Chevrolet Captiva Service Manual. MAINTENANCE AND REPAIR.

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TIS Chevrolet Captiva (Chevrolet Captiva)
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MAINTENANCE AND REPAIR

MAINTENANCE WITHOUT REMOVING FROM THE CAR
Fuel pumping
Important: In order for the VM2.0S diesel fuel system to work properly, the fuel lines must be filled with fuel and free of air. If air enters the
fuel lines, it is necessary to bleed the fuel system before operating the vehicle to remove air. Air can enter the system in one of the following
ways:
The car wasted fuel.
The filter has been removed for maintenance or replacement.
Fuel lines were removed or disconnected for maintenance.
The fuel pump was removed for maintenance.
During engine operation, a tap was opened to drain water from the fuel filter.
If one or more of the above events has occurred, air has entered the fuel system and it is necessary to bleed the system before operating the
vehicle.
1. Turn the ignition switch to the ON position at 5-second intervals.
Attention! Do not turn the ignition key to the START position. This may damage the injection pump.
2. Turn the ignition switch to OFF and wait 3 seconds.
3. Repeat procedure No. 1 ~ 2 times 6 or 7.
Note: Fuel can be pumped using a scan tool.
Visual inspection of fuel pressure (low pressure pipe)

Necessary equipment
DW100-010 Fuel Pressure Gauge
Validation Procedure
Attention! The fuel system is under pressure. Before disconnecting the fuel lines, to avoid fuel spills and burns, depressurise the fuel supply
system.
1. Disconnect the fuel line clutch.
2. Connect the fuel pressure gauge DW100-010 to the fuel supply pipe coupling.
3. Check for fuel leaks.
4. Read the fuel pressure gauge DW100-010. A normal fuel pressure is in the range of 415 kPa (60.2 psi) ~ 535 kPa (77.6 psi).
5. Remove the fuel pressure gauge DW100-010
6. Connect the fuel feed line to the fuel rail.
7 Pump up fuel See “Pumping Fuel” in this section
7. Pump up fuel. See Pumping Fuel in this section.
Fuel tank
Withdrawal procedure
Attention! Smoking or the use of open flame in places where work is done on the fuel system is not allowed. When performing work on the fuel
system, the negative battery cable should be disconnected, except for those checks where battery voltage is required.
1. Disconnect the negative battery cable.
2. Drain fuel from tank. Ensure the fuel level in the tank is less than 1/4 of the full. If necessary, empty the fuel tank at least to this level.
3. Raise and support the vehicle.
4. Remove front silencer. See Section 1G1, Exhaust System - 2.0 Diesel.
5. Disconnect the fuel pump connector on the right side of the fuel tank.
6. Disconnect the filler pipe from the fuel tank.
7. Disconnect the fuel supply and return lines located near the right front side of the fuel tank.
8. Remove rear drive axle, if equipped. See Section 3B, Rear Drive Axle.
9. Support fuel tank.
10. Remove the fuel tank clamp retaining screws.
11. Remove the fuel tank tapes.
12. Gently push and move the front of the fuel pump down, tilting the back of the fuel pump up.
13. Remove the fuel tank.
Installation procedure
1. Reinstall the fuel tank.
2. Install the fuel tank clamps.
Tighten
Tighten the fuel tank clamp retaining bolts to 20 N • m (15 lb-ft).
3. Connect the fuel supply and return lines located near the right front side of the fuel tank.
4. Connect the fuel filler pipe.
5. Connect the fuel pump connector on the right rear side of the fuel tank.
Fuel pump assembly

Necessary equipment
EN-48279 Tool for dismantling / mounting the lock rings of the main fuel pump
EN-48278 Tool for dismantling / mounting the lock rings of the backup fuel pump
2. Fold down the back seat.
3. Raise the mat and insulation.
4. Remove the covers for access to the primary and secondary fuel pumps.
5. Disconnect the electrical connector for the backup fuel pump assembly.
6. Install the backup ring pump EN-48278 lock ring disassembly / assembly tool to the backup fuel pump and turn it counterclockwise.
7. Remove the lock ring of the backup fuel pump.
Note: Be careful not to damage the fuel sensor when dismantling the fuel pump assembly from the fuel tank.
8. Remove the backup fuel pump assembly and O-ring from the fuel tank.
Note: O-ring must not come in contact with fuel.
9. Disconnect the connecting hose connecting the main fuel pump to the backup fuel pump from the backup fuel pump.
10. Disconnect the electrical connector from the main fuel pump.
11. Disconnect the fuel supply and return pipes.
12. Install the tool for dismounting / mounting the lock rings of the main fuel pump EN-48279 on the main fuel pump and turn it counterclockwise.
13. Remove the locking ring of the main fuel pump.
Note: Be careful not to damage the fuel sensor when dismantling the fuel pump assembly from the fuel tank.
14. Remove the main fuel pump assembly and O-ring from the fuel tank.
Note: O-ring must not come in contact with fuel.
1. Clean all contact surfaces under the seals on both fuel pumps and in the fuel tank.
Note: To simplify the connection of the connecting hose connecting the main fuel pump to the backup fuel pump, first install the main fuel
pump assembly.
Note: Make sure that the arrow on the main fuel pump assembly matches the arrow on the fuel tank.
Note: Be careful not to damage the fuel sensor when installing the fuel pump assembly in the fuel tank.
Attention! Do not reuse the O-ring on the main fuel pump.
2. First put the new O-ring of the main fuel pump and the main fuel pump in the fuel tank in the same position as before dismantling.
3. Remove the connecting hose connecting the main fuel pump and the backup fuel pump from the backup fuel pump assembly.
4. Connect the connecting hose connecting the main fuel pump to the backup fuel pump to the backup fuel pump.
Note: Verify that the arrow on the backup fuel pump assembly assembly matches the arrow on the fuel tank.
Note: Be careful not to damage the fuel sensor when installing the fuel pump assembly in the fuel tank.
Attention! Do not reuse the O-ring of the backup fuel pump.
5. Place the new backup fuel pump o-ring and the backup fuel pump in the fuel tank in the same position as before dismantling.
6. Install the backup fuel pump lock ring by turning the EN-48278 lock ring removal / mounting tool clockwise.
7. Connect the electrical connector to the backup fuel pump.
8. Install the lock ring of the main fuel pump by turning the lock ring removal / mounting tool for the main fuel pump EN-48279 clockwise.
9. Connect the electrical connector to the main fuel pump.
10. Connect the supply and return fuel lines.
11. Install covers for access to primary and backup fuel pumps.
12. Connect the negative battery cable.
13. Check fuel pump performance.
14. Set the rear seats to their original position.
Fuel level sensor

Replacement procedure
Note: The illustrations in this section show the fuel gauge ONLY on the main fuel pump. The fuel sensor on the backup fuel pump is similar.
Note: Be careful not to damage the fuel sensor when dismantling or installing the fuel pump assembly in the fuel tank.
1. Remove the fuel pump assembly. See “Fuel Pump Assembly” in this section.
2. Disconnect the fuel sensor connector.
3. Press the protective plug with a suitable tool, such as a screwdriver.
4. Remove the fuel level sensor assembly by sliding it out of the fuel pump.
Note: Improper installation of the fuel level sensor on the fuel pump may result in inaccurate readings.
5. Install the fuel level sensor in the reverse order.
6. Install the fuel pump assembly in the fuel tank. See “Fuel Pump Assembly” in this section.
Fuel filter / Water in fuel sensor / Heater and fuel temperature sensor
Necessary equipment
EN-48303 Fuel Filter Housing Holder
EN-48304 Tool for removing / mounting the fuel filter lock
2. Remove the decorative cover. See Section 1B, “Engine Mechanical System - 2.0 Diesel”.
3. Remove the air filter assembly. See Section 1B, “Engine Mechanical System - 2.0 Diesel”.
4. Disconnect the inlet / outlet fuel line from the fuel filter.
5. Disconnect the connector for the heater and fuel temperature sensor (a).
6. Disconnect the fuel water sensor connector (b).
7. Remove the fuel filter assembly from the bracket up.
8. Install the EN-48303 filter housing holder (a) and the EN-48304 (b) fuel filter lock / disassemble / mount fixture to the fuel filter assembly.
9. Rotate the EN-48304 fuel filter lock / disassemble / mount tool counterclockwise.
10. Remove the fuel filter lock (a).
11. Remove the fuel filter cover (b) together with the o-ring (c).
12. Remove the fuel filter (d) in the fuel filter housing (e).
Note: The fuel filter cover is made with a heater and fuel temperature sensor as a whole. In the same way, the fuel filter housing is made as a
unit with the water-in-fuel sensor.
Attention! If the fuel filter element remains in the air for more than a minute, then it will not be possible to reuse it.
Water drainage procedure
1. Turn the fuel drain screw counterclockwise.
2. After completion, turn the shutter screw in the opposite direction.
3. Pump up fuel. See “Pumping Fuel” in this section.
I t ll ti d
Attention! Do not touch the fuel filter element with your hands. A damaged element affects the performance of the engine and the failure of the
injection pump and nozzles.
1. Install the fuel filter (d) in the fuel filter housing (e).
2. Install the fuel filter cover (b) together with the o-ring (c).
3. Install the fuel filter lock (a) using the EN-48303 filter housing holder and the EN-48304 fuel filter lock / unlock tool.
Tighten
Tighten the fuel filter lock to 30 N • m (22.1 lb-ft).
High pressure fuel feed lines

2. Remove the charge air system. See Section 1B, “Engine Mechanical System - 2.0 Diesel”.
3. While holding the nozzle adapter sleeve (a), unscrew the nut (M14) securing the fuel line to the nozzle.
Attention! To prevent fuel spillage or damage from the nozzle adapter, hold the nozzle adapter with tools and unscrew the pipe nut. And then,
immediately after removing the fuel lines, put the cap on the nozzle connector to avoid dust contamination. Even a small amount of dust can clog
the nozzles.
4. While holding the injection pump coupling (a), unscrew the nut (M14) securing the fuel line to the common fuel rail.
Attention! In order to avoid fuel spillage or damage from the injection pump adapter, hold the injection pump adapter with tools and unscrew the
nut (M14) securing the fuel line to the common fuel rail. And then, immediately after removing the fuel lines, put the cap on the connector of the
injection tube to avoid dust contamination. Even a small amount of dust can clog the nozzles.
5. Unscrew the nut securing the fuel line to the common fuel rail (M17).
6. Unscrew the bolt securing the fuel line to the common fuel rail from the thermostat housing.
7. Remove the pipe from the fuel pipe to the common fuel rail and the pipe from the fuel pipe to the nozzles.
Attention! Immediately after removing the threaded connections, put the caps on the threaded connections of the pipes of the common fuel rail to
avoid dust contamination. Even a small amount of dust can clog the nozzles.
Important: Fuel lines must not be reused When reused contaminated tubes can damage nozzles or leak tubes
Important: Fuel lines must not be reused. When reused, contaminated tubes can damage nozzles or leak tubes.
Attention! Fuel lines must not be reused. When reused, contaminated tubes can damage nozzles or leak tubes.
Attention! Do not wipe with wipes inside the nozzle couplings, injection pump and threaded joints of the common fuel rail tubes. If contaminated,
wipe the dusty area with oiled paper.
1. If the threaded connection of the common fuel rail is dirty, clean with oiled paper.
2. Loosen the nozzle bracket bolts. See “Injector” in this section.
3. Install the fuel lines between the injectors and the common fuel rail and tighten the nuts by hand.
Attention! Do not tighten the fuel line nuts with a tool.
4. Tighten the nozzle bracket bolts.
Tighten
Tighten the nozzle bracket bolt to 28 N • m (20.7 lb-ft).
5. While holding the nozzle adapter sleeve (a), tighten the nut (M14) securing the fuel line to the nozzle.
Tighten
Tighten the fuel line to the injector nut (M14) to 27 N • m (19.9 lb-ft).
6. Tighten nut (M17) securing fuel line to injector.

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Tighten
Tighten the fuel line to the injector nut (M17) to 20 N • m (14.8 lb-ft).
7. Install the fuel line between the common rail and the injection pump and tighten the nuts by hand.
Attention! Do not tighten the fuel line nuts with a tool.
8. While holding the injection pump coupling (a), tighten the nut (M14) securing the fuel line to the common fuel rail.
Tighten
Tighten Nut (M14) securing the fuel line to the common rail to 20 N • m (14.8 lb-ft).
9. Tighten nut (M17) securing fuel line to common fuel rail.

Tighten
Tighten the fuel line to the common rail fuel rail nut (M17) to 20 N • m (14.8 lb-ft).
Fuel injection pump

Fuel injection pump
Attention! Smoking or the use of open flame in places of work on the fuel system is not allowed. When working on the fuel system, the negative
battery cable must be disconnected, except for those checks where battery voltage is required.
1. Remove the high pressure fuel lines. See "High Pressure Fuel Supply Pipelines" in this section.
2. Remove the intake manifold. See Section 1B, “Engine Mechanical System - 2.0 Diesel”.
3. Remove the timing belt. See Section 1B, “Engine Mechanical System - 2.0 Diesel”.
4. Remove the power steering pump. Follow section 6B, Power steering pump.
Attention! Immediately after removing the fuel lines, put the cap on the squeeze sleeve of the injection pump to avoid dust contamination. Even a
small amount of dust can clog the nozzles.
5. Remove the injection pump sprocket together with the segment key.
6. Remove the injection pump assembly.
Attention! Do not blow out air from the spray gun inside the nozzle couplings, injection pump, and threaded joints of the common fuel rail tubes. If
contaminated, wipe the dusty area with oiled paper.
1. Install the injection pump assembly.
Tighten
Tighten the injection pump bolts to 30 N • m (22.1 lb-ft).
2. Insert the segment key into the groove of the drive shaft of the injection pump.
3. Install the injection pump sprocket.
4. Tighten the injection pump sprocket nut by hand.
5. Combine the mark on the sprocket and the mark on the rear cover of the timing belt.
6. Install and align the timing belt. See Section 1B, “Engine Mechanical System - 2.0 Diesel”.
7. Install the injection pump sprocket nut.
Tighten
Tighten the fuel pump sprocket nut to 70 N • m (51.6 lb-ft).

Common fuel rail
2. Disconnect the common rail pressure sensor connector.
3. Disconnect the connector for the common rail regulator.
4. Disconnect the common rail return hose.
5. Remove the engine wire guide from the intake manifold.
7. Remove the common rail assembly.
Attention! Immediately after removing the fuel lines, put the cap on the threaded connections of the pipes of the common fuel rail to avoid dust
contamination. Even a small amount of dust can clog the nozzles.
1. Install the common fuel rail assembly.
Tighten
Tighten
Tighten the common rail fuel rail mounting bolts to 25 N • m (18.4 lb-in).
2. Install fuel lines to a common fuel rail. See "High Pressure Fuel Supply Pipelines" in this section.
3. Connect the pressure sensor connector in the common fuel rail.
4. Connect the fuel rail regulator connector.
Common rail pressure sensor

1. Remove the common rail assembly. See "Common Rail" in this section.
2. Clean the interface section of the pressure transducer in the ramp using suitable degreasing agents and dry with compressed air.
Note: Cleaning products should not be caught in the electrical connector.
3. Remove the rail pressure sensor with gasket, if equipped.
Attention! Immediately after removing the fuel lines, put the cap on the pressure sensor in the common fuel rail to avoid dust contamination. Even
a small amount of dust can clog the nozzles.
Attention! Do not blow out air from the spray gun inside the nozzle couplings, common fuel rail and injection pump. If contaminated, wipe the
dusty area with oiled paper.
Attention! Do not wipe with wipes inside the nozzle couplings, common fuel rail and injection pump. If contaminated, wipe the dusty area with oiled
paper.
1. Inspect and clean the threads and sealing surface of the ramp.
2. Inspect and clean the threads and sealing surface of the ramp pressure sensor.
3. Lubricate the thread (a) and the cutting edge (b) of the rail pressure sensor with Ft1v27 (only a thin film of grease).
4. Install the rail pressure sensor to the common fuel rail.

Tighten
Tighten the ramp pressure sensor to 70 N • m (51 6 lb ft)
Tighten the ramp pressure sensor to 70 N • m (51.6 lb-ft).

6. When replacing, reset the EEPROM for ZFC (Zero Fuel Correction) using the scan tool.
Common rail regulator

1. Remove the common rail assembly. See "Common Rail" in this section.
2. Clean the interface section of the ramp regulator using suitable degreasing agents and dry with compressed air.
Note: Cleaning products should not be caught in the electrical connector.
3. Loosen the component using the WAF30 industrial wrench, grab it by hand and pull it out while turning it counterclockwise.
Important: This common rail fuel rail regulator and o ring must not be reused
Important: This common rail fuel rail regulator and o-ring must not be reused.
1. Inspect and clean the threads and sealing surface of the ramp.
2. Inspect and clean the threads (a) and the cutting edge (b) of the common rail regulator.
Note: Inspect the sealing surfaces of the DRV and the ramp or high pressure pump. Only concentric grooves are allowed. Any cuts in the radial
direction are not allowed. Inspect Torx screws or shoulder for any damage.
3. Lubricate o-rings with fuel.

4. Install the common fuel rail regulator using the WAF30 industrial wrench, holding the hexagonal part of the housing from the reverse wrench with
a WAF35 wrench.
Tighten
Tighten the common fuel rail regulator to 60 N • m (44.3 lb-ft), turn the regulator 90 degrees in the opposite direction and tighten to 85 N • m
(62.7 lb-ft).

Return Fuel Assembly
1. Remove nozzle return hose.
Important: Do not tighten the clamp, but only press it and simultaneously disconnect the nozzle return hose. If you remove the clamp from the
nozzle, then its reuse will be impossible.
2. Disconnect the injection pump return hose.

3. Disconnect the common rail return hose.
4. Remove the locking bolts of the connection block.
5. Remove the fuel return pipe assembly.
1. Install the fuel return assembly.
2. Connect the return hose of the common fuel rail.
Important: Press the nozzle return tube vertically into the nozzle with your hand from top to bottom until you hear a click of the connecting
Important: Press the nozzle return tube vertically into the nozzle with your hand from top to bottom until you hear a click of the connecting
piece that is in place.
3. Connect the injection pump return hose.
4. Install the connection block.

Tighten
Tighten the connecting block mounting bolts to 11 N • m (97.4 lb-in).
nozzle
Necessary equipment
EN-48357 Injector Remover
3. Remove the injector return hoses. See “Return Fuel Assembly” in this section.
4. Disconnect nozzle connector.

5. Remove the nozzle bracket plug.
6. Remove the injector bracket bolt.
7. Pull nozzle bracket by hand by bolt.
8. Pull nozzles up with washers.
Attention! Sequentially number the nozzles with a pencil. If you mix the serial number of the nozzle, then this will affect the performance of the
engine.
Attention! Protect nozzle nozzle tip from floor and hard areas. If possible, put a cap on the tip of the nozzle nozzle.
9. If the nozzle is stuck to the cylinder head, use the EN-48357 nozzle remover.
Attention! The nozzle washer must not be reused.
1. Inspect and clean nozzle and nozzle tip.
Attention! Do not wipe the nozzle tip area. This may damage the nozzle opening.
2. Install the nozzle with a new washer.
3. Insert the nozzle bracket into the groove of the nozzle.
4. Tighten the nozzle bracket bolt.
Tighten
Tighten the nozzle bracket bolt to 28 N • m (20.7 lb-ft).
5. Install the nozzle bracket plug.

5. Install the nozzle bracket plug.
Tighten
Tighten the injector bracket plug bolt to 7 N • m (62.0 lb-in).
Important: When replacing an injector or changing the order of the injector sequence, reprogram and reset the EEPROM for the ZFC (Zero Fuel
Correction) injectors using a scan tool.
Accelerator Pedal (APM)

2. Disconnect the accelerator pedal connector (APM) retaining clamp from the accelerator pedal connector.
3. Disconnect the accelerator pedal connector.
4. Remove the three bolts securing the accelerator pedal (APM) from the accelerator and the brake pedal bracket.
1. Install the accelerator pedal mounting bolts (APM) to the accelerator and brake pedal bracket.
Tighten
Tighten the mounting bolts of the accelerator pedal assembly to 9 N • m (80 lb-in).
2. Connect the accelerator pedal connector (APM) and securely install the retaining clamp.
Mass Air Flow (MAF) Sensor
Removal / Installation Procedure
2. Disconnect the MAF sensor connector.
3. Remove the MAF sensor.
Electronic Throttle Control (ETC)

3 R h h i l h h S S i 1B “E i M h i l S 2 0 Di l”
3. Remove the charge air cooler exhaust hose. See Section 1B, “Engine Mechanical System - 2.0 Diesel”.
4. Disconnect the ETC connector.
5. Remove ETC.
Tighten
Tighten the ETC bolts and nuts to 9 N • m (79.7 lb-in).
Camshaft Position Sensor (CMP)

1. Remove the negative battery cable.
3. Release screw on connection block. See “Return Fuel Assembly” in this section.
4. Disconnect CMK sensor connector.
5. Remove the CMK sensor.
Tighten
Tighten the CMK Sensor Bolt to 7 N • m (62 lb-in).
Vacuum pump
1. Remove the negative battery cable.
3. Release bolts on connection block. See “Return Fuel Assembly” in this section.
4. Remove the bracket for the decorative cover.
5. Remove the engine wiring harness bracket.

6. Disconnect the exhaust gas recirculation and brake booster vacuum hoses.
7. Remove the vacuum pump.

1. Install a vacuum pump.
Tighten
Tighten the vacuum pump tie bolts to 12 N • m (8.9 lb-ft).
2. Install the engine wiring harness bracket.

3. Connect the vacuum hoses for exhaust gas recirculation and brake booster.
Tighten
Tighten Tighten the engine wiring harness bracket nuts to 20 N • m (14.8 lb-ft).
4. Install the decorative cover bracket.
Tighten
Tighten the decorative cover bracket bolts to 11 N • m (97.4 lb-in).
Charge Pressure Sensor (T-MAP Sensor)

3. Disconnect the charge pressure sensor connector.
4. Remove the engine wiring harness cover.
5. Remove boost pressure sensor.
Tighten
Tighten the boost pressure sensor bolt to 8 N • m (70.8 lb-in).
Coolant Temperature Sensor (ETC)

3. Disconnect ECT sensor connector.
4. Remove the coolant temperature sensor.
Tighten
Tighten the ECT to 35 N • m (25.8 lb-ft).
Crankshaft Position Sensor (CKP)

2. Disconnect the crankshaft position sensor connector.
3. Remove the SKR sensor.
Ti h
Tighten
Tighten the crankshaft position sensor mounting screw to 7 N • m (62 lb-in).
Oil pressure sensor

2. Drain engine oil.
3. Disconnect a socket of the gauge of pressure of oil.
4. Remove the oil pressure sensor.
Tighten
Tighten the oil pressure sensor to 30 N • m (22.1 lb-ft).
Exhaust Gas Recirculation Vacuum Solenoid

3. Disconnect the intake / exhaust hoses of the exhaust gas recirculation vacuum solenoid valve.
4. Disconnect the exhaust gas recirculation vacuum solenoid valve connector.
5. Remove the exhaust gas recirculation vacuum solenoid valve.

Tighten
Tighten Tighten the exhaust gas recirculation vacuum solenoid valve bolts to 7 N • m (62 lb-in).
Exhaust gas recirculation (EGR) system

Attention! Ensure that all components are cool. Then do the work.
3. Remove the hoses and air ducts of the charge air system. See Section 1B, “Engine Mechanical System - 2.0 Diesel”.
4. Drain engine coolant. See Section 1D1, “Engine Cooling - 2.0 Diesel”.
5. Remove the battery and the shelf. See Section 1E1, Engine Electrical - 2.0 Diesel.
6. Remove the ECM. See “ECM” in this section.
7. Remove the bracket for the decorative cover. See "Vacuum Pump" in this section.
8. Remove the engine wiring harness bracket. See "Vacuum Pump" in this section.
9. Remove the exhaust pipe for the exhaust gas recirculation cooler.
10. Disconnect the hose from the expansion tank to the water pipe.
11. Disconnect the hose from the heater to the water pipe.
12. Unscrew the water pipe mounting bolt from the front of the engine block.
13. Remove the EGR valve.

14. Unscrew bolts securing the water pipe from the rear and side parts of the engine block.
15. Lower the water pipe.
16. Remove the exhaust gas recirculation cooler.
17. Remove the intake manifold for the exhaust gas recirculation cooler from the exhaust manifold.
1. Install the exhaust gas recirculation cooler inlet pipe to the exhaust manifold.
2. Install the exhaust gas recirculation cooler together with the engine wiring harness bracket.
Tighten
Tighten Tighten the exhaust gas recirculation cooler intake manifold retaining nuts to 33 N • m (24.3 lb-ft).
Tighten the exhaust gas recirculation cooler bolt to 20 N • m (14.8 lb-ft).
3. Install EGR valve.
4. Screw the water pipe mounting bolt into the engine block.
Tighten
Tighten the exhaust gas recirculation valve mounting nuts (to the exhaust gas recirculation cooler) to 20 N • m (14.8 lb-ft).
Tighten the exhaust gas recirculation valve bolts (to the exhaust gas recirculation inlet pipe) to 20 N • m (14.8 lb-ft).
Tighten the water pipe mounting bolt (M6) to 9 N • m (79.7 lb-in).
5. Install the exhaust pipe for the exhaust gas recirculation cooler.
6. Screw the water pipe mounting bolt into the front of the engine block.
Tighten
Tighten Tighten the exhaust gas recirculation cooler exhaust pipe bolts and nuts to 20 N • m (14.8 lb-ft).
Turbocharger
4. Remove the crankcase ventilation valve (PCV) and adapter. See Section 1B, “Engine Mechanical System - 2.0 Diesel”.
5. Remove the preliminary catalytic converter. See Section 1G1, Exhaust System - 2.0 Diesel.
6. Disconnect the turbocharger drive connector.
7. Remove the oil feed pipe to the turbocharger impeller bearing.
8. Disconnect the oil exhaust hose from the turbocharger impeller bearing.
9. Remove the turbocharger.
1. Install the turbocharger to the exhaust manifold.
2. Install the oil supply pipe to the turbocharger impeller bearing.
3. Connect the oil exhaust hose from the turbocharger impeller bearing.
Tighten
Tighten the turbocharger coupling nuts to 34 N • m (25.1 lb-ft).

Tighten the turbocharger coupling nuts to 34 N m (25.1 lb ft).
Tighten the turbocharger impeller bearing oil pipe bolts to 23 N • m (17 lb-ft).
Glow plug
4. Remove the crankcase ventilation valve (PCV) and adapter. See Section 1B, “Engine Mechanical System - 2.0 Diesel”.
5. Remove the heat shield of the glow plug.
6. Disconnect the glow plug harness.
7. Remove glow plug.

Note: If you need to remove the No. 3 and No. 4 glow plugs, you must first remove the turbocharger.
1. Install a glow plug.
Tighten
Tighten the glow plug to 9 N • m (79.7 lb-in).
2. Install the heat shield of the glow plug.

Tighten
Tighten the glow plug heat shield bolt to 20 N • m (14.8 lb-ft).

Tighten the glow plug heat shield nut (engine lift bracket mounting nut) to 28 N • m (20.6 lb-ft).
Exhaust Gas Temperature (EGT) Sensor 1
2. Disconnect the exhaust gas temperature (EGT) sensor connector 1.
3. Remove the exhaust gas temperature (EGT) sensor 1 from the exhaust pipe.
Tighten
Tighten the Exhaust Gas Temperature (EGT) Sensor 1 to 45 N • m (33.2 lb-ft).
Exhaust Gas Temperature (EGT) Sensor 2

3. Remove the exhaust gas temperature (EGT) sensor 2 from the diesel particulate filter (DPF).
Tighten
Tighten the Exhaust Gas Temperature (EGT) 2 Sensor to 45 N • m (33.2 lb-ft).
Diesel Particulate Filter (DPF) Pressure Sensor

1. Remove the air filter assembly. See Section 1B, “Engine Mechanical System - 2.0 Diesel”.
3. Disconnect the diesel engine particulate filter (DPF) high pressure hoses.
4. Disconnect the diesel particulate filter (DPF) pressure sensor connector.
5. Remove the diesel particulate filter (DPF) pressure sensor bracket bracket bolt.
Tighten
Tighten the diesel particulate filter (DPF) pressure sensor bracket bracket bolt to 10 N • m (88.5 lb-in).
Diesel particulate filter (DPF)
3. Disconnect the diesel engine particulate filter (DPF) high pressure hoses.
4. Remove the diesel particulate particulate filter (DPF) assembly.
Tighten
Tighten the diesel particulate filter (DPF) mounting nuts to 30 N • m (22.1 lb-ft).
5. When replacing a diesel particulate filter (DPF), reset the diesel particulate filter (DPF) EEPROM using a scan tool.
Recovery Order
Attention! During recovery of a diesel particulate filter (DPF), the exhaust system is very hot. To prevent fire or damage, raise the vehicle on the lift
and create an inaccessible area around the exhaust system.
1. Warm up the engine.
2. Restore diesel particulate filter (DPF) using a scan tool.
ECM and bracket

3. Disconnect the ECM connectors.
4. Press the ECM controller securing clip between the controller and the bracket with a regular flat screwdriver and simultaneously lift the ECM
from the bracket up.
5. Remove the ECM bracket.
1. Install the ECM bracket.
Tighten
Tighten the ECM controller bracket retaining nuts to 15 N • m (11.1 lb-ft).
2. Install the ECM.
3. Connect the ECM connectors.
Important: When replacing the ECM, reprogram the ECM using the scan tool.
Set engine oil life
Reset EEPROM for ZFC (Zero Fuel Correction)
Reset EEPROM of diesel particulate filter (DPF)

Chevrolet Captiva Service Manual. MAINTENANCE AND REPAIR.

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Chevrolet Captiva Service Manual. MAINTENANCE AND REPAIR.

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MAINTENANCE AND REPAIR

Visual inspection of fuel pressure (low pressure pipe)

Fuel pump assembly

Fuel level sensor

High pressure fuel feed lines

6. Tighten nut (M17) securing fuel line to injector.

9. Tighten nut (M17) securing fuel line to common fuel rail.

Fuel injection pump

8. Pump up fuel. See “Pumping Fuel” in this section.

Common rail pressure sensor

4. Install the rail pressure sensor to the common fuel rail.

5. Pump up fuel. See “Pumping Fuel” in this section.

Common rail regulator

3. Lubricate o-rings with fuel.

5. Pump up fuel. See “Pumping Fuel” in this section.

2. Disconnect the injection pump return hose.

4. Install the connection block.

4. Disconnect nozzle connector.

5. Install the nozzle bracket plug.

Accelerator Pedal (APM)

Electronic Throttle Control (ETC)

Camshaft Position Sensor (CMP)

5. Remove the engine wiring harness bracket.

7. Remove the vacuum pump.

2. Install the engine wiring harness bracket.

Charge Pressure Sensor (T-MAP Sensor)

Coolant Temperature Sensor (ETC)

Crankshaft Position Sensor (CKP)

Oil pressure sensor

Exhaust Gas Recirculation Vacuum Solenoid

5. Remove the exhaust gas recirculation vacuum solenoid valve.

Exhaust gas recirculation (EGR) system

13. Remove the EGR valve.

Tighten the turbocharger coupling nuts to 34 N • m (25.1 lb-ft).

7. Remove glow plug.

2. Install the heat shield of the glow plug.

Tighten the glow plug heat shield bolt to 20 N • m (14.8 lb-ft).

Exhaust Gas Temperature (EGT) Sensor 2

Diesel Particulate Filter (DPF) Pressure Sensor

ECM and bracket

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