WORKSHOP MANUAL
HFC7161MV-S3
Engine
Version No
：
JAC-201611030416001
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江淮汽车 部门：客户服务部
Engine
FOREWORD CONTENT
This Manual is helpful for technical maintenance
staff for JAC and provides effective and correct
maintenance and service for JAC vehicle. To ensure
the customer satisfaction of the JAC products, it is
extremely essential that the professional maintenance
technicians for JAC have the friendly service and the
capability of proper operation; therefore, the
maintenance technicians must fully understand the
contents in this Manual. This Manual shall be
accessible for reference at any time.
All contents in this Manual, including pictures,
technical parameters are the latest. But if product
modification affects maintenance, JAC will provide
technical bulletin or supplementary volume. Therefore,
please obtain the latest information about this Manual.
JAC reserves the right to make change in design,
addition or improvement for the product.
This manual is a guide for vehicle maintenance, maintenance personnel must be strictly in
accordance with the maintenance manual operation. This product is a product that has precise
requirements, maintenance personnel must be professional with relevant skills, and
non-professional personnel are forbidden to disassemble vehicle privately. Due to complexity of
actual problem, for items not contained in the manual, please contact with company's customer
service, and operate under its guidance.
During the process of maintaining JAC vehicle, if genuine parts that are not from JAC or
disqualified oil, the vehicle may be damaged.
Overview & maintenance
Engine
Chassis
Body structure& electrical
Circuit
J
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江淮汽车 部门：客户服务部
Engine
All rights reserved, without the written consent of JAC, it may not be translated all or a part
of this manual.
Tel：0086-551-62296644
Fax：0086-551-62296633
JAC International Customer Service Depart.
2015.11
Engine register directory
ER-1
Engine Register
General Information and Maintenance………………………………
GI-1
General Information…………………………………………………
GI-1
Precautions……………………………………………………………… GI-1
How to Use This Manual……………………………………………………… GI-6
Model Identification Information………………………………… GI-7
Lifting Points………………………………………………………………… GI-11
Tow Truck Towing……………………………………………………………… GI-13
Tightening Torques of Standard Bolts………………………………………………… GI-13
New vehicle management……………………………………………………………… GI-14
Acronyms……………………………………………………………… GI-26
Maintenance……………………………………………………………
MA-1
Preparations……………………………………………………………… MA-1
General Maintenance……………………………………………………………… MA-2
Periodic Maintenance……………………………………………………………… MA-3
Engine Maintenance…………………………………………………………… MA-5
Chassis and body maintenance……………………………………………………… MA-15
Engine Mechanical…………………………………………………
EM-1
Engine Itself……………………………………………………
EM-1
General precautions………………………………………………………… EM-1
Sealant Precautions……………………………………………………… EM-2
Preparations……………………………………………………………… EM-3
Engine Assembly…………………………………………………………… EM-6
Engine belt…………………………………………………………… EM-10
Intake manifold and exhaust manifold………………………………… EM-11
Timing Chain-Wheel system………………………………………………………… EM-14
Camshaft Assembly…………………………………………………………… EM-16
Cylinder head…………………………………………………………………… EM-19
Valves…………………………………………………………………… EM-24
Engine register directory
ER-1
Cylinder Block Assembly…………………………………………… EM-28
Common Symptoms Diagnostics…………………………………………………… EM-42
Service Parameters……………………………………………………………… EM-43
Lubrication System………………………………………………………
LU-1
Precautions……………………………………………………………… LU-1
Preparations………………………………………………………………
Lubrication System Illustrative Diagram…………………………………
Engine Oil……………………………………………………………
Oil Filter……………………………………………………………
Oil sump and oil pump………………………………………………………
LU-2
LU-3
LU-3
LU-6
LU-7
Cooling system………………………………………………………
CO-1
Cooling circuit……………………………………………………………… C0-1
Engine Coolant………………………………………………………… C0-1
Radiator………………………………………………………………… C0-4
Radiator Cooling Fan……………………………………………………… C0-6
Water Pump…………………………………………………………………… C0-6
Thermostat Components…………………………………………………………… C0-8
Water Pipe components……………………………………………………………… C0-9
Failure analysis……………………………………………………………… C0-10
Service Parameters……………………………………………………………… C0-11
Fuel Supply System…………………………………………………
FL-1
Precautions……………………………………………………………… FL-1
Preparations……………………………………………………………… FL-2
Fuel Supply System Components………………………………… FL-2
Fuel Tank…………………………………………………………………
FL-2
Fuel Filter……………………………………………………………
FL-4
Fuel Pump Assembly……………………………………………………………
FL-6
FuelEvaporative Emission Control System………………………………
FL-9
Accelerator Control Device………………………………………
FL-11
Engine register directory
ER-1
Service Data and Specifications……………………………………
FL-12
Emission Control System……………………………………
EES-1
Fuel Evaporative System………………………………………
Positive Crankcase Ventilation Syatem……………………………
EES-1
EES-4
Engine Electrical…………………………………………………
EI-1
Start charging system………………………………
EL-1
Start charging system Illustrative Diagram …………………
EL-1
Battery…………………………………………………………………
EL-1
Start System………………………………………………………………
EL-3
Charging system………………………………………
EL-8
Engine Electronic Control System………………………
EC-1
Precautions………………………………………………………………
Supplemental Restraint System Precautions ... ... ... ... ..... ... ... ... ... ... ...
General precautions…………………………………………………………
Precautions during maintaining……………………………………………………
EC-1
EC-1
EC-1
EC-2
Engine Control System structure and Service ... ...... ... ... ... ...
EC-3
System description………………………………………………………………
Fuel multi-point injection system………………………………………
Onboard Diagnostic System…………………………………………………………
Engine Trouble Diagnosis………………………………………………………
EC-3
EC-3
EC-6
EC-8
Engine Control System structure and Service…………………
EC-14
Intake air pressure/temperature sensor………………………………………
Engine coolant temperature sensor……………………………………………
Electronic Throttle……………………………………………………………
CKP sensor and Camshaft position sensor………………………………
Oxygen sensor………………………………………………………………
Fuel injector…………………………………………………………………
Knock sensor…………………………………………………………
EC-14
EC-15
EC-18
EC-20
EC-22
EC-24
EC-25
Engine register directory
ER-1
A/C switch and Relay…………………………………………………… EC-26
Continuously Variable cam phase regulator and its control valve…… EC-27
EVAP Canister solenoid valve………………………………………… EC-29
Ignition coil……………………………………………………………… EC-30
Electric fuel pump…………………………………………………………… EC-31
Engine electronic control modules………………………………… EC-32
Engine Control System Trouble Diagnosis Flow…………………
EC-37
Diagnosing according to DTCs………………………………………… EC-37
Engine anti-theft system…………………………………………………
EC-67
System overview……………………………………………………………… EC-67
Components and their location map…………………………………… EC-67
Illustrative diagram………………………………………… EC-68
Components inspection…………………………………………… EC-68
The installation and removal of components…………………………………… EC-69
Diagnose and Match…………………………………………………………… EC-69
Engine B
EM - 1
Engine Mechanical
Engine Body
General precautions:
1、Precautions for drain engine coolant:
Drain engine coolant after the engine is cooled down.
2、Precautions for disconnecting the fuel line
1) Before the start of work, please confirm that within the work area, there is no
easily burning or sparks-producing objects.
2) Before disconnection and disintegration, please release the pressure of the
fuel.
3) Plug the openings after disconnecting the pipelines, in order to prevent fuel
leakage
3、 Precautions for disassembly and disintegration
1) When it requires using the special maintenance tools, please use them as
required. Always pay attention to the safe operation, and must follow the instructions.
2) Caution! Do not damage the mating surface or sliding surface
3) If necessary, use adhesive tape or the equivalents, to seal the openings of
engine system, for fear of the entry of foreign bodies.
4) Identify and put the disassembled components and parts in order, for ease of
troubleshooting and reassembly.
5) Loosen the bolt and nut is based on the principle that to release the outermost,
and then release the diagonal locations, and so on. If having specified a release order,
please operate in the specific order.
4、Precautions for Inspection, Repair, and Replace the parts
Inspect the components and the parts thoroughly before repairing or replacing
them. First of all, inspect the newly replaced components and parts as stated above, if
necessary, replace it.
5、Precautions for assembly and installation
1) Using a torque wrench to tighten nuts and bolts.
Engine B
EM - 2
2) The principle of tighten the bolts and nuts is to tighten the center ones in the
same tightness by multi-steps, and then tighten those on inside and outside the
diagonal lines. If having specified the tighten order, please operate in the specific
order.
3) Replace with a new gasket, oil seal or "O" ring.
4) Thoroughly rinse, clean and dry each part and component. Carefully check the
pipelines of engine oil and engine coolant without blocking.
5) Be sure not to damage the sliding surface or the mating surface. Thoroughly
clean the dust and dirt, or other foreign bodies. Smooth the sliding surface with engine
oil before assembly.
6) After exhaust the engine coolant, when re-filling it, please release the air in
the pipe firstly.
7) After repair, start the engine and raise the engine in order to check the engine
coolant, fuel, engine oil or the tail-gas whether leak or not.
6、The components and parts needed to be tightened in the settled angle.
1) Use the angle wrench to tighten the following components and parts on the
engine finally.
- Cylinder Head Bolt
- Main Bearing Cap Bolt
- Connecting Rod Cap Bolt
2) Do not do the final tightening according to the torque value.
3) The torque value of the components and parts applicable to the pre-tightening
procedures.
4) Make sure the threads surface and the base surface clean, and then daub the
engine oil.
Precautions for Sealant:
1、Refer to “Removal of the sealant”， in page EM-2.
After disassembling the fixed nuts and bolts, use the scraper to separate the
mating surface, and disassemble the used sealant.
Engine B
EM - 3
Caution:
Be careful not to damage the mating surfaces.
Insert the scraper, and then knock as shown in the figure
Slide it sideways.
In those areas where the seal cutter is hard to use, please use a plastic hammer to
lightly tap the parts and to disassemble it.
If for some unavoidable reasons,
tools such as a flat screwdriver have to
be used,
Please be careful not to damage the mating surfaces.
2、The application procedure of the sealant
1) Use the scraper to remove the used sealant adhering to the application surface
of the gasket and the used sealant adhering to the mating surface of the gasket
Caution:
Clear up the used sealant from the grooves on the application surface of it, from the set
bolts, as well as from the bolt holes.
2) use of unleaded gasoline to clean the application surface and the mating
surface of the sealant, clear the adhering water,lubricating grease, and foreign bodies.
JAC-T1F017
EM001
EM002
Slide
Tap
Scraper
Engine B
EM - 4
3) Put the sealant with specified dimension fully in the specified location
If there is a groove to put the sealant,
please put it into the groove.
As for bolt holes, normally put sealant inside them，and occasionally outside
them.
Install the binding elements within 5 minutes after gluing the sealant
Components:
If the sealant has stains, please clean them off immediately.
Please do not re-tighten bolts or nuts after the installation.
After 30 minutes of the installation, please fill the engine oil and engine coolant.
Engine Coolant
Caution:
-- If there are special instructions in this manual, please follow the instructions.
Preparations
EM004
EM003
Groove
Bolt hole
Inner side
Inner side
Engine B
EM - 5
1、Service tools:
List of Special Tools
SN
Tool
Outline drawing
Serial Number
Description:
1
The fork
clamp
JAC-T1D001
The timing gear
of the fixed
camshaft
2
Pin
Use
cooperatively
with fork clamp
3
Positionin
g tools of
piston pin
JAC-T1F005
Install and
disassemble
piston pin
4
Guide
Bush
Use
cooperatively
with
positioning
tools of piston
pin,as well as
setting tool
5
Flywheel
stop dog
JAC-T1F011
Fixed flywheel
6
Valve
spring
compresso
r.
JAC-T1F012
Compressed
valve springs
Engine B
EM - 6
7
Oxygen
sensor
sleeve
JAC-T1F015
5)Disassemble
and install
oxygen sensor
8
Oil pan
and
removal
tools
JAC-T1F017
Disassemble
the oil pan
9
The
installer of
valve oil
seal
JAC-T3F001
Install valve oil
seal
10
The oil
seal
installer of
camshaft
JAC-T3F002
Install oil seal
of engine
camshaft
11
Front Oil
Seal guide
of
Crankshaft
JAC-T3F003
It plays a
guiding role
when installing
the front oil
seal of
camshaft
12
Front oil
seal
installer of
Crankshaft
JAC-T3F004
Install front oil
seal of engine
crankshaft
Engine B
EM - 7
13
Rear oil
seal
installer of
Crankshaft
JAC-T3F005
Install rear oil
seal of
Crankshaft
2、Engine assembly auxiliary materials table
SN
Name
Using position
Specifications and Grades
1
Engine
oil
Oil filling, assemble with the engine
oil
5 W - 30 (NORTHERN
WINTER)15 W - 40 (northern
summer and full year the south)
Quality rating is on SJ level or
above
2
Silicone
The oil pump, water pump, oil pan,
crankshaft and rear oil seal shell
LT 5699 or equivalent products
3
Sealant:
Oil pressure switch, drain screw plug,
flywheel bolt
LT 243 or equivalent products
4
Sealant:
Coolant temperature sensor and Water
temperature warning switch
LT648 or equivalent products
5
Petrol
RON #93 and lead-free petrol
above RON #93
6
Sealant:
Stud bolt
LT271 or equivalent products
3、Cylinder assembly auxiliary materials table
Cylinder assembly auxiliary materials table
SN
Name
The materials used and model
Assembly Location
1
Engine oil
5 W - 30 (NORTHERN
WINTER)15 W - 40 (northern
summer and full year the south)
Quality rating is on SJ level or
above
Valve Head, camshaft, oil
seal of camshaft
2
Sealant:
LT271 or equivalent products
Stud bolt
3
Sealant:
LT962T or equivalent products
Spark plug guide bush,
cylinder block/cylinder
head Bowl-type plug
tablet, and filler neck
Engine B
EM - 8
Engine Assembly
1、Precautions for disassembly and installation:
Warning:
Please operate as the following requirements; otherwise, it may result in personal
injury!
Park the car on a flat, solid ground.
Caution:
Always pay attention to the safe operation, and must follow the instructions.
Before the exhaust system and the engine coolant completely cool down, you
must not start work.
If the engine chapter does not contain the required items or work, please refer to
the relevant chapters.
Always use the dedicated support point for lifting, and choose the proper car
lifting machine according to the circumstances.
2、Preparation work for disassembling the engine and the transmission assembly
1) Summary
First of all, disassemble the engine and transmission assembly from the car, and
separate the engine and the transmission.
2) Preparation
① Release the fuel pressure please refer to "Release the fuel pressure"
② Drain engine coolant from radiator
Please refer to “Changing engine coolant”.
③ Drain the engine oil, transmission oil, and clutch oil. Please refer to "Engine
oil" and "Transmission oil" and "clutch circuit".
④ Recycle the refrigerant in the refrigerant lines.
⑤ Drain power steering fluid ，please refer to "power steering fluid":
Caution:
Do not perform this step until engine cools down.
Please do not spill engine coolant on drive belts.
Engine B
EM - 9
⑥ Disassemble the following parts:
The engine trims cover. Please refer to "the intake manifold".
The Engine Hood Assembly， Please refer to the "Engine Hood".
The front wheels and tires. Please refer to the "Wheels and tires".
The engine deflector (left and right)
The air-duct and the air cleaner assembly
Please refer to the air-duct.
The battery, the battery holder, battery holder bracket Please refer to "Battery".
The radiator assembly and radiator fan. Please refer to the "radiator".
3、Disassembly of the related component in the engine compartment
① disconnect the following pipe lines and move aside
Caution:
When you disconnect them, use the plug to prevent leakage.
The fuel inlet line of the injector Please refer to the “Fuel Injectors”.
Vacuum hose of vacuum booster on the engine side please refer to the
"vacuum booster".
The PCV hose please refer to "Fuel evaporation control system".
Inlet connectors of the clutch please refer to the "clutch hydraulic lines".
High-voltage and low-voltage tubes on the Air Conditioning Compressor Please
refer to "A/C compressor".
② Disassemble steering fluid reservoir.
③ Disassemble the wire drawing of the selecting shifts. Please refer to "the
operation mechanism of the selecting shifts".
④ Disconnect the the following wiring harness and connect the plug-in
components, as well as the wire harness retainer, and remove.
Oxygen sensor
Engine coolant temperature sensor
Crankshaft position sensor:
Camshaft position sensor:
Vehicle speed sensor
Engine B
EM - 10
The VVT Oil Control Valve wiring harness
Throttle valve position sensor:
The Air Inlet Absolute Pressure Sensor
Ignition coil
Fuel injector
Knock sensor
The generator
The starter motor
A/C switch
4、Disassembly of related element on Automobile Chassis
① Disassemble the front drive shaft. Please refer to the front drive shaft.
② Disassemble the forepart of the exhaust pipe please refer to the "exhaust
system".
③ Disassemble the engine support beam. Please refer to the "Engine support
beam".
5、Disassembly work
① Hang the lifting hook on the lifting ear of the Engine
② Raise the engine and fix it in place.
③ Use the manual lift table or equivalent tools to firmly support the engine and
the bottom of the transmission assembly and at the same time adjust the lift tensity.
Caution:
Put the pads at the support surface, and to ensure it in a steady state.
④ Separate the left and right, front and rear suspension of the engine. Please
refer to the "Engine Suspension".
⑤ Lower the engine and the transmission assembly. When carrying out the
work, please read the following precautions:
To confirm that they do not interfere with vehicles
To make sure that all connections have been disconnected
To remember the vehicle's center of gravity will change, and if necessary, please
use the jack to support rear lifting point to avoid falling off.
Engine B
EM - 11
6、Separation work
① The engine and transmission assembly, the air conditioning compressor
assembly.
② Disassemble the starter motor.
③ Use the lifting jack to raise, and separate the engine and the transmission.
Caution:
Always confirm that there is no wiring harness before lifting and during the
process of lifting.
7、Installation
Please read the following precautions and install them in the reverse order of
disassembly.
1) Do not damage the engine suspension bolsters. Avoid engine oil spilling over
the cushions.
2) Confirm that all engine suspension are properly fixed, and then tighten the
nuts and bolts.
8 Inspection after installation:
1) Check for leaks.
The following is to check the fluid leaks step, oil leaks step and exhaust leaks
step.
Before starting the engine, please check engine coolant and engine oil level. If it
is less than the required amount, please fill till the assigned position.
Use the following steps to check for fuel leaks.
- turning the ignition switch to the "ON" position, check for the fuel leak in the
connections.
Start engine, and check for fuel leaks at connections again when the engine
speeds up.
Run the engine to check for abnormal noise and vibration.
To warm-up then engine thorough, confirm that there is no fuel, exhaust or any
fluid leaks (including the engine coolant and engine oil leak).
Bleeding or fill from the corresponding line pipes and hoses.
Engine B
EM - 12
After the engine cools down, please re-check the oil level (including the engine
oil and engine coolant). If necessary, re-fill to the assigned level.
2) Check the project overview
Check for leaking item list
Project
Before starting
the engine
Engine running
After the engine is
shut off
Engine coolant:
Fluid Level
Leakage
Fluid Level
Engine Oil
Fluid Level
Leakage
Fluid Level
Transmission Oil, brake
fluid, power steering
fluid, Clutch Fluid
Fluid
Level
Leakage
Fluid Level
Fuel
Leakage Leakage
Leakage
Exhaust
- Leakage
-
Engine belts
1、Check the drive belt:
Warning:
To make sure that performing operations after the engine has been shut off.
1) Check the belt for aging, cracks, wear and traces of oil. If necessary, replace
it.
2、Tensity adjustment
Tensity adjustment table
Position
Adjustment Method
Alternator belt.
Adjust the adjusting bolt on the generator.
Caution:
Please do not allow the engine oil and engine coolant to spill on the belt.
-- Do not excessively twist or bend belt.
3、The disassembly of generator's belt
1) Loosen the generator's adjustment nut and its support nut. Use the adjusting
screw to adjust tensity.
2) Tighten the generator's adjustment nut and its support nut.
Tighten the torque: generator adjustment nut: 22.5 ±2.5 N ·M
generator support nut: 47 ±5 N· m
Engine B
EM - 13
4、The Installation of generator's belt
1) Install the belt on the pulley according to the reverse order of removal.
2) Verify that the belt tensity is in the standard range (450 - 550 N·M).
The intake manifold and exhaust manifold
The intake manifold and exhaust manifold breakdown drawing.
1、The intake manifold
1) Disassembly
Warning:
Please do not drain the engine coolant when the engine warms up, in order to
avoid burns.
① Drain engine coolant: Please refer to “Changing engine coolant”.
② Release the fuel pressure， please refer to "Release the fuel lines pressure"
③ Disassemble the engine trim cover.
Tighten the torque: 8 to 12 N M.
Engine B
EM - 14
④ Disassemble the air cleaner assembly. Please refer to the "air cleaner
assembly".
⑤ Disconnect the the following wiring harness and connect the plug-in
components:
The Air Inlet Absolute Pressure Sensor
Fuel injector
Electronic throttle valve position sensor:
Carbon canister control solenoid valve
⑥ Disconnect the following hose connections.
The water pipe fittings (please install the plug to prevent engine coolant leaking)
The PCV tube
Vacuum hose of vacuum booster on the engine side
Vacuum hoses in the carbon canister solenoid valve side.
Small loop pipes in the throttle body
⑦ Disassemble throttle body mounting screw and throttle body, remove throttle
body assembly.
⑧ Disassemble the injector assembly. Please refer to the “Fuel Injectors”.
Tighten the torque: 18.4 ±1.4 N M.
⑨ Disassemble the intake manifold and the bracket of the engine block.
Tighten the torque: 10 ±20 N M.
⑩ Disassemble the intake manifold mounting bolts and nuts.
Tighten the torque: 18 ±1.0 N M.
⑪ Remove the intake manifold and the intake manifold's gasket.
2）Inspection after Disassembly:
Check the air intake manifold for cracks or any other damages and for whether
the matching surface is deformed or not. Please repair or replace as necessary.
3）Installation
According to the reverse order of removal
Caution:
-- Do not re-use the components and parts that are no longer available.
Engine B
EM - 15
Before starting the engine, please check engine coolant level. If it is less than the
required amount, please fill till the assigned position.
Use the following steps to check for fuel leaks.
- turning the ignition switch to the "ON" position, check for the fuel leak in the
connections.
Start engine, and check for fuel leaks at connections again when the engine
speeds up.
To warm-up then engine thorough, confirm that there is no fuel, or the engine
coolant leak.
After the engine cools down, re-check the engine coolant level. If necessary,
re-fill to the assigned level.
2, Exhaust manifold
1) Disassembly
Warning:
After the exhaust system cools down thoroughly, perform this operation.
① disconnect the oxygen sensor harness connector; if necessary, use a special
tool to remove the Oxygen Sensor.
Tighten the torque: 40 ±60 N M.
Caution:
-- Do not damage Oxygen Sensor.
-- Drops to hard ground from any place higher than 0.5 m , the oxygen sensor
will be not able to use, please replace it.
②Disassemble the mounting bolts of the exhaust manifold insulation mat and
remove exhaust manifold insulation mat.
Tighten the torque: 5 ±10 N M.
③ disconnect the connection between three-way catalytic converters and
exhaust manifold.
Tighten the torque: 38 ±52 N M.
④ disassemble the exhaust manifold bracket cap screws and remove exhaust
manifold bracket.
Engine B
EM - 16
■ Tighten the torque: 20 ±1.0 N M.
⑤ disassemble the mounting bolts of the exhaust manifold and remove exhaust
manifold.
Tighten the torque: M8 35 ±2 N M.
2）Inspection after Disassembly:
Check to see whether the exhaust manifold mating surface is deformed or not.
3) Installation
Install them according to the reverse order of removal.
Caution:
-- Do not re-use the components and parts that are no longer available.
-- Please do not over-tighten Oxygen Sensor to avoid damaging Oxygen Sensor.
Timing chain wheel body
1、 Component description:
Timing belt diagram
2、 Disassembly and installation of timing chain:
1）Disassembly
a) Disassemble the fixed bolt of water pump pulley.
Engine B
EM - 17
Tighten the torque: 7～ 8.2 N·m.
Note:
Disassemble it relying on the drive belt friction when the drive belt has not
yet been removed.
b) Disassemble the drive belt and check the drive belt for wearing, aging, and
cracks, and if the above phenomenon exists, please replace the drive belt.
c) Disassemble oil dipstick components
Tighten the torque: 7～ 8.2 N·m.
d) Disassemble vibration damper
Tighten the torque: 185 ±195 N M.
e) Disassemble generator
f) Disassemble the oil pan and cylinder head cover.
Caution:
First, disassemble the oil pan and cylinder head cover, and then disassemble
the oil pump assembly.
g) Disassemble the pump assembly
h) Check the timing
Check whether the five timing points meet the requirement as shown in the
figure.
Engine B
EM - 18
i) Disassemble automatic tensioner, as
well as the orbit and the dynamic
rail of the timing chain. And check
to see if there is an exception.
Tighten torque:
Automatic Tensioner: 9 ~ 11 N M.
Orbit: 10~12 N·m
Dynamic rail: 19～28 N·m
j) Disassemble exhaust Camshaft
Sprocket bolt
Tighten the torque: 78～98 N·m
k) Disassemble the intake cam timing controller
Tighten the torque: 64.5 ±5.5 N M.
EM005
EM006
Exhaust camshaft
chain wheel
Timing marks of Chain wheel
Timing marks of Chain
Automatic tension device
Timing marks
Timing marks of Chain
Timing marks
Timing marks of Chain
wheel
Timing marks
of Chain
Engine B
EM - 19
2）
Installation
Install it according to the reverse steps of disassembly as stated above.
During the installation process, pay much attention to the timing point and the
torque installation.
Camshaft assembly
1、Component description:
Camshaft breakdown drawing
2、 Disassembly and installation:
1）Disassembly
2
Engine B
EM - 20
① Disassemble the engine trim cover. Please refer to "the intake manifold".
② Disassemble high pressure ignition coil. Please refer to "Ignition coil".
③ Fixation of power steering pump's pressure line
④ Disconnect PCV hoses and camshaft position sensor harness connector.
⑤ Disassemble valve cover from the cylinder head
⑥ disassemble the valve cover gasket from the valve cover, and remove spark
plug tube sealer from the spark plug tube.
⑦ Disassemble the timing chain wheel. Please refer to "Timing chain wheel
body".
⑧ Disassemble the timing gear of the camshaft
a. Fix the camshaft with a wrench
b. Tighten the timing gear bolts of the camshaft
Tighten torque: 59～70N·m
c. Remove the timing gear of the camshaft
⑨ Disassemble camshaft position sensor from the rear of the cylinder head end
Tighten the torque: 9～11 N·m.
Caution:
To be careful to avoid clashing
10 Use the appropriate tools to disassemble the front oil seal of camshaft.
Caution:
Do not damage the matching surface
between cylinder head and the camshaft.
⑪ Remove camshaft from the cylinder
head
2) Inspection after disassembly
①camshaft
The measure of Camshaft cam's height
Intake: 44.7054 ± 0.1mm
Exhaust: 44.2836 ± 0.1mm
If the value does not meet the above standard value, please change the camshaft.
EM007
Engine B
EM - 21
②Mechanical followers
The measurement of thickness of the
mechanical followers
3) Installation
① Install mechanical followers
② Install the camshaft.
Caution:
Paint the engine oil on the camshaft journal and cam.
Pay attention to the installation direction of the camshaft.
③ Install camshaft position sensor:
Caution:
In the rear-end cover flange coated with a sealant.
Tighten the fixed bolt after the stand is fully seated.
④ Install the front oil seal of the camshaft.
⑤ Install the timing gear of camshaft
⑥ please read the following precautions and install them in the reverse order of
disassembly based on this step.
Before installing the valve cover, please eliminate all the sealant on the cylinder
head cover.
Verify that the valve cover gasket is in good condition, and has been put into the
slot of the valve cover.
4) Inspection after installation:
Examine that all components are installed.
Before starting the engine, please check engine oil level. If it is less than the
required amount, please fill till the assigned position.
Run the engine to check for abnormal noise and vibration.
After the thorough warm-up, confirm that there is no engine oil leak.
After the engine cools down, re-check the engine oil level. If necessary, re-fill to
the assigned level.
EM008
Engine B
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3、Valve clearance
1) Inspection
When disassemble or replace the related parts and components of the camshaft or
mechanical followers, or when the engine run abnormally due to the valve clearance's
change, please do the following inspection.
① Disassemble valve cover please refer to the “camshaft".
② Measure valve clearance in accordance with the following steps
a. Fix compression stroke TDC (1-Cylinder). Rotate crank belt pulley clockwise,
align the timing mark.
b. Use filler gauge valve to adjust the screw and stem head clearance
Valve clearance: intake valve 0.22 ±0.03 mm
Exhaust Valve 0.30 ±0.03 mm
c. Rotate crankshaft pulley for 1 ring
③If it exceeds the standard, please adjust. Please refer to the "Adjustments".
2) Adjust
① loosen the nut, loosen the adjusting screw.
② Insert filler gauge that has the equal magnitude with the valve clearance
between the adjustment screws and stem head.
③ Fix the adjusting nut and slowly tighten the adjusting screw until twitch the
filler gauge with a slight resistance, and then tighten the adjusting nut.
④ Verify again whether the valve clearance is in the standard range.
⑤ if not, repeat the steps 1 to 4 until valve clearance is in the standard value.
⑥ the manual rotation of crank, refer to the standard value to confirm cold valve
clearance in the standard value.
⑦ Install them in reverse order of disassembly. Install all the parts and
components that have been disassembled.
⑧ Engine warm-up, check to see if there is an abnormal noise and vibration.
Cylinder head cover
Engine B
EM - 23
1、 the vehicle repair
1) Check the cylinder pressure.
① Warm-up thoroughly, and then shut down the engine.
② Release the fuel pressure please refer to "Release the fuel pressure"
③ Disconnect the fuel pump fuse to avoid fuel oil spray when measuring.
④ Use a special tool to disassemble ignition coil and spark plug. Please refer to
"Ignition coil"and "spark plug".
⑤ Disassemble the engine trim cover. Please refer to "the intake manifold".
⑥ Install the cylinder pressure gage with connector on the spark plug.
⑦ Step the accelerator pedal to the metal, turn the ignition switch to the
"START" position to start. When the instrument pointer stables, read compression
pressure, and engine rotate speed. Perform these steps to check the rest of the
cylinders.
Standard Pressure: 1200 kPa ± 100 kPa ( 200 r/min )
The allowed values between the cylinders: not larger than 98 kPa
Caution:
Always use a fully charged battery to get the specified engine speed.
If the compression pressure is lower than the minimum value, please check valve
clearance, and other related components (valves, valve seat, piston, piston ring,
cylinder diameter, cylinder head and gasket). After checking, measure the
compression pressure again.
If some of the cylinders' compression pressure is low, please fill a small amount
of the engine oil to the spark plug hole of the cylinder, and re-check the cylinder
pressure.
-- If you add engine oil, the cylinder pressure has increased; the piston rings may
be worn or damaged. Check piston rings, if necessary, replace it.
-- If you add engine oil, the compression pressure is still low, the valve may be
faulty. Check valve for damage. Replace the damaged valve or valve seat.
If the two adjacent cylinder compression pressure is low, and after adding the oil
Engine B
EM - 24
pressure is still low, may be the cylinder head gasket has the leaking. Replace cylinder
head gasket.
⑧when the inspection is completed, please install the parts and components that
have been removed.
⑨ Start the engine and verify engine running smoothly.
2、Disassembly and installation:
1）Disassembly
① Release the fuel pressure; please refer to "Release the fuel pressure"
② Drain engine coolant and the engine oil Please refer to “Changing engine
coolant”and "Changing engine oil".
Caution:
Do not perform this step until engine cools down.
Please do not spill engine coolant and the engine oil on driving belts.
③ Disassemble the following components and related parts and components.
Driving belts please refer to the "driving belt".
The oil pumps assembly and the timing mechanism. Please refer to "Timing
chain wheel body".
The engine trims cover. Please refer to "the intake manifold".
The valve cover, please refer to the"camshaft assembly".
The intake manifold, please refer to "the intake manifold".
Exhaust manifold. Please refer to the "exhaust manifold".
The thermostat shell, Please refer to the "thermostat subassembly".
The oil dipstick conduit
④ Loosen the cylinder head bolts.
Disassembly order reverses with the
shown in figure 11.043.
A: The air inlet side
B: Exhaust side
EM009
Engine B
EM - 25
: Front of Engine
⑤ Disassemble cylinder head gasket
2) Inspection after disassembly
① Cylinder Head Bolt
Measure the length of cylinder head bolt.
The limits are: 143.5 ± 0.7 mm, if it exceeds the threshold value, please replac it.
② Cylinder head cover
Check the cylinder head for cracks or other damages.
Check the the watercourse of the cylinder head, and the oil for restriction, if there
is restriction, please clean them.
Check the cylinder head flatness.
Note: Perform this check, and check the cylinder for flatness. Please refer to the
"Block Plane".
a. Wipe clean the oil on the cylinder cover, as well as clear the sealant and
carbon deposits, and so on.
Caution:
Take care and do not allow debris falling into the cylinder head watercourse and
oil passages.
b. Measure the orientation of 6 planes on the mutiple positions of the bottom
surface on of the cylinder head.
Standard Value: below 0.03 mm
Cylinder head height (new): 158 + /- 0.5 mm
If it exceeds the standard value, please grinding or replace it according to the
specifications.
Caution:
The total remaining amount that can be ground of the mating surface between
cylinder head and block is less than 0.2 mm.
Engine B
EM - 26
3）Installation
① Install the new cylinder head gasket.
② Screw it in accordance with the
numerical order as shown in the diagram
on the right.
Tighten cylinder head cap screws, and install
cylinder head as the following steps.
A: The air inlet side
B: Exhaust side
: Forepart of Engine
a. Install the gasket as shown in Figure
1.1.046.
b. Smear the threads and the gaskets of
the threads of the bolts with appropriate
engine oil.
c. Tighten the bolts in the sequential
order as shown in Figure 1.1.047., until each bolt torque reach to 24.5 ± 2N·m.
d. Loosen the bolts entirely.
e.Re-tighten the bolts in the sequential order as shown in Figure 1.1.047, until
each bolt torque reach to 24.5 ± 2N·m.
f. Smear the head of the cylinder cover bolt
EM011
EM012
EM013
EM010
Painting mark
Timing belt side
Engine B
EM - 27
and cylinder cover with paint marks.
(As shown in Figure 1.1.048)
g. Tighten each bolt in the 90 angle according to the tightening sequence
h. Tighten each bolt in 90 angles again, and check whether paint marks on the bolt
head align with cylinder head.
Caution:
If the tightening angle of the bolts is less than 90 angles, they are not likely to
have sufficient forces to tighten cylinder cover.
If the tightening angle of the bolts is greater than 90 angle, they should be
completely disassembled, and then re-install them.
i. If replace the old cylinder cover bolts during the process of repair, please repair
them in accordance with the above steps a-h.
i. If do not replace the old cylinder cover bolts during the process of repair,
please repair them in accordance with the above steps a、b、e、f、g、h.
Installation is the reverse order of removal.
4 Inspection after installation:
The following steps are to check the fluid leaks step, oil leaks step and exhaust
leaks step.
Before starting the engine, please check engine coolant and engine oil/fluid level.
If it is less than the required amount, please fill till the assigned position.
Use the following steps to check for fuel leaks.
- Turn the ignition switch to the "ON" position (when the engine shut down).
Check whether the connections has fuel leak or not.
Start the engine Start engine, and re-check for fuel leaks at connections again
when the engine speeds up.
Run the engine to check for abnormal noise and vibration.
To warm-up the engine thoroughly, confirm that there is no fuel, exhaust or any
fluid leaks (including the engine coolant and engine oil leak).
After the engine cools down, please re-check the oil level (including the engine
oil and engine coolant). If necessary, re-fill to the assigned level.
Engine B
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Valve
1、Component description:
Valve components figure
1-Cylinder cover bolt 2-Cylinder cover bolt gasket 3-Cylinder cover assembly 4-Cylinder
cover gasket 5 - Intake valve clamp 6 - Intake valve spring seat 7 - Intake valve springs 8 - Intake
valve 9 - Exhaust clamp 10 - Exhaust valve spring seat 11 - Exhaust valve spring 12 - Exhaust
valve 13 - Intake valve seal 14 - Intake valve spring seat 15 - Exhaust Valve Seal 16 - Exhaust
valve spring seat 17 - Intake pipe 18 - Exhaust valve guide 19 - Intake valve seat ring 20 - Exhaust
valve seat ring 21 - Cylinder Cover
2、Disintegration and Assembly
1) Disintegration
① Use the spark plug sleeve to disassemble the spark plug.
② Disassemble valve locks, valve
springs and valve spring seat.
Use the valve spring compressor to
compress valve spring.
JAC-T1F001
EM014
Engine B
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Caution:
Pay attention to the position of top dead
center of the piston.
Make labels on the disassembled valve,
valve spring and other parts and
components,
Please note cylinder number and
location.
Store the components safely.
③ Disassemble the oil seal of the
valve.
④ If you must replace valve seat.
Please refer to the "replacement of valve
seat”, and disassemble them.
⑤ If you must replace valve seat.
Please refer to the "Valve guide pipe" to
disassemble.
2) Assembly
① Install valve guide, please refer to the "valve guide pipe".
② Install valve seat, Please refer to the "valve seat",
③ Install valve oil seal
a. Install valve spring seat.
B. Install the special tools as figure 1.1., 052 shows.
EM026
JAC-T1F012
EM015
Engine B
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New valve oil seal.
Caution:
The valve seal can not be re-used.
Must use the correct special tools to
install valve oil seal
④ Install valve
⑤ Install valve spring
Note: The valve and valve spring with paint mark should be installed upwards.
⑥ Install valve spring maintaining seat
⑦ Install valve locking plate
Use the valve spring compressor to install.
After installation, check it with a rubber hammer by gently tapping the edge of
valve stem.
⑧ Use the spark plug sleeve to assemble the spark plug.
3) Inspection after disintegration:
1. Valve
Check valve face whether it has correct touch or
not. If the touch is uneven, or is incomplete, Please
refurbished valve seat surface.
Check the thickness of the valve edge. If
it is not within the set values, please replace
the valve.
Intake valve: 1.35 - 1.65 mm.
Exhaust Valve: 1.85 ±0.15mm
Check the overall length of the valve. If it is not within the set values, please
JAC-T3F001
EM017
EM018
EM019
Well
Badness
Badness
Badness
Touch (must on
the center of
the surface
Edge thickness
Engine B
EM - 31
replace the valve.
Intake valve: 89.51 - 90.01 mm.
Exhaust Valve: 90.69 - 91.19 mm
2. Valve Spring
Check the free height of the valve spring. If it is less than the specified value,
please replace valve spring.
Standard Value: 43.1 mm
Limits: 50.37 mm
Check the verticality of the valve spring. If it exceeds limits, replace the valve
spring.
Standard Value: 2°
Limits: 4°
4. Valve Seat
Check the valve protrusion height between the
end face of the valve rod and the surface of the valve
spring seat. If it exceeds the limit value,
Please replace valve seat.
Standard value:
Intake valve: 53.21 mm
Exhaust Valve: 54.10 mm
Limits:
Intake valve: 53.71 mm
Exhaust Valve: 54.60 mm
Cylinder block assembly
1、Component description:
EM020
EM021
Verticality
Free height
Valve rod end
face
Protrusion height
of the valve
Valve spring
seat face
Engine B
EM - 32
Cylinder block assembly breakdown drawing
1 - Flywheel bolts 2 - Signal wheel screws 3 - Flywheel 4-Crankshaft oil seal bolts 5 - Crankshaft
oil seal shell 6 - Bearing cap screws 7-Bearing cap 8 - The upper main bearing shell 9-Crank 10 -
The down main bearing shell 11 - Crank the cone piece, 12 - Crank signal wheel 13-Cylinder
block
2、Disintegration and Assembly
1) Disintegration
① disassemble the engine assembly from the vehicle, and then remove the
transmission from the engine. Regarding the specific separation process, please refer
to the engine assembly.
Engine B
EM - 33
②Disassemble the engine accessories, about the specific disassembling process,
please refer to the relevant chapters.
The engine air intake manifold and the engine exhaust manifold
The generator belts
The generator
Timing chain wheel body of the engine
The water pump
The water pipe subassembly
The generator mounting bracket, air conditioning compressor mounting bracket
Ignition coil
③ Fix the overall engine.
④ Drain engine oil, please refer to "Changing engine oil".
⑤ Disassemble flywheel assembly, please use the special tool to fix flywheel,
and then disassemble the fixed bolts and spacer plate.
Tighten the torque: flywheel: 95～105N·m.
The spacer plate: 8～12 N·m.
Caution:
- Do not place the signal plate of the crankshaft position sensor on the flywheel
facedown.
The mounting bolts should be released in diagonal order.
⑥ Disassemble the following system. About the specific disassembling process,
please refer to the relevant chapters.
The cylinder cover
The oil pump shell
Oil pan
⑦ Disassemble knock sensor.
Tighten the torque: 16～24 N·m
Caution:
-- Do not fall or tap sensors.
Engine B
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⑧ Disassemble the rear oil seal holder.
Tighten the torque: 7.0～70N·m
Put the screwdriver between the crankshaft and the rear oil seal to disassemble.
Caution:
Once the rear oil seal has been disassembled, and cannot be used again, please
replace it with new parts.
⑨ Disassemble the piston and the connecting rod assembly.
Disassemble the piston and the connecting rod assembly; please check the
clearance of connecting rod big end. Please see below "Inspection after disassembly":
a. Turn crank, and put the crankshaft journal corresponding to the connecting rod
that to be disassembled in the middle of the bottom.
Note: In order to re-install, you can print
the cylinder serial number on the side face of
the connecting rod big end which could be
disassembled.
b. Disassemble the connecting rod
cover.
Tighten the torque: 15±2N·m + 92°
～94°
c. Use a rubber mallet or similar tools to push the piston, and the connecting rod
assembly out of the cylinder cover side.
Caution:
Be careful not to let connecting rod big end damage the cylinder walls and
crankshaft journal.
⑩ Disassemble the connecting rod bearing shell from the connecting rod and
the connecting rod cover.
Caution:
Identify the location position, and place them on the right place, and do not get
EM022
The cylinder
number
Engine B
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confused.
⑪ Disassemble the piston rings from the piston.
Check piston ring side clearance before disassemble the piston rings. Please see
below "Inspection after disassembly":
Caution:
Use the piston ring expander.
⑫ Disassemble the piston from the connecting rod as
the following methods:
a. Insert push rod from the previous arrow marking
side
(Special tools), then install the guide sleeve D.
b. Put the front mark of the piston upwards, and assemble the connecting rod
assembly in the installed base of the piston pin
(Special tools)
c. Pinch out the piston pin by using the press machine.
d. Separate the connecting rod and the piston from the piston and the connecting
rod assembly.
Caution:
After disassembling the piston pin, put piston, piston pin,
and the connecting rod together.
Must not put the cylinder piston, piston pin or connecting
rod together
⑬ Disassemble crankshaft bearing cover
Measure crankshaft end clearance before loosening
crankshaft bearing cover, . Please see below "Inspection after disassembly":
EM023
EM024
Push rod
Front
mark
Front mark
Guide sleeve D
Base
Piston ring expander
Engine B
EM - 36
Loosen the crankshaft bearing cover
bolts in the following order.
Tighten the torque: 35±2 N·m＋60°～
64°
As the figure 1.1.065 shows:
Upper 4 8 10 6 2
Lower 1 5 9 7 3
As shown in Figure 1.1031, when disassembling, please use crankshaft bearing
cap bolts to waggle crankshaft bearing cap back and forth in order to disassemble
it.
⑭ Disassemble crankshaft
2）Inspection after disintegration:
① Crankshaft end clearance
When the crankshaft moves back and
forth toe the end the along with the dial
indicator,
Measure the main bearing shell in the center
and the clearance among the crank arms.
Standard: 0.05～0.18mm
Limit: 0.25 mm
If the measured value exceeds the limit, please replace the main bearing shell in
EM026
EM027
Bearing cover
No.
EM025
Engine B
EM - 37
the center, and restart the measurement. If it is still exceed the limit, please replace the
crankshaft.
② Connecting rod big end clearance
Use a filler gauge to measure the
clearance between the connecting rod and
crank arm.
Standard: 0.10～0.25mm
Limit: 0.4 mm
If the measured value exceeds the limit,
please replace connecting rod, and
re-measure. If it is still exceed the limit, please replace the crankshaft.
③The side clearance of piston ring
Use the filler gauge to measure piston ring and
the side clearance of the piston ring groove.
Standard:
The first groove: 0.03～0.07mm
The second groove: 0.02～0.06mm
Limits:
The first groove: 0.1mm
The second groove: 0.1mm
If the measured value exceeds the limit, please replace the piston ring, and restart
the measurement. If it is still exceed the limit, you still have to replace the piston.
④ Piston ring end gap
Confirm that the cylinder inner diameter is within the assigned range.
Please refer to the "Cylindricity".
Use the new oil to lubricate the piston, and piston rings
then insert the piston ring till the middle part of the cylinder,
and use the filler gauge to measure piston ring end gap.
EM028
EM029
EM030
Badness
Well
Filler gauge
Filler gauge
Ring
Piston ring
Piston ring
Filler gauge
Measuring point
Piston
Press and fix
Engine B
EM - 38
Standard:
The first groove: 0.15～0.30mm
The second groove: 0.30～0.50mm
Limits:
The first groove: 0.8mm
The second groove: 0.8mm
If the measured value exceeds the limit, please replace the piston ring, and restart
the measurement. If it is still exceeding the limit, and the bore the cylinder inner
diameter, please use the appropriate piston and piston rings.
⑤ The flatness of the block.
Clean the pad on the block surface, as well as engine oil, incrustation, carbon and
other contaminants.
Caution:
Be careful! Do not allow gasket sheet falling into the engine oil or the engine
coolant.
Use a straight ruler and a filler gauge in the different directions of 6 positions to
measure cylinder cover flatness.
Standard Value: below 0.03 mm
Limit value: below 0.1 mm
If it exceeds the limit value, please
replace cylinder block.
⑥ Cylindricity of the cylinder
Use the dial indicator to measure the
cylinder diameter at 6 different points of each
cylinder, to check for wearing, out-of-round and cylindricity.
Standard Values: cylinder inner diameter: 75.000 - 75.015 mm
Cylindricity: Less than 0.01 mm
⑦ Piston skirt diameter
Use the outside micrometer to check
EM031
EM032
Micrometer
Straightedge
Filler gauge
Engine B
EM - 39
piston skirt is whether deform or not.
Standard Value: 74.973 ± 0.005mm
⑧ The clearance between piston and cylinder diameter.
Calculate through the skirt of the piston and the cylinder innner diameter.
(Clearance) = (cylinder inner diameter) - (piston skirt diameter)
Standard Value: 0.02 ~ 0.04 mm
If calculated value exceeds the limit,
please replace the piston and piston ring
assembly.
⑨The diameter of the crankshaft main
journal
Use the outside micrometer to check the
diameter of the crankshaft main journal.
Standard: 46.009 - 46.029 mm
If it exceeds the standard, please replace main bearings.
⑩The journal diameter of connecting rod
Use the outside micrometer to measure the main journal diameter of the
connecting rod.
Standard Value: 39.975 - 40.0 mm, if it exceeds the standard, please replace
connecting rod. Divide the main shaft of the connecting rod as the following table:
Group
Number
Mark
Size (mm)
1
1
46.024-46.029
2
2
46.019-46.024
3
3
46.014-46.019
4
4 46.009-46.014
EM033
Micrometer
Engine B
EM - 40
5
5
46.004-46.009
⑪The clearance of the connecting rod bearing shell
Note: Use a plastic wire gauge to measure.
a. Wipe off all the engine oil on the connecting rod
journals and connecting rod bearing shell.
b. Put the plastic wire gauge on the rod journals, it can
be cut in length the same with the width of the bearing shell.
Plastic wire rails must be located in the center of the
connecting rod journals, and parallel with its axis
c. Gently place the connecting rod covers on their positions, and tighten the bolts
to the specified torque.
d. Disassemble the bolts, and slowly remove the connecting rod cover.
e. Use the ruler printed on the plastic wire gauge bag, to measure the extrusion
part at the widest point.
Standard Value: 0.02～0.04mm
Limit value: 0.1mm
⑫ Out-of-roundness of the crank and
cylindricity
As shown in the figure, use the outside
micrometer to measure each crankshaft
main bearing journals and 4 different
points' size of the connecting rod
crankshaft main journal.
Use the different sizes to show the out-of-roundness among the "A” and” " B 's
"X " and " " Y.
Use the different sizes to show the cylindricity among the "X" and "Y”‘s "A" and
" B".
Limits: Out-of-roundness: no more than 0.05 mm
EM035
EM034
Engine B
EM - 41
Cylindrical degrees: Less than 0.05 mm
If the measured value exceeds the limit,
please correct or replace the crankshaft.
⑬ Crankshaft clearance
a. Wipe off all the engine oil on the
surface of crankshaft journal and
inside the bearing shell.
b. Install the bearing shell.
c. Cut the plastic wire gauge into the
length that matching with the bearing shell.
Put it on the bearing journal along the axis of
the bearing journal.
d. Gently assemble the crankshaft
bearing cover, and tighten the bolts to the
specified torque.
e. Disassemble the bolts, and gently remove the crankshaft bearing shell.
f. Use the ruler printed on the plastic wire gauge bag, to measure the extrusion
part at the widest point.
Standard Value: 0.02～0.04mm
Limit value: 0.1mm
Caution:
The crankshaft rod journals and crankshaft main journal have been rolled down,
and don't have to process to the reduced size.
⑭ Flywheel
Check the flywheel and signal plate for deformation or cracks.
Caution:
-- Do not disintegrate flywheel.
- Do not place the flywheel's signal plate facing down.
When processing the signal plate, be careful not to damage or scratch it.
EM036
EM037
Plastic
wire gauge
Engine B
EM - 42
Do not magnetize the signal plate when processing it. If it is magnetized, please
change the flywheel.
3) Assembly
① Blown out the crankcase engine coolant and engine oil in the cylinder block,
cylinder diameter, and crankcase.
Caution:
To use safety goggle to protect your eyes
② Install the main bearing shell and the middle bearing shell as shown below.
Caution:
Select bearing shell in accordance with the identification mark or color code of
the crankshaft (refer to the following table). If they can not be recognized, you should
measure the shaft diameter of crankshaft, and select the appropriate bearing bush to
match.
Print the packet mark on K face of
crankshaft (seen as figure 1.1.043), the packet
marking has 10 digits, the first five digits
respectively corresponds from the first main
journal to the fifth; the sixth digit is printed
"B", showing that the packet is finished. The
packet of rod journal starts;
From the seventh digit to the tenth digit respectively corresponds the first rod journal
to the fourth.
The size of spindle hole is labeled on exhaust back-end on the lower part of the
engine block.
Mark (refer to Figure 1.1.044), respectively,
corresponding from the first spindle hole size,
to the fifth spindle hole size.
The main bearing shell should be
EM038
EM039
Engine B
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selected and matched as the table stipulate.
When installing, align the bulge of the bearing bush with the kerf of the main
bearing shell.
Confirm that the oil holes in the cylinder block have been aligned with the oil
hole on the bearing shell.
③ Crankshaft is installed on cylinder block. When turning crankshaft by hand,
please check whether the turning is flexible.
④ Install the main bearing shell.
Through the identification mark can
identify main bearing shell.
From the timing belt side, install the main
bearing shell in accordance with the sequence.
The arrow must point to timing belt side.
⑤ Tighten main bearing bolts as the right digitals show in the diagram.
a. Use the new engine oil smear the threads and mounting surface of the main
bearing shell bolts.
b. Tighten main shell bolts by multi-steps.
Tighten the torque: 35±2N·m
c. Turning all bearing shell bolts in clockwise order of 30°.
EM040
Bearing cover No
Arrow pointing to timing side of the engine
Packet marking of Main
bearing bore
Packet marking pf Crankshaft
0 (up/down)
1 (up/down)
2 (up/down)
Black/Black
Yellow/Black
Red/Black
Black/Yellow
Yellow/Yellow
Red/Yellow
Black/Red
Yellow/Red
Red/Red
Black/White
Yellow/White
Red/White
Black/Purple
Yellow/Purple
Red/Purple
Engine B
EM - 44
After installing the main bearing cap bolts, confirm that the crankshaft can be
rotated flexibly by hand.
Check crankshaft end clearance Please refer to" crankshaft end clearance".
⑥ Install piston onto the connecting rod as shown below
a. Measure the length (as shown in the
following figure)
A: The dimension from the piston to
piston boss outside face.
B: The dimension from the piston to
piston boss inside face.
C: Piston pin length
D: Connecting rod small end thickness
b. Put the measurement value into the following formula:
L= [（A-C）-(B-D)]/2
c. Insert the push rods (special tools) into the piston pin, and then put it into the
guide sleeve A (special tools)
d. The front mark should be on the same side, when installing of the piston and
connecting rod.
e. Smear the engine oil on the out circle of the piston pin.
f. From the guide sleeve A, press the guide sleeve A, piston pin and push rods in
the the front side marker of piston.
g. Tighten guide sleeve B into A, between the two guide sleeves, the clearance
of it is equal to 3mm plus L value that calculated in the second step.
h. In the state of the piston front marker facing down, install the piston and
connecting rod assembly into the piston pin installed base.
i. Install the piston pin by press machine.
EM042
Connect
ing
rod
Pis
ton
Pis
ton
pin
EM041
Guide Sleeve B
Guide Sleeve A
Engine B
EM - 45
Caution:
If the press-fit load exceeds requirements, replace the piston pin and piston
assembly and connecting rod, or both.
Standard Value: 108±54N·m.
⑦ Install piston ring, the installation position of piston ring seen as the figure
shows
Caution:
When installing the piston ring, be careful not to damage the piston ring.
Be careful not to damage the piston ring due to the over-expansion.
Piston ring sketch map
The first compression ring
opening direction
The second compression ring
opening direction
Front part of the engine
Grommet of oil ring
opening direction
The opening direction of
the upper blade of oil ring
The opening direction of
the downward blade of oil
ring
Engine B
EM - 46
⑧ Install the connecting rod bearing shell onto the rod and the rod cap.
Read the connecting rod packet marking as the figure shows identification, select
bearing shell as shown in the following table.
Crankshaft rod journals
The selection of connecting rod bearing
shell
Mark
Size (mm)
Mark
Thickness (mm)
1
39.992 - 40
1 (yellow)
1.487 - 1.490
2
39.984 - 39.992
2 (black)
1.490 - 1.493
3
39.975 - 39.984
3 (red)
1.493 - 1.496
■ Before installing connecting rod bearing shell, please use the engine oil to
smear the bearing surface. Do not use the engine oil.
Smear the back, but to thoroughly clean the back.
⑨ Disassemble the piston and the connecting rod assembly onto the crankshaft.
a. Put the crankshaft journal corresponding to the connecting rod that to be
disassembled, in the middle of the bottom.
Use the enough engine oil to smear the cylinder diameter, piston and crankshaft
journal.
-- As 1.1.049 figure, aligned with the opening of the air ring and oil ring.
When installing the cylinder, please correspond to the position of it with the
connecting rod mark which is to be installed.
Make sure the previous mark of the piston top facing toward timing chain side;
press the piston and the connecting rod in the cylinder from the above head of the
cylinder.
Use a piston ring compressor or a suitable tool
Install the piston with the front marks toward the front of
engine to the head of the piston.
Caution:
EM043
Engine B
EM - 47
Be careful not to let connecting rod big end damage the cylinder walls and
crankshaft journal.
⑩ Install the connecting rod cap.
⑪ Tighten connecting rod bolts, in accordance with the method of
“5N.m->10N.m->13N.m+ 45°+ 45°”, alternately tighten them. Connecting rod cap
can be used only for once, it cannot be re-used.
Caution:
-- If before installing the connecting rod nut, a cylinder cover has been
previously installed, you must first disassemble the spark plugs.
When the bolts are re-used, you must check for scratches. When the nut can
smoothly tighten all the threads, which can illustrate there are no scratches on the
threads of the bolts, otherwise the bolts must be replaced.
Before installing the nuts, please smear the engine oil in the threads of it and its
seat surface.
Caution:
If the nut rotation angle is less than 90°, the fasten force of the connecting rod
may not be sufficient.
If the nut rotation angle is greater than 94°, they should be completely loosened,
and re-tighten.
After tightening the connecting rod nuts, confirm the rotation flexibility of
crankshaft.
⑫ Install the rear oil seal shell, which has been installed the crankshaft rear oil
seal, into the cylinder block.
Use the special tools as shown in the figure; press
the rear oil seal into the block.
JAC-T3F005
EM044
Oil seal housing
Oil Seal
Engine B
EM - 48
When installing the crankshaft rear oil seal bracket, ensure that the gluing surface
clean, and free of oil, dirt, and so on, and as shown in figure 1.1 .051, smear Dow
Corning 3-0115 sealant or equivalent product in the rear mounting surface of the
cylinder block, sealant can also be smeared in the corresponding part of the crankshaft
rear oil seal bracket. Adhesive diameter 2±0.5mm, smear the lubricating oil on the oil
seal lip and the jointing part of crankshaft.
⑬ Install the knock sensor
Caution:
-- Do not tighten the nuts, when holding the connector.
If the knock sensor has been shaken, please replace with a new one.
Note: Be sure that there are no foreign bodies on the matching surface and on the
back of the knock sensor.
⑭ please read the following precautions, and install them in the reverse order of
disassembly after finishing this step.
The flywheel
Cross-tighten the fixing bolts to specified torque.
Common fault phenomenon diagnosis
Common fault phenomenon diagnosis
Fault phenomenon
The possible reason of fault
phenomenon
Troubleshooting.
Section A- A Section B-B
Engine B
EM - 49
The cylinder pressure is
low
Cylinder head gasket
leaking
Replace cylinder head
gasket
Piston rings are worn or damaged
Replace piston rings
Cylinder or piston worn
Repair or replace the piston or
cylinder block
Valve seat damaged or worn
Repair or replace valve seat
Engine oil pressure is low
Engine oil quantity is less
Check the engine oil quantity
Oil Pressure Sensor Fault
Replacement
Oil filter block
Replacement
The oil pump gear or cover damage
Replacement
Engine Oil Viscosity is low
Check and replace oil
Oil pressure switch plunger normally
open
Repair
Bearing Clearance is large
Replacement
Engine oil pressure is high
Oil pressure switch plunger normally
close
Repair
Engine jitters
Engine mounting bolts loose
Tighten
Transmission Mounting Bracket is
loose
Tighten
Engine stand looses
Tighten
Engine heat resistant pad damage
Replacement
Engine support heat resistant pad
damage
Replacement
Transmission heat resistant pad
damage
Replacement
Valve noise
Oil is watery, (oil pressure is low)
Replacement
Valve or valve guides worn or
damaged
Replacement
connecting rod bearing and
spindle bearing noise
Oil quantity is low
Check the engine oil quantity is
enough
Oil is watery, (oil pressure is low)
Replacement
Bearing Clearance is large
Check and determine the reason
Toothed belt noise
Tensioning force is not correct
Adjust tension force.
Cooling effect is poor.
Heat sink or pipe leaky
Repair or replace
Water tank lid does not seal
Tighten or replace
Thermostat leak
Replace thermostat gasket
Radiator leak
Repair or replace
Water Pump Leak
Replacement
Heat sink is blocked
Coolant has contamination
Replacement
Engine coolant temperature
Water tank lid is not sealed tightly
Replacement
Engine B
EM - 50
is high
Cooling system is blocked
Clean or replace.
Thermostat malfunction
Replacement
Belt slip
Adjust or replace.
Water pump malfunction
Replacement
Sensor malfunction
Repair or replace
Fan malfunction
Repair or replace
Insufficient engine coolant
Add coolant:
Engine coolant temperature
is low
Thermostat malfunction
Replacement
Sensor or wiring harness malfunction
Repair or replace
Fan does not work
Sensor or starter damage
Repair or replace
Fan relay or wiring harness damaged
Repair or replace
Exhaust air leaks
Connecting points loose
Tighten
Exhaust Pipe or muffler damage
Repair or replace
Abnormal noise
The muffler looses
Replacement
Rubber pads falling off
Replacement
Exhaust Pipe or muffler is connected
with car body
Correction
Exhaust pipe or muffler damage
Repair or replace
Service Parameters
1、Tighten torque
Name
Quantity
Tighten torque (N · M)
Main Bearing Shell Bolt
10
(35±2)N.m+60°～64°
Connecting Rod Bolts
8
5N.m->10N.m->13N.m+ 45°+ 45°
Camshaft Bearing shell bolts
16
11±1
The front bearing shell bolts of
camshaft
3
20±1
Cylinder Head Bolt
10
（24.5±2） N.m +180°～ 184°
Crankshaft pulley bolt
1
（50±2） N.m +60°± 2°
Flywheel bolts
6
100±5
Exhaust Camshaft Sprocket Bolt
1 88±5
Valve timing adjusting bolt
1
70±5
Engine B
EM - 51
Crankshaft Rear Oil Seal Bolts
6
The rear lifting lug bolts
2
18.4±1.4
The intake manifold bolts
5
18±1
Oil pan bolts
14
11±1
Sprocket Cover Bolts I
2
39.5±3.0
Sprocket Cover Bolts II
2
39.5±3.0
Sprocket Cover Bolts III
2
8.4±0.6
M 6 * 20 E 10 model bolt
6
8.4±0.6
M 6 * 12 E 10 model bolt
7 8.4±0.6
When the above two bolts securing oil filter
bracket
11.5±1.1
Cylinder Head Bolts and
Bracket Bolts
10 9±1.0
M 6 * 45 E 10 model bolt
2 8.4±0.6
M 6 * 25 E 10 model bolt
9
8.4±0.6
M 6 * 12 E 10 model bolt
1
8.4±0.6
Oil filter braclet bolts
3
20±1
warm water steel tube bolts
2
7.6±0.6
Oil pressure rail bolt
2
18.4±1.4
Main oil galley plug I
2
60±5
Main oil galley plug II
1
35±5
Drain plugs
1
25±5
Oil Galley Plug
1
20±5
VVT oil blockage
1
44±5
Oil drain plug
1
39±5
The rail bolt components
2
10±2
The rail bolt components
1
23.5±4.5
Starter bolts
2 24±3
Oil pressure switch
1
10±2
Engine B
EM - 52
Spark plugs
4
25～30
Exhaust manifold dual-head stud
6
12±2
Catalytic convert heat shield
nuts
3
10±1
Crank signal wheel bolts
3
12.5±2.5
Water temperature sensor
1
20±4
Hall sensors bolt
1
8.4±0.6
Knock sensor bolt
1
20±4
Exhaust manifold bolt
5 35±2
Throttle self-tapping screws
4 6±0.5
Absolute pressure sensor
self-tapping screws
6±0.5
Square head bolt
1 47±5
Idler Wheel Bolts
1 49±9
Oxygen sensor
2
35±5
Oil Filter
1
11±01
The standard parts and the threaded connections that the ablve table is not
provided for:
M6 ： 9 ～ 11N.m M8: 20 ～ 25N.m M10: 30 ～ 50N.m
M12：60～80N.m
2. Technical Parameter
Project
Standard value
Limit
value
Camshaft
Camshaft height (mm)
The air intake
44.7054±0.1mm
Exhaust
44.2836±0.1mm
Cylinder Head and Valves
Cylinder head gasket surface flatness (mm)
Below 0.03
0.1
Cylinder head cover total height (mm)
112.9～113.1
-
The thickness of the valve
Intake valve
1.35
0.85
Engine B
EM - 53
edge.
Exhaust Valve
1.85
1.35
Valve stem diameter (mm)
φ5.5
-
Clearance between valve
stem and valve guide (mm)
The air intake
0.020～0.036
0.10
Exhaust
0.030～0.045
0.15
Valve cone
45°～45.5°
-
Valve stem overhang (mm)
Intake valve
53.21
53.71
Exhaust Valve
54.10
54.60
The overall length of the
valve.
Intake valve
89.61
89.11
Exhaust Valve
90.94
90.44
Valve spring free height (mm)
43.1
42.7
Valve spring load/mounting height (N) / (mm)
152/33.4
-
310/25.2
-
Valve Spring verticality
Less than 2°
4°
Valve seat contact width (mm)
0.9～1.3
-
valve guide inner diameter (mm)
φ5.5
-
Valve guide overhang (mm)
13±0.3
-
Oil pump gear top clearance (mm)
0.06～0.18
Side clearance of the pump (mm)
0.04 ～0.11
Shell clearance of oil pump (mm)
0.10～0.18
Out diameter of piston skirt (mm)
74.968～74.978
The first air ring side clearance (mm)
0.03～0.07
The second air ring side clearance (mm)
0.02～0.06
The first piston ring gap clearance-compression
(mm)
0.15～0.30
The second piston ring gap clearance-compression
(mm)
0.30～0.50
Combination oil ring gap clearance (mm)
0.20～0.50
Piston pin out diameter(mm)
18.0
Piston pin out diameter(mm)
4900～14700
Connecting rod journal clearance (mm)
0.02～0.04
0.1
Rod head side clearance (mm)
0.10～0.25
0.4
Crankshaft end clearance
0.09～0.27
Crankshaft main journal diameter (mm)
46.009-46.029
Connecting rod journal diameter (mm)
39.975～40.0
Crankshaft main journal to clearance (mm)
0.02～0.04
Cylinder head gasket surface flatness (mm)
Below 0.03
Cylinder block total height (mm)
256
Cylinder Block cylindricity (mm)
Below 0.01
Cylinder bore inner diameter
75.000～75.015
Clearance between piston and cylinder (mm)
0.02～0.04
Lubrication System
LU-1
Lubrication System
Precautions
Sealant Application Procedure:
1, Using a scrapers, Clear old sealant
adhering to the application surface and
the mating surface.
Note:
■Clear sealant completely from the groove of the sealant application surface, mounting bolts
and bolt holes
2, Clear the sealant application surface and the mating surface with unleaded
Petrol to remove adhering moisture, grease and foreign materials.
3, Locate sealant completely to the specified position with the specified
dimensions
1) Within 5 minutes after liquid gasket application, install the mating
component.
2) If sealant has stains, please clean them off immediately.
3) Please do not re-tighten bolts or nuts after the installation.
4) Refill engine oil and engine coolant in 30 minutes after the installation,
Preparations
1、Service tools:
List of Service Tools
SN Tools Outline drawings Descriptions
001 LU
scrapers
Lubrication System
LU-2
1
Oil
pressure
gauge
Measuring oil
pressure
2
soft hose
Connecting oil
pressure gauge to
cylinder block
3
Oil
pressure
switch
socket
Removing and
installing oil
pressure Switch
Lubrication System Illustrative Diagram
Lubrication System
LU-3
Engine Oil
1, check
1) The level of Engine Oil
Note: Before starting engine, park vehicle horizontally and firmly, check the
engine oil level. If engine is already started, stop it and check it 10 minutes later
○
1 pulls out the Engine Oil
Dipstick and wipe it clean.
○
2 Insert Engine Oil dipstick and
Confirm engine oil level with the range
shown in the figure.
○
3 please adjust, if it's out of the range
2) Engine oil appearance
○
1 Check the engine oil for white turbidity or heavy contamination.
○
2 If engine oil appears cloudy or contaminated, it is highly probable that it is
contaminated with engine coolant. Repair or replace the damaged parts.
3) Engine Oil leakage
Check for engine oil leakage around the following areas:
■Oil sump
■Oil sump draining bolt
■Oil pressure switch
■Oil filter
■Mating surface between cylinder block and cylinder head
■Crankshaft oil-seals (front and rear)
■The mating surface between Oil Pump and Cylinder Block
■Mating surface between valve vocer and cylinder head
■Front camshaft oil seal
4) Oil pressure check:
Note:
002 LU
Confirm engine oil level between “L”and “H”
Lubrication System
LU-4
■Be careful not being burnt, as engine oil may be very hot
■Oil pressure check should be done after
parking
○
1 Check engine oil level Please refer
to"The level of Engine Oil"
○
2 Lift the vehicle and disconnect the oil
pressure switch
Disconnect harness connector at oil pressure switch, and remove the switch.
○
3 Install oil pressure gauge and soft hose
○
4 Start the engine and warm it up to normal operating temperature.
○
5 Check the oil pressure when the
engine is idling.
Note: the engine oil pressure is high
when the engine oil temperature is low.
■If difference is distinct; please check
engine oil passage and oil pump for engine
oil leakage
○
6 After inspections install oil pressure switch as follows:
a. Clear old sealant adhering to oil pressure switch and engine
b. To use sealant as required and tighten pressure switch
■Please use appointed sealant: A New 1243 threads sealant or its equivalent.
■Tightening torque: 8-12N.m
c. After warming up engine, make sure there is no leakage of engine oil when
engine is running normally.
2, Change engine oil:
Note:
■Be careful not being burnt, as engine oil may be very hot
004 LU
003LU002 LU
003LU00
2 LU
Lubrication System
LU-5
■Avoid long-time direct skin contact with used engine oil
If skin contact happened, you should wash thoroughly with soap or cleanser as
soon as possible.
○
1 Warm up the engine, and check for oil leakage from engine compartment
please refer to “The leakage of Engine Oil"
○
2 Shut off engine and wait for 10 Mins.
○
3 Open engine oil filler cap, and then remove the oil draining bolt.
○
4 Drain the engine oil
○
5 Install oil draining bolts with new gasket
Note:
■Be sure to clean draining bolts and install with new gasket
■The tighten torque for draining bolts: 34 ~ 44 N M.
○
6 Fill with new engine oil.
The specifications and viscosity of engine please refer to "Maintenance".
■The oil quantity: 4.5 L
Note:
■When filling engine oil, do not pull out oil dipstick.
■The refill capacity depends on the engine oil temperature and draining time,
above is only for reference.
■Always use oil dipstick to check for proper engine oil refill capacity.
○
7 Warm up the engine and check the area around draining bolts and oil filter for
engine oil leakage.
○
8 Shut off engine and wait for 10 Min.
○
9 Check engine oil level please refer to “The level of Engine Oil"
Oil Filter
1, Removal and installation:
Lubrication System
LU-6
1) Removal
Using oil filter wrench to remove oil filter
Note:
■Use the original oil filter provided JAC vehicles or its equivalent.
■Be careful not is being burnt, for engine and engine oil may be very hot.
■When removing, prepare a shop cloth to absorb any engine oil leakage or
spillage.
■Please do not let engine oil adhere to driving belts.
■Completely wipe off any engine oil that spills onto engine and vehicle.
2) Installation.
○
1 Remove foreign materials adhering to
oil filter.
○
2 Smear just enough engine oil to the
oil seal surface of new oil filter.
○
3 Tighten oil filter until O-ring is seated on mounting surface, and then screw oil
filter for another turn to make the tighten torque within 10-12N·m.
Note:
■Oil filter must be tightened with oil filter wrench.
■Hand-tightened filter will result in oil leakage due to insufficient tightening
torque.
LU006 LU
LU005
LU
Wrench
Lubrication System
LU-7
2, Inspection after installation:
1) Check the engine oil level. Please refer to"Engine Oil"
2) Start the engine, and check whether there is engine oil leakage or not.
3) Shut off engine and wait for 10 Min.
4) Check the engine oil level, and fill with engine oil. Please refer to"Engine Oil"
Oil Sump and Oil Pump
1, Component
Exploded view of Oil Sump and Oil Pump
1 - Engine Oil Filter support pad 2 - Oil filter support bolts 3 - Oil Filter 4 - oil sump bolts 5 - Oil
Sump 6 - Oil strainer 7 - Oil Strainer bolts 8 - Oil strainer support 9 - Oil Drain bolt 10 - Oil Drain
bolt pad 11 - water pump pad 12 - oil pump assembly 13 - Automatic Tensioner cover 14 - Front
Oil Seal 15 - water pump
1
2
3 4
5
6
7
8
9
10
11
12
13
14
41
15
Lubrication System
LU-8
2, Removal
Warning:
■Do not drain engine oil when engine is
hot, in case of being burnt.
1) Drain the engine oil Please refer to"
Changing Engine Oil"
2) Removing oil sump
a. Following the order that medium first
then two sides to loosen the bolt.
■Tightening torque: 7-8.2N.m
b. As shown in the1.2.007 figure,
between the oil sump and cylinder block
Insert special tools.
c. Tap the side of special tools to move
the tools along the sealing surface of oil
sump and cylinder block, and then remove
Oil sump
Caution:
■Be careful not to damage the mating surfaces.
3) Remove oil strainer.
Note:
■Do not drop pads.
■Tightening torque: 12-16N.m
4) Remove oil pump housing.
■Tightening torque: 12-15N.m
5), Remove mounting bolts on oil pump housing, and take away oil pump cover
and gear.
6) Remove crankshaft front oil seal, pressure reducing valve and oil filter from
the pump housing,
LU007 LU
LU008 LU
Lubrication System
LU-9
3, Inspection after removal
1), Oil strainer
■Clean any materials adhering to oil strainer
2), Oil pumps housing.
■Check whether the holes of oil pump housing are clogged or not, if yes, please
clean it.
■Check oil pumps housing for cracks and other damage. If any, please replace.
3), Oil pump
Note:
■To check the clearance among oil
pumps, if it is not within required range,
please replace it.
■Before check please put the rotor into
Front Cover.
1 Check the clearance among gear tips.
Standard value: 0.06~0.18mm
2 check the side clearance.
Standard value: 0.04~0.11mm
3 Check the housing clearance.
Standard value: 0.10~0.18mm
Limit value: 0.35mm
LU009
010lu
LU011
Lubrication System
LU-10
4. Installation.
1), Install oil pumps housing.
■Clean the seal surface and the front oil seal housing of cylinder block.
■Please refer to figure 1.2 .0 13, the diameter of adhesive at A point is 2+/-0.5
mm; the diameter of adhesive at B ponit is 1.5 + /- 0.5 mm.
■Appointed sealant: A New 1590 thread sealant or its equivalent.
2), Install crankshaft front oil seal
■Put the special tool on front end of crankshaft and apply engine oil to its outer
circumference.
JAC-T3F003
lu012
Lubrication System
LU-11
■Smear engine oil onto the sealing lip,
and then push oil seal in along its guide by
hand, until it comes into contact with front oil
seal housing
Using special tool to tap oil seal to snap
into place
3) Install the pressure reducing valve assembly.
4) Install oil Filter.
■Please refer to"Oil Filter"
5) Install oil sump.
■Clean mating surfaces of cylinder
block and oil sump.
■Smear 2.5+/-1mm wide edge-curled
sealant around entire outer circumference of
oil sump flange
■The appointed sealant: Dow Corning 3 - 0115 flat seal or its equivalent.
6) Install oil sump draining bolt.
■Install oil sump draining bolt pad as
shown.
Note:
■Fill engine oil in at least 30 Mins after
the installation of oil sump
5, Inspection after installation:
1) Check the engine oil level, and fill with engine oil. Please refer to"Engine
Oil".
2) Start the engine, and make sure that there is no engine oil leakage.
JAC-T3F004
3
lu013
lu015
lu014
Oil sump
Lubrication System
LU-12
3) Shut off engine and wait for 10 Min.
4) Re-check the engine oil level. Please refer to"Engine Oil".
Cooling System
CO -1
Cooling system
Cooling circuit
Cooling Illustrative diagram
Cooling Illustrative diagram
Engine Coolant
1, check
1) Level check:
Check whether the engine coolant level of reservoir tank is within the “MIN” to
“MAX” after the engine cools down.
■Adjust the engine coolant level if necessary.
001 CO
Radiator
Thermost
at
Water pump
Cylinder block
Cylinder cap
Expansion tank
Thermost on
Thermost off
Thermostat
housing
Thro
ttle
Body
Heate
r
excha
nger
Cooling System
CO -2
2) Leakage check:
Using Radiator cap tester to check for leakage though increasing pressure to the
cooling system.
3) Test pressure
Warning:
■Do not remove radiator cap when engine is hot. Otherwise serious burns could
be caused by high-pressure engine coolant escaping from radiator.
Note:
■Higher testing pressure than specified may cause radiator damage.
■In a case that engine coolant decreases, please replenish radiator with engine
coolant. If any part is found damaged, please repair or replace.
2, changing engine coolant
Warning:
■To avoid being scalded, please do not change engine coolant when the engine is
hot.
■Wrap a thick cloth around radiator cap and carefully remove the cap. Release
the pressure in radiator first. Then turn radiator cap all the way.
■Be careful not to spill engine coolant on drive belts
1), Drain engine coolant:
○
1 Remove the right engine shroud.
○
2 Open the drain plug at the bottom of radiator, and then open the radiator cap.
○
3 If necessary, please remove the coolant reservoir to drain engine coolant and
clean it before re-install.
002 CO
Cooling System
CO -3
○
4 Check whether there is rust, debris or discoloration in the drained engine
coolant,
■If contaminated, please flush the engine cooling system. Please refer to
"Flushing cooling system".
2) Refilling with engine coolant:
○
1 Install the removed reservoir tank and radiator drain plug.
Note:
■Be sure to clean drain plug and install with new O-ring
○
2 Make sure that each soft hose clips are firmly tightened.
○
3 Remove the air cleaner cover and air intake hose. Please refer to" Remove air
cleaner assembly".
○
4 Disconnect warm water outlet pipe. Please raise hose high enough.
○
5 add coolant to radiator and coolant reservoir to the required level. Fill engine
coolant slowly, so as to emit the air in the system.
Note:
■Please use JAC genuine engine coolant. Please refer to"Recommended Oils and
Lubricants"
■Disconnect when engine coolants overflow warm-water hose,
And then reconnect warm-water hose and continue filling engine coolant.
○
6 Install the air cleaner cover and air intake hose. Please refer to" Remove air
cleaner assembly".
○
7 Install radiator cap
○
8 Warm up till the thermostat opens.
Touch the radiator down-hose and feel that whether there is a heated flow to
confirm whether the thermostat opens or not.
Note:
■Check the Engine Water Temperature Gauge, avoid engine overheating.
Cooling System
CO -4
○
9 Shut off engine to reduce the temperature
○
10 Add the engine coolant level of reservoir tank within the “MIN” to “MAX".
○
11 Install the radiator cover and repeat steps 3 to steps 9 two or more times until
the engine coolant level no longer drops.
○
12 Start the engine and check cooling system for leakage.
3) Flushing cooling system:
○
1 Install the removed radiator drain plug and reservoir tank.
Note:
■Be sure to clean drain plug and install with new O-ring
○
2 Remove the air cleaner cover and air intake hose. Please refer to" Remove air
cleaner assembly".
○
3 Disconnect warm water outlet pipe. Please raise hose high enough.
○
4 Fill radiator and reservoir tank with engine coolant, and install radiator cap.
Disconnect when engine coolant overflows warm-water hose, and then reconnect
warm-water hose and continue filling engine coolant.
○
5 Install the air cleaner cover and air intake hose. Please refer to" Remove air
cleaner assembly".
○
6 Run engine and warm it up to normal operating temperature.
○
7 Speed engine up several times under no-load.
○
8 Shut off engine and wait for cooling down.
○
9 Drain water from the system please refer to “Draining engine coolant"
○
10 Repeat steps 1~9 until clear water begins to drain from radiator.
Radiator
1, Removal and installation:
Cooling System
CO -5
Warning:
■Do not remove radiator cap when engine is hot. Otherwise burns could be
caused by high-pressure engine coolant. Wrap a thick cloth around radiator cap and
slowly turn this cap to release air pressure inside. Wait until pressure is completely
released, then screw off radiator cap and take it off carefully.
1) Removal
○
1 Remove engine shroud
○
2 Drain engine coolant from radiator
Please refer to “Changing engine coolant”.
Note:
■Do not operate this step until engine cools.
■Please do not spill engine coolant on drive belts.
○
3 remove the air intake, and take it off.
○
4 Disconnect the harness connector of radiator fan motor, and put it aside.
○
5 remove the water inlet and outlet hoses of radiator and the water inlet hose of
reservoir tank.
○
6 Remove radiator's installation support and take off radiator and radiator
cooling fan component.
Note:
■When removing, please do not damage or scratch radiator core
○
7 Take off cooling fan component from radiator.
2).Installation.
Install according to the reverse order of removal.
3) Inspection after installation:
■Use radiator cap tester to check for leakage of engine coolant
Please refer to"Leakage check".
■Start the engine and warm it up. Visually check for leakage of engine coolant.
Cooling System
CO -6
2, Check radiator cap
1) Pull out negative-pressure valve to
open it. Make sure that it closes completely
after pressure release.
■Make sure that there is no dirt or
damage on the valve seat of radiator cap
negative-pressure valve
■Make sure that there are no
unusualness in the opening and closing of
negative-pressure valve
2) Check radiator cap and release pressure.
Standard value: 78~98KPa
Limit: 59 KPa
Connect radiator cap to the radiator cap tester, and please smear engine coolant
onto the cap seal surface.
Please replace radiator cap if negative-pressure valve operates abnormally or
relief pressure drops to below the limit.
3, Check radiator
■Check radiator for mud or clogging
If necessary, please clean radiator surface as follows.
■Be careful not to bend or damage radiator fans
■If the radiator needs to be cleaned without removal, please remove all
surrounding parts such as cooling fan, cowl and horns. Then tape harness connectors
to prevent water from entering.
1) To flush the back side of the radiator core vertically downward by water hose.
2) To flush all radiator core surfaces per minute.
003 CO
004 CO
Cooling System
CO -7
3) Stop flushing when no dirt flows out from radiator.
4) Blow the back side of radiator core vertically downward by compressed air.
Use compressed air which is lower than 490 KPa and keep distance more than 30cm.
5) Blow all the radiator core surfaces per minute with compressed aird, until no
water sprays out.
Radiator Cooling Fan
1, Removal and installation:
1) Removal
○
1 Remove the air intake hose, and take it off.
○
2 Disconnect the harness connector of radiator fan motor, and put it aside.
○
3 Remove cooling fan component from radiator.
Note:
■When removing, please do not damage or scratch radiator core
2) Installation.
Install according to the reverse order of removal.
2, Disassembly and Reassembly
1) Disassembly
○
1 Remove the cooling fan from fan motor.
○
2 Remove the fan motor from shroud.
2) Inspection after disassembly
○
1 Cooling Fan
Check cooling fan for cracks or unusual bend. If any is found, please replace
cooling fan.
○
2 Fan motor
Check the motor for seizure.
3) Assembly
Cooling System
CO -8
Assemble according to the reverse order of disassembly.
Water Pump
1, Removal and installation:
Note:
■When removing water pump, be careful not to get engine coolant on drive belts
■Water pump cannot be disassembled and should be replaced as a unit.
■After installing water pump, connect hose and secure with clamp, then check
for leakage by radiator cap tester
1) Removal
○
1 Drain engine coolant from radiator
Please refer to “Changing engine coolant”.
○
2 Loosen the mounting bolts of tensioner nut.
○
3 Remove drive belts
Please refer to “Drive belts".
○
4 Remove the mounting bolts of water pump
Note:
■Please distinguish the position of mounting bolts.
■Tightening torque: 12-15N.m
2), Inspection after removal
■Check the water pump assembly for serious corrosion, water-seal leakage or
corrosion.
■Check for excessive play which will result in malfunction
■Check the water pump bearing for seizure or other damage. If necessary, please
replace.
3) Installation.
○
1 Clean the sealant on water pump mount and the water pump side hose.
Cooling System
CO -9
○
2 Install the new O-ring on the side
hose of water pump.
Note: Smear engine coolant onto
O-ring.
○
3 Smear 3 mm wide edge-curled
sealant onto the surface of installed water
Pump
■Appointed sealant LT5699 or its equivalent
○
4 Install water pump
Note:
■When install, please do not drop pad.
■Tighten the mounting bolts into water pump alternately and evenly.
a) Install water pump tensioner nut.
b) Install the drive belt, and adjust to required tension. Please refer to"Drive
belts".
c) Fill with engine coolant Please refer to"Refilling with engine coolant".
2, Inspection after installation:
■Use radiator cap tester to check for leakage of engine coolant
Please refer to"Leakage check".
■Start the engine and warm it up. Visually check for leakage of engine coolant.
Thermostat Components
1, Removal and installation:
1) Removal
○
1 Drain engine coolant from drain plug of radiator.
Please refer to “Changing engine coolant”.
Note:
■Do not operate this step until engine cools.
005 CO
Cooling System
CO -10
■Please do not spill engine coolant on drive belts.
○
2 Disconnect the water inlet and outlet pipes and minor cycle water pipe of
radiator at thermostat housing side
○
3 Disconnect harness connectors of coolant temperature sensor and coolant
temperature warning switch and bolts securing mounts of harness connectors of front
and rear oxygen sensors, and move them away.
○
4 Remove mounting bolts Heater's water-return pipe and remove warm air
return pipe.
○
5 Remove mounting bolts on thermostat upper cover, and take out thermostat.
2) Inspection after removal:
○
1 Thermostat
■Check thermostat valve-opening
condition under normal room temperature
Thermostat Opening Temperature ：
82C （begin to open）
95 C (Completely open)
The maximum lift of valve stem: ≥ 8mm
Thermostat closing temperature: > 77 C
If the massured value is outside the specified range, please replace thermostat.
○
2 Thermostat upper cover and Thermostat housing
Check for cracks and other damage.
3) Installation.
Please note the following items and install in the reverse order of removal.
○
1 Be careful not to spill engine coolant on drive belts. Use rag to absorb engine
coolant.
○
2 Replace the water pipes' O-ring with a new one, and then smear coolant onto
the O-ring, so that they can be easily embedded in the water-pump thermostat
006 CO
Cooling System
CO -11
housing.
Note:
■Never smear the O-ring with engine oil or other oil material.
■The pipes at the back of thermostat housing must be installed firmly.
If engine coolant temperature sensor needs to be reused,
Please smear the thread with appointed sealant.
■The appointed sealant: LT648 or equivalent
2, Inspection after installation:
■Use radiator cap tester to check for leakage of engine coolant
Please refer to"Leakage check".
■Start the engine and warm it up. Visually check for leakage of engine coolant.
Water Pipe components
1, Removal
○
1 Drain engine coolant from drain plug at the bottom of radiator. Please refer to
“Changing engine coolant”.
Note:
■Do not operate this step until engine cools.
○
2 remove air cleaner assembly
Please refer to" Remove air cleaner assembly".
○
3 Remove the water hose of radiator.
○
4 Remove warm-water hose and minor cycle water pipe.
○
5 Remove mounting bolts of inlet water pipe, and then remove the water inlet
pipe from the back of water pump.
Note:
■Before removing, please remove the battery negative terminals.
2. Installation.
Please note the following items and install in the reverse order of removal.
1) Firmly install each pipe. Install the clamp and make sure that clamp will not
Cooling System
CO -12
hold the bump of water pipes.
2) Replace the water pipes' O-ring with a new one, and then smear coolant onto
the O-ring, so that they can be easily embedded in the water-pump thermostat
housing.
Note:
■Never smear the O-ring with engine oil or other oil material.
■The pipes at the back of thermostat housing and water pump must be installed
firmly.
3, Inspection after installation:
1) Check for leakage of engine coolant using the radiator cap tester. Please refer
to"Leakage check".
2) Start the engine and warm it up. Visually check for leakage of engine coolant.
Failure analysis
Analysis list of over-heating
Symptoms Check items
Parts
malfunction
of cooling
system
Poor heat
radiation
Water pump
malfunction
Worn or excessive
loosing drive belt
-
Thermostat stuck at
OFF position
Damaged
radiator fans
Mud or paper clogging
Mechanical damage
Radiator cooling
clogged
Excessive foreign
materials (erosion, dirt,
sand, etc.)
Inadequate
air flow
Cooling fan does
not operate.
Fan assembly - Excessive resistance
to fan rotation
Damaged fan blades
Shroud damage - - -
Improper
coolant mixture
ratio
- - -
Poor engine
coolant quality
- Viscous engine coolant
Insufficient
engine coolant
Engine coolant
leakage
Coolant hose
Clamps loosen
Cracked hose
Cooling System
CO -13
Water Pump
Poor sealing
effect
Radiator cap
Loosened
Poor sealing
effect
Radiator
O-ring for
damage, aging
or improper
installing
Radiator water
tank
Cracked
Radiator core
cracks
Reservoir tank
Reservoir tank
breaks
Overflowing
reservoir tank
Exhaust gas leaks into
cooling system.
Cylinder head
aging
Cylinder head
pad aging
In addition - Engine overloads Drive improperly
Engine rpm is
excessive when
unloaded
Drive for
extended time
Drive at
extremely high
speed
Malfunction
s of parts
out of
cooling
system
Powertrain system
malfunction
Installed with wheels
and tires of improper
sizes
Retardant brakes
Incorrect ignition
timing
Blocked air
flow
Blocked bumper
vent
-
-
Blocked radiator
grille
Installed car hood
Mud or paper clogging
Clogged radiator -
Blocked condenser Blocked air flow
Cooling System
CO -14
Service Parameters
Specifications table of cooling system
Thermostat Opening Temperature
82C（begin to open） 95C（completely）
Thermostat closing temperature
≥77C
The maximum lift of valve stem >8mm
Fuel Supply System
FL-1
Fuel Supply System
Precautions
Warning:
When replacing or removing fuel system parts, be sure to observe the following
tips.
■Put a “NO FIRE” signs in the operation position.
■Be sure to work in a well ventilated area and equip operation position with CO2
fire extinguishers.
■Be sure to put drained fuel into a container and well-caped
Keep the container in safe area.
■When removing fuel line parts please operate the following procedures:
Release fuel pressure inside the fuel pipelines.
Disconnect the negative cable of battery.
■Please do not twist fuel pipes when install.
■Please operate at a flat place.
■After connecting fuel pipes connectors, make sure they are connected firmly.
Ensure that connector and resin tube not touch with any adjacent parts.
■Please do not tighten hose clamps excessively to avoid damaging hoses.
■After installing fuel pipes please make sure there are no fuel leakage at all
junctions by operating the following steps.
Increase fuel pressure to fuel lines by turning ignition switch “ON”. (Do not start
engine!)
Then check for fuel leakage at junctions.
Start engine and rev it up and check for fuel leakage at junctions.
■Please get a container and rag ready in advance as fuel may leak.
■Avoid open flames and sparks
■Please keep removed parts away from any fire source.
■Be sure to keep junctions clean and avoid damage and entry of foreign material
Please cover them completely with plastic bags or similar articles
Fuel Supply System
FL-2
■Please use genuine fuel system spare parts provided by JAC.
Preparations
Special tools:
List of Special Tools
SN Tool Outline drawings Number Descriptions
1
Fuel
pressur
e gauge
JAC-T1F018
Measure fuel
pressure
Fuel Supply System Components
Fuel System Assembly Drawing
1.Fuel tank assembly 2.Fuel tank band 3.Canister assembly 4.fuel filler pipe assembly
5.fuel filler cap 6.Fuel supply line 7.Fuel transfer pump assembly 8.Fuel pump
access cover 9. Fuel filter
1
2
3
4
9
8
7
6
5
Fuel Supply System
FL-3
Fuel Tank
1, Removal
1) Release left fuel pressure inside the fuel pipelines.
2) Open fuel filler cap to release the pressure in fuel tank.
3) Remove rear seat.
4) Remove fuel tank service-cover.
■Pry off with a flat screwdriver directly
5) Disconnect the harness connector on
the fuel pump.
6) Remove the sub-frame assembly.
7) Disconnect the connections of fuel
lines, fuel tank and canister.
8) Disconnect the pipe on fuel tank and
the pipe installed under the protection cover.
FL001
FL002
FL003
Fuel Supply System
FL-4
9) Support the fuel tank with bracket
mount, remove mounting bolts and nuts of
fuel tank strap so as to remove the fuel tank
strap.
Note:
■The support points should not intervene the fuel tank strap
10) Take off the fuel tank, if necessary; take the needed parts and components
from it.
2, Inspection after removal:
■Check the surface of fuel tank assembly for scratch or serious distortion
3, Installation
Install according to the reverse order of removal.
■When install the fuel tank strap, the tighten torque of bolt and lock nut is from
40 N. m ~50 N. m.
4) Inspection after installation
Check for fuel leakage according to the following procedure.
Turn ignition switch to “ON” position (do not start engine), and check the
junctions of fuel pipes for leakage.
Start engine and rev it up, to confirm there is no leakage at junctions of fuel
system hose and pipes.
Fuel Filter
1, Removal
Note:
■Fuel filter should be replaced regularly
according to the maintenance guide in the
“Operation Manual”.
1) Remove fuel tank assembly; please see detailed procedure"Fuel Tank
FL004
FL005
Fuel Supply System
FL-5
Removal".
2) Disconnect the fast plug between fuel pipes and fuel filter.
Note:
■Wrap fuel filters with a towel or similar article to avoid ejection of fuel caused
by residual pressure.
3) Pull out the fuel filter from the filter mounting bracket along the line direction
on the surface of fuel tank.
2, Inspection after removal:
■Check filter assembly surface for scratch or serious distortion.
3, Installation
Please note the following and install according to the reverse order of removal.
1) Fuel filter
■Pay attention to installation direction
of fuel filter
Toward the fuel outlet line
2) Connect the fast plug connector
Connect fuel pipe connector as followed:
Check the junctions for foreign materials or damage.
Align the connector with resin tube at the two end of filter, and then insert the
connector straight into the tube until a click sound is heard.
4) Inspection after installation
After installation, check for fuel leakage according to the following procedure.
Turn ignition switch “ON” (with engine stopped) after lifting the vehicle to a
certain height, and then check fuel filter line junctions for leakage.
Start engine and run it at idle speed and high speed, and make sure again there
FL006
Fuel Supply System
FL-6
are no fuel leakages at the fuel filter junctions.
Fuel Pump Assembly
Fuel Pump Assembly Drawing
1, Removal
Warning:
■Be sure to read the "General Considerations"
1) Check the readings on fuel gauge. If fuel gauge indicates a “FULL” or close to
“FULL” position, then drain the fuel in fuel tank until the level indicated by fuel
gauge is below “E”.
2) Release fuel pressure in the fuel pipelines.
3) Open fuel filler cap to release the
pressure in fuel tank.
4) Remove rear seat cushion.
5) Remove fuel tank service-cover.
■Pry off with a flat screwdriver directly
6) Disconnect the fuel pump harness
connector and fuel lines connector.
FL007
FL008
FL008
Fuel Supply System
FL-7
Note:
■Do not use any tools to disconnect connector.
■Keep junctions clean and avoid damage and entry of foreign material. Please
cover them completely with plastic bags or similar articles.
7) Using special lock nut retainer to
loosen lock nut and take it off.
8) Remove Y-ring seal.
9) Pull out fuel pump.
Note:
■When pulling it out, tilt fuel pump to avoid damage to fuel level sensor.
■To avoid contamination with residual fuel, please wrap the fuel pump with rag
and pull it out straightly.
2, Inspection after removal
1) Fuel pump:
■Check for breakage and impurities in fuel
Figure1.4.015
FL009
FL
010
FL011
Fuel Supply System
FL-8
If any, please replace or clean.
■Resistance check
Measure the resistance between 2 terminals of fuel pump. Its value should be
approx. 2~30Ω.
■Fuel supply pressure check. Connect a 12V power source and test it while
running in gasoline.Observe whether fuel is output from delivery pipe of fuel pump,
check whether fuel supply pressure can be built up.
■Please do not run it for extended time so as to avoid damage to pump core.
2) Y-ring seal
■Check for starving and breakage
3) Lock nut
■Check for deformation, cracks, starving, breakage, and mounting thread
damage.
4) Fuel level sensor
■Check fuels float for interference and check its surface for oxidation.
3, Installation
Please note the following and install according to the reverse order of removal.
1) Fuel Pump Assembly
■When install, make sure the Y- ring match with the fuel tank completely.
■The fuel pump should be tilted into, and please note the installation direction of
fuel pump assembly.
■When install fuel pump, make sure that the Y-ring is not edged.
■Pre-tighten the lock nut then install, then install the horizontal lock, the tighten
torque is 75 N. m±5 N. m
2) Fast plug connector
○
1 Check the junctions for foreign materials or damage.
○
2 Align the connector with resin tube, and then insert the connector straight
into the tube until a click sound is heard.
○
3 After connecting, make sure that the connection is secure by following
Fuel Supply System
FL-9
method.
■Pull the resin tube and the connector heavily to confirm that they are ecurely
connected.
4) Inspection after installation
Check for fuel leakage according to the following procedure.
1) Turn ignition switch to “ON” position (do not start engine), and check the
junctions of fuel pipes for leakage.
Start engine and rev it up, and re-confirm that whether there is leakage at
connections of fuel system or not.
Fuel Evaporative Emission Control System
System description:
Fuel Evaporative System Drawing
Fuel Evaporative System Illustrative Diagram
○
1 The fuel evaporative system is used to reduce the hydrocarbons emitted into
the atmosphere from the fuel system. This reduction of hydrocarbons is accomplished
effectively by applying activated charcoals in the canister.
Air Cleaner
Intake
Manifold
Fuel
Tank
EVAP
Canister
EVAP.Canister
solenoid
valve.
Air
Fuel
Vapor
Fuel Supply System
FL-10
○
2 The fuel vapor evaporated from the sealed fuel tank is led into the canister
which contains activated carbon and stored there, when the engine is not operating or
when refueling to the fuel tank.
○
3 The fuel vapor in the canister is routed into the intake manifold through purge
pipelines when the engine is operating. Canister purge volume control solenoid valve
is controlled by ECU. When the engine operates, the flow rate of vapor controlled
by canister purge volume control solenoid valve is proportionally regulated as the air
flow increases.
○
4 Canister purge volume control solenoid valve also shuts off the vapor purge
pipes during decelerating and idling.
○
5 Riveted on fuel tank, fuel vapor control valve can prevent fuel vapor from
being excessively emitted into canister.
2, Fuel evaporative emission pipeline drawings
1. Canister Assembly 2, Fuel pipeline Assembly
Note:
■Please do not use soapy water or any type of cleanser while installing vacuum
hose or purge pipelines.
3, Components inspection:
1
2
2
Fuel Supply System
FL-11
1) Canister:
○
1 The location of canister: Located on the mounting suuport of the canister on
fuel tank.
○
2 canister removal
1) Release left fuel pressure inside
the fuel pipelines.
2) Open fuel filler cap to release the
pressure in fuel tank.
3) Disconnect the connection of the
pipelines in connector box on canister.
4) Pull upward the holder of the
support of canister.
Pull out the canister from installing support.
5) Fuel filler cap
The fuel filler cap is provided with a vacuum relief valve. When pressure in fuel
tank is high (much fuel vapor), the vacuum reducer valve will close to prevent fuel
vapor from emitting into the atmosphere. When pressure in fuel tank is low (negative
pressure), the vacuum reducer valve will open to allow outside air to enter fuel tank.
Accelerator Control Device
1. Components: Electronic accelerator pedal
FL012
FL013
FL012
Fuel Supply System
FL-12
2, Removal
1) Disconnect the harness connector on electronic accelerator pedal.
2) Remove the 3 mounting screws on the
pedal.
3, Inspection after removal
Check pedal for cracks and mobility of movable joint.
4, Installation
Install according to the reverse order of removal.
5, Inspection after installation:
■Check whether accelerator pedal can operate smoothly or not.
Service Data and Specifications
Specification Table of Fuel System
Items Descriptions
Fuel tank capacity 45L
Fuel pump
FL014
Fuel Supply System
FL-13
Working voltage
6～15 V
Rated working voltage 12 V
System pressure 350 kPa
Range of permissible
operating temperature
-30℃～+70℃
Radio disturbance
characteristic
Requirements of clause 6.2,6.4 in GB/18655
Emission control System
EES-1
Emission Control System
Fuel Evaporative System
1, System description:
Fuel Evaporative System Drawing
Fuel Evaporative System Illustrative Diagram
The fuel evaporative system is used to reduce the hydrocarbons emitted into the
atmosphere from the fuel system. This reduction of hydrocarbons is accomplished by
applying activated charcoals in the canister. The fuel vapor evaporated from the
sealed fuel tank is led into the canister which contains activated carbon and stored
there, when the engine is not operating or when refueling to the fuel tank. The fuel
vapor in the canister is routed into the intake manifold through purge pipelines when
the engine is operating. EVAP Canister solenoid valve is controlled by ECU. When
the engine operates, the flow rate of vapor controlled by EVAP Canister solenoid
valve is proportionally regulated as the air flow increases. EVAP canister control
solenoid valve will shut off the vapor purge pipes during decelerating and idling.
Air
Cleaner.
Intake
Manifold
Fuel
Tank
EVAP
Canister
EVAP
Canister
solenoid
valve.
Air
Fuel
Vapor
Emission control System
EES-2
2,Fuel evaporative emission pipeline drawings
Fuel Evaporative System Line Drawing
1- Canister Assembly2 - Engine Oil Inlet Hose 3 - Canister to solenoid valve hose
4- Canister to solenoid valve hose 5 - Engine Oil Tube 6 - Fuel Filter
Note:
■Please do not use soapy water or any type of cleanser while installing vacuum
hose or purge pipelines.
3, Components inspection:
1) P Canister
○
1 Check EVAP canister according to
the following procedure
a. block port 1, and blow from port 3,
Confirm that air flow out from port 2
smoothly.
b. block port 3, and blow from port 1,
1
2
3
4
5
6
1
2
3
EES001
Emission control System
EES-3
Confirm that air flow out from port 2 smoothly.
○
2 Vacuum hose removal
Using slip-joint pliers to loosen the clamps connecting canister to fuel tank and
canister solenoid valve, and pull off vacuum hose.
○
3 canister removal
Lift up the canister from the left
daughter board lining
Remove it from its holder.
2) EVAP Canister solenoid valve.
The changes of the openning of vapor bypass line in canister solenoid valve
controls air flow rate. Canister solenoid valve repeats ON/OFF operations according
to signals sent by ECM and the opening of the valve changes in order to achieve the
best of engine control. The optimal values stored in ECM depend on different engine
conditions. When engine is running, air flow rate of fuel vapor from canister is
regulated with changes of airstream.
○
1 Component description:
EVAP Canister solenoid valve uses ON/OFF duty cycle to control THE flow rate
of fuel vapor flowing out of EVAP canister. EVAP canister solenoid valve is driven
by the on/off (ON/OFF) Duty Cycle signal sent from ECM. The longer the pulse
width is, the more fuel vapor flow through the valve.
○
2 Remove
a, Disconnect EVAP canister solenoid valve vacuum hose.
b, Disconnect EVAP canister solenoid valve harness connector.
c, Take off EVAP canister solenoid valve from its holder.
Left
front
frame
EES002
Emission control System
EES-4
3) Fuel filler cap
The fuel filler cap is provided with a vacuum relief valve. When pressure in fuel
tank is high (much fuel vapor), the vacuum reducer valve will close to prevent fuel
vapor from emitting into the atmosphere. When pressure in fuel tank is low (negative
pressure), the vacuum reducer valve will open to allow outside air to enter fuel tank.
Positive Crankcase Ventilation Syatem
1, System description:
Positive Crankcase Ventilation System Diagram
1 - Air Cleaner 2-air intake hose 3 - throttle valve 4 - Purge tank 5-PCV valve
6 - Air Hose 7 - Air Intake Manifold 8 - Fuel Injectors
The function of Positive Crankcase Ventilation System is to make the blowby air
from cylinder flow back to the intake manifold.
Crankcase Ventilation VALVE (PCV) in the crankcase makes the blow by air
from cylinder in crankcase flow back to the intake manifold. With the engine TPS
circuit turning on, the intake manifold can draw the blowby air in crankcase through
PCV valve. Under normal circumstances, the ventilation ability of PCV valve is
adequate to draw the crankcase blowby air and a small volume ventilation air.
Ventilation air is drawen from the air intake hose into crankcase. In this process, air
will go through the air intake hose and the hose of rocker arm cover. When TPS
1 2
3
4
5
6
7
8
Emission control System
EES-5
circuit fully opens, the vacuum of intake manifold is insufficient to open PCV valve
and draw the blowby air in crankcase. Air will flow through hose connections in the
opposite direction. PCV valve can't meet requirements if air blowby situation is very
seirous. Because, in any case, there will be some gas goes through the hose and gets
into the air intake hose.
2, Components inspection:
Check Positive Crankcase Ventilation as follows:
1) Operation Principle
PCV Valve Operation Principle Diagram
Engine working
condition
Not running Engine working
condition
Idling or deceleration
PCV valve Not Work PCV valve Fully open
Vacuum change Limit Vacuum change Slight
No vacuum
Valve Chamber
Cover Side
High
vacuum
Valve Chamber
Cover Side
Emission control System
EES-6
Engine working
condition
Working normally Engine working
condition
Acceleration and
high-speed negative
PCV valve Working normally PCV valve Working trady
Vacuum change Large extent Vacuum change Very large
3, Removal and installation
○
1 Removal
a. Disconnect PCV valve hoses and cylinder head cover.
b. Remove PCV valve from the cylinder head cover.
3), Inspection after removal
○
1 PCV valve
When the air stream flows though,
functional valve will come out with hissing
noise. When put your finger on the valve
inlet, you will feel a strong vacuum pressure.
○
2 PCV valve ventilation hose
a. Check the hoses and hose connections for leakage.
b. Disconnect all hoses and use compressed air to clean them. If you cannot
Vacuum
medium
Valve Chamber
Cover Side
No
vacuum
Valve Chamber
Cover Side
EES003
Emission control System
EES-7
clear obstructions in the hose, please replace it.
Start charging system
EL-1
Engine Electrical
Start charging system
Start charging system Illustrative Diagram
Start charging system Illustrative Diagram
Battery
1, How to use the battery
Note:
■If it is necessary to use auxiliary battery and cross-wire to start the engine, be
sure to use 12 V auxiliary batteries.
■After connecting the battery, confirm that cross-wire is clamped to the battery
terminals and good contacted.
2, Methods to prevent the battery from over-discharging
To prevent battery from over-discharging, the following precautions should be
attached great importance to.
■Always keep the battery surface (especially the top) clean and dry.
Batter
y
Start charging system
EL-2
■The port of the connecting part should be cleaned and tightened.
■If the vehicle is not in operation for a long period, please disconnect the
negative battery terminal.
■Check the battery for charge status
3, check
1) Visually check
■Check the battery terminals for damage, fluid leakage, if any, please replace it.
2) Check voltage (U)
○
1 If U > 13.2 V, please check the electrical system.
○
2 If 12.5 V <U <12.9 V, It means the system is working normally.
○
3 If 11 V <U <12.4 V, please check the charging system.
○
4 If U <11 V, it means the battery is damaged or there is a problem with the
charging system, please check the charging system and the battery.
4, Removal and installation
1) Removal
■Turn ignition switch to “OFF” position
○
1 Disconnect negative terminal.
○
2 Remove the battery positive terminal and the battery plate mounting bolts,
then take out the board.
○
3 Remove the battery.
○
4 Remove the battery carrier.
2), Inspection after removal
○
1 Battery carrier
■Check for corrosion
If any, please clean it with hot water.
○
2 Battery harness
Figure2.2.0
02
Start charging system
EL-3
■Check for wear or damage
If any, please replace.
3) Installation
Install according to the reverse order of removal.
Note:
■When connecting, please connect the battery positive terminal first.
■After installation, please smear mineral oil on terminals.
Start System
1, System description:
When starter solenoid switch is closed, there is a closed line between the battery
and starter motor. Connect starter to engine block. After being provided with power,
starter turns crankshaft, then the engine will start.
2, Removal and installation
Starter Motor Components Figure
1 - M port 2-S port 3-B port
1) Removal
○
1 Disconnect negative battery terminal.
Note: Before disconnecting negative battery terminal,
4
1
2
3
Start charging system
EL-4
please take out the vehicle key first.
○
2 Disconnect starter wiring harness connector
○
3 Remove mounting bolts of starter, take off starter.
2) Installation
Install according to the reverse order of removal.
Note:
■Be sure to tighten the B “end nut
3, Disassembly and Reassembly
1) Disassembly
Start charging system
EL-5
Exploded view of starter
1 - Screw 2 - Front support 3 - Retaining Ring 4-Ring 5-Pinion gear 6-Ring 7-Solenoid Switch
8-Stars gear 9 - Planetary gear 10-Ball 11-Gasket 12 - Stator 13 - Armature 14 - Brush holder
15 - Rear support 16 - Tighten bolts
2) Check
○
1 Check solenoid switch
11
15
14
13
12
2
3
5
6
7
4
1
10
9 8
16
Start charging system
EL-6
■Before checking, please disconnect negative battery terminal first.
■Disconnect "M" port of starter.
a. Test whether the "S" port and switch is
connected or not.
■If not, please replace the solenoid
switch.
b. Test whether the "S" port and "M" port is connected or not.
■If not, please replace the solenoid
switch.
○
2 Check pinion gear
a. Visually check engaged gear's gear
■If the gear is worn or damaged, please replace it (please check gear of flywheel
at the same time).
b. Check the gear of pinion gear.
■If the gear is worn or damaged, please replace it (please check the gear of
Armature shaft at the same).
c. Check whether the pinion gear locks in one direction rotates smoothly in
another direction.
■If the pinion gear can lock or rotate in both direction, or if there is no normal
resistance, please replace it.
EL001
EL002
Start charging system
EL-7
3) Assembly
When assembling the starter, please add high temperature grease to lubricate
bearings, gears and friction surface. Do as the following instructions.
○
1 Gear Clearance Adjustment
■Push the pinion gear out when the
magnetic switch is powered on
Using a feeler gauge to check the clearance
between pinion gear and thrust block.
■If the clearance is not within the specified
range, please use adjustment shims to adjust.
4, Common trouble diagnosis flow (if any abnormalities are found, please quickly
disconnect the negative battery)
EL003
EL004
Start charging system
EL-8
Start System common trouble diagnosis flow
Charging system
N
Starter motor does not stop
Replace the solenoid
switch.
Check Ignition/fuel
system
Is engine running normally?
Y
Y
Does the engine start after
crankshaft rotates?
Engine does not start
Y
Repair Starter
Check the battery in the
following items:
1.Charge status
2.Terminal connections status
3.Terminal corrosion
A
Normal
Abnormal
Starter motor is running?
Check pinion gear clutch
Replacement
Check the reducer, armature and gear shaft
A
N
Y
Abnor
mal
Abnormal
Check safety wire and fuse wire
Gear shaft is running?
Check Start System lines
Repair Starter
N
Y
Normal
Normal
Abnormal
Replace the solenoid
switch.
Whether the starter rotates or not?
when connected without load.
Check the engagement between
pinion gear and ring
1. Adjust the pinion gear shift
2. Check the pinion gear
operates train
3. Check the ring
Repair Starter
N
Y
Abnormal
Solenoid Switch is operating
with noises?
1.Battery charge
2.Repair bad connections and
corrosion of the battery
terminals
Check the battery in the
following items:
1.Charge status
2.Terminal connections status
3.Terminal corrosion
Repair.
N
Start charging system
EL-9
1, System description:
Generators provide DC voltage to automotive electrical system and keep the
battery charging status. Voltage output is controlled by IC regulator.
Port "B" is used to supply power to automotive electrical system and to provide
power source for battery. IC regulator check the input voltage at Port 4 (the "S" port),
and so as to control output voltage.
After being powered and grounded, charge warning lights will light on. When
generators are able to provide sufficient high-voltage, ground line open, the charge
warning light will light off. If the charge warning light remains on when the engine is
running, that indicates a failure.
2, Charge warning light
If the generator works with the following occurs, the warning function of IC
regulator will start and illuminate the charge warning light.
■No voltage or excessive high voltage
3, Removal and installation
Figure2.2.0
17
Start charging system
EL-10
1) Removal
○
1 Disconnect negative battery terminal.
○
2 Disconnect generator wiring harness connector
○
3 Loose generator adjusting nut and support nut
Then use the adjusting nut to adjust tension.
■Tightening torque: Generator adjusting nut: 22.5 ±2.5 N. M
Generator support nut: 47 ±5 N m.
○
4 Remove generator belt
○
5 Remove the generator from the vehicle.
2) Installation
■Install according to the reverse order of removal
■Install generator, please check the generator belt tension. Please refer to"Drive
belts".
Note:
■Tighten the B “port nut
Tightening torque: 10～12N.m
5, charging system trouble diagnosis
Before testing the generator, please confirm the battery is fully charged. Please
use a 30V-voltmeter and suitable testing probe while testing. Reference to checking
list will facilitate generator check.
■Before starting, please check fuse wire.
■Use a fully charged battery
Start charging system
EL-11
Charging System trouble diagnosis flow
Note:
■If there is a problem with the charging system while the test result is normal;
please check "B" port connection (check tightening torque and voltage).
■Check the condition of rotor coil, rotor slip ring, brush and stator coil
If necessary please replace the faulty parts.
Check the following:1Warning
light bulb 2Warning light
safety wire
Ignition
switch"N"
Warning
lights
off
Disconnect
connectors,
pairs L
Harness
Ground
Warning
lights on
Warning
lights
off
Warning
lights on
Check the
following:
1.rotor
2.rotor
slip
rings
3.brush
Damaged IC regulator,
Please replace it
Engine starts,
engine speed
1500 RPM
Warning
lights on
Check the
following: 1.
Drive Belt 2.
Generator "S"
port 3.
Connector
Engine is
idling
Warning
lights
off
Normal
Warning
lights on
Warning
lights off
Normal
Engine speed 2500
RPM, measure the
voltage at B port
Higher than 16.0 V
Damaged IC regulator,
Please replace it
Lower than 13.0V
2.Checkthefollowing:1.r
otor 2.rotor slip rings
3.brush 4.stator
Damaged IC
regulator or 2a
diode assembly,
Please replace it
Warning Lights: "charging" warning
light in the instrument cluster
Electronic Control System
EC-
1
Engine Electronic Control System
Precautions
Supplemental Restraint System Precautions
The supplemental restraint system (SRS) such as “air bag” and (SB) “seat belt
pre-tensioner”, used along with the front seat belt, help reduce the risk or severity of
injury to the driver and front passenger in the event of a vehicle collision. For the
information of the proper maintenance of the system, please refer to the air bag
section in the service manual.
Warnings:
■To avoid rendering the SRS inoperative, which could increase the risk of
personal injury or death in the event of a collision, all maintenance operations must be
performed by an authorized JAC dealership.
■Improper maintenance, including incorrect removal and installation of the SRS,
can cause unintentional activation of the system which will lead to personal injury or
death.
About the removal methods of clock spring (gossamer webs) and air bag
controller, please refer to the airbag section.
■Do not use electrical test equipment on any circuit related to the SRS unless
under the instruction of this manual. Airbag circuit wiring harness can be identified by
the harness connectors.
General Precautions:
1、When checking the electrical control system, only the use of digital millimeter
is allowed.
2、During maintenance operation, please use JAC genuine parts. Otherwise the
normal operation of the system cannot be ensured.
3、Only unleaded petrol is allowed to use during maintenance and use.
4、 When performing maintenance operation, please observe the standard service
and diagnostic flows.
Electronic Control System
EC-
2
5、 During maintenance, it is forbidden to disassemble and remove the parts of
the system.
6 、 During maintenance, please be cautious when take and put the electronics
components (electronic control modules, sensors, etc.) to avoid dropping.
7、Establish a sense of environmental protection and effectively dispose of the
wastes produced during maintenance.
Precautions during Maintenance
1、When performing simulation of thermal conditions of a malfunction or other
maintenance operation that may make temperature rise, Do not allow temperature of
the electronic control module to exceed 80℃.
2、For the fuel pressure of the fuel injection system is high (350 kpa), all the oil
pipes used in the system must be able to withstand high pressure. Even when the
engine is not in operation, the oil pipes still have maintained a quite high pressure.
Therefore, during maintenance please note that do not easily remove oil pipes. if it is
necessary to maintain the fuel system, please make sure that release the pressure in the
fuel system before you remove oil pipes.
3、Removal of oil pipes and replacement of fuel filter should be performed by
professional maintenance personnel at a well-ventilated place.
4、Do not energize the fuel pump when removing the electric fuel pump from the
fuel tank so as to avoid producing electric sparks which will cause fire. Operation test
of the fuel pump is not allowed with the pump dry or in water; otherwise service life
of the pump will be reduced. In addition, never connect positive (+) and negative (-)
of the fuel pump inversely.
5、When checking the ignition system, perform spark test only when necessary
and for a duration as short as possible. During inspection, do not open the throttle;
otherwise a large amount of unburned gasoline will enter the exhaust pipe causing
damage to the three way catalyst.
6、 Idle speed adjustment is completely accomplished by the electronic control
system, so no manual regulation is required. The throttle stop screw of the throttle
Electronic Control System
EC-
3
body has been adjusted properly by the manufacturer at factory. Users are not allowed
to change its initial position optionally.
7、 When connecting the battery, do not misconnect its positive (+) and negative
(-) so as to avoid damage to electronic components. This system uses negative ground
(minus earth).
8 、 It is not allowed to remove the battery cable when the engine is running.
Before on-vehicle welding operation, be sure to remove battery positive and negative
cables and the ECU.
9、Do not detect input and output electric signals of parts by piercing wire skins.
Electronic Control System
EC-
4
Structural Principle and Maintenance of Engine Control System
System Description
1- Canister 2-Canister Control Solenoid Valve 3 - Electronic Throttle Body
Assembly 4 - Intake Air Pressure/Temperature Sensor 5 - Injector 6-Camshaft
Position Sensor 7-Ignition Coil 8-Front Oxygen Sensor 9-Three Way Catalytic
Converter 10-Rear Oxygen Sensor 11 - Engine Coolant Temperature Sensor 12 -
crankshaft position sensor 13 - Fuel Filter 14 - Electric Fuel Pump 15 - Fuel Tank 16
- Diagnostic Interface 17 - Engine Control Module
Note:
■ This is the diagram of control system. If the sensor location is not in
conformity with the entity, please refer to the entity.
Multi-point Fuel Injection System
1
、
System Description
Multi-point fuel injection (MPI) system consists of the engine's electronic
control module (ECM) and the sensor that detects the engine performance.
Electronic Control System
EC-
5
The control of the system is based on the sensors' signals.Each actuator
operates under control of the ECM. The functions of ECM are to control fuel
injection , idle speed and ignition timing,etc. Also, ECM has several diagnosis
methods that can simplified the troubleshooting process when malfunctions occur.
2、Input/Output Signal
Input/Output Signal table
3
、
Start Control
During start-up, special calculation method should be taken to control the air
intake flow, fuel injection and ignition timing. At the beginning of the start-up, the
air in the intake manifold is still while the pressure is same as the atmospheric
pressure. When the throttle is switched off, the electronic throttle is specified as a
fixed parameters based on the starting temperature. In a similar process, the specific
"injection timing" is specified as the initial jet pulse. The fuel injection flow varies
with the engine temperature so as to facilitate an oil film formation on the wall of
the intake manifold and cylinder. Therefore, when the engine reaches a certain
speed, the rich mixture shall be added. As soon as the engine starts running, the
system immediately begins to reduce the cranking enrichment until it completely
stops the cranking enrichment when the starting status is finished. (600 to 700 rpm)
At the start-up, the ignition advance angle is also adjusted constantly, varying with
the engine temperature, intake air temperature, and engine speed.
Sensor
Input signal to ECM
ECM
Functions
Actuator
Crankshaft position
sensor(position)
Engine speed piston position
Fuel Injection
and mixture
ratio control
Fuel
injector
Camshaft position sensor(phase
position)
Intake air pressure sensor
Air intake flow
Intake air temperature sensor
Oxygen sensor
Oxygen concentration of exhaust gas
Electronic throttle position sensor
Throttle position
Knock sensor
Engine Knock conditions
A/C switch
A/C pressure
Wheel speed sensor
Speed
Engine coolant temperature sensor
Engine coolant temperature
Electronic Control System
EC-
6
4、Heating control of the heater and three-way catalytic converters
After the engine is started at low temperatures, the air intake flow in cylinder,
fuel injection and electronic ignition are adjusted to meet the requirement of higher
torque; The process continues until the temperature reaches to the appropriate one.
In this phase, the quick heating of three-way catalytic converters is the most
important because exhaust emissions can be significantly reduced by the quick
transition to the operation of three-way catalytic converters. In this condition, make
use of the exhaust emissions to heat the three-way catalytic converters by
moderately delaying the ignition advance angle.
5
、
Acceleration/deceleration and motoring with fuel cut-off control
Some of the fuel that injected to the intake manifold will not be delivered to the
cylinder in time to participate in the follow-up process. Instead, it forms a thin oil
film on the wall of the intake manifold. With the workload increasing and the fuel
injection lasting, the volume of fuel that stored in oil film will increase sharply.
When the throttle opening is increased, some of injection fuel will be absorbed by oil
film. Therefore, it is necessary to add appropriate fuel as compensation, and prevent
gas mixture from thinning when accelerating. Once the load factor decreases, the
additional fuel contained in the oil film on the wall of the intake manifold will be
released, then during deceleration, there is a must to reduce the injection duration.
Motoring or traction condition refers to the situation where the value of the engine
power that provided to the flywheel is negative. In this case, the friction of engine
and pumping losses are available to the vehicle deceleration. When the engine is in
motoring or traction condition, the fuel injection is cut off to reduce consumption
and emissions, and more importantly, to protect the three-way catalytic converters.
Once the speed drops to a specific speed which is higher than idle speed and suitable
for fuel supply, the fuel injection system restarts supplying. In fact, there is a speed
range of recovery in ECM procedures. The range varies with the engine temperature,
dynamic changes of engine speed and other parameters, and prevents the engine
speed from decreasing to the specified minimum speed by calculating. Once the
Electronic Control System
EC-
7
injection system starts supplying fuel, the system starts the initial injection pulse to
supply additional fuel, and reforms oil film on the wall of the intake manifold. After
recovery of fuel injection, a torque-based control system makes the engine torque
increase slowly and smoothly (smooth transition).
6、 Idle Control
When the engine is idling, it does not provide torque to flywheel. To ensure
that the engine has a stable operation when the idle speed is as low as possible, the
closed loop idle control system must maintain the balance between the torque
produced by engine and the "power consumption" of engine. The idling needs a
certain power to meet the load requirements. The load comes from the engine
crankshaft, valve mechanism and accessories, such as internal friction in water
pump. The torque-based system controls strategy. Based on closed-loop idle control,
it decides the output torque for maintaining the required idle speed in any operation
conditions. The output torque increases as the engine speed decreases, and
decreases as the engine speed increases.The system responds to the new
"interference factors" by requiring greater torque, such as the start and stop of the
air conditioning compressors. When the engine temperature is low, the torque also
increases to compensate for greater loss from internal friction or maintain a higher
idle speed. All the requirements for output torque is passed to the torque
coordinator. Then the torque coordinator figures out the gas density, the mixture
composition and ignition timing by calculating.
7、
Closed-loop Control
The exhaust reprocessing of three-way catalytic converters is effective to
reduce the concentration of harmful substance from the emissions. Three-way
catalytic converters can reduce the hydrocarbon (HC), carbon monoxide (CO) and
nitrogen oxides (NOX) with 98 per cent or more, and converts them into water
(H
2
O) , carbon dioxide (CO
2
) and nitrogen (N
2
). However, only when the engine
excess air coefficient
=1 and with a very narrow near range, can it attain such a
high efficiency. The purpose of the
closed-loop control is to ensure that the mixed
Electronic Control System
EC-
8
gas density is within this range. Closed-loop control system only works when it is
equipped with oxygen sensors. Oxygen sensors installed at the side of three-way
catalytic converter detects oxygen content from emissions. Thin gas mixture（

1）
generates about100 mV sensor voltage, while thick mixture（
1) generates about
900 mV sensor voltage. When =1, the sensor has a voltage leap. Closed loop
control responds to the input signal (1= thin gas mixture, 1= thick gas mixture)
by modifying the control variable and outputting correction factor as a multiplier to
correct fuel injection duration.
8、Evaporative Emission Control
Due to the heat delivery of external radiation and the oil return, the fuel in fuel
tank is heated which results in the fuel vapor. According to evaporative emissions
regulations, the fuel vapor which contains much HC composition is not allowed to
directly pump into the atmosphere. In the system, fuel vapor is collected in the
charcoal canister through conduit, and flushed into the engine for combustion
processes in due course. The flush air flow is achieved by ECM's control of the
canister control valve. That only works, when the closed-loop control system is
under operation.
9、Fuel Injection Control
The control of fuel injection timing and fuel injection pulse width supplies the
engine with the best air/air-fuel ratio to keep pace with the changing operating
condition of engine. Each of the cylinder inlets is installed with the injector. Fuel is
pumped out from the fuel tank by fuel pump and sent to each fuel injector. Under
normal circumstances, the crank operates every two circles while fuel is injected
once to each cylinder. The working order of each cylinder is 1-3-4-2.
10、Ignition Timing Control
The power transistor of ignition primary circuit controls the ignition timing by
switching on or off the primary current that flows to the ignition coil, and provide
the best ignition timing based on engine operating condition. Ignition timing is
controlled by ECM according to the engine speed, air intake flow, engine coolant
Electronic Control System
EC-
9
temperature and pressure of the atmosphere.
11
、
Self-diagnostic Function
When abnormalities are detected by the sensor or actuator that related to the
emission control, the engine warning light (the check engine light) is lit to inform
the driver. That the abnormalities are detected by the sensor or actuator is
equivalent to that the diagnostic trouble code of the abnormal situation will be
outputted. RAM data in ECM which is related to sensors and actuators, can be read
by diagnostic equipment. And in some circumstances, the actuators can be forced to
drive.
12、Other Control Functions
1
）
Fuel Pump Control
Connect the fuel pump relay, and then it supplies electricity to the fuel pump
when the engine crankshaft is running.
2) Fan Relay Control
The speed of radiator fan and condenser fan is controlled based on the engine
coolant temperature, vehicle speed and switching signal of air condition (AC).
On-Board Diagnostic System
1
、
Description
The on-board diagnostic system (for short, OBD system) refers to a diagnostic
system integrated in the engine control system for monitoring faulty parts affecting
exhaust emission and main functions of the engine. It has the functions of
identifying, storing and displaying [through self-diagnosis malfunction indicator
light (MIL)] fault messages.
2
、
Fault Messages Record
The ECU continuously monitors sensors, actuators, related circuits, MIL,
battery voltage and so on and even the ECU itself. Also it inspects credibility of
output signals of sensors as well as driving signals and internal signals of actuators
Electronic Control System
EC-
10
(e.g. closed-loop control, coolant temperature, idle speed control, and battery
voltage control, etc.). The ECU will set a fault message record in the RAM fault
memory immediately once a link is found out of order or a signal value incredible.
The fault message records are stored in the form of diagnostic trouble codes (DTCs)
and are displayed in the order of appearance of faults.
Faults can be divided into “steady faults” and “incidental faults” (e.g. those
caused by brief open circuit in harness or poor contact of connector) by frequency
of occurrence.
3
、
Description and control strategies of malfunction indicator light
1
）
Malfunction Indicator Light
（
MIL): Indicates the removal of related parts
or system failure according to law and regulations. MIL is generally an indicator
light that can be displayed on the instrument panel and has a shape conforming to
requirements of laws and regulations and standards.
2
）
MIL activation abides by the following principles:
①When ignition switch is turned ON (without starting the
engine), the MIL will keep lighting up.
②If there is no fault request for MIL lighting up in the fault memory 3
seconds after engine start, the MIL will go out.
③
When there is a fault request for MIL lighting up in the fault memory or a
same request outside the ECU, the MIL will light up.
④When there is a MIL flashing request outside the ECU, or a misfire cause
requiring MIL flashing, or a fault request for MIL flashing in the fault memory,
the MIL will flash at a frequency of 1Hz.
4、 Troubleshooting Steps
1）For vehicles with OBD functions, their troubleshooting should generally
follow the procedure below:
Service Procedure Chart for OBD Malfunctions
Electronic Control System
EC-
11
1.Connect diagnostic test
equipment to diagnostic interface, and turn on
the equipment.
2.Turn ignition switch ON.
3.Read fault-related information
[DTCs, freeze frames (FFs), etc.]; refer to the
service manual and recognize faulty
components and fault types; prepare
maintenance scheme according to fault-related
information and experience.
4. Perform troubleshooting.
5.Clear fault memory; drive your
vehicle appropriately with driving patterns
satisfying corresponding trouble diagnostic
criteria; read fault information and make sure
the trouble has been cleared.
Engine Troubleshooting
1、Troubleshooting overview of engine control system
If the electronic engine control system components (e.g. sensors, ECM, injectors,
etc.), Have malfunctions, fuel supply interruption, or wrong supply of fuel capacity
for the engine in different conditions, the followings will occur.
a.Difficult or completely unable to start the
engine
b.Unstable idle speed
Electronic Control System
EC-
12
c.Poor driving performance
If any of the above occurs, firstly carry out the routine tests including the engine
basic checks (ignition system failure, engine correct adjustment etc.). Then check the
engine electronic control system components with fault diagnosis instruments.
Note:
■ Read the diagnostic trouble codes first before removing or installing any parts,
and then disconnect the negative battery terminal.
■Please disconnect the wiring harness to the battery terminal before you turn
off the ignition switch. If the engine is running or the ignition switch is turned on,
the disconnection of the battery harness will cause damage to ECM.
■The harness between ECM and sensors should be shielded by the shielded
ground wire that connected to the car body, which aims to prevent the ignition
system interference and radio interference. If the shielded wiring harness
malfunctions, wire harness must be replaced.
■Check the alternator charging status, and do not disconnect the battery positive
to avoid ECM damage.
■When using an external charger to charge the battery, please disconnect the
battery terminals to avoid ECM damage.
Electronic Control System
EC-
13
2
、
Trouble Diagnosis Flowchart
Electronic Control System
EC-
14
3、Fault symptom check list
Fault symptom check list
Fault Symptom
Check
Sequence
Number
Unable to communicate with
the diagnostic scanner
Unable to communicate with all system
1
Only unable to communicate with ECM
2
Engine warning light and the
corresponding components
When the ignition switch is turned on ,the engine
warning light does not light up immediately
3
Engine warning lights light up simultaneously and
do not go out
4
Start
No initial ignition (unable to start)
5
With initial ignition, but not completely burned
(unable to start)
6
Long start-up time (unable to have a normal start)
7
Idle speed stability (idle speed
abnormality）
Unstable idle speed (idle speed fluctuations,
hunting)
8
High idle speed (idle speed abnormality)
9
Low idle speed (idle speed abnormality)
10
Idle speed stability (engine
flameout)
When engine is cold, flameout occurs during
idling (flameout in deceleration)
11
When engine is hot, flameout occurs during
idling (flameout in deceleration)
12
Engine flameout occurs in start (flameout in
acceleration)
13
Engine flameout occurs in acceleration
14
Driving
Surge in vehicle and decrease or instability of
vehicle speed
15
There is an impact or vibration when accelerating
16
There is an impact or vibration when slowing
down
17
Poor acceleration performance
18
Surge
19
Cylinder knocking
20
Unable to stop
21
High CO and HC concentration during idling
22
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Low alternator voltage
23
Idle speed is abnormal when the air conditioning is turned on
24
Fan is not functioning properly
25
4
、
Fault symptom list
Fault symptom list
Items
Symptoms
Start
No start
Starter drag engine, but if no combustion in the cylinder, the
engine will not start
Engine stops after
combustion
There is combustion in the cylinder , but the engine stops
immediately
Hard starting
Engine starts after crankshaft operates for a few minutes
Idle speed
stability
Hunting
Engine speed is not constant and changes within idle speed
range
Idle speed fluctuations
Usually, it can be judged by the swing of tachometer
pointer, as well as the vibration that is passed to the steering
wheel, shift lever, and body, etc.
Idle speed is not correct
Engine is idling in the incorrect speed
Flameout occurs (flameout
in deceleration)
When the foot is off the accelerator pedal, engine stops no
matter whether the vehicle is moving or not.
Flameout occurs (flameout
in acceleration)
When accelerator pedal is hit or stepped on, the engine stops
Driving
Surge in vehicle and
decrease of vehicle speed
"Surge phenomenon " is a phenomenon that the motor
speed (engine speed)is slower than the current speed when
speed pedal is hit to speed up, or there is a temporary speed
(engine speed) decline during acceleration
Poor acceleration
performance
Poor acceleration performance refers to that the vehicle
cannot obtain a throttle opening to change the speed, which
is still a fault even accelerating smoothly; or refers to the
incapability to achieve the maximum speeds
Instability
Engine speed increases slowly when first hitting the
accelerator pedal to speed up
Impact
A large impact or vibration can be sensed when the engine
speed up or slow down
Surge
There is a repeated surge forward when driving at a constant
speed or variable speed
Cylinder knocking
A strong voice which is like a hammer striking against the
cylinder wall during driving, is harmful to driving
Electronic Control System
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Parking
Continuous running (Unable
to stop)
5、Basic Fault Check
When check the engine failure, the first should be the basic system check in
terms of order. If there are the phenomena of engine failure to start, unsteady idle
speed and insufficient fuel supply, please check the following basic systems:
a. Power Supply: battery, fusible line and blown fuse.
b. Earth wire
c. Fuel supply: oil tube, fuel filter and fuel pump.
d. Ignition system ignition plug, high-tension and line ignition coil.
e. Emission Control System: vacuum leaks
f. Others: ignition timing and idling.
The Electronic Engine Control System failure is usually caused by poor
contact of the harness connector; therefore check all the wiring harness connector
to verify that they are properly connected.
6、Idle Speed Check
1
）
Check Conditions
Note:
■First of all, check the general projects including ignition plug, fuel injector,
and cylinder compression pressure and so on.
①Engine warms up.
② Lights, electronic fan and all of the other accessories are turned off.
③
the transmission is in neutral.
④
Steering wheel is in the middle (with power steering system).
2
）
Connect diagnostic apparatus
3）Start engine and make it run at the minimum idle speed.
4) Make the engine run for 5s or more at the speed of 2000 to 3000 r/min.
Then, make the engine idle for 2 minutes.
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5) Read the idle speed (750±30r/min).
7
、
Fuel Pressure Test
Note:
■Release the pressure in fuel line first to eliminate dangers before
disconnecting the fuel line
■Always use the" O" ring to maintain good sealing performance of the
connector of fuel hose.
■Please do not operate electric system when you check.
Note: Prepare a container to avoid fuel spills before disconnecting the fuel lines.
1
）
Release the fuel pressure to zero. Please refer to "Release fuel pressure"
section.
2) Remove the fuel pressure check nut from the fuel injector rail.
3）Connect the fuel pressure gauges.
4) Turn the ignition switch to the "ON" position and check whether there is a
fuel leak.
5) Start the engine and male it idle, and check whether there is a fuel leak.
6) Take the reading on the fuel gauge.
■The fuel pressure
：
350KPa
Note:
■Do not perform Fuel Pressure Check when the system is running.
■During checking the fuel pressure, always make sure to check the junctions of
fuel pipes for leakage.
7) If the measurement of the fuel pressure is beyond the standard value,
analyze the possible cause in accordance with the following table, then carry
out necessary maintenance
Fuel System
Troubleshooting
table 1
Trouble
Symptoms:
Possible causes
Solutions to troubles
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Oil pressure is too
low
Fuel filter is blocked
Replace the fuel filter
Pump damage or fuel leak in the fuel return pipe at
the side of oil pressure regulator
Replace fuel pump.
Oil pressure is too
high
Oil pressure regulator cementation
Replace fuel pump.
Fuel return pipe is blocked or bent
Repair or replace fuel
pipe.
8) Stop the engine and check the reading changes of fuel pressure gauge for 5
minutes. If oil pressure gauge reading drops, observe the lower rate. Analyze and
perform troubleshooting according to the following table.
Fuel System
Troubleshooting
table 2
Trouble Symptoms:
Possible causes
Solutions to troubles
Oil pressure declines slowly after engine
stopped
Fuel injector leakage
Replace fuel injector
Oil pressure declines completely after
engine stopped
Fuel pump faults
Replace fuel pump.
9) Reduce the pressure in the fuel line.
10) Disconnect the fuel pressure gauge and install the check nut.
11) Check whether there is a fuel leak or not by the following steps.
①Turn ignition switch to “ON” position (do not start engine), and check the
junctions of fuel pipes for leakage.
②
Start engine and rev it up, and re-confirm that whether there is leakage at
connections of fuel system or not.
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Structural Principle and Maintenance of Engine electronic
components
Intake Air Pressure/Temperature Sensor（MAP/MAT）
1、Component Description
Intake air pressure/temperature sensor is used to measure the absolute pressure
and intake air temperature of the intake manifold, providing the information of engine
load and intake air temperature. The piezoelectric to measure intake air pressure can
provide "the load signal" to the controller according to the differential between
atmospheric pressure and the intake manifold pressure; 5 V voltages is provided by
the controller. And 0-5 V voltage is back fed to the controller in accordance with the
intake air pressure.
NTC (negative temperature coefficient) sensor whose resistance changes with the
intake air temperature to measure the intake
temperature, transmit the voltage that
indicates the temperature change to ECU.
2、Installation Positions of Components:
It is mounted behind the throttle body;
please refer to the diagram at the right.
3、Terminal Definition
Terminal 1 (grounded): By ECU (17 #
pin) grounded
Terminal 2 (temperature signal: output
temperature signal to ECU (42#pin)
Terminal 3 (5V power supply): ECU (33#
pin) provides 5V voltage
EC001
EC002
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Terminal 4 (temperature signal: output temperature signal to ECU (37#pin)
Working voltage：5±0.1V
3、Trouble Diagnosis
No signal fluctuations；
Sensor signal improper
The intake air pressure detected by sensor is above the upper limit.
The intake air pressure detected by sensor is below the lower limit.
The voltage of temperature signal is too low.
The voltage of temperature signal is too high.
4、Troubleshooting
Check whether there is a short circuit or open circuit in the connection
between the ECU and 4 wires of the sensor.
Whether the sensor inspection holes are blocked.
Whether there is a short circuit, open circuit or grounded circuit among the
sensor harness.
Disconnect the sensor harness and turn on the ignition switch, and the
voltage value of terminal 3 should be 5V.
To measure the temperature sensor's characteristics: disconnect the sensor
harness, and measure the sensor's resistance between terminal 1 and terminal
2. (Resistance Reference Value: 0℃-5280～6570Ω，20℃-2280～2740Ω，
40℃-1060～1300Ω，60℃-530～660Ω）
Measure the voltage of the pressure signal. (Pressure Signal Reference
Value：20kPa-0.40V,35kPa-1.10V,
95 kPa - 3.80 V, 115 kPa - 4.65 V)
Check whether the sensor has been exposed to a impact that can cause a
sensor failure.
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Range of working pressure : 10kPa～115kPa
Range of operating temperature：-40～125℃
5、Removal and Installation
1) Removal
① Disconnect the harness connector of the intake air pressure/temperature
sensor.
Note:
■Make sure ignition switch is in OFF position.
② Remove the mounting screws of the intake air pressure/temperature sensor,
and take off the sensor with crosshead screwdriver.
2）Installation.
Please note the followings and install in the reverse order of removal.
■Apply a little engine oil to sensor seal ring for easier installation.
■Make sure sensor and intake manifold have fitted perfectly.
■Make sure harness connector is installed securely.
Engine Coolant Temperature Sensor
1、Component description
The engine coolant temperature sensor detects the coolant temperature of the
engine, and then sends the signal to ECM for the control of starting, idling,ignition
timing during normal operation and the pulse width of fuel injection. Simultaneously
the sensor provides water temperature signal to the gauge for displaying temperature.
It uses a negative temperature coefficient thermistor whose resistance value decreases
with temperature rise.
2、Installation Positions of Components
As the installation positions, please refer to the diagram.
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3、Terminal Definition
Terminal A (water temperature signal):
Outputs cooling water temperature signal
To the ECU (39#pin);
Terminal B: connected to water
thermometer.
Terminal C (grounded): grounded by
ECU (17 # pin)
4、Trouble Diagnosis
The signal of water temperature is above the limit.
The signal of water temperature is below the limit.
Water temperature sensor with short circuit or open circuit
Data of normal temperature resistance value：2.5±5% k
。
Characteristics of the sensor's temperature-resistance:
I - ECU II - Gauge
Temperature
°C
Standard
resistance kΩ
Temperature
°C
Standard
resistance Ω
EC003
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-20 13.71 - 16.49 60 100-120
25 1.825-2.155 90 41-46
80 0.303-0.326 115 24-26
110 0.1383-0.1451 120 20.5-23.5
5、Troubleshooting
Check whether there is a short circuit or open circuit in the connection
among the 3 wires in the sensor, the ECU and the gauge .
Whether there is a short circuit,open circuit or grounded circuit among the
sensor harness；
The wires poorly grounded will easily lead to a high indication of the water
temperature gauge of the engine;
Working voltage：5V；
Range of operating temperature：-40～135℃.
6、Removal and installation
1) Removal
① Drain engine coolant from the radiator
Please refer to “Changing engine coolant”.
② Disconnect the harness connector of engine coolant temperature sensor.
③ Remove engine coolant temperature sensor
2）Installation
Please note the followings and install in the reverse order of removal.
■Smear threaded portion of the sensor with plane seal gum, and tighten it as
required.
Tightening torque：11-16N.m
■Make sure harness connector is installed securely.
Start the engine and turn it to idle running. Visually check for engine coolant
leakage.
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Electronic Throttle
1、Component Description
Electronic Throttle body assembly is one of the key parts of the intake control
management system in modern engine management systems. It has direct control over
the engine air intake volume, which in turn controls the speed of the engine and the
output power.
The mechanical control system that control the throttle body mechanically is
removed from electronic throttle body while the drive motor and drive gear
mechanism are added as well as necessary mechanical drive components and the
special throttle position sensor that is more powerful in terms of functions and
reliability.
2、Installation Positions of Components
It is mounted on the intake manifold.
3、 Throttle Terminals Definition
Terminal 1 (motor negative): connected
with ECU (66 #、67# pin);
Terminal 2 (sensor grounded): By ECU
(78# pin) grounded
Terminal 3 (sensor supply): power
supplied by ECU (32# pin)
Terminal 4 (motor positive): connected
with ECU (64#、65# pin)
Terminal 5 (signal 2): connected with ECU (38# pin)
Terminal 6 (signal 1): connected with ECU (40# pin)
EC004
EC005
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4、Trouble Diagnosis
Drive motor failure of the throttle body:
Open circuit of drive motor assembly;
Short circuit of the internal coil in drive motor assembly;
The internal line of drive motor assembly is burned out;
Excessive wear or damage inside the drive motor assembly.
Riveting failure of the throttle body:
Excessive wear and damage of the throttle body gear.
Bearing seizure and damage of the throttle body gear ;
Poor contact of throttle position sensor; instable output signal;
Valve that clogged by debris or sludge should be given periodic
cleaning.
5、Troubleshooting
Mainly check whether there is a short circuit,open circuit or grounded
circuit between the sensor and ECU harness;
Use multimeter to detect whether there is a beating between the sensor signal
port and ground wire when the throttle is switched on or switched off;
Adaptive temperature to working conditions:-40～125℃;
Throttle Response Time:≤100ms (fully open to fully closed), ≤150ms (fully
closed to fully open)
Throttle position sensor measurement range:
6、Removal and installation of throttle position sensor
1) Removal
Voltage division ratio Angle sensor 1 Angle sensor 2
New State BDC 10%±4% 90%±4%
TDC 93%±4% 7%±4%
Old State BDC 10%±5% 90%±5%
TDC 93%±5% 7%±5%
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① Disconnect TPS harness connector.
Note: Make sure ignition switch is in OFF position.
Remove throttle body assembly.
③ Remove bolt securing TPS, and take off the sensor.
2）Installation
Please note the following procedure and install in the reverse order of removal.
■Make sure harness connector is installed securely.
■Tightening torque：5.5～6.5 N·m
Crankshaft Position Sensor and Camshaft Position Sensor
1、Component Description
The Camshaft Position Sensor and Crankshaft Position Sensor belong to the
category of Hall Sensor.They operate with the camshaft and crankshaft signal wheel
which is corresponding to a specific location of the engine.According to the sensor's
digital voltage signal ECU determines the working conditions of engine, and
implements a one-to-one control.
Performance:
Operating temperature: -40～150℃
System Input voltage: 5.0 V (power
supplied by the controller)
The clearance: 0.1 - 1.5 mm
2、Installation Positions of Component
Separately installed near the camshaft and crankshaft
Camshaft position
EC007
EC006
Crankshaft
Crankshaft Position Sensor
Camshaft Position Sensor
Electronic Control System
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27
3、Terminal Definition
Crankshaft position sensor:
Terminal 1: power supplied by ECU
(33# pin) （5V）
Terminal 2: signal outputted to ECU
(15#pin)
Terminal 3: grounded by ECU (17#pin)
Camshaft position sensor:
Terminal 1: power supplied by ECU
(32# pin) （5V）
Terminal 2: signal outputted to ECU
(79#pin)
Terminal 3: grounded by ECU (36#pin)
4、Trouble Diagnosis
The ECU carries out real-time monitoring on sensor and wires
Sensor open circuit;
Sensor Internal short circuit
Line-to-ground Sensor Hall elements;
Short circuit between the Sensor Hall elements and system reference voltage
signal line.
5、Troubleshooting
Check whether the sensor line is normal or the line is shorted to ground.
Use Tee connecting sensor and the harness connector for to check whether
the power, ground wire and signal lines are connected properly.
① ② ③
EC008
① ②
EC009
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6、Removal and installation
1) Removal
① Disconnect Crankshaft position sensor and harness connector of the Camshaft
Position Sensor
② Remove bolt securing CKP sensor, and take off the sensor.
2）Installation
Please note the followings and install in the reverse order of removal.
■Pay attention to mounting clearance
Standard value: 0.1～1.5mm
■Tightening torque: 8～10 N·m
Oxygen sensor
1、Component Description
Oxygen sensor is used to provide the information that whether oxygen is excess
after complete combustion of intake air and fuel that injected into the engine cylinder.
Based on this information, ECU takes a closed loop control of fuel amount to ensure
that the three main toxic ingredients in engine exhaust can achieve maximum
transformation and purification from the operation of three-way catalytic converter.
The sensing component is a kind of ceramic tube with pores.The outside tube
wall is surrounded by engine while the inside is open to the atmosphere. The sensor
indirectly calculates pulse width of fuel injection according to the difference of
oxygen concentration outside and inside and deliver the difference to ECU which in
turn controls fuel injection again. Also test the data outputted by rear Oxygen Sensor,
and make a comparison between the data outputted by front oxygen sensor and the
rear one to monitor whether three-way catalytic operates well.
Oxygen Sensor operating voltage fluctuates between 0.1v and 0.9 V with the
frequency of 5 to 8 times in 10s. Those aged sensor whose frequency is below that
value needs to be replaced. And the sensor cannot be repaired.
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2、Installation Positions of Components
The front (upstream) oxygen sensor is mounted on the exhaust manifold portion
in front of three way catalytic converter (catalyst).
The rear (downstream) oxygen sensor is
mounted behind three way catalytic
converter.
3、Terminal Definition
Front oxygen sensor
Terminal 1 (heater wire +): power supplied by main relay;
Terminal 2 (heater wire -): connected with ECU (26# pin);
Terminal 3 (grounded): grounded by ECU (36# pin);
Terminal 4 (signal): output signal to ECU (18#pin).
Rear oxygen sensor
Terminal 1 (heater wire -): connected with ECU (28# pin);
Terminal 2 (signal): output signal to ECU (55#pin).
Terminal 3 (heater wire +): power supplied by main relay;
Terminal 4 (grounded): grounded by ECU (36# pin).
4、Trouble Diagnosis
The ECU detects the oxygen sensor line, ECU internal power amplification
circuit and detection circuit. Once one of the following situations is found, oxygen
sensor fault location is set:
The battery voltage is not credible
The manifold absolute pressure signal is not credible
Engine coolant temperature signal is not credible
Drive fault of fuel injector
EC010
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After oxygen sensor fault location is set, the closed loop control of fuel amount is
turned off and fuel amount is determined by the basic fuel injection time that stored in
the ECU.
5、Trouble Diagnosis
Mainly check whether there is a poor plug connection between the wires of
the sensor ,a short circuit or open circuit;
Sensor damage is generally caused by the lead and phosphorus poisoning,
therefore pay attention to the quality of oil products, as well as the engine
excessive oil consumption which is also likely to lead to sensor failure.
The frequency of oxygen sensor changes should not be less than a certain
number of times in a certain period.
6、Removal and Installation
1) Removal
① Disconnect oxygen sensor harness connector
② Using oxygen sensor special socket to remove oxygen sensor
Note:
■Seal mounting hole of oxygen sensor with lint-free cotton yarn to prevent
foreign materials or oil/water from entering exhaust manifold
■Visually check oxygen sensor appearance.
Brownish red: lead poisoning
Off white: normal
Black: carbon deposition
2）Installation
Please note the followings and install in the reverse order of removal.
Pay attention to the route of oxygen sensor harness.
Tightening torque：40～60 N·m
After replacing the oxygen sensor, rust inhibiting oil should be smeared on
the Oxygen Sensor to prevent rust which can be an obstacle of removal.
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Fuel injector
1、Component Description
The fuel provided by injection pump is stored and allocated by fuel pressure rail
component, which provides a more stable pressure environment for fuel system,
balancing the cylinder pressure and fuel supply to make the engine running smoothly.
The fuel injector injects fuel according to injection signals transmitted from the ECU
and determines fuel injection flow by the opening time of fuel injector solenoid valve.
2、Installation Positions of Components
They are installed on the fuel rail.
3、Terminal Definition
Terminal 1 (power supply): after relay power supply;
Terminal 2 (signal): connected with the ECU (first cylinder 27#pin, second
cylinder 6#pin, third cylinder 7 #pin, fourth cylinder 47#pin).
4, Components inspection:
Note:
■Please clean and analyze fuel injectors using the special fuel injector cleaner
and analyzer within a certain period.
1）Check resistance
Note: Check after harness connector is disconnected.
■Standard resistance value: 11-16Ω
2） Use trouble diagnostic tester to check the working time of fuel injector
■Standard working time: 2.0～3.0ms at idle (increased at acceleration).
3）Check operating sound of each fuel injector
Note:
■Listen to click sound of fuel injector at idle with stethoscope, or check the vibration of fuel
Electronic Control System
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injector with fingers.
If no vibration is perceived, check harness connector, injector, or ECU signal
controlling fuel injector.
5、Removal and installation
Please refer to "Fuel System" section.
Knock sensor
1、Component Description
Knock Sensor is installed at the side of the cylinder typically between Cylinder-2
and Cylinder-3, which is conducive to engine knock balance. ECU makes use of the
vibration frequency signal outputted from of the knock sensor to pass through its
internal filtering, which in turn determines whether there is an engine knock. When a
knock signal is detected, ECU will gradually decrease until there is no knock, and
then recovers gradually until to the knock edge,and so forth.
2、Installation Positions of Components
They are mounted at the side of cylinder.
3、Components inspection
1）Terminal Definition
Terminal 1(Knock sensor signal A):
sends signal to ECU (19#pin);
Terminal 2(Knock sensor signal A):
sends signal to ECU (20#pin);
Terminal 3 (shield)
2）Check resistance
EC011
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33
Resistance values: >1MΩ（25±5℃）
4、Trouble Diagnosis:
The ECU detects the knock sensor, power amplification circuit and detection
circuit. Once one of the following situations is found, knock sensor fault flag bit is set:
Knock sensor fault;
Knock control data processing circuit fault;
Sub-cylinder signal is not credible;
Sensor line fault.
After the knock sensor failure position is set, knock closed loop control is turned
off, and the ignition advance angle stored in the ECU is fixed in a safety angle by the
software application. When the error frequency of drops below the set value, fault flag
bits are reset
5、Removal and Installation
1) Removal
① Disconnect knock sensor harness connector.
② Remove knock sensor lock bolt, and take off the sensor.
Note:
■Do not drop or damage the sensor.
2）Installation
Install according to the reverse order of removal.
■Tightening torque: 16～24N·m
A/C Switch and Relay
1、Component Description
When Air conditioning is on, A/C switch transmit the battery voltage signal to
ECM. After the signal that A/C is switched on is inputted, the ECM drive electronic
throttle raises the engine idle speed, and corrects the ignition advance angle.
Meanwhile ECM controls the operation of A/C relay to make the compressor
electromagnetic clutch operate.
Electronic Control System
EC-
34
2、Components Inspection
When the engine is idling, use the fault diagnostic apparatus to check whether
the air conditioning switch operates well
A/C switch checklist
Check items A/C switch Normal instructions
A/C switch
Off Off
On On
A/C compressor
Off Off(compressor clutch does not work)
On On(compressor clutch works)
Continuously Variable Cam Phase Regulator and its Control Valve
1
、
Component Description
Continuously Variable cam phase regulator is used for changing the timing of
valve mechanism. It can continuously adjust the phase relationships between camshaft
and crankshaft according to the system requirements to achieve the control of timing
phase.
VVT pressure regulating valve is a four path pulse-width control solenoid valve
with two-way movement, it can achieve the oil flow control through the axial
movement of plunger valve. According to the duty cycle signal of the adjustable
pulse-width , Engine ECU changes the oil flow leading to both sides of the rotor
blades, so as to control the cam timing and phases that relative to crankshaft .
Main functions of the system
：
Improve the intake efficiency:
Improve dilution control to get better fuel economy when there is partial
load.
Being as an alternative to Exhaust Gas Recirculation (EGR) system with the
ability to reduce equivalent amount and NOx emission, it also has the
potential to reduce HC emissions and heat radiation;
The use of the default variable cam phase system return helps improve the
Electronic Control System
EC-
35
cold start performance and reduce HC emission.
2、Installation Positions of Components
3、Component Circuit Diagram
Terminal 1 (control signal): ECU (48# pin)
provides a control signal.
Terminal 2: main relay control.
4、Trouble Diagnosis
Diagnostic system is one of the most complex parts of the Cam Phase Adjust
control system. The cam sensor, target wheel and oil control valve must be possessed
with a component-level diagnostic capabilities and must constantly confirm the
integrity of cam signal to ensure the cam phase measurement. The drive signal of oil
control valve needs a check as well as the fuel injection nozzles and ignition coil
driver. But for the oil control valve and the phaser, usually there is more responsible
diagnosis. The phase regulator and oil control valve circuit are detected by ECU for
the following problems:
EC012
EC003
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Slow response of the air intake VCP phase.
Phase error of the air intake VCP camshaft.
The air intake VCP and cam teeth learning are out of range.
The air intake VCP hydraulic control valve is clamped.
5、Troubleshooting
Check whether there is a short circuit or open circuit of sensor signal.
Check whether there are crossed lines between the harness.
Check whether there is a short circuit between the sensor line and the power.
Check whether there is a blockage or good ventilation inside the VCP and
oil control valve.
Check VCP working conditions as follows:
Items Value
Input voltage 11.5 - 18.0 VDC; nominal 13.5 ±1.0
VDC
The average working current
when remain in position *
1.0 AMP
The maximum current Duty cycle when 100%, 2.5 AMP when
- 40ºC,15.5V
Ambient temperature -40ºC to 150ºC
Under-the-hood temperature -40ºC to 150ºC
Solenoid valve temperature -10ºC to 150ºC
Check the oil control valve working conditions as follows:
Type Oil control solenoid valve
Coil impedance Nominal: 7.0 Ω@20 ºC
5.6Ω@-30 ºC
10.6 Ω@150 ºC
Coil inductance 18mH@1KHz
The minimum current for
complete route of plunger valve
1.07 AMP
Input voltage(by coil) Nominal: 13 ± 0.5V
Minimum: 11.0V
Maximum: 18.0 volts (CARB
requirements)
Start the response in normal <50ms in T
coil
<65ºC
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input voltage
Turn off the response <50ms in T
coil
<65ºC
6
、
Removal and Installation
Please refer to the "timing chain wheel system”
Canister solenoid valve
1
、
Component Description
Control the cleaning air flow from the canister to the intake manifold. Because
the canister has a limited adsorbing capacity, if gasoline volatilizes to the outside, it
will cause atmospheric pollution and add additional insecurity factors.
Inside the canister solenoid valve is a solenoid valve structure whose opening
control is determined by the digital control square pulse outputted by ECU .The
canister solenoid valve opening varies according to the different engine working
conditions.To ensure the output of engine power when there is heavy engine load and
idling, the canister solenoid valve refuses to work.
2
、
Installation Positions of Components
3
、
Terminal Definition
Terminal 1: main relay output end.
Terminal2 (control signal): ECU (46# pin)
EC013
Electronic Control System
EC-
38
provides a control signal.
4、Trouble Diagnosis
Short circuit between sensor line and ground
Short circuit between sensor line and power supply
Open circuit of sensor line
5、Troubleshooting
Check whether there is a short circuit or open circuit of sensor signal.
Check whether there are crossed lines between the harnesses.
Check whether there is a short circuit between the sensor line and the power.
Check whether there is a blockage or good ventilation inside the canister
control solenoid valve.
Operating temperature: -40～120℃;
Coil resistance: 20.5±1.5Ω（20℃）；
Working voltage：8～16V；
Rated operational voltage：12V.
6、Removal and installation
1) Removal
① Disconnect the horse at the side of canister solenoid valve.
② Disconnect the canister solenoid valve harness connector.
③ Take off canister solenoid valve from its holder.
2）Installation
Please note the followings and install in the reverse order of removal.
■When installing, ensure that the air flow direction is within the specification
and check whether canister solenoid valve has wears or cracks.
■During removal and installation, avoid entry of such fluids as water and oil into
the valve.
Ignition coil
1、Component Description
Ignition Coil transforms the low voltage of primary winding into the high voltage
Electronic Control System
EC-
39
of the secondary winding, and the spark plugs discharge sparks to ignite the fuel air
mixture in the cylinder.
Ignition Coil Voltage Range:6～16V
Ignition Coil secondary resistance: 8.7±0.87 KΩ
2、Installation Positions of Components
Installed on the top of the cylinder head cover
3、Terminal Definition
Terminal 1 (control signal): ECU (NO.1 cylinder
corresponds to 27# pin, NO.2 cylinder corresponds to 6# pin,
NO.3 cylinder corresponds to 7#pin, NO.4 cylinder corresponds
to 47# pin) transmits control signal;
Terminal 2 (power supply): main relay control;
Terminal 3 (grounded): engine grounded.
4、Trouble Diagnosis
As ECU does not have a function of fault diagnosis on ignition coils, if the
ignition coil has any fault, ECU would output no trouble codes. Only by checking the
ignition coil resistance can determine whether the ignition coil is working
properly.Under normal circumstances,the heat given by working ignition coil is
relatively large,which will lead to increasing resistance value of ignition coil.As a
result, the faults like unsteady engine operation and auto shut-off may occur. However,
the control line of the ignition coil can be monitored by ECU. When ECU detects an
ignition coil fault, it will turn off the injector that corresponding to the cylinder.
Electronic Control System
EC-
40
Short circuit between control lines and ground.
Short circuit between control lines and power supply circuit.
Open circuit of control line.
5、Trouble Diagnosis
Short Circuit and/or Broken Circuit inside coil
Coil leakage and shell cracks;
Aging coil causes inadequate ignition energy.
5、Removal and installation
Refer to “Ignition System” for removal and installation.
Electric Fuel Pump
1、Component Description
The fuel is delivered from the fuel tank to the engine fuel manifold in terms of a
certain oil pressure and flow, and a stable oil pressure is maintained (by the pressure
regulator).
2、Installation Positions of Components
They are installed inside the fuel tank.
3、Component circuit diagram
Pin description: electric fuel pump has two pins, beside which is the fuel pump
housing carved with a “+" and " -" sign, which respectively means the positive (pump
relay) and ground connection.
Electronic Control System
EC-
41
4、Components Inspection:
1) Check the internal resistance of the fuel pump.
The internal resistance is not zero or infinite.
2) Check the fuel pressure.
Please refer to "Fuel System".
5、Removal and Installation
Please refer to "Fuel Pump Assembly" section.
Note:
■In order to prevent the fuel pump accidental damage, please do not operate in
oil-free status.
■If fuel pump needs to be replaced, please note that rinse the fuel tank and fuel
lines and replace the fuel filter.
Engine Electronic Control Module （ECM）
1
、
System Description
M (E) 7 system is the EMS system that based on engine theoretical model:
- Air Inflation Calculation Model: through the residual exhaust sub-model, the
exhaust back pressure sub-models and intake air temperature sub-models, it can
accurately calculate the actual mass of intake air of each cycle, which serves as a
basis for torque control and fuel injection calculation.
- Load forecast model: based on gradient changes of the intake manifold pressure,
it can calculate the actual mass of intake air in a circle which serves as a basis for
oil film calculation in dynamic working conditions before fuel injection,
- Torque Calculation Model: It is a torque model that is based on a real-time test
Electronic Control System
EC-
42
and consists of ignition timing and fuel-air ratio changes, and it is a main line
running through this system.
- Temperature Protection Model: It is a exhaust temperature model that is based
on a real-time test and consists of fuel-air ratio changes, ignition timing and the
influence of ambient temperature changes. It is able to achieve a better balance
between catalytic converters protection and fuel consumption.
1) Function
Main power supply relay control of fully built unit car
Speed and density of air flow
Closed-loop control of multi-point sequential fuel injection (including MAP
CID pressure to judge cylinders)
Closed-loop control of multi-point sequential fuel injection
Different ways of fuel supply such as fuel return, no fuel return , half fuel
return and so on
Fuel Pump Operation Control
Direct ignition without distributor and ECU built-in ignition module with
sequential ignition order of 4 cylinders
Use Electronic Throttle to control the quick response and accuracy of the air
intake flow and use ECU to achieve torque control and improve reliability
VVT - I (Electronically controlled air intake phase variable Cam Control
Unit) controls the engine air intake charge, torque and increases power
Knock control
Canister solenoid valve control
Air-conditioning and cooling water tank fan control
Mileage memory
Over voltage protection
Electron security
CAN - BUS communication interface can communicates with automatic
transmission control module or ABS system
Open and modular C language programming and so
Electronic Control System
EC-
43
2) ECM Pin Definition:
ECM pin Definition Table
Pin Function Pin Function
1 Ignition coil （NO.2 cylinder） 12 UPS
2 Ignition coil （NO.3cylinder） 13 Ignition switch
3 Ignition 14 Main relay
4 Ignition coil （NO.4cylinder） 15 Engine speed sensor
5 Ignition coil （NO.1cylinder） 16 Accelerator pedal sensor
6 Fuel injector 4 (No. 2 cylinder) 17 Sensor 1
7 Fuel injector 4 (No. 3 cylinder) 18 Upstream Oxygen sensor
8 Engine speed output 19 Knock sensor terminal A
9 Water temperature output 20 Knock sensor terminal A
10 Fuel consumption output 21 Brake light
11 SVS light 22
23 62
24 63 Non-continuous power supply
25 64 Throttle actuator
26 Upstream Oxygen sensor heating 65 Throttle actuator
27 Fuel injector 1 (No. 1 cylinder) 66 Throttle actuator
28 Downstream Oxygen sensor heating 67 Throttle actuator
29 68 Fan Control 2
30 69 Fuel pump relay
31 MIL light 70 A/C compressor relay
32 5V power supply 2 71 Diagnostic K-line
33 5V power supply 1 72 High Knock sensor
34 73
35 Sensor 3 74 Clutch Switch
36 Sensor 2 75 A/C switch
37 Intake air pressure sensor 76 Power steering switch
38 Throttle position sensor 2 77 Headlight switch
39 Engine coolant temperature sensor 78 Sensor 4
40 Accelerator pedal sensor 79
Phase sensor
41 80
Power
42 Intake air temperature sensor 81
43
44 Non-continuous power supply
45 Non-continuous power supply
46 Carbon tank valve
47 Fuel injector 3 (No. 4 cylinder)
48 Variable camshaft timing (intake air)
49
Electronic Control System
EC-
44
50 Fan Control 1
51 Electronic 2
52
53 Electronic 1
54 Throttle position sensor 1
55 Downstream Oxygen sensor
56
57
58 Brake switch
59
60 A/C medium voltage switch
61 Power 1
* Specific pin numbers are subject to harnesses schematic. (Spare terminal definition means
“NC”.)
Electronic Control System
EC-
45
3) Electrical Schematic
Electronic Control System
EC-
46
4、Components Inspection
1) Read the engine failure based on the engine data from K-line.
2) Check whether ECM connection line is intact, with a focus on whether the ECM power
supply and ground line is normal.
3) Check whether the external sensor is working properly, the outputted signal is credible and
whether its line is intact.
4) Check whether the actuator is working properly and whether its line is intact.
5) Finally replace ECM and carry out experiment.
6、Removal and Installation
1) Removal
① Turn the ignition switch to "OFF" position, and remove the battery negative terminal.
② Remove the bottom parts of instrument panel. Please refer to the “Instrument Panel".
③ Disconnect the ECM port harness connector. Please refer to the "Precautions".
④ Remove bolt securing ECM and remove ECM.
2）Installation
■Install in the reverse order of removal
■As the installation precautions, please refer to the "Precautions"
Electronic control System
EC-40
Engine Control System Trouble Diagnosis Flow
Diagnosing according to DTCs
1, Descriptions
1) Operate the following servicing only when confirm it is a current steady fault,
otherwise it may result in diagnostic errors.
2) It is forbidden to check electronic control system lines with an analog
multimeter, the “multimeter” mentioned hereunder refers to a digital multimeter.
3) When servicing a vehicle with anti-theft system, if“Replace ECU” appears in
“Next step” column, please pay attention to ECU programming after replacement
4) If a DTC indicates too low voltage in a circuit, it means that short/open to
ground may exist in the circuit; If a DTC indicates too high voltage in a circuit, it
means that short to power may exist in the circuit; if a DTC indicates a circuit fault, it
means that open or several kinds of improper wiring may exist in the circuit.
2, Seek for diagnosis help
1) A DTC can not be cleared is a steady fault; in the case of an incidental fault,
check harness connector for looseness carefully.
2) Inspection has been made with the above procedure. No abnormality is found.
3) During servicing, do not overlook the effects of maintenance condition,
cylinder pressure, and mechanical ignition timing of the vehicle to the system.
4) Replace the old ECU with new one and test.
■If the DTC can be cleared, and then the fault is located in the ECU; if the DTC
still can not be cleared, change back with the old ECU and repeat the flow to operate
another servicing.
3, Diagnose DTCs
■All related ECU pins mentioned hereunder are subject to actual wiring
diagrams.
Electronic control System
EC-41
DTC P0010 VVT Intake Control Valve Circuit Fault
Set up emergency control
programs. Light on malfunction indicator light till the fault disappears
Terminals: ME7 VCP control
Normal
Measurement signal
Variable timing control
signal. E48 1
0～1000mV
Main relay: 143 2 12V
Possible source of trouble Reference troubleshooting solutions
1. Poor connection of Connector 2. Open of circuit
of variable timing control signal 3. Short to ground
of variable timing control signal circuit 4. Improper
wiring of main relay 5.Sensor damage 6. Timing
control signal input interface failure of ECM
1. Re-connect 2. Repair harness 3. Repair
harness 4. Repair harness 5. Replace Sensor 6.
Replace ECM
DTC P0016 The installation position of camshaft and crankshaft is improper
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears
torque limitation
Possible source of trouble Please refer to troubleshooting solutions
1. Mechanical timing errors (timing errors, chain
skip gear or chain elongation)
2. ECM failure
1. Check Timing and Chain 2. Replace ECM
DTC P0030 Upstream oxygen sensor heater control circuit open
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears turn
off heater
Terminals: ME7 Pins of Sensor
Normal
Measurement signal
Main relay: 131 1 12V
Heating control signal: E26 2 Low-voltage
Possible source of trouble Please refer to troubleshooting solutions
1, An open exists between the circuit connected to
ECU pin and 2# pin of upstream oxygen sensor.
2, The circuit connecting 1# pin of upstream oxygen
sensor to main relay open.
3, Circuit between 1# and 2# pins of upstream
oxygen sensor open.
1. Measure Resistance and repair wiring
harness
2. Measure Resistance and repair wiring
harness
Replace the Oxygen sensor.
Electronic control System
EC-42
DTC P0031
The voltage of upstream oxygen sensor heating control circuit is
too low
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears turn
off heater
Terminals: ME7 Pins of Sensor
Normal
Measurement signal
Main relay: 131 1 12V
Heating control signal: E26 2 Low-voltage
Possible source of trouble Please refer to troubleshooting solutions
1,The circuit connecting 2# pin of upstream oxygen
sensor to pins of ECU is short to ground
1,The circuit connecting 2# pin of upstream
oxygen sensor to pins of ECU is open to ground
Note: It may be an intermittent fault
DTC P0032
The voltage of upstream oxygen sensor heating control circuit is
too high
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears turn
off heater
Terminals: ME7 Pins of Sensor
Normal
Measurement signal
Main relay: 131 1 12V
Heating control signal: E26 2 Low-voltage
Possible source of trouble Please refer to troubleshooting solutions
1,The circuit connecting 2# pin of upstream oxygen
sensor to pins of ECU is short to power source
2. The circuit connecting ECU pins and 1# line short
1. Measure the voltage of 2# pin
2． Measure resistance between ECU pins and
1# pin of sensor
Note: It may be an intermittent fault
Electronic control System
EC-43
DTC P0036 Downstream oxygen sensor heating control circuit open
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears turn
off heater
Terminals: ME7 Pins of Sensor
Normal
Measurement signal
Main relay: 130 1 12V
Heating control signal: E28 2 Low-voltage
Possible source of trouble Please refer to troubleshooting solutions
1, An open exists between the circuit connected to
ECU pin and 2# pin of upstream oxygen sensor.
2, The circuit connecting 1# pin of upstream oxygen
sensor to main relay open.
3, Circuit between 1# and 2# pins of upstream
oxygen sensor open.
1. Measure Resistance and repair wiring
harness
2. Measure Resistance and repair wiring
harness
Replace the Oxygen sensor.
DTC P0037
The voltage of downstream oxygen sensor heating control circuit
is too low
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears turn
off heater
Terminals: ME7 Pins of Sensor
Normal
Measurement signal
Main relay: 130 1 12V
Heating control signal: E28 2 Low-voltage
Possible source of trouble Please refer to troubleshooting solutions
1,The circuit connecting 2# pin of upstream oxygen
sensor to pins of ECU is short to ground
1,The circuit connecting 2# pin of upstream
oxygen sensor to pins of ECU is open to ground
Note: It may be an intermittent fault
Electronic control System
EC-44
DTC P0038
The voltage of upstream oxygen sensor heating control circuit is
too high
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears turn
off heater
Terminals: ME7 Pins of Sensor
Normal
Measurement signal
Main relay: 130 1 12V
Heating control signal: E28 2 Low-voltage
Possible source of trouble Please refer to troubleshooting solutions
1,The circuit connecting 2# pin of upstream oxygen
sensor to pins of ECU is short to power source
2. The circuit connecting ECU pins and 1# line short
1. Measure the voltage of 2# pin
2． Measure resistance between ECU pins and
1# pin of sensor
Note: It may be an intermittent fault
DTC P0053 Upstream oxygen sensor internal heating resistance improper
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears turn
off heater
Terminals: ME7 Pins of Sensor
Normal
Measurement signal
Main relay: 131 1 12V
Heating control signal: E26 2 Low-voltage
Possible source of trouble Please refer to troubleshooting solutions
1,Oxygen sensor heating resistance is
abnormal,function is disabled.
1,Replace the Oxygen sensor.
DTC P0054 Downstream oxygen sensor internal heating resistance improper
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears turn
off heater
Terminals: ME7 Pins of Sensor
Normal
Measurement signal
Main relay: 130 1 12V
Heating control signal: E28 2 Low-voltage
Possible source of trouble Please refer to troubleshooting solutions
1, Oxygen sensor heating resistance is abnormal,
function is disabled.
1, Replace the Oxygen sensor.
Electronic control System
EC-45
DTC P0105 IAP sensor signal unchanged
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears turn
off heater
Terminals: ME7 Pins of Sensor
Normal
Measurement signal
Power-supply wire: E33 3 5V
Ground wire: E17 1 0V
Signal wire. E37 4
0～5V
Possible source of trouble Please refer to troubleshooting solutions
1,IAP sensor frozen or clogged
2,IAP sensor serious aging
1. Re-install the sensor at normal room
temperature after the ice in the sensor
melted or clearing the carbon fuel on
surface, please replace the sensor if faults
cannot be eliminated
2. Replace the intake air pressure sensor
DTC P0106 IAP sensor signal improper
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears
Terminals: ME7 Pins of Sensor
Normal
Measurement signal
Power-supply wire: E33 3 5V
Ground wire: E17 1 0V
Signal wire. E37 4
0～5V
Possible source of trouble Please refer to troubleshooting solutions
1,The components of IAP sensor leaks air
2． Pressure sensor damaged
3． Installation position of the sensor leaks air
4． Migration characteristics of the pressure sensor
1. Re-install the intake air pressure sensor,
repair air leakage of junctions of air intake
pipes
2, Replace the intake air pressure sensor
Electronic control System
EC-46
DTC P0107 The signal voltage of IAT sensor is too low
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Power-supply wire: E33 3 5V
Ground wire: E17 1 0V
Signal wire. E37 4
0～5V
Possible source of trouble Please refer to troubleshooting solutions
1. Poor connection of Connector
2. Harness pressure signal circuit open
3. Harness pressure signal circuit short to ground
4. 5V reference voltage circuit break
5. Sensor signal ground circuit break
6. Harness 5V reference voltage reverses to
reference ground harness(This failure may result
in damage of sensor)
7. Sensor damage
8. MAP signal input interface on ECM failure
1. Re-connect
2. Repair harness
3. Repair harness
4. Repair harness
5. Repair harness
6. Repair harness
7. Replace sensor.
8. Replace ECM
DTC P0108 The signal voltage of IAT sensor is too high
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Power-supply wire: E33 3 5V
Ground wire: E17 1 0V
Signal wire. E37 4
0～5V
Possible source of trouble Please refer to troubleshooting solutions
1. Pressure signal circuit short to 5 V reference
voltage or power positive.
2.Sensor damage
3. Pressure signal input interface failure on ECM
1. Repair harness
2. Replace sensor
3. Replace ECM
Electronic control System
EC-47
DTC P0112 The voltage of intake air temperature sensor is low
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Power-supply wire: E33 3 5V
Ground wire: E17 1 0V
Signal wire. E42 2
0～5V
Possible source of trouble Please refer to troubleshooting solutions
1.Poor connection of Connector
2.Temperature signal circuit open
3. Sensor signal ground circuit open 4.Temperature
signal circuit short to ground 5. Sensor damage
6. ECM Signal input interface failure
1. Re-connect
2. Repair harness
3. Repair harness
4. Repair harness
5. Replace sensor.
6. Replace ECM
DTC P0113 The voltage of intake air temperature sensor is high
Set up emergency control
programs.
Light on malfunction indicator l
ight till the fault disappears
intake air temperature equals to the coolant temperature, but not
more than 44.25 degree.
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Power-supply wire: E33 3 5V
Ground wire: E17 1 0V
Signal wire. E42 2
0～5V
Possible source of trouble Please refer to troubleshooting solutions
1. Temperature signal circuit short to ground 2.
Sensor damage
3. ECM Signal input interface failure
1. Repair harness
2. Replace sensor.
3. Replace ECM
Electronic control System
EC-48
DTC P0117 The voltage of coolant temperature sensor is low
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears
apply the intake air temperature when start, fix it when the
temperature increase to 79.5 degrees with time going by
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
ECU signal wire: E39 A
0.5～4.5V
ECU ground wire. E17 B 0V
Instrument signal wire:
Instrum
ent
c
Possible source of trouble Please refer to troubleshooting solutions
1.Poor connection of Connector
2. Temperature signal circuit open 3. Sensor
signal ground circuit open
4.Sensor damage
1. Re-connect
2. Repair harness
3. Repair harness
4. Replace sensor.
DTC P0118 The voltage of coolant temperature sensor is high
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears
apply the intake air temperature when start, fix it when the
temperature increase to 79.5 degrees with time going by
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
ECU signal wire: E39 A
0.5～4.5V
ECU ground wire. E17 B 0V
Instrument signal wire:
Instrum
ent
c
Possible source of trouble Please refer to troubleshooting solutions
1.Temperature signal circuit short to power positive
2.Sensor damage
1. Repair harness
2. Replace sensor.
Electronic control System
EC-49
DTC P0121
Electronic throttle sensor signal 1 is improper (signal voltage is
out of the normal range)
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappear ECM
cut throttle actuator current, and the return valve back to 6
degrees of throttle position though spring. And then, according
to opening of the accelerator pedal, ECM adjust the engine
power output through control of fuel injection (intermittent fuel
shut off) and ignition timing, to allow vehicles to continue to
maintain a minimum speed.
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Sensor ground E78 2 0V
Sensor power E32 3 5V
Sensor 1 signal E54 6
0.65～-4.65V
Possible source of trouble Please refer to troubleshooting solutions
1.Throttle seizure
2.Throttle body damage
3.Signal circuit open
4.Position sensor damage
1. Replace throttle
2. Replace throttle
3. Repair harness and terminals
4. Replace throttle
DTC P0122 The voltage of electronic throttle sensor signal 1 is too low
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappear ECM
cut throttle actuator current, and the return valve back to 6
degrees of throttle position though spring. And then, according
to opening of the accelerator pedal, ECM adjust the engine
power output through control of fuel injection (intermittent fuel
shut off) and ignition timing, to allow vehicles to continue to
maintain a minimum speed.
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Sensor ground E78 2 0V
Sensor power E32 3 5V
Sensor 1 signal E54 6
0.65～-4.65V
Possible source of trouble Please refer to troubleshooting solutions
1. Sensor harness circuit open or short to ground
2.Position sensor damage
3. Sensor signal circuit open
1. Reconnect the sensor or repair harness
2. Replace throttle
3. Check the power voltage circuit for open
Repair or replace throttle
Electronic control System
EC-50
DTC P0123 The voltage of electronic throttle sensor signal 1 is too high
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappear
ECM cut throttle actuator current, and the return valve back to 6
degrees of throttle position though spring. And then, according
to opening of the accelerator pedal, ECM adjust the engine
power output through control of fuel injection (intermittent fuel
shut off) and ignition timing, to allow vehicles to continue to
maintain a minimum speed.
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Sensor ground E78 2 0V
Sensor power supply E32 3 5V
Sensor 1 signal E54 6
0.65～-4.65V
Possible source of trouble Please refer to troubleshooting solutions
1. Sensor harness short to power
2． Sensor harness short to power source
3.Position sensor damage
1. Reconnect the sensor or repair harness
2. Repair harness
3. Replace sensor
DTC P0130 Upstream oxygen sensor signal improper
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears
System stops controlling the oxygen signal closed-loop
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Signal negative E36 3 /
Signal positive E18 4
0～1V
Possible source of trouble Please refer to troubleshooting solutions
1. Upstream oxygen sensor signal continuously in
the lower range (0.1 - 0.4) V, but Downstream
oxygen sensor signal continuously above 0.5V
2. Upstream oxygen sensor signal continuously in
the lower range (0.5 - 0.4) V, but Downstream
oxygen sensor signal under 0.1V
Upstream oxygen sensor signal circuit and heater
circuit are coupled
1. Reconnect the sensor or repair harness
2. Check the air-fuel ratio, after
troubleshooting, replace oxygen sensor
3. Repair harness
Electronic control System
EC-51
DTC P0131 The voltage of upstream oxygen sensor signal is low
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Signal negative E36 3 /
Signal positive E18 4
0～1V
Possible source of trouble Please refer to troubleshooting solutions
The voltage of upstream oxygen sensor signal is
negative
1. Oxygen Sensor is contaminated by water, fuel or
other materials
2. Signal wire ground.
1. Check and repair fuel problems or
Replace oxygen sensor
2. Repair harness
DTC P0132 The voltage of upstream oxygen sensor signal is high
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears
System stops controlling the oxygen signal closed-loop
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Signal negative E36 3 /
Signal positive E18 4
0～1V
Possible source of trouble Please refer to troubleshooting solutions
The voltage of upstream oxygen sensor signal is
bigger than 1.5V
1. Circuit short to the heating power
2. Circuit short to the power
1. Repair harness
2. Repair harness
Electronic control System
EC-52
DTC P0133 Upstream oxygen sensor aging (hop frequency is too small)
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears
System stops controlling the oxygen signal closed-loop
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Signal negative E36 3 /
Signal positive E18 4
0～1V
Possible source of trouble Please refer to troubleshooting solutions
Upstream oxygen sensor aging, oxygen signal hop
frequency is smaller than critical limits.
Check and repair fuel problems and
Replace oxygen sensor
DTC P0134 Upstream oxygen sensor circuit malfunction (open)
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears
System stops controlling the oxygen signal closed-loop
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Signal negative E36 3 /
Signal positive E18 4
0～1V
Possible source of trouble Please refer to troubleshooting solutions
Upstream oxygen sensor signal always change
within 0.4 - 0.6 V system determines the circuit open
1. Signal to ECU circuit open
2. Poor connection of connector, pin oxidation
1. Repair harness
2. Repair connector
DTC P0136 Downstream oxygen sensor signal improper
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Signal negative E36 4 /
Signal positive E55 2
0～1V
Possible source of trouble Please refer to troubleshooting solutions
1.Upstream oxygen sensor signal circuit and heater
circuit are coupled
1. Repair harness
Electronic control System
EC-53
DTC P0137 The voltage of downstream oxygen sensor signal is low
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Signal negative E36 4 /
Signal positive E55 2
0～1V
Possible source of trouble Please refer to troubleshooting solutions
The voltage of downstream oxygen sensor signal is
negative
1.Oxygen Sensor is contaminated by water, fuel or
other materials
2.Signal wire ground.
1. Check and repair fuel problems or
Replace oxygen sensor
2. Repair harness
DTC P0138 The voltage of downstream oxygen sensor signal is high
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Signal negative E36 4 /
Signal positive E55 2
0～1V
Possible source of trouble Please refer to troubleshooting solutions
The voltage of downstream oxygen sensor signal is
bigger than 1.5V
1. Circuit short to the heating power
Circuit short to the power
1. Repair harness
2. Repair harness
Electronic control System
EC-54
DTC P0140 Downstream oxygen sensor circuit malfunction (open)
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears
System stops controlling the oxygen signal closed-loop
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Signal negative E36 4 /
Signal positive E55 2
0～1V
Possible source of trouble Please refer to troubleshooting solutions
Downstream oxygen sensor signal always change
within 0.4 - 0.6 V system determines the circuit open
1.Signal to ECU circuit open
2.Poor connection of connector, pin oxidation
1.Repair harness
2.Repair connector
DTC P0201 Control circuit of fuel injector in No. 1 cylinder malfunction
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Control wire E27 2
1～10V
Main relay 132 1 12V
Possible source of trouble Please refer to troubleshooting solutions
1. Control circuit of fuel injector open
2. Fuel injector connector to the main relay circuit
open
3.Fuel injector coil open
1. Repair harness
2. Repair harness
3. Replace fuel injector
DTC P0202 Control circuit of fuel injector in No.2 cylinder malfunction
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Control wire E06 2
1～10V
Main relay 133 1 12V
Possible source of trouble Please refer to troubleshooting solutions
1.Control circuit of fuel injector open
2.Fuel injector connector to the main relay circuit
open
3.Fuel injector coil open
1. Repair harness
2. Repair harness
3. Replace fuel injector
Electronic control System
EC-55
DTC P0203 Control circuit of fuel injector in No.3 cylinder malfunction
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Control wire E07 2
1～10V
Main relay 134 1 12V
Possible source of trouble Please refer to troubleshooting solutions
1. Control circuit of fuel injector open
2. Fuel injector connector to the main relay circuit
open
3.Fuel injector coil open
1. Repair harness
2. Repair harness
3. Replace fuel injector
DTC P0204 Control circuit of fuel injector in No.4 cylinder malfunction
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Control wire E46 2
1～10V
Main relay 135 1 12V
Possible source of trouble Please refer to troubleshooting solutions
1.Control circuit of fuel injector open
2.Fuel injector connector to the main relay circuit
open
3.Fuel injector coil open
1. Repair harness
2. Repair harness
3. Replace fuel injector
Electronic control System
EC-56
DTC P0221
Electronic throttle sensor signal 2 is improper (signal voltage is
out of the normal range)
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappear ECM
cut throttle actuator current, and the return valve back to 6
degrees of throttle position though spring. And then, according
to opening of the accelerator pedal, ECM adjust the engine
power output through control of fuel injection (intermittent fuel
shut off) and ignition timing, to allow vehicles to continue to
maintain a minimum speed.
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Sensor ground E78 2 0V
Sensor power supply E32 3 5V
Sensor 2 signal E38 6
0.65～-4.65V
Possible source of trouble Please refer to troubleshooting solutions
Throttle2 signal bigger than 4.65 V
1.Throttle seizure
2.Throttle body damage
3.Signal circuit open
4.Position sensor damage
1. Replace throttle
2. Replace throttle
3. Repair harness and terminals
4. Replace throttle
DTC P0222 The voltage of electronic throttle sensor signal 2 is too low
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappear
ECM cut throttle actuator current, and the return valve back to 6
degrees of throttle position though spring. And then, according
to opening of the accelerator pedal, ECM adjust the engine
power output through control of fuel injection (intermittent fuel
shut off) and ignition timing, to allow vehicles to continue to
maintain a minimum speed.
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Sensor power supply E32 3 5V
Sensor ground E78 2 0V
Sensor 1 signal E38 6
0.65～-4.65V
Possible source of trouble Please refer to troubleshooting solutions
1. Sensor harness circuit open or short to ground
2.Position sensor damage
3. Sensor signal circuit open
1. Reconnect the sensor or repair harness
2. Replace throttle
3. Check the power voltage circuit for open
Repair or replace throttle
Electronic control System
EC-57
DTC P0223 The voltage of electronic throttle sensor signal 2 is too high
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappear
ECM cut throttle actuator current, and the return valve back to 6
degrees of throttle position though spring. And then, according
to opening of the accelerator pedal, ECM adjust the engine
power output through control of fuel injection (intermittent fuel
shut off) and ignition timing, to allow vehicles to continue to
maintain a minimum speed.
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Sensor ground E78 2 0V
Sensor power E32 3 5V
Sensor 1 signal E38 6
0.65～-4.65V
Possible source of trouble Please refer to troubleshooting solutions
1. Sensor harness short to power
2． Sensor harness short to power source
3.Position sensor damage
1. Reconnect the sensor or repair harness
2. Repair harness
3. Replace sensor
DTC P0261 Control circuit of fuel injector in No. 1 cylinder is too low
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Control wire E27 2
1～10V
Main relay 132 1 12V
Possible source of trouble Please refer to troubleshooting solutions
1． Control circuit of fuel injector short tp ground
1. Repair harness
Electronic control System
EC-58
DTC P0262 Control circuit of fuel injector in No. 1 cylinder is too high
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Control wire E27 2
1～10V
Main relay 132 1 12V
Possible source of trouble Please refer to troubleshooting solutions
1． Control circuit of fuel injector short to power
1. Repair harness
DTC P0264 Control circuit of fuel injector in No.2 cylinder is too low
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Control wire E06 2
1～10V
Main relay 133 1 12V
Possible source of trouble Please refer to troubleshooting solutions
1.Control circuit of fuel injector short to ground 1. Repair harness
DTC P0265 Control circuit of fuel injector in No.2 cylinder is too high
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Control wire E06 2
1～10V
Main relay 133 1 12V
Possible source of trouble Please refer to troubleshooting solutions
1.Control circuit of fuel injector short to power 1. Repair harness
Electronic control System
EC-59
DTC P0267 Control circuit of fuel injector in No.3 cylinder is low
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Control wire E07 2
1～10V
Main relay 134 1 12V
Possible source of trouble Please refer to troubleshooting solutions
Control circuit of fuel injector short tp ground Repair harness
DTC P0268 Control circuit of fuel injector in No.3 cylinder is high
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Control wire E07 2
1～10V
Main relay 134 1 12V
Possible source of trouble Please refer to troubleshooting solutions
Control circuit of fuel injector short to power Repair harness
DTC P0270 Control circuit of fuel injector in No.4 cylinder is low
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Control wire E46 2
1～10V
Main relay 135 1 12V
Possible source of trouble Please refer to troubleshooting solutions
1.Control circuit of fuel injector open to ground 1. Repair harness
Electronic control System
EC-60
DTC P0271 Control circuit of fuel injector in No.4 cylinder is high
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Control wire E46 2
1～10V
Main relay 135 1 12V
Possible source of trouble Please refer to troubleshooting solutions
1.Control circuit of fuel injector open to power 1. Repair harness
DTC
P0300 Several cylinder misfire occurred
P0301 One cylinder misfire occurred
P0302 Two cylinder misfire occurred
P0303 Three cylinder misfire occurred
P0304 Four cylinder misfire occurred
Set up emergency control
programs.
light or flash malfunction indicator light Power Limited or
normal
Possible source of trouble Please refer to troubleshooting solutions
1. Crankshaft camshaft timing failure
2. Ignition fuel injection system failure
3. EVAP system failure
4. Basic mechanical or cylinder pressure abnormal
1. Re-install crankshaft and camshaft signal
or repair
2. Repair ignition fuel injection system
failure
3. Repair EVAP failure
4. Repair the air intake system failure
DTC P0321 Crankshaft TDC on the gear signal improper
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Power-supply wire E33 1 5V
Signal wire E15 2
0～-5V
Ground wire E17 3 0V
Possible source of trouble Please refer to troubleshooting solutions
1. Circuit intermittent open
2. Crankshaft signal deviation
3. Sensor installed aslant
1.Repair harness
2. Repair signal failure
3. Re-install sensor
Electronic control System
EC-61
DTC P0322 Speed sensor signal failure
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Power-supply wire E33 1 5V
Signal wire E15 2
0～-5V
Ground wire E17 3 0V
Possible source of trouble Please refer to troubleshooting solutions
1. Coil open
2. Signal wire to ECU circuit open
3. Signal wire to ECU circuit short
1. Replace sensor
2.Repair harness
3.Repair harness
DTC P0327 The voltage of KS signal circuit voltage is too low
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears
Close knock closed-loop control, the ignition advance is in the
default value
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Signal A E19 1
0～-1V
Signal B E20 2 /
Possible source of trouble Please refer to troubleshooting solutions
1. Coil open
2. Circuit open
3. Circuit short to low-voltage
1. Replace sensor
2.Repair harness
3.Repair harness
DTC P0328 The voltage of KS signal circuit voltage is too high
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears
Close knock closed-loop control, the ignition advance is in the
default value
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Signal A E19 1
0～-1V
Signal B E20 2 /
Possible source of trouble Please refer to troubleshooting solutions
Coil short to power or high-voltage
2. Internal mechanical loose vibration failure
1.Repair harness
2 Repair mechanical failures
Electronic control System
EC-62
DTC P0340 Phase sensor improperly installed
Set up emergency control
programs.
Light on malfunction indicator light torque limits
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Power supply E32 1 5V
ground E36 3 0V
Signal E79 2 0-5V square wave
Possible source of trouble Please refer to troubleshooting solutions
1.Phase sensor improperly installed
2.Poor connection of connector
1.Correct the installation
2.Repair connector
DTC P0341 Phase sensor signal improper
Set up emergency control
programs.
Light on malfunction indicator light torque limits
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Power supply E32 1 5V
ground E36 3 0V
Signal E79 2 0-5V square wave
Possible source of trouble Please refer to troubleshooting solutions
1.Phase position between crankshaft and camshaft
improper
1. Repair OCV valve failure
2. Repair VCP actuator failure
3. Repair mechanical timing failure
DTC P0342 The voltage phase sensor is too low
Set up emergency control
programs.
Light on malfunction indicator light torque limits
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Power supply E32 1 5V
ground E36 3 0V
Signal E79 2 0-5V square wave
Possible source of trouble Please refer to troubleshooting solutions
1. Signal wire short to ground 1.Repair harness and connector
Electronic control System
EC-63
DTC P0343 The voltage phase sensor is too high
Set up emergency control
programs.
Light on malfunction indicator light torque limits
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Power supply E32 1 5V
ground E36 3 0V
Signal E79 2 0-5V square wave
Possible source of trouble Please refer to troubleshooting solutions
1. Signal wire short to power
2. power-supply wire short to power
1.Repair harness and connector
2.Repair harness
DTC P0420 TWC oxygen storage capacity deterioration
Set up emergency control
programs.
Light on malfunction indicator light
Possible source of trouble Please refer to troubleshooting solutions
Downstream oxygen sensor change frequency and
amplitude exceeds the limits
1.Please use leaded gasoline
2.Oxygen sensor failure
3.Fuel pressure is too high
4.Misfire fault
5.Catalytic converter fault
1. Replace fuel.
2. Repair oxygen sensor circuit failure,
then replace oxygen Sensor
3. Remove fuel pressure fault
4. Repair misfire fault
5. Replace catalytic converter
DTC P0444 EVAP Canister solenoid valve fault
Set up emergency control
programs.
Light on malfunction indicator light
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Power supply Main relay138 2 12V
Control E46 1
0-12V square
wave
Possible source of trouble Please refer to troubleshooting solutions
1. control circuit open
2. Coil open
1.Repair harness and connector
2. Replace the solenoid valve.
Electronic control System
EC-64
DTC P0458 The voltage of EVAP Canister solenoid valve is too low
Set up emergency control
programs.
Light on malfunction indicator light
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Power supply Main relay138 2 12V
Control E46 1
0-12V square
wave
Possible source of trouble Please refer to troubleshooting solutions
1.Control circuit short to ground 1.Repair harness
DTC P0459 The voltage of EVAP Canister solenoid valve is too high
Set up emergency control
programs.
Light on malfunction indicator light
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Power supply Main relay138 2 12V
Control E46 1
0-12V square
wave
Possible source of trouble Please refer to troubleshooting solutions
1.Control circuit short to power 1.Repair harness
DTC P0506 Idle control speed below target idle speed
Set up emergency control
programs.
Light on malfunction indicator light
Possible source of trouble Please refer to troubleshooting solutions
1.Air intake and Exhaust clogged
2. Engine mechanical failure.
3. Throttle generator power-supply failure
4. Throttle seizure
5. Throttle internal fault
6.ECM failure
1.Troubleshoot
2.Troubleshoot
3. Repair harness fault
4. Replace throttle
5. Replace throttle
6. Replace ECM
Electronic control System
EC-65
DTC P0507 Idle control speed above target idle speed
Set up emergency control
programs.
Light on malfunction indicator light
Possible source of trouble Please refer to troubleshooting solutions
1. The intake pipe leakage
2. Throttle seizure
3. Throttle internal fault
4.ECM failure
1.Troubleshoot
2. Replace throttle
3. Replace throttle
4. Replace ECM
DTC
P0560 System battery voltage signal improper
P0562 System battery voltage too low
P0563 System battery voltage too high
Set up emergency control
programs.
Light on malfunction indicator light being prone to pack up
Possible source of trouble Please refer to troubleshooting solutions
1. The battery is dead or poor connected
2. Excitation circuit open
3. Generator does not generate
4. Alternator regulator failure
1.Troubleshoot
2. Repair circuit failure
3. Replace alternator
4. Replace alternator
DTC P0602 Electronic Control Unit encoding failure
Set up emergency control
programs.
Light on malfunction indicator light
Possible source of trouble Please refer to troubleshooting solutions
1. ECM data error 1. Replace or refresh ECM
DTC P0604 Electronic Control Unit RAM failure
Set up emergency control
programs.
Light on malfunction indicator light
Possible source of trouble Please refer to troubleshooting solutions
1. The battery wire not connected
2. Internal control module error
1. Resume power supply
2. Replace ECM
DTC P0605 Electronic Control Unit ROM failure
Set up emergency control
programs.
Light on malfunction indicator light
Possible source of trouble Please refer to troubleshooting solutions
1. Internal Module error 1. Replace ECM
Electronic control System
EC-66
DTC P0606 Electronic Throttle security monitoring function failure
Set up emergency control
programs.
Light on malfunction indicator light, may be accompanied by
throttle pedal and throttle error codes
Possible source of trouble Please refer to troubleshooting solutions
1. Throttle pedal position sensor fault
Electronic throttle position sensor fault
3. ECM internal fault
1. Repair throttle pedal related failure
2. Repair Electronic Throttle related
failure
3. Replace ECM
DTC P0627 Control circuit of fuel pump relay fault
Set up emergency control
programs.
Light on malfunction indicator light, cannot start
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Power supply 154 87 12V
Coil Power 153 86 12V
Output 152 30 12V
Control E69 85
1～8V
Possible source of trouble Please refer to troubleshooting solutions
1. control circuit open
2. Coil open
1.Repair harness and connector
2. Replace the relay
DTC P0628 The voltage of control circuit of fuel pump relay is too low
Set up emergency control
programs.
Light on malfunction indicator light, cannot start
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Power supply 154 87 12V
Coil Power 153 86 12V
Output 152 30 12V
Control E69 85
1～8V
Possible source of trouble Please refer to troubleshooting solutions
1.Control circuit short to ground 1.Repair harness and connector
Electronic control System
EC-67
DTC P0629
The voltage of control circuit power of fuel pump relay is too
high
Set up emergency control
programs.
Light on malfunction indicator light, cannot start
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Power supply 154 87 12V
Coil Power 153 86 12V
Output 152 30 12V
Control E69 85
1～8V
Possible source of trouble Please refer to troubleshooting solutions
1.Control circuit short to power 1.Repair harness and connector
DTC P0650 MIL driving circuit fault
Set up emergency control
programs.
Light on malfunction indicator light
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Power supply 140 12V
Control E31
1～8V
Possible source of trouble Please refer to troubleshooting solutions
1.Control circuit open/short to ground/power
2.MIL burned out
1.Repair harness
2. Replace malfunction indicator light
Electronic control System
EC-68
DTC P1545
Electronic Throttle actual position and target position error
exceeds the limit
Set up emergency control
programs.
Light on malfunction indicator light,ECM cut throttle actuator
current, and the return valve back to 6 degrees of throttle
position though spring. And then, according to opening of the
accelerator pedal, ECM adjust the engine power output through
control of fuel injection (intermittent fuel shut off) and ignition
timing, to allow vehicles to continue to maintain a minimum
speed.
Possible source of trouble Please refer to troubleshooting solutions
1. Motor driving circuit failure
2.Throttle position sensor fault
3. Throttle motor failure
4. Throttle seizure
Check whether the actual position is
consistent with the theoretical position
1. Replace throttle
2. Repair throttle position sensor circuit
fault
3. Replace throttle
4. Replace throttle
DTC P1558 Too much resistance for opening throttle
Set up emergency control
programs.
Light on malfunction indicator light
Possible source of trouble Please refer to troubleshooting solutions
1. Too much carbon cumulated on throttle
2. Throttle seizure
3. Throttle internal fault
1. Clean Throttle
2. Replace throttle
3. Replace throttle
DTC P1565
Throttle lower limit position initialization self-learning
failure
Set up emergency control
programs.
Light on malfunction indicator light
Possible source of trouble Please refer to troubleshooting solutions
1. Self learning failures
2.ECM failure
1. Self-learning throttle again
2. Replace ECM
Electronic control System
EC-69
DTC P1568 Too much resistance for pulling back throttle
Set up emergency control
programs.
Light on malfunction indicator light
Possible source of trouble Please refer to troubleshooting solutions
1. Too much carbon cumulated on throttle
2. Throttle seizure
3. Throttle internal fault
1. Clean Throttle
2. Replace throttle
3. Replace throttle
DTC P1651 SVS light driving circuit fault
Set up emergency control
programs.
Light on malfunction indicator light
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Power supply 160 12V
Control E11
1～8V
Possible source of trouble Please refer to troubleshooting solutions
1.Control circuit open/short to ground/power
2.SVS light burned out
1.Repair harness
2. Replace malfunction indicator light
DTC P2088 The voltage of VVT Intake Control Valve Circuit is too low
Set up emergency control
programs.
Light on malfunction indicator light, off VVT control
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Power supply 143 1 12V
Control 48 2
1-12V square
wave
Possible source of trouble Please refer to troubleshooting solutions
1. Harness circuit open or short to low-voltage
2. OCV valve coil fault
1.Repair connector and circuit
2. Replace OCV valve
Electronic control System
EC-70
DTC P2089 The voltage of VVT Intake Control Valve Circuit is too high
Set up emergency control
programs.
Light on malfunction indicator light, off VVT control
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Power supply 143 1 12V
Control 48 2
1-12V square
wave
Possible source of trouble Please refer to troubleshooting solutions
1.Control circuit short to power 1.Repair harness
DTC P2106 Electronic Throttle drive-level failure
Set up emergency control
programs.
Light on malfunction indicator light, torque limits electronic
throttle function disabled with the other error codes coming
out
Possible source of trouble Please refer to troubleshooting solutions
1. Electronic throttle harness open or short
2.Electronic throttle motor failure
3.Throttle position sensor fault
4, Intake air pressure sensor failure
5.ECM failure
1. Repair harness
2. Replace throttle
3. Replace throttle
4. Repair oxygen sensor failure
5. Replace ECM
DTC P2122
The voltage of accelerator pedal position sensor1 signal is too
low
Set up emergency control
programs.
Light on malfunction indicator light, applying sensor 2 signal, if
both failed, maintain a high idling speed
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Sensor 1 ground E36 3 0V
Sensor 1 power supplied E33 2 5V
Sensor 1 signal E16 4
0.7～-4.55V
Possible source of trouble Please refer to troubleshooting solutions
1. Circuit open
2. Signal wire open to ground
3. Sensor internal Open
1. Repair harness
2. Repair harness
3. Replace pedal
Electronic control System
EC-71
DTC P2123
The voltage of accelerator pedal position sensor1 signal is too
high
Set up emergency control
programs.
Light on malfunction indicator light, applying sensor 2 signal, if
both failed, maintain a high idling speed
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Sensor 1 ground E36 3 0V
Sensor 1 power supplied E33 2 5V
Sensor 1 signal E16 4
0.7～-4.55V
Possible source of trouble Please refer to troubleshooting solutions
1. Power-supply wire or Signal wire short to power
2. Sensor internal failure
1. Repair harness
2. Replace pedal
DTC P2127
The voltage of accelerator pedal position sensor2 signal is too
low
Set up emergency control
programs.
Light on malfunction indicator light, applying sensor 1 signal, if
both failed, maintain a high idling speed
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Sensor 2 ground E35 1 0V
Sensor 2 power supplied E32 5 5V
Sensor 2 signal E40 6
0.3～-2.3V
Possible source of trouble Please refer to troubleshooting solutions
1. Circuit open
2. Signal wire open to ground
3. Sensor internal Open
1. Repair harness
2. Repair harness
3. Replace pedal
Electronic control System
EC-72
DTC P2128
The voltage of accelerator pedal position sensor2 signal is too
high
Set up emergency control
programs.
Light on malfunction indicator light, applying sensor 1 signal, if
both failed, maintain a high idling speed
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Sensor 2 ground E35 1 0V
Sensor 2 power supplied E32 5 5V
Sensor 2 signal E40 6
0.3～2.3V
Possible source of trouble Please refer to troubleshooting solutions
1. Power-supply wire or Signal wire short to power
2. Sensor internal failure
1. Repair harness
2. Replace pedal
DTC P2138 Accelerator pedal position sensor signal improper
Set up emergency control
programs.
Light on malfunction indicator light,maintain a high idling
speed
Possible source of trouble Please refer to troubleshooting solutions
1. Sensor 1 and 2 circuit couple
2. Accelerator pedal fault
1.Repair harness
2.Replace accelerator pedal
DTC P2177
Air-fuel ratio closed loop control self-learning value above
upper limit (medium load zone)
Set up emergency control
programs.
Light on malfunction indicator light
Possible source of trouble Please refer to troubleshooting solutions
Fuel dilute continuously, long-term fuel correction +
20 %
1.Fuel and gas mixture too dilute.
2. Upstream oxygen sensor failure
1. Repair the air intake and exhaust, fuel
systems failure
2. Repair upstream oxygen sensor signal
error fault
Electronic control System
EC-73
DTC P2178
Air-fuel ratio closed loop control self-learning value above
lower limit (medium load zone)
Set up emergency control
programs.
Light on malfunction indicator light
Possible source of trouble Please refer to troubleshooting solutions
Fuel dilute continuously, long-term fuel correction +
-20%
1.Fuel and gas mixture too thick.
2. Upstream oxygen sensor failure
1. Repair the air intake and exhaust, fuel
systems failure
2. Repair upstream oxygen sensor signal
error fault
DTC P2195 Upstream oxygen sensor aging (too dilute)
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears
System stops controlling the oxygen signal closed-loop
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Signal negative E36 3 /
Signal positive E18 4
0～-1V
Possible source of trouble Please refer to troubleshooting solutions
1. Fuel and Gas mixture long-term dilute.
2. Oxygen sensor aging, oxygen signal long-term
dilute.
1. Repair the air intake and exhaust, fuel
systems failure
2, Replace Oxygen sensor.
DTC P2196 Upstream oxygen sensor aging (too thick)
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears
System stops controlling the oxygen signal closed-loop
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Signal negative E36 3 /
Signal positive E18 4
0～-1V
Possible source of trouble Please refer to troubleshooting solutions
1. Fuel and Gas mixture long-term thick.
2. Oxygen sensor aging, oxygen signal long-term
thick.
1. Repair the air intake and exhaust, fuel
systems failure
2, Replace Oxygen sensor.
Electronic control System
EC-74
DTC P2270 Downstream oxygen sensor aging (too dilute)
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Signal negative 130 1 12V
Signal positive E28 2 Low-voltage
Possible source of trouble Please refer to troubleshooting solutions
2. Fuel and Gas mixture long-term dilute.
2. Oxygen sensor aging, oxygen signal long-term
dilute.
1. Repair the air intake and exhaust, fuel
systems failure
2,Replace Oxygen sensor.
DTC P2271 Downstream oxygen sensor aging (too thick)
Set up emergency control
programs.
Light on malfunction indicator light till the fault disappears
Terminals: ME7 Pins of Sensor
Normal
Measurement
signal
Signal negative 130 1 12V
Signal positive E28 2 Low-voltage
Possible source of trouble Please refer to troubleshooting solutions
2. Fuel and Gas mixture long-term thick.
2. Oxygen sensor aging, oxygen signal long-term
thick.
1. Repair the air intake and exhaust, fuel
systems failure
2, Replace Oxygen sensor.
Anti-theft System
EC-67
Engine anti-theft system
System overview
Engine anti-theft system achieves security feature through two electronic
encryption: Transponder and IMMO, IMMO and ECM, after going though
Transponder's wireless identification, IMMO will go under EC0M's wired
identification, if identified, ECM will ignite and inject fuel normally, and if it is not
identified, the motor will not start, and thus to achieve encryption anti-theft and make
the vehicle more reliable and secure.
Anti-theft system consists of 4 components: Intrusion Indicator light (integrated
on the dashboard) and anti-theft controller, transponders, Anti-Theft coil; details are
as follows:
Part name Quantit
y
Remarks
Anti-theft
controller.
1 The controller is installed under the frame support
Transponders. 2 The transponders are installed within the two keys
Anti-Theft coil 1 The coil is installed on the ignition lock
Alarm indicator
light
1 the intrusion indicator symbol integrated in the
instrument cluster: .
Components and their location map
1 4
5
2
3
Anti-theft System
EC-68
1 - Anti-theft controller 2-Beam support 3 - Ignition lock 4 -Anti-Theft sensor coil 5 -
Transponders.
Illustrative diagram
Anti-theft System Illustrative Diagram
Components inspection
1. Check whether the power supply of Anti-theft system controller works (9 V -
16 V).
2. The terminal definitions of Anti-theft system control model are as follows:
Controller Terminal Definition Table
Anti-theft controller connectors
Pin definition
Rem
arks
1 Antenna 1
2
B＋
3
IG1
4
W-wire
5
R-wire
6
Antenna 2
7
GND
8
LED
Anti-theft System
EC-69
9
NC
10
K-wire(Dia
gnostic
Interface)
The installation and removal of components
The installation and removal of
Anti-theft controller
1) Removal procedures
Disconnect negative battery
terminal.
Remove mounting bolts of
controller on the beam support under instrument desk .
Disconnect the controller port and wire port connector.
2) Install according to the reverse steps of removal.
The removal and installation of
Anti-theft sensing coil.
1) The removal and installation of
Anti-theft sensing coil.
Disconnect negative battery
terminal.
Remove the ignition lock.
Remove the screw of Anti-theft coil and ignition lock.
Disconnect the Anti-theft port connector;
2) Install according to the reverse steps of removal.
The transponders are installed in the keys and are supplied together with key
EC014
EC015
Anti-theft System
EC-70
assembly.
Diagnose and Match
1) Trouble Diagnosis
When a vehicle fails, the service technician can use diagnostic instruments to get
the digital code which represents failure information from the memory of Anti-theft
controller. Based on the code that corresponds to the specified error message, the
service technicians are able to quickly locate the point of failure, and to troubleshoot
and repair; common types of failures are as follows:
NO Meaning
1 Anti-theft coil short to ground
2 Anti-theft coil open to power source
3 Anti-theft coil short to power source
4 Anti-theft controller does not store any
key information
5 PIN code isn't put into Anti-theft
controller.
6 Anti-theft controller does produce SK.
7 Anti-theft controller failed the ECM
identification.
8 Key Identification failed
9 Base station cannot communicate
2) Off line/After-sales Match Functions
The diagnostic function of Anti-theft controller can be used for the match of the
whole engine anti-theft system (including keys, Anti-theft controller, and engine
control module) when engines are off line from the plant.
The function also supports to replace the keys, Anti-theft controller, and engine
control module within the whole engine anti-theft system.
Anti-theft System
EC-71
Any of the devices needs to be re-matched, if you need to replace any one of
keys, anti-theft controller and engine control module. As to the matching process,
please reference to operating manual of the diagnostic scanner.
Note: There are 3 flashing mode in IMMO indicator light: When the whole
vehicle battery is powered on and key is in the ignition switch OFF position, the
indicator light's flash cycle is 5 seconds, each cycle indicator lights for 250 MS; When
key is switched onto the ignition switch ON position, if anti-theft system
identification succeeds, the indicator light is off and remains at dim status; if
authentication fails, the LED flashes 0.5 seconds to cycle, each cycle indicator lights
for 250 MS, the vehicle will not start. If identification fails and cannot start, please
contact your service technician to diagnosis the system.
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