel rail 26–34Nm

Screw-MAP sensor to throttlebody inlet pipe 5–7Nm

Screw-turbocharger valve to bracket 2.5–3.5Nm

Bolt-fuel rail to camshaft cover 23-27Nm

Bolt -purge valve bracket to intake manifold 9–11Nm

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Service Procedures

Spark Plug

Remove

1 Disconnect the battery negative

2 Remove the engine cover

3 Remove the ignition coil

IgnitionIgnition CoilCoilCoil RemoveRemove

4 Clean the area around the spark plug Remove the dust

around the spark plug with high pressure gas

5 Remove 4 spark plugs with the spark plug socket

Re t

1 The gap of each new spark plug shall be within

0.70—0.80mm

2 Fit the spark plug and tighten it to15-20Nm

3 Fit the ignition coil

IgnitionIgnition CoilCoilCoil RefitRefit

4 Fit the engine cover

5 Connect the battery negative

Ignition Coil

Remove

3 Disconnect the connector of the ignition coil (1)

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

5 Hold the rubber bush end of the ignition coil, and pullout the ignition coil from the spark plug (if it is hard topull it out, rotate the ignition coil from left to right)

6 Repeat step 3 to 5 to remove other ignition coils

Re t

1 Fit the ignition coil into the spark plug When tting theignition coil, align the hole of the ignition coil with thebolt hole on the camshaft cover, and ensure the ignitioncoil is inserted into the spark plug Fit 2 bolts, tighten

to7-10Nm and check the torque

2 Connect the ignition coil connector

3 Repeat step 1 and 2 to t other ignition coils

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Engine Control Module (ECM)

Remove

2 Disconnect the connector from theECM

Caution: ECM

3 Remove 4 nuts xing theECM to the rewall

Re t

1 Fix theECM to the rewall, t 4 nuts, tighten them to

7–10Nm and check the torque

2 Fix the wire harness and connect it to theECM

connector

Caution: ECM

4 Perform the programming and encoding and mixed gas

self-learning forECM

5 Perform self-learning for the electronic throttle

ElectronicElectronic ThrottleThrottleThrottle Self-learningSelf-learning

6 Place the ignition switch in "ON" position, perform

"Engine Control Module Reset Self-learning Value" with

VDS

7 Wait for 2-5 seconds, turn off the ignition switch, then

restart the vehicle

ECT Sensor

Remove

2 Remove the coolant expansion tank cap to release thepressure of the cooling system, and t the cap.Warning:

3 Remove the reservoir from the reservoir bracket

4 Disconnect the ECT sensor connector

5 Prepare a proper container to collect the spilledcoolant

6 Remove the ECT sensor and discard the seal ring

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

to14–18Nm

4 Connect the connector of the ECT sensor

5 Fit the reservoir to the reservoir bracket

7 Check the coolant level, re ll if necessar y

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Intake Camshaft Position Sensor

Remove

3 Disconnect the connector of the intake camshaft

position sensor

4 Remove 1 bolt xing the intake camshaft position

sensor to the cylinder block, and remove the sensor

Re t

1 Clean the mating surface of the intake camshaft position

sensor and cylinder block

2 Fix the intake camshaft position sensor to the cylinder

block, t 1 bolt, tighten to9–11Nm, and check the

torque

3 Connect the connector of the intake camshaft position

sensor

6 Turn the ignition switch to ON position ConnectVDS

and execute” ECM Adaption Reset ”

7 Wait the 2-5 seconds, turn off the ignition switch, then

restart the vehicle

Exhaust Camshaft Position Sensor

Remove

3 Disconnect the connector of the exhaust camshaftposition sensor

4 Remove 1 bolt xing the exhaust camshaft positionsensor to the cylinder block, and remove the sensor

3 Connect the connector of the exhaust camshaftposition sensor

6 Turn the ignition switch to ON position ConnectVDSand execute” ECM Adaption Reset ”

7 Wait the 2-5 seconds, turn off the ignition switch, thenrestart the vehicle

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Oil Pressure Switch

Remove

2 Remove the bottom de ector

BottomBottom DeflectorDeflectorDeflector RemoveRemove

3 Place the oil sink under the switch to collect the spilled

1 Clean the thread of the oil pressure switch

2 Fit the new seal ring to the oil pressure switch

3 Fix the oil pressure switch to the oil lter module,

tighten the switch to14–18Nm and check the torque

4 Connect the oil pressure switch connector

5 Remove the oil sink

6 Fit the bottom de ector

BottomBottom DeflectorDeflectorDeflector RefitRefit

7 Connect the battery negative cable

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

Hot Film Meter (HFM)

Remove

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

3 Release the clamp and disconnect the turbochargerintake pipe and air ow meter (2)

4 Remove 2 screws xing the air ow meter to the upperair lter housing, and remove the air ow meter

Re t

1 Fix the air ow meter to the upper housing of the airlter, t 2 screws, tighten to1.4– 1.8Nm, and checkthe torque

2 Fit the turbocharger air inlet hose to the air ow meter,and secure with clamps

3 Connect the connector of the air ow meter

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High-pressure Fuel Pump

Remove

Caution:

3 Remove the shield of the high-pressure oil pump

4 Place cloths with strong absorptivity around the

high-pressure fuel pump to collect the spilled fuel

Warning: The spilling of fuel is unavoidable during this

operation Ensure that all necessar y precautions are

taken to prevent re and explosion

5 Unscrew the high-pressure pipe nut (1) on the

high-pressure fuel pump (one or two circles),

and release the nut completely after the fuel stop

over owing

6 Take away the cloth from the high-pressure fuel pump

and put it into a permissible container

Caution:

7 Remove the high-pressure fuel pipe nut (2) from the fuel

rail to release the high-pressure fuel pipe, and discard it

11 Remove the high-pressure fuel pump and roller tappet

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and tappet.

3 Fit a new seal ring to the high-pressure fuel pump

4 Fix the high-pressure fuel pipe to the camshaft cover, t

2 bolts, tighten to9-11Nm, and check the torque

Caution:

5 Connect the low-pressure fuel pipe to the high-pressure

fuel pump, tighten the nut to20-24Nm and check

the torque

6 Connect the connector of the high-pressure fuel pump

7 Replace the high-pressure fuel pipe with a new one,

for it is disposable

8 Fix the high-pressure fuel pipe to the high-pressure

fuel pump and fuel rail, tighten 1 nut connecting the

high-pressure fuel pipe and the high-pressure fuel pump

to26-34Nm, and tighten the other nut securing the

high-pressure fuel pipe and fuel rail to26–34Nm, then

check the torque

9 Fit the shield of the high-pressure oil pump

Fuel Rail Pressure Sensor

RemoveCaution:

3 Disconnect the connector of the fuel rail pressuresensor

4 Place cloths with strong absorptivity around the fuel railpressure sensor to collect the 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 Before removing the fuel rail pressure sensor, keep thevehicle stationary for more than 2 hours, unscrew thefuel rail pressure sensor (less than half circle) until thefuel does not over ow

6 Take away the cloth from the fuel rail pressure sensorand put it into an permissible container

Caution:

Re t

1 Fix the fuel rail pressure sensor to the fuel rail, tighten

to30–35Nm and check the torque

2 Connect the connector of the fuel rail pressure sensor

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Crankshaft Position Sensor

Remove

2 Remove the starter motor

StarterStarter MotorMotorMotor RemoveRemove

3 Disconnect the connector of the crankshaft position

sensor

4 Remove 1 bolt (1) xing the crankshaft position sensor

to the cylinder block, and remove the sensor

Re t

1 Clean the mating surface of the cranks haft position

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

t 1 bolt, tighten to9–11Nm, and check the torque

3 Connect the connector of the cranks haft position

sensor

4 Fit the starter motor

StarterStarter MotorMotorMotor RefitRefit

6 Turn the ignition switch to ON position ConnectVDS

and execute” ECM Adaption Reset ”

7 Wait the 2-5 seconds, turn off the ignition switch, then

restart the vehicle

Intake Air Temperature/Manifold AbsolutePressure Sensor

Remove

1 Disconnect the battery negative cable

3 Disconnect the connector of the TMAP sensor

4 Release 2 screws xing the TMAP sensor to the intakemanifold and remove the sensor

Re t

1 Clean the mating face of the intake airtemperature/manifold absolute pressure sensorand intake manifold

2 Fit the intake air temperature/manifold absolutepressure sensor to the intake manifold and tighten thescrew to5–7Nm

3 Connect the connector of the intake airtemperature/manifold absolute pressure sensor

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Manifold Absolute Pressure/Temperature Sensor

Remove

2 Disconnect the connector of the manifold absolute

pressure sensor

3 Release 2 screws xing the manifold absolute pressure

sensor to the throttle intake pipe and remove the

sensor

Re t

1 Clean the mating face of the manifold absolute pressure

sensor and throttle intake pipe

2 Fit the manifold absolute pressure sensor to the

throttle intake pipe and tighten the screw to5–7Nm

3 Connect the connector of the manifold absolute

pressure sensor

Knock Sensor

Remove

2 Raise the vehicle on a lift

Warning: Do not work on or under a vehicle supportedonlyby a jack.Always support the vehicle on safety stands

3 Disconnect the knock sensor connector

Warning: Exhaust components get extremely hot duringoperation Ensure exhaust components are suf cientlycooled before handling

4 Remove 1 bolt (2) xing the knock sensor to thecylinder block, and remove the knock sensor

3 Connect the knock sensor connector

4 Lower the vehicle

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Heated Oxygen Sensor - Front

Remove

3 Remove the front oxygen sensor connector from the

connector bracket of the front oxygen sensor

4 Disconnect the front oxygen sensor connector

5 Remove the front oxygen sensor from the front

three-way catalytic converter with theTEN00011

Warning: Exhaust components get extremely hot during

operation Ensure exhaust components are suf ciently

cooled before handling

Re t

1 Clean the mating face of the front oxygen sensor and

front exhaust pipe

2 Apply high temperature antiwelding agent to the

thread of the front oxygen sensor, t the front oxygen

sensor to the three-way catalytic converter with the

theTEN00011, tighten to 45–60Nm and check the

torque

3 Connect the front oxygen sensor connector

4 Fit the front oxygen sensor connector to the connector

bracket of the front oxygen sensor

Heated Oxygen Sensor - Rear

Remove

2 Raise the vehicle on a lift

Warning: Do not work on or under a vehicle supportedonlyby a jack.Always support the vehicle on safety stands

BottomBottom DeflectorDeflector RemoveDeflector Remove

4 Remove the rear oxygen sensor connector from theconnector bracket of the rear oxygen sensor

5 Disconnect the rear oxygen sensor connector

6 Remove the rear oxygen sensor from the front exhaustpipe with theTEN00011

Warning: Exhaust components get extremely hot duringoperation Ensure exhaust components are suf cientlycooled before handling

Re t

1 Clean the mating face of the rear oxygen sensor andrear exhaust pipe

2 Apply high temperature antiwelding agent to the thread

of the rear oxygen sensor Fit the rear oxygen sensor

to the front exhaust pipe with theTEN00011, tighten

to45–60Nm, and check the torque

3 Connect the rear oxygen sensor connector

4 Fit the rear oxygen sensor connector to the connectorbracket of the rear oxygen sensor

5 Fit the bottom de ector

BottomBottom DeflectorDeflector RefitDeflector Refit

6 Lower the vehicle

Trang 19

Turbocharger Solenoid Valve

Remove

2 Note the hose connection on the solenoid valve and

disconnect 3 hoses

3 Disconnect the connector of the solenoid valve

4 Release 2 bolts xing the turbocharger solenoid valve

to the bracket, and remove the solenoid valve

Re t

1 Fix the solenoid valve to the bracket, t 2 bolts, tighten

to2.5– 3.5Nm, and check the torque

2 Connect the connector of the solenoid valve

3 Connect 3 hoses to the solenoid valve correctly

Fuel Rail

RemoveCaution:

3 Remove the shield of the high-pressure oil pump

4 Place cloths with strong absorptivity around thehigh-pressure fuel pump to collect the 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 Unscrew the high-pressure pipe nut (1) on thehigh-pressure fuel pump (one or two circles),and release the nut completely after the fuel stopover owing

6 Take away the cloth from the high-pressure fuel pumpand put it into a permissible container

Trang 20

8 Disconnect the connector of the injector nozzle ,

high-pressure sensor, intake camshaft oil control valve

and front oxygen sensor

9 Remove the engine harness clip from the fuel rail bolt

10 Remove 7 bolts xing the fuel rail to camshaft cover in

the sequence shown

11 Remove the fuel rail assembly

Re t

1 If the injector is disconnected from the fuel rail, replace

all seal rings and spring clips of the injector; if it is not

disconnected, replace the seal ring of the combustion

chamber only

2 Fit the fuel rail, ensure the injector will not contact the

camshaft cover, t 7 bolts and pre-tighten the bolt

3 Tighten the bolts to23-27Nm in the sequence shown

and check the torque

Caution:

4 Fit the engine harness clip to the fuel rail bolt

5 Connect the connector of the injector nozzle ,high-pressure sensor, intake cam shaft oil control valveand front oxygen sensor

6 Replace the high-pressure fuel pipe with a new one,for it is disposable

7 Fix the high-pressure fuel pipe to the high-pressurefuel pump and fuel rail, tighten 1 nut connecting thehigh-pressure fuel pipe and the high-pressure fuel pump

to26-34Nm, and tighten the other nut securing thehigh-pressure fuel pipe and fuel rail to26–34Nm, thencheck the torque

8 Fit the shield of the high-pressure oil pump

Trang 21

Remove

FuelFuel RailRailRail AssemblyAssembly RemoveAssembly Remove

3 Remove the spring clip from the fuel injector

4 Remove the fuel injector with theTEN00121

5 Remove and discard the fuel injector seal ring

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

Re t

1 Remove the block cap from each fuel injector

2 Clean the groove of the fuel injector and fuel rail

3 Fit the fuel injector seal rings to the steering tool of

theTEN00064, then t the fuel injector seal rings to

the fuel injector with theTEN00064, and t the fuel

injector seal rings in sequence

4 Replace the spring clip, and t the new clip to the

injector nozzle

5 Fit the fuel injector to the fuel rail assembly

Canister Solenoid

Remove

3 Disconnect the connector of the activated carboncanister solenoid valve

4 Loosen the clamps, and disconnect the two pipesconnecting the activated carbon canister solenoid valve

5 Remove the activated carbon canister solenoid valvefrom the bracket

6 Remove 1 bolt xing the bracket of the activatedcarbon canister solenoid valve to the intake manifoldand remove the bracket

Re t

1 Fix the activated carbon canister solenoid valve bracket

to the intake manifold, t 1 bolt, tighten to9–11Nmand check the torque

2 Fit the activated carbon canister solenoid valve to thebracket

3 Connect the 2 pipes of the activated carbon canistersolenoid valve and secure them with clamps

Trang 22

6 Connect the battery negative.

Trang 23

Special Tools

Tool

TEN00011 Wrench O2sensor

TEN00121 Injector removetool

TEN00064 Injector sealinstaller and

sizer

Trang 24

Engine Control System-1.5T

Speci cations

Torque

Bolt-fuel pump bracket to engine 19–25Nm

Bolt-fuel rail assembly to injector 4–6Nm

Bolt-fuel rail assembly to engine 9–11Nm

Bolt-the camshaft phase adjust the solenoid valve 8–12Nm

Bolt-After oxygen sensor bracket to transmission 14-18Nm

Bolt-emissions pressure relief valve 8–10Nm

Trang 25

Service Procedures

Fuel Pump

Remove

Caution:

3 Place cloths with strong absorptivity around the fuel rail

high-pressure fuel pipe to collect the spilled fuel

4 Slowly loosen the high-pressure fuel pipe nut at the

high-pressure fuel rail end until the fuel ows out, and

remove the nut when no fuel ows out

5 Remove the cloth from the high-pressure fuel rail, and

put it into a permissible container

Caution:

6 Remove the high-pressure fuel pipe nut of the

high-pressure fuel pump to remove and discard the

high-pressure fuel pipe

contamination

7 Disconnect the connector of high-pressure fuel pump

8 Remove the clip xing the harness to the high pressure

fuel-pump bracket, and remove the harness

9 Disconnect the low-pressure fuel pipe from the

high-pressure fuel pump

10 Remove 3 bolts xing the high-pressure fuel pump

protecting bracket to the engine cylinder block, and

remove the high-pressure fuel pump protecting bracket

12 Remove 2 bolts xing the fuel pump to the engine, andrem ove the high-pressure fuel pump and roller tappet

4 Fit the fuel pump sponge noise enclosure

5 Fix the high-pressure fuel pump protecting bracket

to the engine cylinder block, t 3 bolts, tighten to19–25Nm, and check the torque

6 Connect the low pressure oil pipe

7 Locate the harness to the high-pressure fuel pumpbracket, x it with clips, and connect the connector ofhigh-pressure fuel pump

8 Fix a new high-pressure fuel pipe to the fuel pump andfuel rail, t 2 nuts, and tighten to28–32Nm

Trang 26

Fuel Rail

Remove

Caution:

2 Remove the engine hood

3 Place cloths with strong absorptivity around the fuel rail

high-pressure fuel pipe to collect the spilled fuel

4 Slowly loosen the high-pressure fuel pipe nut at the

high-pressure fuel rail end until the fuel ows out, and

remove the nut when no fuel ows out

5 Remove the cloth from the high-pressure fuel rail, and

put it into a permissible container

Caution:

6 Remove the connecting nut between the high-pressure

fuel pump and high-pressure fuel pipe , remove the

high-pressure fuel pipe , and discard the high-pressure

IgnitionIgnition CoilCoilCoil RemoveRemove

11 Disconnect the connector on the fuel injector

12 Remove 8 bolts xing the fuel rail to the fuel injector

13 Remove 8 bolts xing the fuel rail to the cylinder head,and rem ove the fuel rail

2 Fit 8 bolts xing the fuel rail to the fuel injectors,tighten them to4–6Nm, and check the torque

3 Tighten 8 bolts manually in the sequence of8-4-2-6/7-3-1-5 Tighten 8 bolts in the sequence of 1-8.Tighten the bolt to half of the nal torque at the rsttime, then further tighten to the nal torque9–11Nm,and check the torque

4 Connect the connector on the fuel injector

IgnitionIgnition CoilCoilCoil RefitRefit

6 Connect the fuel rail harness and engine harness

7 Fix a new high-pressure fuel pipe to the fuel rail

Trang 27

Fuel Injector

Remove

2 Remove 4 fuel injectors with theTEN00121 and

TEN00140, and discard 16 fuel injector seal rings

Re t

1 Clean the groove of the fuel injector and fuel rail

2 Fit the fuel injector seal rings to the steering tool of

the special toolTEN00064, then t the fuel injector

seal rings to the fuel injector with the special tool

TEN00064, and t the fuel injector seal rings in

sequence

3 Fix the fuel injector into the fuel injector seat hole in

the cylinder head, and t it in place

4 Fit the fuel rail assembly

FuelFuel RailRailRail AssemblyAssembly RefitAssembly Refit

Spark Plug

Remove

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 to20Nm, and check thetorque

IgnitionIgnition CoilCoil RefitCoil Refit

Trang 28

Engine Control Module (ECM)

Remove

2 Disconnect the connector from theECM

ECMWhen disconnecting the connector, avoid shaking the

connector all round; avoid applying force on one side only;

avoid damaging the connector structure

3 Remove 4 nuts xing theECM to the rewall

Re t

1 Fix theECM to the rewall, t 4 nuts, tighten them to

7-10Nm and check the torque

2 Fix the wire harness and connect it to theECM

connector

Caution: ECM

4 Perform the programming and encoding and mixed gas

self-learning forECM

5 Perform self-learning for the electronic throttle

ElectronicElectronic ThrottleThrottleThrottle Self-learningSelf-learning

6 Place the ignition switch in "ON" position, perform

"Engine Control Module Reset Self-learning Value" with

VDS

7 Wait for 2-5 seconds, turn off the ignition switch, then

restart the vehicle

Ignition Coil

Remove

2 Disconnect 4 ignition coil connectors

3 Remove 4 bolts xing the ignition coil to the cylinderhead

4 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

Trang 29

Crankshaft Position Sensor

Remove

2 Raise the vehicle on the lift

3 Disconnect the electrical connector from 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 mating surface of the cranks haft position

2 Secure the crankshaft position sensor to the cylinder

block, t 1 bolt and tighten to8–12Nm

3 Connect the crankshaft position sensor connector

4 Lower the vehicle

6 Place the ignition switch in ON, and useVDS to

perform "ECM Adaption Reset"

7 Wait for 2-5 seconds, and turn off the ignition switch,

then re-start the vehicle

Engine Coolant Temperature Sensor

Remove

2 Remove the coolant expansion tank cap to release thepressure of the cooling system, and 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 pump,and remove the vacuum hose

4 Loosen the clip of the coolant temperature sensor

5 Disconnect the coolant temperature sensor connector

6 Pull up and remove the coolant temperature sensor

7 Prepare a proper container to collect the spilledcoolant

Re t

1 Clean the coolant temperature sensor

2 Check the sensor seal ring for aging, deformation,fracture, etc., if any, the sensor assembly is to bereplaced

3 Fit the coolant temperature sensor, and x it with clips

4 Connect the coolant temperature sensor connector

5 Fit the vacuum hose to the vacuum pump

7 Check the coolant level, re ll if necessar y

Trang 30

Manifold Absolute Pressure Sensor

Remove

2 Disconnect the manifold absolute pressure sensor

connector

3 Remove 1 screw xing the manifold absolute pressure

sensor to the manifold

4 Remove the manifold absolute pressure sensor

Re t

1 Fix the manifold absolute pressure sensor to the

manifold, t 1 screw, and tighten to4–6Nm

2 Connect the manifold absolute pressure sensor

connector

Camshaft Position Sensor

Remove

2 Disconnect the connectors of the intake/exhaustcamshaft position sensors respectively

3 Remove 2 bolts xing the intake/exhaust camshaftposition sensors to the cylinder block respectively, andremove the 2 camshaft position sensors

4 Connect the connectors of 2 camshaft position sensors

6 Place the ignition switch in "ON" position, and perform

"Engine Module Reset Self-learning Value" withVDS

7 Wait for 2-5 seconds, turn off the ignition switch, thenrestart the vehicle

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Camshaft Phase Adjustment Solenoid Valve

Remove

3 Disconnect the connectors of 2 camshaft phase

adjustment solenoid valves

4 Remove 2 bolts xing 2 camshaft phase adjustment

solenoid valves to the engine

5 Remove 2 camshaft phase adjustment solenoid valves

Re t

1 Fix 2 camshaft phase adjustment solenoid valves to the

engine, t 2 bolts, tighten them to8–12Nm, and check

the torque

2 Connect the connectors of 2 cam shaft phase adjustment

solenoid valves

Oil Pressure Sensor

Remove

StarterStarter MotorMotor RemoveMotor Remove

3 Disconnect the connector of the oil pressure sensor

4 Place the oil sink under the sensor to collect theover owing uid

5 Remove the oil pressure sensor with the socket

Re t

1 Clean the thread of the oil pressure sensor

2 Fit new sealant to the oil pressure sensor, t the oilpressure sensor to the engine, tighten the sensor to31–39Nm, and check the torque

3 Connect the connector of the oil pressure sensor

StarterStarter MotorMotor RefitMotor Refit

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

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Knock Sensor

Remove

StarterStarter MotorMotorMotor RemoveRemove

3 Disconnect the knock sensor connector

4 Remove 1 bolt securing the knock sensor onto the

cylinder block, and remove the knock sensor

3 Connect the knock sensor connector

StarterStarter MotorMotorMotor RefitRefit

Oxygen Sensor

Remove

2 Disconnect the front oxygen sensor connector (1)

3 Remove the front oxygen sensor (2) from the three-waycatalyst with the special toolTEN00011

BottomBottom DeflectorDeflector RemoveDeflector Remove

5 Disconnect the rear oxygen sensor connector (1)

6 Remove 1 bolt xing the rear oxygen sensor connectorbracket to the gearbox (2)

7 Remove the rear oxygen sensor (3) from the frontexhaust pipe with the special toolTEN00011

Re t

1 Fit the rear oxygen sensor to the front exhaustpipe with the special toolTEN00011, tighten to40–60Nm, and check the torque

2 Fit 1 bolt xing the rear oxygen sensor connectorbracket to the gearbox, and tighten to14-18Nm

Trang 33

and check the torque.

6 Connect the front oxygen sensor connector

Canister Solenoid

Remove

2 Disconnect the connector of carbon canister solenoidvalve (1)

3 Disconnect the vacuum hose from the canister solenoid(2)

4 Disconnect the fuel breathing hose from the canistersolenoid (3)

5 Remove the canister solenoid from the canistersolenoid bracket of the engine cylinder block

3 Connect the canister solenoid valve connector

4 Fix the canister solenoid valve to the canister solenoidvalve bracket of the engine cylinder block

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Turbocharger Electrically Controlled Bypass

Valve

Remove

2 Disconnect the connector of the turbocharger

electrically controlled bypas s valve (1)

3 Disconnect 3 hoses connected with the turbocharger

electrically controlled bypas s valve (2)

4 Remove 1 bolt xing the control valve to the

turbocharger, and remove the turbocharger electrically

controlled bypass valve (3)

Re t

1 Fix the turbocharger electrically controlled bypass valve

to the turbocharger, t 1 bolt, tighten to4–6Nm, and

check the torque

2 Connect 3 hoses to the turbocharger electrically

controlled bypass valve

3 Connect the connector of the turbocharger electrically

Turbocharger Relief Valve

Remove

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

3 Disconnect the joint (1) of turbocharger to intercoolerhose turbocharger from the turbocharger and removethe pipeline

4 Disconnect a hose of the turbocharger electricallycontrolled relief valve and remove the pipeline

Trang 35

the turbocharger.

7 Remove the turbocharger relief valve

Re t

1 Fix the turbocharger relief valve to the turbocharger, t

3 bolts, tighten to8–10Nm, and check the torque

2 Connect the connector of the turbocharger relief valve

3 Connect a hose of the turbocharger electrically

4 Remove the turbocharger to intercooler hose to the

turbocharger

5 Fit the turbocharger inlet pipe to the turbocharger, and

x it with clamps

Intake Air Temperature and Pressure Sensor

Remove

2 Remove 2 bolts xing the expansion tank to the upperradiator beam, remove the expansion tank

3 Disconnect the connector of the intake air temperaturepressure sensor

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 air intake 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 the battery bracket, t 2 bolts,tighten them o4–6Nm, and check the torque

Trang 36

Special Tools

Tool

TEN00121 Injector rem ovetool

TEN00140 Fuel injectorremover

TEN00064 Injector sealinstaller and

sizer

TEN00011 Wrench O2sensor

Trang 37

Engine Electrical System-2.0T

Speci cations

Torque

Bolt - Alternator to cylinder body 45–53Nm

Bolt -Harness bracket to Alternator 5–7Nm

Bolt - PAS bracket to cylinder head 23–27Nm

Nut- Battery lead to starter motor 11–13Nm

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Service Procedures

Alternator

Remove

2 Remove the auxiliary drive belt

AuxiliaryAuxiliary DriveDriveDrive BeltBeltBelt RemoveRemove

3 Remove the turbocharger intake hose

TurbochargerTurbocharger IntakeIntakeIntake HoseHoseHose RemoveRemove

4 Remove the turbocharger control solenoid valve

TurbochargerTurbocharger ControlControlControl SolenoidSolenoid ValveSolenoid ValveValve RemoveRemove

5 Remove 3 bolts xing the E-PAS idler assembly support

to cylinder head, and remove the support and E-PAS

idler assembly

6 Remove the harness bracket bolt from the engine and

take away the harness

7 Loosen and remove the connector from the alternator

8 Remove 3 bolts securing the alternator and cylinder

4 Fit the connector of the alternator and engine harness

5 Fix the E-PAS idler assembly support to the cylinderhead, t 3 bolts, tighten to23–27Nm，and checkthe torque

6 Fit the turbocharger control solenoid valve

TurbochargerTurbocharger ControlControlControl SolenoidSolenoidSolenoid ValveValve RefitValve Refit

7 Fit the turbocharger intake hose

TurbochargerTurbocharger IntakeIntake HoseIntake Hose RefitHose Refit

8 Fit the auxiliary drive belt

AuxiliaryAuxiliary DriveDrive BeltDrive Belt RefitBelt Refit

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Auxiliary Drive Belt

Remove

2 Raise the vehicle to a suitable height for operation

Warning: Do not work on or under a vehicle supported

onlyby a jack.Always support the vehicle on safety stands

3 Remove the liner of the right front wheel house

FrontFront WheelWheel HouseWheel House LinerHouse LinerLiner RemoveRemove

4 Inser t theTEN00119 into the 4 square holes

of the tensioner, and turn the torque wrench

counterclockwise to disconnect the tensioner from

the belt

Caution:

5 Keep the tension pulley at the position, and use an

appropriate pin to t it into the hole on the rear panel

of the tension pulley

6 Take out the belt

Re t

1 In the sequence shown, t the auxiliary drive belt into

each pulley groove, tension pulley and idler

2 Fit theTEN00119 into the four holes of the tensioner,turn it counterclockwise to release the tensioner,and remove the locking pin Ensure the belt of themulti-wedge pulley on the position shown is stuck intothe groove, only put the belt of the wheel in the middle

of the pulley and mark "Quali ed" with the marker.Ensure the belt tted is basically in the middle of thetension pulley and a minimum margin of 2mm shall beleft on both sides of the tension pulley

3 Take out the tool

4 Fit the right from wheel house liner

RightRight FrontFrontFront WheelWheel HouseWheel House LinerHouse LinerLiner RefitRefit

5 Lower the vehicle

Trang 40

Starter Motor

Remove

2 Raise the vehicle to a suitable height for operation

Warning: Do not work on or under a vehicle supported

onlyby a jack.Always support thevehicle on safety stands

3 Disconnect the connector (1) from the starter motor

4 Remove the nut, and disconnect the battery wire (2)

from the starter motor

5 Unscrew 2 bolts xing the starter motor and rem ove

the starter motor

Re t

1 Clean the mating face of the starter motor and

transmission Clean the pin and pin hole

2 Locate the starter motor to the transmission housing,

t and tighten 2 bolts to75–90Nm

3 Connect the battery wire to the starter motor, and

tighten nuts to11–13Nm

4 Fit the harness connector

Automatic Tensioning Wheel - Auxiliary DriveBelt

Remove

1 Remove auxiliary drive belt

AuxiliaryAuxiliary DriveDrive BeltDrive Belt RemoveBelt Remove

2 Remove 2 bolts of the automatic tensioning wheel

3 Remove the automatic tensioning wheel of the auxiliarydrive belt

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Dung lượng	13,39 MB