Attention! Upon completion of the replacement of engine parameter sensors, it is necessary to read information about malfunctions from the memory of the memory of the ECU-KSUD of the system «DME». Eliminate malfunctions and erase information about malfunctions from the memory of the memory.
The engine crankshaft speed sensor is installed under the starter, it must be replaced in the following order. Switch off the ignition and remove the stiffening plate. Unlock the loop and disconnect it from the engine crankshaft speed sensor (23 see fig. 3.3). Remove the screw (24) and remove the sensor.
1 - cylinder block; 2 - screw plug (M14x1.5); 3 - sealing ring; 4 - centering sleeve (∅13,5); S - shield; 6, 30 - centering sleeve (∅10.5); 7, 8 - nozzle; 9 - bolt (M6x16); 10 - plug; 11 - cover; 12 - centering sleeve (∅14,5); 13 - sealant; 14 - stuffing box cover; 15.16 - bolt (М8x32); 17 - stuffing box; 18 - centering sleeve (∅10,5); 19 - bolt (М8x22); 20 - oil level damper; 21 - bolt (M6x12); 22 - O-ring (17x3); 23 - crankshaft sensor; 24 - bolt (M6x16); 25 - hairpin (M8x35); 26 - hairpin (М10x40); 27 - bolt (М8x22); 28 - intermediate insert; 29 - screw plug (M24x1.5); 30 - centering sleeve (∅13,5); 31 - knock sensor; 32 - bolt (M8x30); 33 - bolt (М10x92); 34 - screw plug (M14x1.5); 35, 36 - cover pin
Intake camshaft position sensor (35, see fig. 3.63) located on the cylinder head, it must be replaced in the following order.
1, 19 - plug; 2 - nut; 3 - protective cover; 4 - overlay; 5, 28, 31, 33, 39 - sealing ring; 6, 23 - locating pin; 7 - rubber-metal hinge; 8, 9 - cap nut; 10 - gasket washer; 11 - sealant; 12, 13, 14 - profile gasket; 15, 37 - sealing ring (17x3); 16, 35 - camshaft sensor; 17, 34 - bolt (M6x16); 18 - precision bolt; 20 - plug with a sealing ring; 21 - flange hook; 22 - mount; 24 - nut M6; 25 - jumper «masses»; 26 - bolt (M6x10); 27 - nut M8; 29, 32 - hollow bolt; 30 - oil pipeline; 36 - EMC; 37 - ring (17x3); 38 - piston; 39 - spring; 40 - cylinder head; 41 - metal seal; 42 - executive unit; 43 - oil filler cap; 44 - head cover
Switch off the ignition and remove the air filter housing. Remove solenoid valve (36) D-VANOS control unit for intake camshaft. Disconnect the loop on the cable box.
Connect a piece of auxiliary wire about 50–60 cm long to the sensor loop, which will facilitate the installation of a new sensor in the future. Remove the screw (34) sensor mounts (35). Remove the sensor from the cylinder head. Pull out the end of the sensor wire until the auxiliary cable goes into its place in the cable box. Remove the sensor together with the wire connecting it to the system. Disconnect the auxiliary wire from the faulty sensor. Fix on the auxiliary wire AL of the new sensor. Pull the cable of the new sensor into the cable box using the auxiliary wire.
Check O-ring (33) for possible damage, replace it if necessary. Replace o-ring (37) solenoid valve (36) D-VANOS system and fasten the valve with a torque of 30 Nm (3.0 kgf·m).
Exhaust camshaft position sensor (16, see fig. 3.63) located at the front of the cylinder head on the exhaust side, it must be replaced in the following order. Turn off the ignition and disconnect the loop from the sensor.
Remove bolt (17) mounting the sensor on the cylinder head. Pull out encoder (16) from the cylinder head. Check O-ring (15) for possible damage, replace it if necessary.
knock sensors (31, see fig. 3.3) are located on the engine block and must be replaced in the following order.
Switch off the ignition and remove the intake manifold. Release the loop from the holder on the cable box and disconnect it. Remove bolts (32) and remove the knock sensors from cylinder group 1-3 and from cylinder group 4-6.
When installing, clean the contact surface of the knock sensors and their mounting locations on the cylinder block. Install knock sensors and tighten screws (32) fastening torque 20 Nm (2.0 kgf·m).
Lubrication system sensors (3 pcs.) installed in two places. Two oil sensors are installed on the oil filter housing - temperature (10, see fig. 3.16) and pressure (11), placed diagonally.
1 - replaceable element; 2 - ring (7,0x2,5); 3 - ring (91x4); 4 - filter cover; 5 - sealing gasket; 6 - oil pipeline; 7 - sealing ring (А14х20); 8 - hollow bolt; 9 - bolt (M8x100); 10 - oil temperature sensor; 11 - oil pressure sensor; 12 - bolt (M8x55); 13 - bolt (148x70); 14 - ring (20x3); 15 - suction pipeline; 16 - bolt (M6x16); 17.45 - bolt (М8x55); 18 - oil pump; 19 - bushing; 20 - probe; 21 - ring (9x2.2); 22 - bracket; 23, 25, 27, 28, 34 - bolt; 24 - guide; 26 - ring (19,5x3); 29 - oil pan; 30 - pin (M6x30); 31, 35 - sealing ring; 32-oil level sensor; 33 - nut (M6); 36 - cork (M12x1.5); 37 - sealing gasket; 38 - mounting ring; 39 - nut (М10x1); 40 - asterisk; 41 - inner rotor; 42 - outer rotor; 43 - chain; 44 - control valve; 46 - spring; 47 - ring (17x1,8); 48 - spacer sleeve; 49 - retaining ring (2x1); 50 - branch pipe of the oil separator hose; 51 - oil filter housing
The temperature sensor is mounted a little higher.
The oil temperature sensor must be replaced in the following order. Switch off the ignition. Unscrew the cover (4) oil filter to drain the oil into the oil pan. Remove the air filter housing. Disconnect the loop from the oil temperature sensor and unscrew the oil temperature indicator sensor.
When installing, tighten the oil temperature sensor with a torque of 27 Nm (2.7 kgf·m). Check the oil level and top up if necessary.
Replacing the pressure sensor (11) oils must be carried out in the following order. Switch off the ignition. Unscrew the cover (4) oil filter to drain the oil into the oil pan. Remove the air filter housing and disconnect the loop from the oil pressure sensor. Unscrew the oil pressure sensor.
When installing, tighten the oil pressure sensor to a torque of 27 Nm (2.7 kgf·m). Check the oil level and top up if necessary.
Sensor replacement (32, see fig. 3.16) oil level installed in the oil sump must be carried out in the following order.
Switch off the ignition. Unscrew the oil filter cap to allow the oil to drain into the engine oil pan. Remove the stiffening plate, unscrew the plug (36) and drain the oil from the engine. Dispose of the drained oil for recycling. Disconnect the AL from the oil level sensor.
Loosen the nuts (33) and remove the oil level sensor (32). Clean the sealing surface on the oil sump. Replace o-ring (31) oil level sensor and o-ring (3) lids (4) oil filter. Pay attention to the locking pin (30).
Install and tighten the oil filter cap to 33 Nm (3.3 kgf·m). Fit stiffening plate and tighten to 56 Nm + 90°. Fill the engine with oil and check its level.
Temperature sensor replacement (19, see fig. 3.18) incoming air must be carried out in the following order.
1 - rubber bushing; 2 - air intake; 3 - casing; 4 - shock absorber; 5 - ring (91x6); 6 - bracket (34 mm); 7 - snob (42 mm); 8 - noise silencer / housing; 9 - spacer sleeve; 10 - bracket; 11 - bolt (M6x12); 12 - bell; 13 - hinge; 14 - valve x.x; 15 - valve bracket; 16 - replaceable filter element; 17 - bolt T (M6x18); 16 - executive unit; 19 - temperature sensor; 20 - ring (8x3); 21 - nut (MB); 22 - bushing; 23 - intake manifold; 24 - nut (M7); 25 - gaskets; 26 - ring (7X3); 27 - screw; 28 - adapter
Switch off the ignition and remove the nozzle cover. Disconnect the loop from the intake air temperature sensor. Press the latch and remove the temperature sensor from the intake manifold.
When installing the sensor, check the O-ring (20) for damage and replace the ring if damaged.
Accelerator pedal position sensor (gas) located in the passenger compartment and is directly connected to the pedal, its replacement must be carried out in the following order. Switch off the ignition. Carefully pry out the locking tab (1, fig. 3.164) down and remove the module (2) accelerator pedal on the side.
Disconnect the AL from the accelerator pedal module and remove the accelerator pedal position sensor.
Install the accelerator pedal position sensor in reverse order.
The coolant temperature sensor is located under the exhaust manifold in the cylinder head, next to the 6th cylinder and must be replaced in the following order. Switch off the ignition and remove the intake manifold. Disconnect loop (1, fig. 3.165) and remove the coolant temperature sensor.
The installation of the temperature sensor should be carried out in the reverse order, while it is necessary to return the temperature sensor and tighten it with a torque of 13 Nm (1.3 kgf·m). Reassemble the engine, check the coolant level and, if necessary, restore it.
Idle air control valve replacement. Idle valve (14, see fig. 3.18) installed under the intake manifold, directly above the throttle body.
Replacement of the valve of adjustment of idling it is necessary to carry out in a following order. Switch off the ignition and disconnect «–» terminal from AB. Remove the suction hose between the air filter housing and the throttle body. Disconnect the loop from the resonant valve (18) and from the idle air control valve (14).
Unscrew the cable box fixing bolt and holder bolts (13) idle valve. Remove idle air valve from intake manifold with bracket.
Take out the valve (2, fig. 3.166) idle rubber bracket (4).
Sealing gasket (1) between valve (2) idle and intake manifold must be replaced. When replacing the gasket, install it initially on the intake manifold.
To facilitate installation of the idle air valve, lubricate the inside of the seal with grease to facilitate sliding.
Replacing the fuel pump relay must be carried out in the following order. Read the information from the fault memory of the ECU-ECU of the DME system, turn off the ignition. Open the glove box and remove it.
Loosen the screws and remove the fuse box towards the bottom (without disconnecting the loop).
Remove relay (1, fig. 3.167) fuel pump.
Attention! After removing the fuel pump relay, when the ignition key is turned to the start position, the fuel pump does not turn on and the engine does not start.
The installation of the fuel pump relay should be carried out in the reverse order, while it is necessary to read the information from the fault memory of the ECM of the DME system. Check recorded error messages. Troubleshoot and erase information from the fault memory.