We remove the sensors and the engine electronic control unit for replacement, as well as during repairs.
Replacing the engine electronic control unit
We disconnect the negative terminal of the battery, then disconnect the positive terminal of the battery.
Using a 10 mm spanner, we undo the bolt securing the positive cable bracket to the battery tray bracket.
We move the bracket with the cables aside from the tray.
We press the clip of the wiring connector clamp of the engine control unit.
We turn the connector clamp.
We disconnect the wiring harness connector from the upper socket of the unit.
We disconnect the middle wiring connector from the unit.
We disconnect the connector from the lower socket of the control unit.
Using a 10 mm spanner, we undo the two nuts of the studs of the upper mounting of the control unit to the battery tray bracket.
We undo the nut of the stud of the lower mounting of the unit.
We remove the control unit from the studs of the battery tray bracket and take it out of the engine compartment.
We install the unit in the reverse order.
Removal and installation of the crankshaft sensor
We remove the crankshaft sensor for cleaning, replacement, or when removing the gearbox.
Depending on the type of engine and gearbox, the sensors differ in design and location.
If the vehicle has the 2.0 l F4R engine
We place the vehicle on an inspection pit or a lift.
We remove the powertrain protection (article — Removal of engine protection, wheel arch liners and mudflaps).
The location of the sensor is shown in figure 1.
We disconnect the connector from the sensor socket.
Using a 10 mm socket, we undo the sensor securing bolt.
We remove the sensor from the opening in the gearbox housing.
We install the crankshaft position sensor in the reverse order.
If the vehicle has the 1.6 l K4M engine
In the engine compartment, we remove the air intake and the air duct resonator.
We press the clip of the engine management system wiring connector.
We disconnect the connector from the sensor socket.
Using a 10 mm socket, we undo the sensor securing bolt and remove the sensor.
We install the sensor in the reverse order.
On this engine, the sensor may be of a different design and be fitted to the clutch housing, figure 9.
We disconnect the connector from the sensor socket.
Using a 10 mm socket, we undo the sensor mounting.
We remove the sensor from the clutch housing.
We install the crankshaft position sensor in the reverse order.
After replacing the crankshaft sensor, it is necessary to calibrate it using a test, which includes:
- deceleration of the vehicle with fuel cut-off in II, III, IV or V gear at an engine speed of 3500–3000 min⁻¹ for at least 2 seconds;
- repeated deceleration with fuel cut-off in II, III, IV or V gear at an engine speed of 2400–2000 min⁻¹ for at least 3 seconds;
- checking for fault codes and, if necessary, rectifying faults;
- erasing the codes.
Removal of the camshaft position sensor, 2.0 l F4R engine
We remove the sensor for replacement or when repairing the cylinder head.
We withdraw the oil dipstick.
We remove the air intake with the resonator.
Using an 8 mm socket, we undo the two bolts securing the hose bracket (lifting eye).
We move the bracket with the hoses aside from the cylinder head.
We disconnect the wiring connector from the camshaft position sensor socket.
Using an 8 mm spanner, we undo the sensor securing bolt.
We remove the sensor from the opening in the cylinder head.
We install the sensor in the reverse order, replacing the sealing ring.
Removal of the absolute air pressure sensor
The sensor is installed on the intake pipe.
The sensor detects the change in pressure (vacuum) in the intake pipe depending on the change in load and engine crankshaft speed and converts them into an output signal voltage.
Depending on the sensor signal, the ECU calculates the amount of air entering the engine.
No tools are required to replace the sensor.
We disconnect the negative terminal of the battery.
We press the clip of the engine management system wiring harness connector.
We disconnect the wiring connector from the sensor socket.
We remove the sensor from the opening in the receiver.
We replace damaged sealing rings if defective. We install the sensor in the reverse order.
Replacing the intake air temperature sensor
The sensor is installed in the intake pipe.
It is a thermistor with a negative temperature coefficient.
The electrical resistance of the sensor decreases as the temperature rises.
The control unit regulates the amount of injected fuel based on the information from the sensor.
We press the wire clip of the wiring connector and disconnect the connector from the sensor socket.
Using a thin flat screwdriver, we prise up the sensor flange.
We remove the sensor from the opening in the receiver.
We install the sensor in the reverse order. If the rubber ring is damaged, we replace it.
We insert the sensor into the receiver opening until the sensor clips engage.
Replacing the coolant temperature sensor
The sensor is installed in the thermostat housing. Usually, if it fails, the sensor is replaced with a new one.
To replace the sensor, it is not necessary to drain the engine coolant.
The new sensor must be screwed in immediately in place of the old one.
We remove the air intake and the resonator of the engine air duct.
We disconnect the wiring connector from the sensor socket.
Using a 21 mm ring spanner, we unscrew the sensor from the opening in the thermostat housing.
The sensor is sealed to the thermostat housing by an aluminium gasket.
We install the sensor and tighten it to a torque of 33 Nm. If necessary, we top up the coolant.
Replacing the oxygen concentration sensors
We replace the sensors in the event of failure and when replacing the exhaust gas system.
Replacing the control oxygen concentration sensor
The location of the sensor is shown in the figure.
The sensor wiring connector is secured on the plastic holder of the bracket.
We withdraw the sensor wiring harness from the plastic clamp secured on the bracket.
We press the holder clip and slide the sensor wiring connector downwards off the holder.
We press the connector clip and disconnect the control oxygen sensor wiring connector.
We pass the wire with the connector through the ring of the 22 mm Z-shaped ring spanner and unscrew the sensor.
If it is not possible to unscrew the sensor in this way, we remove the receiver and the air filter housing.
We remove the upper heat shield of the exhaust manifold.
We pass the sensor wiring connector through the spanner ring and fit it onto the sensor hexagon.
We unscrew the sensor from the opening in the exhaust manifold.
We install the sensor in the reverse order.
Before installing the sensor, we apply graphite grease to the threaded part of the sensor.
We tighten the sensor to a torque of 45 Nm.
Replacing the diagnostic oxygen concentration sensor
We place the vehicle on an inspection pit or a lift.
Using a flat screwdriver, we prise up the sensor wiring connector holder and withdraw the holder from the opening in the heat shield.
We press the connector clip and disconnect the connector from the engine management system wiring socket.
We withdraw the sensor wiring harness from the holder secured on the body.
We pass the sensor wiring harness connector through the 22 mm ring spanner.
We fit the spanner ring onto the sensor hexagon.
We unscrew the sensor from the opening in the exhaust gas pipe.
We install the diagnostic sensor in the reverse order. We apply a thin layer of graphite grease to the threaded part of the sensor and tighten it to a torque of 45 Nm.
Replacing the knock sensor
We remove the sensor for replacement, as well as during engine repairs.
The engine knock sensor is attached to the cylinder block between cylinders 2 and 3.
It detects knocking shocks in the engine.
If the vehicle has the 2.0 l engine installed
We remove the fuel rail guard (removal of the guard is described in the article — Removal of the engine cooling radiator fan).
We withdraw the alternator wiring harness holder from the opening in the engine bracket.
We press the clip and disconnect the wiring connector from the sensor socket.
Using a 10 mm socket, we undo the nut securing the sensor.
We remove the knock sensor from the stud of the cylinder block.
Before installing the sensor, we clean the sensor mounting surface and install the sensor and all parts in the reverse order.
If the K4M engine is installed
We remove the fuel rail and withdraw the oil dipstick.
Using an 8 mm socket, we undo the bolt of the oil dipstick guide tube.
We withdraw the guide tube from the opening in the cylinder block.
After pressing the clip, we disconnect the wiring connector from the sensor socket.
Using a deep 24 mm socket, we unscrew the sensor from the opening in the cylinder block.
We install the sensor in the reverse order.
Removal of the accelerator pedal module
We remove the accelerator pedal module for replacement.
We squeeze the wiring connector clip and withdraw the connector from the module socket.
Using a 10 mm socket, we undo the three nuts securing the pedal module to the front bulkhead.
We remove the module.
We install the accelerator pedal.
Removal of the clutch pedal position sensor
We remove the sensor when removing the pedal assembly, as well as for replacement.
We disconnect the connector from the clutch pedal position sensor socket.
We turn the sensor anticlockwise and withdraw it from the opening in the pedal assembly bracket.
Before installing the sensor, we extend the pin from its body.
We press the clutch pedal and insert the sensor into the opening in the pedal assembly bracket.
We turn the sensor clockwise and secure it in the bracket opening.
We release the clutch pedal smoothly.
In doing so, the clutch pedal buffer presses the sensor pin into its body to the required depth.
Removal of the brake signal switch
We disconnect the connector from the brake signal switch socket.
We turn the switch anticlockwise and withdraw it.
Before installing, we extend the switch pin from its body.
We press the brake pedal and insert the switch into the opening in the pedal assembly bracket.
We turn the switch clockwise and secure it in the bracket opening.
We release the brake pedal smoothly; in doing so, the pedal buffer presses the switch pin in by the required amount.
