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江淮汽车 部门：客户服务部
1.5T Engine
Maintenance Manual
Preface
To help JAC engine authorized professional maintenance technicians for an
effective and proper maintenance and repair of the JAC 1.5T engines, this special
engine maintenance manual is prepared.
In order to ensure the customer satisfaction of JAC engine products, it is
absolutely necessary for the service technician of JAC engine to have a friendly and
correct operation. Therefore, the maintenance technicians must fully understand the
contents of this manual. This manual shall be accessible for reference at any time.
All contents in this manual, including pictures, technical parameters are the latest.
Due to the product updates, JAC will provide technical briefs or supplemental
volumes, so please pay close attention to the latest developments in obtaining relevant
information. JAC reserves the right to make changes in product design, additions or
improvements.
This manual may not be reproduced or modified in any form, including but not
limited to electronic, paper, audio-visual and mechanical, without the written
authorization of JAC.
The final interpretation of this manual belongs to JAC.
In the process of maintenance and repair of JAC engine product, the use of
non-JAC engine parts or unqualified fuel, may cause damage to the engine.
Anhui Jianghuai Automobile Group Co., Ltd
November 2018
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1.5T Engine
Maintenance Manual
Contents
Preface
............................................................................................................................
I
Contents
........................................................................................................................
II
Abbreviation Definition
.................................................................................................
1
Chapter 1 Engine Machinery
......................................................................................
2
1.1 Engine main technical specifications and parameters
......................................
2
1.1.1 Main technical specifications
................................................................
2
1.1.2 Main parts specifications
.......................................................................
3
1.1.3 Environmental protection key component identification
......................
3
1.1.4 Main inspection and adjustment parameters
.........................................
4
1.1.5 Bolt torque table
....................................................................................
4
1.1.6 Maintenance limitation
..........................................................................
6
1.2 Engine body
.....................................................................................................
7
1.2.1 Common precautions
............................................................................
7
1.2.2 Precautions for sealant
..........................................................................
9
1.2.3 Preparation work
.................................................................................
11
1.2.4 Engine elastic belt
...............................................................................
15
1.2.5 Air inlet manifold and exhaust manifold
............................................
17
1.2.6 Timing sprocket mechanism
...............................................................
22
1.2.7 Camshaft Assembly
........................................................................
26
1.2.8 Cylinder head
......................................................................................
33
1.2.9 Valve
...................................................................................................
38
1.2.10 Cylinder block assembly
...................................................................
42
1.3 Engine lubricating system
...................................................................
65
1.3. Installation precautions
.........................................................................
65
1.3.2 Preparation work
..........................................................................
66
1.3.3 Lubrication system schematic
..................................................
67
1.3.4 Engine oil
............................................................................................
67
1.3.5 Engine Oil Filter
..................................................................................
69
1.3.6 Oil pan and Oil pump
..........................................................................
71
1.4 Engine cooling system
...................................................................................
75
1.4.1 Cooling circuit
.....................................................................................
75
1.4.2 Engine Coolant
....................................................................................
75
1.4.3 Water pump
.........................................................................................
78
1.4.4 Thermostat assy.
..................................................................................
79
1.4.5 Water pipe assy.
..................................................................................
81
1.4.6 Common fault analysis
........................................................................
83
1.5 Engine emission control system
.........................................................
86
1.5.1 Fuel evaporation system
...................................................................
86
1.5.2 Crankshaft box force ventilation system
.............................................
90
Chapter 2 Engine Electric Appliance
........................................................................
94
2.1 Ignition system
...............................................................................................
94
2.1.1 Ignition coil
.........................................................................................
94
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2.1.2 Common fault diagnosis
.....................................................................
95
2.1.3 Maintenance parameters
......................................................................
96
2.2 Starting and charging system
..............................................................
96
2.2.1 Storage battery
....................................................................................
96
2.2 Starting system
.......................................................................................
97
2.2.3 Charging System
...............................................................................
108
Chapter 3 Engine Electronic Control System
.........................................................
113
3.1 Attentions
.....................................................................................................
113
3.1.1 Common maintenance precautions
...................................................
113
3.1.2 Diagnostic tool
..................................................................................
115
3.1.3 Engine OBD System Cautions
..........................................................
115
3.2 Structure Principle and Maintenance of the Engine Control System
........
118
3.2.1 System description
............................................................................
118
3.2.2 Electronic control system components
..............................................
118
3.2.3 Vehicle diagnostic system
......................................................
121
3.2.4 Engine fault diagnosis
.......................................................................
126
3.3 Structure Principle and Maintenance of the Engine Electric Components
..
134
3.3.1 Air inlet temperature pressure sensor
.............................
136
3.3.2 Coolant temperature sensor
...............................................................
138
3.3.3 Electronic throttle valve
....................................................................
141
3.3.4 Hall sensor
.........................................................................................
144
3.3.5 Oxygen sensor
...................................................................................
147
3.3.6 Fuel injector
......................................................................................
149
3.3.7 Knock sensor
.....................................................................................
151
3.3.8 Continuously variable CAM phase regulator and control valve
.......
153
3.3.9 Carbon canister solenoid valve
.........................................................
154
3.3.10 Ignition coil
............................................................................
156
3.3.11 Spark plug
..................................................................................
160
3.3.12 Turbocharger pressure control valve
...................................
162
3.3.13 RCV valve
.......................................................................................
164
3.3.14 ECM
................................................................................................
166
3.4 Engine Control System Common Fault Diagnosis
...................................
170
3.4.1 Electronic control system common failure and main causes
............
170
3.4.2 Electronic control system common fault diagnose
...........................
172
3.5 Engine Control System Fault Diagnosis Process
......................................
179
3.5.1 Diagnose according to the fault code
................................................
179
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Abbreviation Definition
Mil: malfunction indicator light
SVS: system fault light
DTC: fault code
ECM: engine control module
ECU: electronic control unit
PWM: duty cycle signal
ETC: electronic throttle valve control
TPS1: throttle valve position sensor signal 1
TPS2: throttle valve position sensor signal 2
APP1: electronic throttle foot pedal position sensor signal 1
APP2: electronic throttle foot pedal position sensor signal 2
OFF: Off
OBD: vehicle diagnostic system
ROM: read only memory
RAM: read and write memory
VVT: variable valve timing
VCP: variable cam phaser
OCV: oil control valve
Delphi: Delphi system
CTS: coolant temperature sensor
MAT: intake air temperature
MAP: intake air pressure
RPM: revolutions per minute
OCV: oil control valve
Unit:
1MPa=10bar=1000KPa
1V=1000mV
1Kg=1000g
1min=1 minute
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Chapter 1 Engine Machinery
1.1 Engine main technical specifications and parameters
1.1.1 Main technical specifications
Engine technical specification table
1. Model HFC4GB2.4D
2. Type
Inline four-cylinder, double overhead
camshaft, 16-valve, VVT, turbocharge
3. Cylinder number 4
4. Cylinder diameter * stroke (mm) 75×84.8
5. Engine displacement(L) 1.499
6. Compression ratio 9.5
7. Cylinder liner type Dry (aluminum containment)
8. Rated power(Kw) 110
9. Rated rotate speed（rpm） 5500
10. The maximum torque (N · m) 210
11. Maximum torque speed（rpm） 2000-4500
12. Idling speed(rpm) 750±30
13. Total load minimum fuel
consumption (g/kW· h)
260
14. Engine oil and fuel consumption
ratio at rated power
≤0.15%
15. Crankshaft rotation direction
(power output end)
Counterclockwise
16. Ignition sequence 1-3-4-2
17. Driving start mode Electrical power start
18. Lubrication method Pressure and splash composite
19. Cooling form Water cooling
20. Outside dimension (L×W×H)mm 555×590×630
21. Engine oil filling capacity (L)
4.6L for the first time adding, 4.0L for
replacing the oil
22. Net weight (kg) 108
23. Fuel 92# gasoline
24. Engine oil
Engine
oil type
JAC G01
5W-30
Working temperature -30 ℃
40℃; When
environment
temperature is lower
than
-30℃, please use JAC
G01
0W-30; If non JAC oil is
used,
quality grade should be SM
or
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above. Replace the engine
oil
every 5000km or 6 months
after
first maintenance.
JAC G02
5W-30
Working temperature -30 ℃ ~
40℃; When environment
temperature is lower than
-30℃, please use JAC G02
0W-30; If non JAC oil is
used, quality grade should
be SM or above. Replace the
engine oil every 7500km or 6
months after first
maintenance.
1.1.2 Main parts specifications
Main parts parameter table
Component name Technical features (HFC4GB2.4D)
Engine oil filter Full flow rotary filter Thread specification
M20×1.5-6H
Engine oil pump Internal rotator type
Cooling water pump Centrifugal
Thermostat Mechanical wax package: open at 82 ° C, fully
open at 95 ° C.
Generator Internal regulator ac generator
specification:14V 110A
Starter Permanent magnet deceleration starter voltage
12V power 1.2kW
Spark plug Iridium platinum alloy type
Oil pressure guide
rail
No oil return
1.1.3 Environmental protection key component identification
Environmental
protection key
parts
Label
Catalytic
converter
Notification No.: 1200110
Manufacturer: Kunming Sino- Platinum Metals
Catalyst Co.,Ltd
Packaging: CATARC
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Coating: Kunming Sino- Platinum Metals Catalyst
Co.,Ltd
Carrier: NGK
Front oxygen
sensor
Notification No.: RE94
Manufacturer: DELPHI
Rear oxygen
sensor
Notification No.: RE94
Manufacturer: DELPHI
PCV valve
Notification No.: 1014140GG010
Manufacturer: XF
ECU
Notification No.: MT62.1
Manufacturer: DELPHI
Turbocharger
Notification No.: VT01
Manufacturer: Ningbo Fengwo Turbocharger System
Co., Ltd
1.1.4 Main inspection and adjustment parameters
Main inspection and adjustment parameters table
Valve clearance（mm） Intake valve 0.22±0.03 Exhaust valve 0.30±0.03
Emission standard China V
Oil pressure Idle oil pressure>100kPa
Oil temperature ≤140℃
Water temperature ≤110℃
Sparking plug electrode gap 0.8
～
-0.9mm
1.1.5 Bolt torque table
Fastener tightening torque list
Name Specification Quant Fastening torque
(Nm)
High strength bolt
Main bearing cover
M9×1.25×74.5
10
（
35±2
）
Nm +
（
62±2
）
°
Connecting rod bolt
M6×0.75×33 8 5N·m→10N·m→15N·m+45°+45°
Camshaft bearing
M6×1×35
16
11±1
Camshaft front
M8×1.25×30
3
20±1
Cylinder head bolt
M9×1.25×143.5
10
（
24.5±2
）
Nm+
（
182±2
）
°
Crankshaft belt
M14×1.5×54 1 (100±5)N.m+(90±2)°
Flywheel bolt
M11×1.25×25
6
125±8
Exhaust camshaft
M12
×
30
1
88±10
Air valve timing
M10
×
41
1
70±5
E-type bolt
Crankshaft rear oil
M6×10 E8
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Rear lifting lug bolt
M8×20 E10
2
Air inlet manifold
M8×40 E10
5
Oil pan bolt
M6×12 E8
16
Sprocket chamber
M10×90 E14 2 39.5±3.0
Sprocket chamber
M10×50 E14
2
Sprocket chamber
M6×30 E10
2
M6×20 E10
type bolt
M6×20 E10
6
M6×12 E10
type bolt
M6×12 E10 7 8.4±0.6
When the above two bolts fix engine oil suction
M6×45 E10
type bolt
M6×45 E10
2
M6×25 E10
type bolt
M6×25 E10
9
M6×12 E8
type bolt
M6×12 E8 1 8.4±0.6
Cylinder head guard
M6×27 E10
10
Engine oil filter
M8×30 E12
3
Blower water return
M6×20 E8
2
Oil pressure guide
M8×35 E12 2 18.4±1.4
Plug
Main oil duct plugⅠ Inner hexagon
2
Water Drain Screw Inner hexagon
2
VVT
oil duct plug
M14
×
1.5
×
14
1
±
Oil drain plug
M14×1.5×14
1
Other bolts
Fixed track bolt
M6×1×12
2
Movable track bolt
M8×1.25×15 1 23.5±4.5
Starter bolt
M8×55
2
Engine oil pressure
R 1/8
1
Spark plug
M14
4
～
Exhaust manifold
M8×1×12
5
Q1840830(Exhaust
manifold bracket
bolt)
M8×30 2
Refer to “Standard
component and thread
connecting unlisted in the
table above”
Turbocharger inlet
M10×1.25×52 3
Impact wrench tightening
Supercharger outlet
M10×1.25×40
3
Impact wrench tightening
Exhaust manifold
M6×1×16
3
±
Catalyst bolt II
M8×1.25×12
2
1003013GD190
（Turbocharger
M10×1.25 6
40
±
5
1044209GH500
（Turbocharger
M8×1.25×30
2
22.5
±
2.5
Q1840820F61
（Compressor inlet
M8×1.25×20
4
22.5
±
2.5
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Q1840825F61
（Turbocharger
M8×1.25×25 2
22.5
±
2.5
Crankshaft signal
wheel bolt
M6 3 12.5±2.5
Q1841080F61(
Generat
or mounting bolt
)
M10 1 47±5
Water temperature
sensor
1 20±4
Hall sensor bolt
Inner hexagon
spline
2 8.4±0.6
Knock sensor bolt
Inner hexagon
spline
M8×1.25
1 20±4
exhaust manifold nut
M8
5
throttle valve
4
Absolute pressure
sensor self-tapping
screw
1 6±0.5
Oxygen sensor 2 50±10
Oil filter 1
Rotate 1 turn or 22-28Nm
after contact with the
mounting
surface
Piston cooling
nozzle
M10
×
1
4 20-25Nm
Perforated bolt
(supercharger inlet oil
M10
×
1.25
1 22.5 N.m±2.5N.m
Perforated bolt
(supercharger inlet oil
M10
×
1.25
1 30 N.m±2.5N.m
Perforated bolts
(supercharger inlet and
M12
×
1.25
2 35±5N.m
Standard component and thread connecting unlisted in the table above
M6
～
M8
～
M10
～
M12
60
～
80
1.1.6 Maintenance limitation
Items Standard value
Limit
Value
Camshaft
Camshaft height (mm)
Air inlet
44.7054±0.1mm
Exhaust
44.2836±0.1mm
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Items Standard value
Limit
Value
Cylinder head and air valve
Cylinder head surface flatness (mm) Below 0.03
0.1
Cylinder head total height (mm)
112.9～113.1
Air valve edge thickness
(mm)
Air inlet valve
3.0
0
35.1
0.85
Exhaust valve
1.85±0.15 1.35
Clearance between air
stem and air valve guide
pipe (mm)
Air inlet
0.020
～
0.036 0.10
Exhaust
0.030
～
0.045 0.15
Valve taper angle
45°
～
45.5°
Air valve total total
length
Air inlet valve
89.61 89.11
Exhaust valve
90.94 90.44
Free height of each valve spring（mm）
43.1 42.7
Valve spring loading/installing height
（
N
）
/
（
mm
）
152/33.4
310/25.2
The first air ring sideshake
（
mm
）
0.03～0.07
0.10
The second air ring sideshake
（
mm
）
0.02～0.06
0.1
The first air ring open clearance
（
mm
）
0.15
～
0.3
0.8
The second air ring open clearance
（
mm
）
0.3
～
0.45
0.8
Piston pin external diameter
（
mm
）
19.002
～
19.005
Connecting rod journal clearance（mm）
0.03
～
0.055
0.07
Big head side clearance of connecting rod
0.10
～
0.30
0.4
Crankshaft axial clearance（mm）
0.09～0.27
Crankshaft main journal diameter （mm）
46.004～46.029
Connecting rod shaft journal diameter（mm）
39.982～40.0
Crankshaft main journal diameter clearance
（mm）
0.02～0.05
Cylinder head surface flatness (mm)
Below 0.05
Cylinder body total height (mm)
280
Cylindricity of cylinder body
0.007
Cylinder hole inner diameter (mm)
75.000
～
75.015
Clearance between piston and cylinders
（
mm
）
0.02
～
0.04
1.2 Engine body
1.2.1 Common precautions
1. Precautions for discharging engine coolant
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Discharge engine coolant after engine is cooling.
2. Precautions for disconnect fuel tube
1) Make sure there is no object in the working area that will cause combustion or
spark before starting work.
2) Release the fuel pressure before disconnection and disassembly.
3) Disconnect the pipe and plug the opening to prevent fuel leakage.
3. Precautions for disassembly
1) When a dedicated service tool is required, please use a dedicated service tool.
Please always pay attention to safety work and do not operate without following the
instructions.
2) Take special care not to damage mating or sliding surfaces.
3) If necessary, block the opening of the engine system with tape or the like to
prevent foreign objects from entering.
4) Organize the disassembled parts systematically for troubleshooting and
reassembly.
5) The basic principle for loosening the bolts and nuts is to loosen the outermost
part and then release its diagonal position. If you have specified a release order, please
follow the order specified.
4. Precautions for inspection, maintenance and disassembly
Before repair or replacement, thoroughly inspect the parts and replace if
necessary.
5. Precautions for assembly
1) Tighten the nuts and bolts with a torque wrench.
2) The basic principle of tightening the bolts and nuts is to tighten the middle
with multi-step with the same degree of tightness, then tighten the internal and
external diagonal position. If you have specified a release order, please follow the
order specified.
3) Replace with new liner, oil seal or "O" ring.
4) Rinse thoroughly, clean and dry each part. Carefully check engine oil or
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engine coolant lines for any blockage.
5. Do not damage the sliding surface and matching surface. Thoroughly remove
foreign materials such as fabric debris or dust. Before assembly, lubricate the sliding
surface with oil.
6) After draining the engine coolant and refilling, release air from the line first.
7) After repair, start the engine and increase the engine speed Check the engine
coolant, fuel, engine oil and intake and exhaust leaks.
6. Parts with the setting tightening angle
1) Use an angle wrench to finally tighten the following engine parts:
1
Cylinder head bolt
2
Main bearing cover bolt
3
Connecting rod cover nut
2) Do not make the final torque according to the torque value.
3) The torque values for these parts apply to the pretensioning step.
4) Make sure thread and base surface are clean and oil is applied.
1.2.2 Precautions for sealant
1. Remove the sealant
After removing the retaining nut and
bolt, separate the mating surfaces using a
scraper and remove the old sealant.
Caution:
■ Be careful not to damage mating
surfaces.
■ Insert the squeegee and tap it to slide it sideways as shown.
■
Where the scraper is difficult to use, please use a rubber hammer to tap the
parts for removal.
■ If you have to use tools such as a
screwdriver, be careful not to damage the
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mating surfaces.
2. Sealant application steps
1) Use a squeegee to remove the old sealant attached to the pad application
surface and mating surface.
Caution:
■ Thoroughly remove the old sealant from the grooves, fixing bolts and bolt
holes in the sealant application surface.
2) Wipe clean sealant application surface and mating surface with unleaded
gasoline, remove the attached water, grease and foreign matter.
3) Place the specified size of the sealant completely in the designated location.
■If there is a groove for the sealant,
please put the sealant into the groove.
■ For bolt holes, please place the sealant
inside the hole.Occasionally use outside the
hole.
■Install the binding element within 5
minutes of applying the sealant
■If there is a stain on the
sealant,
remove it immediately.
■ Do not retighten the bolts or nuts after
installation.
■ Thirty minutes after installation, refill
with engine oil and engine coolant.
Caution:
■If there are any special instructions in this manual, please follow the
instructions.
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1.2.3 Preparation work
1. Maintenance tool
Special tools chart
The
seria
l
num
ber
Tool Outside view Description
1
Flywhee
l stop
Fixed flywheel
2
Air
valve
spring
compres
sor
Compression air
valve spring
3
Oxygen
sensor
sleeve
Remove and
install oxygen
sensor
4
Oil pan
remover
Remove the oil
pan
5
Air
valve oil
seal
installin
g device
Install the air
valve oil seal
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6
Camshaf
t oil seal
installin
g device
Installing
camshaft oil seal
7
Cranksh
aft front
oil seal
director
Guide when
installing
crankshaft front
oil seal
8
Cranksh
aft front
oil seal
installer
Install crankshaft
front oil seal
9
Cranksh
aft rear
oil seal
installer
Install the
crankshaft rear oil
seal
10
Piston
pin
locatin
g tool
Install and
disassemble the
Piston pin
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11
Guide
sleeve
Coordinate with
piston pin
locating tool
12
Elastic
belt
tools
Install the elastic
belt
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2. Sealing and fastening adhesive for engine assembly
Sealing adhesive Fastening glue list
Sealing parts Sealing adhesive
Crankshaft rear oil seal
assembly-engine body
Dow Corning 3-0115 plane sealant
Threebond 1217G
Tonsan 1590
Oil pan-engine body-crankshaft
rear oil seal assy.
Dow Corning 3-0115 plane sealant
Threebond 1217G
Tonsan 1590
Sprocket wheel cover-engine
body-cylinder head
Dow Corning 3-0115 plane sealant
Threebond 1217G
Tonsan 1590
Water outlet pipe - Cylinder head
Tonsan 1608
Blower water inlet steel tube- Tonsan 1608
Bowl plug - cylinder head
Loctite 12086 Bowl plug sealant
Crankshaft signal wheel bolt
Loctite 262 thread tighten glue
Water temperature sensor
Tonsan 1243 thread sealing adhesive
Engine oil pressure switch
Tonsan 1243 thread sealing adhesive
3. Lubricant oil
Type of lubricant oil
Engine oil type Environment temperature Quality grade
JAC G01 5W-30 -30
℃～
40
℃
SM and above
JAC G02 5W-30 -30℃～40℃ SN and above
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1.2.4 Engine elastic belt
1. Check elastic belt
Caution:
■Be sure to operate after the engine has stalled.
■ It should be carried out when the engine is cold, or it has been
shut down for 30min.
1
）
Check whether or not they have aging
、
cracks
、
wear and oil stain. If necessary,
please replace it.
Caution:
■Elastic belt after the engine is running around 15 min, the tension
will decay 30%-40% to reach stability at 330 ~ 330 N, if it continues
to decay more than 10% after reaching stability , the skid appears,
the belt has reached the limit, the belt should be replaced.
Caution:
■The belt groove should not be wrong with teeth during elastic belt
installation, otherwise it will damage the belt;
Special auxiliary equipment should be used when elastic belt is
installed, otherwise it is
easy to cause belt damage.
■When installing the
belt, make sure it meshes
properly
with the belt
wheel groove。
■Do not let engine oil and
engine
coolant splash on the belt.
■Do not twine or bend the belt too much.
Caution:
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■Make sure the belt meshes properly with the belt wheel groove。
■Make sure engine oil and engine coolant do not splash on the belt
and each pulley groove.
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1.2.5 Air inlet manifold and exhaust manifold
1. Elements
2. Air inlet manifold
1) Disassembly
1
Disconnect the wire harness connector of the absolute pressure senso
Air inlet
manifold
Air inlet
manifold
bracket
Throttle
seal ring
Fixed
bolt
Canister
Vacuum booster
connecting
tube
Exhaust
manifold
Exhaust
manifold
Thermal
insulatio
n cover
Compressor
air inlet
pipe
Turbochar
ger
Catalytic
converter
Three-way
Compressor
outlet pipe
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2
Disconnect hose connectors below:
■PCV valve connection hose
■Brake vacuum booster hose at the side of air inlet manifold
■Vacuum hose at the side of charcoal canister solenoid valve
3
Disassemble throttle valve self-tapping bolt,take down electronic throttle
valve.
4
Remove the fixing bolts of air inlet manifold and intake manifold bracket.
■Tightening torque: (22.5±2.5) N·m
5
Disassemble air inlet manifold bolt
■Tightening torque: (18±1.0) N·m
6
Take down Air inlet manifold assy.
2
）
Inspection after disassembly
Check whether or not the air inlet manifold has crack or other damage, the
mating surface is deformed, and the air inlet manifold seal ring and throttle seal ring
are damaged. If yes is any abnormal, repair or replace.
3) Installation
■Follow the opposite sequence of the demounting sequence.
Caution:
■Do not reuse the unusable parts
3. Exhaust manifold
1) Disassembly
Caution:
■This operation is performed when the exhaust system is completely cooled.
Warning:
■Emissions from the engine are harmful to the environment.
1
Disconnect the wire plug of the front oxygen sensor. Remove the front
oxygen sensor with a special tool if necessary.
■Tightening torque: (50±10) N·m
Caution:
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■Don't damage the oxygen sensor
。
■Any oxygen sensor that falls from a place more than 0.5m to the hard ground
cannot be used again. Please replace it
。
2
Disassemble the fixing bolts of thermal insulation cover I on the exhaust
manifold,take down the cover.
■Tightening torque: (10±1) N·m
3
Disconnect the boost pressure control valve connection hose and RCV valve
plug.
4
Disconnect the turbocharger compressor intake and outlet connecting pipe
5
Loosen the three-way catalytic converter and bracket connection bolts.
■Tightening torque: (22.5±2.5) N·m
6
Loosen the three-way catalytic converter and the booster connecting bolt and
take off the three-way catalytic converter. Loosen the booster and exhaust pipe
connection bolts and remove the supercharger.
■Tightening torque: (40±5) N·m
7
Disassemble exhaust manifold nuts,and then take down exhaust manifold.
■Tightening torque: (35±2) N·m
2) Inspection after disassembly
1
Check whether the exhaust manifold mating surface is deformed or not.
2
Check whether the gaskets are intact and not damaged.
3
There is no stuck problem with the booster actuator push rod.
4
The turbocharger compressor blade has no foreign matter damage; the shaft
rotation is smooth and there is no stuck; the blade and the volute have no scratching
phenomenon.
3) Installation
Follow the opposite sequence of the demounting sequence.
Caution:
■Do not reuse the unusable parts
■Do not over-tighten the oxygen sensor to avoid damaging the oxygen sensor.
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4、Turbocharger fault diagnosis
When the whole vehicle failure encountered during use is suspected to be a
turbocharger problem, the fault should be diagnosed first. Do not remove the
supercharger immediately. Sometimes the malfunction is not the cause of the
supercharger itself, so replacing the supercharger if the cause is not ascertained
sometimes does not solve the problem fundamentally.
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Common Faults phenomena Troubleshooting table
Oil
leakag
e at
the
compre
ssor
end
(exhau
st blue
smoke,
engine
oil
consum
ption
is too
large)
Turbin
e oil
leakag
e
Turboc
harger
pressu
re is
not
enough
Turbo
charg
er
press
ure is
too
high
Turboc
harger
has
abnorm
al
noise
Possible causes
● ●
Air filter is too dirty
● ●
Deformation or air leakage of
compressor intake pipe,
outlet pipe
● ● ●
Engine exhaust resistance is
large / front clogging /
turbine inlet leakage
● ●
Oil inlet pipe and return
pipe blocked or deformed
● ●
Crankcase ventilation system
blocked, deformed or failed
● ●
Coking or carbon deposition
in the inner chamber
● ●
Engine fuel injection system
failure
● ● ●
Valve guide, piston ring,
engine or cylinder liner
wear/leakage increase
(measure the cylinder
pressure)
●
Compressor or intercooler is
●
Close failure when the
●
Open failure when the
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● ●
Wastegate bypass connection
● ●
Turbine end piston ring seal
● ● ● ●
Turbocharger bearing damage
● ●
Foreign matter entering
●
Turbine outlet and exhaust
● ●
Engine intake pipe cracking /
gasket lost or loose
● ●
Turbine shell damage
●
Turbocharger lack of oil
●
Idle time is too long
1.2.6 Timing sprocket mechanism
1、Element
Timing sprocket mechanism breakdown drawing
1- Timing chain 2-Exhaust camshaft sprocket 3-Sprocket bolt 4-Track bolt
assembly 5-Track assembly 6-tensioner bolt 7-Automatic tensioner 8-Track
assembly 9-Orbital bolt assembly
10-Valve timing regulator
2. Timing chain disassembly and installation
1) Disassembly
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1
Remove the fixing bolt of water pump belt pulley.
■Tightening torque: (8.4±0.6) N·m
Note: the elastic belt can be disassembled by the friction of the driving belt when
elastic belt is not disassembled.
2
Remove the drive belt and check the drive belt for wear, aging, cracks, etc.
Replace the drive belt if necessary.
3
Disassemble oil level gauge assembly.
■Tightening torque: (8.4±0.6) N·m
4
Remove crankshaft pulley.
■Tightening torque:
（
100±5
）
N·m+
（
90±2
）
°.
5
Remove the generator.
6
Remove oil pan and cylinder head shield.
Note: The oil pump housing can only be removed after removing oil pan and
cylinder head shield.
Remove oil pump housing.
7
Check the timing condition.
Note: check whether or not the timing points shown in the diagram meet the
requirements.
8
Remove the fixing and moving rails of automatic tensioner and timing chain.
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And check for exceptions.
■Tightening torque: automatic tensioner (10±1) N·m.
Fixing rail:
（
10±2
）
N·m.
Moving rail:
（
23.5±4.5
）
N·m.
9
Remove the exhaust camshaft sprocket bolts.
■Tightening torque: (88±10) N·m
10
Remove air valve timing regulator.
■Tightening torque: (70±5) N·m
2) Installation
Follow the reverse procedure above for disassembly. Pay attention to the timing
points and installation torques during installation.
Oil pump housing installation meets the following requirements:
a. When the oil pump housing is assembled, the glue coating surface should be
clean, no oil, dirt, etc
And gelatinizing with corning 3-0115 surface sealant or equivalent products
according to the following picture. The diameter of the rubber strip at point A is
22mm±0.5mm. The diameter of the rubber strip at point B is 1.5mm±0.5mm..
Oil pump housing gelatinizing introductions
A
B
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b.
Before assembling the sprocket cover, ensure that the sealing surface
of the cylinder and cylinder head is clean, free from oil and dirt,
etc., and remove the residual sealant at the joint between the
sprocket cover and the cylinder and cylinder head. Then apply a new
sealant evenly, the strip diameter is 4mm.
Glue description of cylinder and cylinder head joint surface
c. The tightening sequence of the oil pump housing bolts should follow the
principle of pre-tightening and
then tightening from the middle to the sides. It is required to first tighten the bolts
with larger diameters and then tighten the bolts with smaller diameters.
■ Bolts’ tightening torque of point 1-4: (39.5±3.0) N·m
■ Bolts’ tightening torque of point 5-15: (8.4±0.6) N·m
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Oil pump housing bolts tightening sequence
1.2.7 Camshaft Assembly
1、Element
Camshaft assembly breakdown drawing
1-Camshaft front end bearing cap bolt 2-camshaft front end bearing cap 3-camshaft
bearing cap bolt
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4-Camshaft bearing cap 5-Exhaust camshaft 6-Mechanical tappet 7-Intake camshaft
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2. Disassembly and installation
1) Disassembly
1
Disassemble the ignition coil.
2
Disassemble cylinder head guard assy.
3
Rotate crankshaft , let cylinder-1 piston stay at the stop point of
compression.
4
Measure valve clearance.
a. The valve clearance is measured at position A in the figure
b. If valve clearance does not meet the standards, it needs to be adjusted.
■It is important to note the measurement value as an important parameter to
calculate the proper tappet label.
Standard valve clearance (Cooling engine state)
Items Specified state
Air inlet (0.22±0.03) mm
Exhaust (0.30±0.03) mm
6
Turn the crankshaft 360º clockwise , let cylinder-4 piston stay at the stop
point of compression.
7
Measure the valve clearance at position B in the figure.
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■It is important to note the measurement value as an important parameter to
calculate the proper tapper label.
8
Remove engine front end belt, idler wheel and shock absorbing belt pulley.
9
Remove oil pan and engine oil suction filter.
10
Remove oil pump housing and timing chain.
11
Remove air valve timing regulator.
a. Fix the camshaft with a wrench.
b. Loosen the valve timing adjuster bolts.
■Tightening torque: (70±5) N·m
c. Remove the valve timing adjuster.
12
Remove air inlet and exhaust camshaft.
a. Remove camshaft front bearing cover, in reverse numerical order as shown
in the figure below.
b. Remove camshaft bearing cover, in reverse numerical order as shown in the
figure below.
13
Measure the height of the camshaft
Inlet: (44.7054±0.1) mm
Exhaust: (44.2836±0.1) mm
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If the measured value is
not
within the standard value,
replace the camshaft.
14
Remove the mechanical tappet in the unqualified valve clearance and adjust
the valve clearance.
■Mark the removed tappet and the corresponding installation position to prevent
forgetting the position of the column.
a. Measure the thickness of the removed mechanical tappet with a screw
micrometer.
b.
According to the measured
valve clearance and the thickness
of the old tappet,calculate the
thickness of the new tappet to
make the valve clearance reach the
specified range.
New tappet thickness table
※Example
Measured intake valve clearance＝0.26mm，marked as A.
Items Specification
Air inlet New tappet thickness=old tappet thickness+[ measured valve
clearance-0.22mm]
Exhaust New tappet thickness=old tappet thickness+[ measured valve
clearance-0.30mm]
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Measured old tappet thickness
＝
2.79mm
，
marked as B.
Measured intake valve clearance+Measured old tappet thickness
＝
The
clearance between the base circle of the camshaft and the top of the valve tappet,
marked as C. C
＝
3.05mm.
C
＝
Intake valve clearance standard value+Ideal new tappet thickness. So
Ideal new tappet thickness
＝
3.05mm
－
0.22mm
＝
2.83mm.
■When calculating the thickness of the exhaust side tappet, the above equation
should be replaced with exhaust valve clearance standard value.
c. The closest new tappet thickness
＝
2.82mm or 2.84mm. Select tappet 282 or
tappet 284.
d. Select a new tappet with the closest thickness to the calculated value.
■The available tappets have 31 sizes, ranging from 2.70 to 3.30mm, increasing
by 0.02mm.
■The identification number in the mechanical tappet indicates the thickness (e.g.,
272 indicates the thickness value of 2.72mm).
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Tappet thickness group table
Tappet Thickness Tappet Thickness Tappet Thickness
270 2.70 292 2.92 314 3.14
272 2.72 294 2.94 316 3.16
274 2.74 296 2.96 318 3.18
276 2.76 298 2.98 320 3.20
278 2.78 300 3.00 322 3.22
280 2.80 302 3.02 324 3.24
282 2.82 304 3.04 326 3.26
284 2.84 306 3.06 328 3.28
286 2.86 308 3.08 330 3.30
288 2.88 310 3.10
290 2.90 312 3.12
2) Installation
1
Install the new tappet selected after the calculation.
■Confirm the specific position of each new tappet selected after calculation
(corresponding to the mounting hole), preferably mark the new tappet.
2
Install the camshaft and bearing cover and pre-tighten the bolts in the
opposite order of disassembly.then tighten in this order.
■Engine oil should be applied to the camshaft journal and cam.
■Camshaft bearing cover bolts (3) tightening torque: (20±1) N·m
■Camshaft bearing cover bolts (16) tightening torque: (11±1) N·m
3
Measure again whether or not the valve clearance after adjustment meets the
standard. If it is beyond the standard range, first check whether the tightening torque
of bearing cover bolts meets the requirements or not.
■If the bolt torque meets the requirement, remove the mechanical tappet in the
unqualified valve clearance and adjust the valve clearance.
■If the tightening torque of bolts does not meet the requirements, loosen all the
bolts on this camshaft and tighten them to the specified torque in order. Measure
valve clearance again. If there is any unqualified clearance, remove the mechanical
tappet in the unqualified valve clearance and adjust the valve clearance.
4
Install air valve timing regulator.
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5
Install timing chain and oil pump housing.
6
Install engine oil suction filter and oil pan.
7
Install front-end power accessory and elastic belt.
8
Install cylinder head guard
、
ignition coil.
■Check the sealing ring of cylinder head guard before installation to ensure no
loss, no damage, no scratch, no crease and other defects, so as to ensure its sealing
performance.
■The cylinder head guard bolts must be pre-tightened and fastened in the order
shown in the figure with tightening torque:
（
9±1)N·m.
1.2.8 Cylinder head
1. Maintenance on vehicle (the abnormal parts will be maintained and reinstalled
back)
Check cylinder pressure:
1
Turn off the engine after thoroughly warming it up.
2
Release the fuel pressure.
■Remove the fuel pump fuse from the fuse box.
■Start the engine.
■After the engine is out, start the engine to idle two or three times to release the
fuel pressure completely .
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3
Remove ignition coils and spark plugs.
4
Install a spliced cylinder pressure gauge on the spark plug hole.
5
Step the accelerator pedal to the bottom and turn the ignition switch to
"START" to start. When the meter pointer is stable, read the compression pressure
and engine speed. Do the above steps to check the remaining cylinders
■Standard pressure: 12 ± 1bar
（
200rpm
）
.
■ Cylinder pressure difference limit: 9.1 bar.
■Allowable difference between cylinders: no more than 98kPa.
Caution:
■Prevent foreign matter from entering the cylinder through the inlet.
■Always use a fully charged battery to get the required engine speed
(200r/min).
■If the compression pressure is below the minimum, check the valve clearance
and other related parts (valve, valve seat, piston, piston ring, cylinder diameter,
cylinder head and cylinder head gasket). After checking, measure the compression
pressure again.
■If the compression pressure of some cylinders is low, add 10ml engine oil into
the spark plug hole of the cylinder and re-check the cylinder pressure.
■If the cylinder pressure increases after the engine oil is added, the piston ring
may be worn or damaged. Check the piston ring and replace it if necessary.
■If the compression pressure is still low after the engine oil is added, the valve
may fail. Check if the valve is damage. Replace damaged valve or valve seat.
■If the compression pressure of two adjacent cylinders is low and the pressure
is still low after adding oil, the cylinder gasket may leak. Please replace cylinder
head gasket.
6
After the inspection, please install the removed parts.
7
Start the engine and make sure it runs smoothly.
2. Disassembly and installation
1) Disassembly
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1
Release the fuel pressure.
2
Discharge engine coolant and oil. Refer to "Replace engine coolant" and
"Replace engine oil".
Caution:
■Be sure to operate after the engine is cooling.
■Do not let engine oil and engine coolant splash on the belt.
3
Remove the following components and related parts:
■Cylinder head guard.
■Elastic belt. Refer to “Elastic belt”.
■Oil pan.
■Oil pump housing and timing mechanism. Refer to “Timing sprocket
mechanism”.
■Air inlet manifold. Refer to “Air inlet manifold”.
■Exhaust manifold. Refer to “Exhaust manifold”.
■Thermostat housing. Refer to “Thermostat assy.”.
■Engine oil dipstick guide pipe.
4
Unscrew cylinder head bolt.
■Disassemble in numerical order as shown below.
5
1
9
7
8 4
3
10
6
2
5
Remove cylinder head gasket.
2) Inspection after disassembly
1
Check whether the cylinder head has cracks or other damage.
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2
Check whether the waterways and oil channels between cylinder body and
cylinder head are blocked. Please clean it if necessary.
3
Check cylinder head flatness.
Note: when this inspection is carried out, the flatness of cylinder block should
also be checked. Refer to“Cylinder block flatness”.
a.Wipe the oil off the cylinder head and clear away sealant and carbon
deposition.
Caution:
■Be careful not to let impurities fall into the cylinder head channel and oil
channel.
b.Measure the flatness in six directions at multiple positions on the bottom
surface of the cylinder head.
Standard value: 0.03mm below
Limit value: 0.10mm
Cylinder head height (new): (113±0.1)mm
If the value is exceeded standard value, please grinding according to the
specification. If the value is exceeded the limit value, please replace according to the
specification.
Caution:
■The total grindable allowance of cylinder head and cylinder block mating
surface is no more than 0.2mm.
3) Installation
1
Install new cylinder head gasket
2
Install the cylinder head as follows:
a.Install the washer as shown in the
picture
on the right.
b.Apply appropriate amount of engine oil
to
the screw position and washer of cylinder head bolt.
c.Tighten bolts in numerical order as shown in the figure below until each bolt
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reaches torque (24.5 + 2) N·m.
d.Loosen the bolts completely.
e.Tighten bolts in the order again until each bolt reaches torque （24.5±2）N·m.
f.Paint the head of the cylinder head
bolt
and cylinder head (as shown in the
right
picture).
g.According to tighten the
sequence,
tighten each bolt by extra 90 ° twist.
H.tighten each bolt 90 ° again,
check
whether the paint marks on bolt head aligns with the cylinder head.
Caution:
■If the bolt tightening Angle is less than 90 °, that means the fastening torque
is not enough.
■If the bolt tightening Angle is more than 90 °, the bolt should be completely
removed, and reinstall again.
i.If the cylinder head bolts are replaced during maintenance,maintain according to
the above steps a ~ h.
j.If the cylinder head bolts are not replaced during maintenance,maintain
according to the order of a, b, e, f, g, h.
3
Follow the opposite sequence of the disassembly procedures to install.
6
10
2
4
3 7
8
1
5
9
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4
）
Inspection after assembly
The following are the steps to check oil leakage, lubricant leakage and tail gas
leakage:
1
Before starting the engine, please check the level of the engine cooling fluid
and engine oil.
2
Turn the ignition switch to the "ON" position (when the engine is off) to
check the connection for fuel leakage.
3
Start the engine. When accelerating the engine ,check the connection again
for fuel leakage.
4
Run the engine to check for abnormal noise and vibration.
5
Thoroughly warm up the engine and check for leakage of fuel oil, exhaust
gas or any oil/liquid (including engine oil and engine coolant).
6
After the engine has cooled, recheck the oil/liquid level(including engine oil
and engine coolant). If necessary, refill to the specified level.
1.2.9 Valve
1. Elements
Valve element diagram
1-Exhaust valve seat ring 2-Exhaust valve 3-Intake valve 4-Intake valve seat 5-valve
oil seal 6-Valve spring lower seat 7-Valve spring 8-Valve spring seat 9-Valve lock
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clamp 10- Valve guide
2. Disassembly and installation
1) Disassembly
1
Use spark plug sleeve to
remove spark plug.
2
Remove the valve lock,
valve
spring and valve spring seat.
■Use the valve spring compressor
to
compress the valve spring.
Attention:
■All the valve, valve spring and
other
components that being removed should
be
attached with the label, indicating
the
cylinder number and location.
■Store the parts securely.
3
Remove the valve oil seal.
4
Remove the valve seat ring.
5
Remove the valve guide pipe.
2) Installation
1
Install the valve guide pipe.
2
Install the valve seat ring.
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3
Install the valve oil seal.
a.Install the valve spring lower seat
b.Install new valve oil seal with special tools..
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Caution:
■Valve oil seal cannot be reused.
■The valve oil seal must be installed with the correct special tool.
4
Install the valve.
5
Install the valve spring.
Note: the items with paint mark should be installed facing up.
6
Install the air valve spring upper seat.
7
Install the valve lock clamp.
■Install with valve spring compressor.
■After installation, tap the valve stem edge with a rubber hammer to check the
installation.
8
Use spark plug sleeve to
install spark plug.
3) Inspection after disassembly
1
Air valve
■ Check that the gas facade is
in
proper contact. If the contact is uneven
or
incomplete, repair the valve seat surface.
■Air valve edge thickness inspection. If it is less than the limit, please replace
the valve.
Intake valve Standard value:
1.35mm
Limit value: 0.85mm
Intake valve Standard
value:
1.85mm
Limit value: 1.35mm
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■Check the total length of the air valve. If it is less than the limit, please replace
the valve.
Intake valve Standard value: 89.61mm
Limit value: 89.11mm
Intake valve Standard value: 90.94mm
Limit value: 90.44mm
2
Air valve spring
■Check free height of valve spring. If the limit is exceeded, replace the valve
spring.
Standard value: 43.1mm
Limit value: 42.7mm
■Check the verticality of the
valve
spring. If the limit is exceeded, replace
the
valve spring.
Standard value:
＜
2°
Limit value: 4°
1.2.10 Cylinder block assembly
1
、
Element
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Cylinder block assembly exploded view
1-Main bearing cap bolts 2-Main bearing caps 3-Spindle lowers 4-Spindle uppers
5-cylinders 6-Crankshaft rear oil seal assembly 7-Crankshaft rear oil seal bolts
8-Thrust blades 9-Flywheel bolts 10 Flywheels 11-Crankshaft 12-Crankshaft signal
wheel locating jacket 13-Crankshaft signal wheel 14-Crankshaft signal wheel bolt
15-Crankshaft pulley 16-Crankshaft pulley retaining ring 17-Crankshaft pulley bolt
2. Disassembly and installation
1) Disassembly
1
Remove the following engine accessories. Refer to the relevant chapters for
details of the disassembly process.
■Engine air inlet manifold and engine exhaust manifold.
■Generator elastic belt.
■Generator.
■Engine timing mechanism.
■Water pump.
■water pipe components.
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■Generator fixing bracket, air condition compressor fixing bracket.
■ignition coil.
2
Fix the engine overall.
3
Discharge engine oil Refer to “Replace the engine oil”.
4
Remove flywheel assembly. Please use the special tool to fix the flywheel
and then remove the fixing bolt.
Caution:
■Fixing bolts should be loosened in diagonal order.
5
Remove crankshaft rear bearing
Caution:
■Once the rear bearing of crankshaft is disassembled, it cannot be used again.
Please replace it with a new one.
6
Remove the following system. Refer to the relevant chapters for details of
the disassembly process.
■Cylinder head
■Oil pump housing
■Oil pan
7
Remove knock sensor
Caution:
■Do not drop or tap the sensor.
8
Remove rear oil seal bracket.
■The driver is inserted between the crankshaft and the rear oil seal housing for
disassembly.
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Caution:
■Once the rear oil seal is disassembled, it cannot be used again. Please replace
it with a new one.
9
Remove piston and connecting rod assembly
Before removing piston and connecting rod assembly, please check the clearance
of the connecting rod head. Refer to “Inspection after disassembly" below.
a. Rotate the crankshaft. Place the corresponding crankshaft of the connecting
rod to be removed in the center of the bottom.
Note: For ease of reinstallation, a cylinder number can be printed on the side of the
removed connecting rod head.
b.Remove connecting rod cover.
■Connecting rod bolts could only be used once and shall not be reused.
c.Use a rubber hammer or similar tool to push the piston and connecting rod
assembly out of the cylinder block.
Caution:
■Be careful not to let the connecting rod head damage the cylinder wall and
crankshaft journal.
10
Remove the connecting rod bearing bush from the connecting rod and the
connecting rod cover.
Caution:
■Identify installation locations and keep them in place without confusion.
11
Remove piston ring from piston.
Check the side clearance of the piston ring before removing it. Refer to
“Inspection after disassembly" below.
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Attention:
■Using piston ring expander.
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12
Remove the piston from connecting rod as follows：
a.Insert the push rod (special tool) from the arrow mark side in the
front
and install guide sleeve D.
b.place the piston front mark up
and install the piston and connecting rod assembly on the piston pin
mounting base
(special tool).
c.Press the piston pin out with the press machine.
d.Separate the connecting rod and piston from from
the piston and connecting rod assembly.
Caution:
■After removing piston pin, put the piston, piston pin and connecting rod
together in the same cylinder. Do not mix with the piston, piston pin and connecting
rod of other cylinders.
13
Remove crankshaft main bearing cover.
Before releasing the crankshaft bearing cover, measure the crankshaft axial
clearance. Refer to “Inspection after disassembly" below. Please loosen the main
bearing cover bolts of crankshaft in numerical order as shown in the figure below
1
2
3
4
5
6
7
8
9
10
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As shown in the picture on
the
right,When disassembling, the
crankshaft
bearing cover bolts can be used to shake
the
crankshaft bearing cover backwards
and
forwards to disassemble it.
14
Remove crankshaft.
15
Remove crankshaft signal wheel.
■Crankshaft signal wheel bolts are removed clockwise.
2
）
Inspection after disassembly
1
Crankshaft axial clearance
Use the driver to lever the
crankshaft,
record the reading of the dial indicator at
the
same time.
Standard : 0.09
～
0.27mm
If the measured value is not within the standard value, please replace the thrust
plate and remeasure it. If it is still not within the standard range, please replace the
crankshaft.
2
Connecting rod big head clearance
Measure the clearance between
the
connecting rod and the crankshaft arm with
a
feeler gauge.
Standard clearance: 0.10
～
0.25mm
Limit value: 0.4mm
If the measured value exceeds the limit, replace connecting rod and measure
again. If the limit is still exceeded, replace the crankshaft.
3
piston ring side clearance
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Measure the clearances between piston ring and piston ring grooves with a feeler
gauge.
Standard:
First groove: 0.03
～
0.07mm
Second groove: 0.02
～
0.06mm
Limit value:
First groove: 0.10mm
Second groove: 0.10mm
If the measured value exceeds the limit, replace piston ring and measure again. If
the limit is still exceeded, replace the piston ring.
4
piston ring opening clearance
Make sure the cylinder inner diameter is within the specified range. Refer to
“Cylinder cylindricity”.
Lubricate the piston and piston ring with engine oil and insert the piston ring until
the piston reaches the middle of the cylinder,and use feeler gauge to Measure piston
ring opening clearance.
Standard:
First groove
：
0.15
～
0.30mm
Second groove: 0.30
～
0.50mm
Limit value:
First groove: 0.8mm
Second groove: 0.8mm
If the measured value exceeds the
limit,
replace piston ring and measure again. If the limit is still exceeded, replace the
cylinder block.
5
Cylinder block flatness
Clean the liner on the cylinder block surface, as well as engine oil, scale carbon
or other contaminants.
Caution:
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■Be careful not to let gasket chips fall into engine oil or engine coolant.
The flatness of cylinder block is measured with a ruler and a feeler gauge in six
different directions.
Standard value: 0.05mm below
Limit value: 0.1mm
If the limit is exceeded, replace
the
cylinder block.
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6
Cylinder block cylindricity
Use the dial gauge to measure the thrust direction and the axial bore
diameter at positions A and B of each cylinder.
Standard value: cylinder inner diameter: 75.000 ~ 75.015mm
Cylindricity: less than 0.007mm
If the average cylinder diameter of the four positions is greater than
the maximum value, the cylinder is replaced.
7
Piston skirt diameter
Check the piston skirt for
deformation
with an outer diameter micrometer.
Standard value:
（
74.970±0.005
）
mm
Please replace the piston if it
surpasses
the standard value.
8
Piston and bore clearance
Calculated by the piston skirt and cylinder bore.
(Clearance) = (Cylinder inner diameter) - (Piston skirt diameter)
Standard value: 0.025 ~ 0.05mm
If the calculated value exceeds the limit, replace the piston and piston ring
assembly.
9
Crankshaft main journal
diameter
Measure the crankshaft journal with
the
outside micrometer.
Standard clearance: 46.004
～
46.029mm
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Please replace the main bearing if it surpasses the standard value.
10
Connecting rod shaft journal diameter
Use the outer diameter micrometer to measure the diameter of the connecting rod
main journal.
Standard value: 39.982 ~ 40.000mm
If the standard is exceeded, replace the connecting rod.
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Connecting rod bearing bushing
Crankshaft connecting rod journal Connecting rod bearing selection
(up/down)
Mark Dimension Mark Dimension
1
φ40
0
006.0
1 (yellow)
1.5
010.0
013.0
2
φ40
006.0
012.0
2 (black)
1.5
007.0
010.0
3
φ40
012.0
018.0
3 (red)
1.5
004.0
007.0
11
Connecting rod journal clearance
Note: use plastic wire gauge for measurement.
a.Remove all engine oil from the connecting rod journal and the connecting rod
bearing bush.
b.Place the plastic wire gauge on
the
connecting rod journal and cut it into
the
same length as the width of the bearing
bush.
Plastic wire gaugemust be at the
center of connecting rod journal and
parallel to its axis.
c.Gently place the connecting rod cover in its position and tighten the bolts to the
specified torque.
d.Remove the bolts and slowly remove the connecting rod cover.
e.Measure the extruded part of the plastic wire gauge at the widest point using a
ruler printed on the plastic wire gauge bag.
Standard value: 0.03 ~ 0.055mm
Limit value: 0.07mm
f.Remove the plastic clearance gauge completely after measurement.
If the clearance is greater than the limit, replace the connecting rod bearing
bush. Replace the crankshaft if necessary.
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12
Crankshaft main journal
diameter
clearance
a. Clean the engine oil of
crankshaft
journal and inner surface of
bearing
bush.
b. Install bearing bush.
c. Cut the length of the plastic gauge to match the width of the bearing. Then
place it on the journal along the axis of the journal.
d. Lightly install the crankshaft bearing cover and tighten the bolts to the
specified torque.
e. Remove the bolts and gently remove the crankshaft bearing cover.
f. Measure the extruded part of the plastic wire gauge at the widest point using
a ruler printed on the plastic wire gauge bag.
Standard value: 0.02 ~ 0.05mm
Limit value: 0.10mm
If the clearance is greater than the limit, replace the main bearing bush. Replace
the crankshaft if necessary.
3) Installation
1
Preinstall the crankshaft signal wheel.
■Ensure no engine oil in the threaded hole of crankshaft signal wheel when
assembling.
■Crankshaft signal wheel screw must be coated with Loctite 262 thread fastener
or equivalent product before installation
■Crankshaft signal wheel bolts are tightened counterclockwise as shown in the
figure below
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2
Blow engine coolant and engine oil out of cylinder block, cylinder diameter
and crankshaft box ,remove foreign matter.
Caution:
■Use goggles to protect your eyes.
3
Install main bearing bush upper bearing bush
Caution:
■Select the bearing bush according to the identification mark or color code of
the crankshaft (refer to the assembly table of the main bearing bush). If it cannot
be identified, the crankshaft diameter should be measured and the corresponding
bearing bush should be selected to match it.
There are grouping marks on the crankshaft, marking a total of 10 digits. The first
5 digits correspond to the 1st to 5th main journals respectively. The 6th bit is printed
"B", indicating the end of main journal grouping and the beginning of connecting rod
journal grouping; The 7th to 10th bits correspond to the 1st to 4th connecting rod
journals respectively.
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The exhaust rear end of the lower end face of cylinder block is marked with the
dimension mark of the main shaft hole, corresponding to the dimension of the 1st to
5th main shaft hole respectively.
Main
bearing
Main bearing bush shall be selected according to the following table
Main bearing bush installation table
Main bearing
hole grouping
Mark
Crankshaft grouping marks
1 2 3 4 5
0 (
up／down）
Black／
Black
Black／
yellow
Black／red
Black／
white
Black／
purple
1 (
up
／
down
）
Yellow／
Black
Yellow／
Yellow
Yellow
／
red
Yellow／
white
Yellow
／
purple
2 (
up
／
down
）
Red
／
Black
Red
／
Yellow Red
／
Red
Red
／
white
Red／
purple
■When installing, aim the protrusion of the bearing bush at the cutting of the
cylinder block and the main bearing cover.
■Make sure the engine oil hole on the cylinder block is aligned with the oil hole
on the corresponding bearing bush
4
Install crankshaft to cylinder block. When rotating the crankshaft by hand,
please check whether the rotation is flexible or not.
■Before installing crankshaft, appropriate amount of engine oil should be applied
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to the inner part of upper bearing bush.
5
Install thrust plate
Install oiled thrust plate in installation groove side of the main bearing seat
(fourth), 100% measure and ensure that the crankshaft axial clearance is 0.09 ~ 0.27
mm, when installing two thrust surfaces ensure that the flat side joint fourth position,
with groove side facing the cylinder holes.
Fourth
gear
Thrust
washer
Grooved
side
Flat
side
6
Install main bearing cover.
■The main bearing cover can
be
identified by identification marks.
■Starting from the front end (timing belt side), install the main bearing cover in
order of number.
■The arrow must point to the front
7
Tighten the main bearing cover bolts as shown in the figure below.
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9
2
7
8
5
6
3
1
10
4
a.Apply engine oil to the thread and fixed surfaces of the main bearing cover
bolts.
b.Tighten the main bearing cover bolts in several steps.
■Tightening torque:
（
35±2
）
N·m+
（
62±2
）
°.
■After installing the main bearing cover bolts, make sure the crankshaft can be
rotated flexibly by hand.
■Check crankshaft axial clearance. Refer to “Crankshaft axial clearance”.
8
Preassemble piston connecting rod assembly.
■When installing the piston pin, make sure the top of the piston marked forward
and the connecting rod marked forward are the same.
a.Measure the following lengths（As shown in diagram below）
A：Dimensions from piston boss to piston boss outside
B：Dimensions from piston boss to piston boss inside
C：Piston pin length
D：Connecting rod small end thickness
b.The measured value is putted into the following formula：
L=[（A-C）-(B-D)]/2
c.Insert the push rod (special tool) into the piston pin and install
guide sleeve A (special tool)。
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d.When piston and connecting rod are installed, the front marks should
be on the same side.
e.Apply engine oil to the outer ring of the piston pin.
f.Starting with guide sleeve A, press guide sleeve A ,piston pin and
push rod into the front marking side of the piston successively.
g.Screw guide sleeve B into
guide
sleeve A, and the gap between the two
sleeves is 3mm plus the L value
calculated in step 2.
h.Install the piston and the
connecting rod on the piston pin
mounting base in a downward marked state
in front of the piston.
C.install the piston pin with the press machine.
Caution:
■If the pressure distribution load exceeds the specified limit, the
piston pin and the piston assembly and the connecting rod shall be
replaced, or both shall be replaced
Standard value: 108±54N·m
9
Install piston ring.
■Be careful not to damage the piston when installing piston rings.
■Be careful not to damage the piston ring because of overextending.
a. Install the oil ring.
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Install the oil liner ring into the piston ring groove. Then install the oil ring
body.
When installing the ring body, put one end of the ring body into the groove by
hand, and then press the rest into the position.
Caution:
■Do not use piston ring expander to install ring body, otherwise it may lead to
wiper blade fracture
After installing the combined oil ring body, check whether it can move
smoothly in both directions.
b. Install1st and 2nd air ring.
Install the air ring with the piston ring expander. The identification mark on
the air ring should be toward the top of the piston.
c. Piston ring opening direction.
10
Install the connecting rod bearing bush on the connecting rod and the
connecting rod cover.
■Apply engine oil to the surface of the connecting rod bearing bush before
installing it.
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■Connecting rod bearing bush shall be installed with special tool to ensure the
installation position: as shown in the figure below, the difference between A and B
length is less than 0.5mm.
11
Install piston connecting rod assembly on crankshaft.
■Rotate crankshaft journal corresponding to the connecting rod to be removed in
the center of the bottom.
■Apply engine oil to cylinder diameter, piston and crankshaft journal.
■Install the connecting rod to the corresponding cylinder hole according to the
mark on the connecting rod
■Make sure the mark on the top of the piston is pointing forward.
■Using the piston guide tool, put the piston connecting rod assembly into the
guide tool from the cylinder fire surface and press the piston into the cylinder block
with the rubber rod.
Attention:
■Be careful not to let the connecting rod head damage the cylinder wall and
crankshaft journal.
12
Install connecting rod cover.
13
Tighten connecting rod bolts, according to the
“5N·m→10N·m→13N·m+45+45°” approach to tighten alternately.
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Caution:
■ When assembling, use high-pressure air purging or vacuum suction connecting
rod to increase the cross-section to ensure foreign matter such as inorganic oil and
metal scraps, and report good adhesion without gaps. Forbid mixed and reverse
installation of connecting rod big end cover.
■Before installing the bolts, apply engine oil to the threaded parts and seating
surfaces.
■After installing the piston connecting rod assembly, rotate the crankshaft to
check whether the crankshaft can rotate flexibly.
■ Connecting rod big head backlash: 0.10-0.30mm.
14
Install the rear oil seal bracket with the crankshaft rear oil seal on the
cylinder block. Use special tools to press the rear oil seal on the rear oil seal bracket
■When installing crankshaft rear oil seal bracket, ensure that the coating surface
is clean, no oil, dirt, etc., apply Dow corning sealant 3-0115 or equivalent product on
the surface of the cylinder block back-end as shown below, the sealant can also be
applied on the corresponding position of crankshaft rear oil seal bracket. Rubber strip
diameter（2±0.5）mm. Apply lubricating oil to the rear oil seal lip and crankshaft joint,
Be careful not to scratch the oil seal when installing.
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■Tightening torque: (7.6±0.6) N·m.
Crankshaft rear oil seal glue line.
15
Install the knock sensor.
■Tightening torque: (20±4) N·m.
Note: make sure there is no foreign matter between cylinder block and knock
sensor.
16
Install the flywheel
■Tightening torque: (100±5) N·m.
Caution:
■Follow the principle of pre-tightening first and then symmetrical cross -
tightening.
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1.3 Engine lubricating system
1.3. Installation precautions
Sealant application steps:
1. Use a squeegee to remove the old sealant attached to the pad application
surface and mating surface.
Caution:
■ Thoroughly remove the old sealant from the grooves, fixing bolts
and bolt holes in the sealant application surface.
2. Wipe clean sealant application surface and mating surface, remove the attached
water, grease and foreign matter.
3. Place the sealant in the designated location.
1
）
Install the binding element within 5 minutes of applying the sealant
2
）
If there is a stain on the sealant, remove it immediately.
3
）
Do not retighten the bolts or nuts after installation.
4
）
Thirty minutes after installation, refill with engine oil and engine coolant.
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1.3.2 Preparation work
1、Maintenance tool
Maintenance tool list
The
serial
numb
er
Tool Outside view Description
1
Oil
pressure
gauge
Measure the oil
pressure
2 Hose
Connect the oil
pressure gauge to
the cylinder block
3
Oil
pressure
switch
sleeve
Disassemble and
install the oil
pressure switch
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1.3.3 Lubrication system schematic
1.3.4 Engine oil
1. Inspection
1
）
Engine oil level
Note: before starting the engine, stop the car horizontally and check the engine oil
level. If the engine has started, turn off
the
engine and wait for 10min to check again.
1
Pull out the engine oil dipstick
and
wipe it clean.
2
Insert the engine oil dipstick
and
make sure the oil level of the engine is
within
the range as shown in the figure.
3
Please adjust it if it is out of the range.
2
）
Engine oil appearance
1
Check engine oil for white turbidity or serious contamination.
2
If engine oil is turbid or contaminated, it is likely to be contaminated by
engine coolant. Repair or replace damaged parts.
3
）
Engine oil leakage
Check for oil leakage around the following areas:
■Oil pan
■Oil pan oil drain bolt
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■Engine oil pressure switch
■Engine oil filter
■The mating surface of cylinder block and cylinder head
■Front and rear crankshaft oil seal
■The mating surface of cylinder block and oil pump
■The mating surface of cylinder head guard and cylinder head
■Front camshaft oil seal
4
）
Oil pressure inspection
Caution:
■The engine oil is very hot, be careful
not
to get scalded.
■Check the oil pressure after parking.
1
Check the oil level.
2
Lift the vehicle, disconnect the wire connector of engine oil pressure switch
and remove the switch.
3
Install oil pressure gauges and hoses.
4
Start the engine and warm it to normal working temperature.
5
Check oil pressure during engine running with no-load.
Note: when the engine oil temperature is low, the oil pressure increases.
■If there is any obvious difference, please check the oil pipeline and oil pump for
leakage.
6
After inspection, install the pressure switch as follows:
a.Remove old sealant that is attached to pressure switches and engines.
b.Use sealant as required and tighten pressure switch.
■Please use the specified sealant
：
Tonsan 1243 thread sealing adhesive.
■Tightening torque: (10±2) N·m.
c.After warming up the engine, make sure there is no oil leakage when the
engine is running normally.
2、Engine oil replacement
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1
Start engine and preheat until the engine coolant temperature reaches (80 ~
90 ℃).
2
Remove engine oil filler cover from the cylinder head guard.
3
Remove the drain screw plug from the oil pan to drain the oil. The oil
discharge time shall not be less than 15min.
Caution:
■The engine oil is very hot, be careful not to get scalded.
4
Use special spanner to disassemble the oil filter;
5
Clean filter installing surface on oil filter bracket.
6
Replace the new oil filter: Apply a small amount of oil to the O-ring of the
oil filter. When the O-ring of the oil filter contacts the flange of the oil filter bracket,
use a special wrench to rotate one turn or equivalent to (22-28) N·m.
7
Install oil duct screw plug on the oil pan.
■Tightening torque: (39±5) N·m.
8
Inject the oil from the oil inlet on the cylinder cover guard, about 4L.
9
After starting the engine without load and running for (2-3) min, check the
interface between filter and bracket to ensure no oil leakage.
10
Turn off the engine and wait for 10min to check whether the oil level is
between the upper and lower scale. If oil is insufficient, please add.
■Measurement method of the engine oil: when measuring, Cars should be parked
horizontally, after the oil level of oil is stable, pull out oil dipstick, wipe engine oil
with a clean cloth, then insert it in oil pan to measure the oil level The engine oil level
shall be kept in the middle and upper part of two scale lines of the oil dipstick. The
height of oil level should also be checked before leaving the vehicle and every driving
(300 ~ 500)km. If the oil quantity is insufficient, it should be added timely.
1.3.5 Engine Oil Filter
1. Disassembly and installation
1) Disassembly
Use special tools to disassemble the oil filter.
Caution:
■Use original JAC oil filter
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■The engine oil is very hot, be careful not to get scalded.
■When disassembling, prepare a cloth to dry the leaking or splattering engine
oil.
■Do not let the engine oil stick to the elastic belt.
■Thoroughly dry the engine oil spilled on the engine and the car.
2) Installation
1
Clean the filter installing surface
on oil filter bracket.
2
Replace the new oil filter: Apply a
small
amount of oil to the O-ring of the oil filter. When
the
O-ring of the oil filter contacts the flange of the
oil
filter bracket, use a special wrench to rotate one turn or equivalent to (22-28) N·m.
Caution:
■The oil filter must be tightened with the filter wrench.
■If the filter is tightened by hand, oil may leak due to insufficient tightening
torque.
2. Inspection after installation
1
）
After starting the engine without load and running for (2-3) min, then check the
interface between filter and bracket ,engine oil should not leak.
Turn off the engine and wait for 10min,then check whether or not the oil level is
between the upper and lower scale. If the oil is insufficient, please add.
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1.3.6 Oil pan and Oil pump
1. Disassembly
1
）
Discharge engine oil.
2
）
Remove oil pan.
a.Loosen the retaining bolt in the order
of
both sides first and middle.
b.As shown in the figure, tap in a special
tool between the oil pan and the cylinder block.
c.Tap the side of the special tool and move the tool along the oil pan/cylinder
block sealing face, then remove the oil pan.
Note:
■ Be careful not to damage mating surfaces.
3
）
Remove engine oil suction filter
■Tightening torque: (8.4±0.6) N·m
4
）
Remove oil pump housing.
2. Inspection after disassembly
1
）
Engine oil suction filter
■Clean the attachment clearly.
2
）
Oil pump housing
■ Check whether all the oil holes on the oil pump are clogged, and clean the holes
if it is necessary .
■Check the oil pump housing for cracks or other damage Replace it if necessary.
3. Engine oil pump
■ Check that the oil pump rotor is flexible and has no stuck.
3. Installation
1
）
Install oil pump housing.
■
Ensure the glue coating surface be clean, no oil, dirt, etc.
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■
Apply Dow corning 3-0115 surface sealant or equivalent products.
Refer to "Timing sprocket mechanism - oil pump housing installation".
2
）
Install crankshaft front oil seal.
■Place the special tool at the front
of
the crankshaft and apply engine oil to
its
periphery.
■Apply the engine oil to the sealing lip, then push the oil seal along the guide
sleeve by hand until it touches the front oil seal housing.
Tap the oil seal with a
special tool to put it in place.
4
）
Install engine oil suction filter.
5
）
Install oil pan.
■Before installing the oil pan, make sure the cylinder block
、
sprocket chamber
cover
、
the bottom end face of the oil seal bracket are clean
、
no machine oil
、
no dirt,
etc.
■Remove the remaining sealing glue of the previous process at the three-point
joint surface of the sprocket chamber cover, oil seal bracket and cylinder block, and
uniformly apply the new sealing glue on the joint surface. The diameter of the rubber
strip is
4mm.
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■Ensure the glue coating surface be clean, no oil, no dirt, etc.
■
Apply Dow corning 3-0115 surface sealant or equivalent products along
the center of glue tank on flange face of oil pan.
■The control method for the amount of glue applied is: combine the diameter of
the glue strip with its weight, and the diameter is: the diameter of glue strip in zone A
is 3mm±0.5mm. The diameter of glue strip in zone B is 4mm±0.5mm, as shown in the
figure below.
■Glue strip weight: The glue weight of each oil pan is controlled between 13g
to15g.
■Tightening method of oil pan bolts: follow the tightening from the middle to
both sides, as shown in the following sequence.
■First pre-tighten, then tighten to the specified torque:
（
11±1
）
N·m.
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6) Install oil drain bolts on oil pan.
■Tightening torque: (39±5) N·m.
7
）
Add engine oil with an amount of about 4L.
Caution:
■Wait at least 30 minutes after installing the oil pan before adding the engine
oil
4. Inspection after installation
1）Start the engine and make sure there is no oil leakage
2）Turn off the engine and wait for 10min,then check whether or not the oil level
is between the upper and lower scale. If the oil is insufficient, please add.
Gluing
positio
n and
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1.4 Engine cooling system
1.4.1 Cooling circuit
1. Cooling principle schematic
Cooling principle map
1.4.2 Engine Coolant
1. Inspection
1）Liquid level inspection
■ When the engine is cooled down, check if the engine coolant level in a range
from MIN to MAX.
■If necessary, adjust the engine
coolant
level.
■If the coolant level is too low,
check
for leakage.
2）Leakage inspection
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Apply pressure on the cooling system to 120kPa by the radiator cap leak detector
to check and confirm that the pressure has not decreased If the pressure drops, check
hoses
、
radiators and water pump for leaks.
If no external leakage is found,
checkthe heating core, cylinder block and cylinder cover.
Caution:
■Do not remove the radiator cap when the engine is hot; otherwise, the
high-pressure engine coolant escaping from the radiator can cause serious burns.
■ Exceeding test pressure may damage the heat sink.
■When engine coolant decreases, add engine coolant to the radiator. If parts
are found damaged, please repair or replace them.
3
）
Coolant quality inspection
Check the quality of the antifreeze. If there is turbidity, deterioration, odor,
foaming, etc., you need to replace the coolant and clean the water channel.
2. Engine coolant replacement
Caution:
■To avoid burns, do not replace the coolant when the engine temperature is
high.
■Cover the radiator cap with a thick cloth and unscrew it carefully. Release the
pressure inside the radiator and then completely unscrew the cover.
■Be careful not to spill engine coolant on the drive belt.
1
）
Discharge the engine coolant
1
Open the radiator drain plug at the bottom of the radiator and open the
radiator cap.
2
Check the engine coolant for iron rust and other impurities or discoloration
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2
）
Refill the engine coolant
1
Install the removed tank and radiator drain plug.
Caution:
■Be sure to clean the drain plug and install a new O-ring.
2
Confirm that each hose clamp is firmly tightened.
3
Disconnect the warm air outlet hose. Raise the hose as high as possible
4
Fill the radiator and reservoir with coolant to the specified level.Slowly add
the engine coolant so that the air in the system is gradually discharged.
Caution:
■Use the original JAC engine coolant. Refer to “Recommended oil/liquid and
lubricants”.
■Reconnect and continue filling engine coolant when engine coolant overflows
blower water outlet hose.
5
Install the radiator cover.
6
Warm to open the thermostat.
Make sure the thermostat is open by touching the radiator down pipe to feel if
there is any warm water coming out.
Caution:
■Check the engine water temperature indicator to avoid overheating.
7
Turn off the engine to reduce the temperature.
8
The engine coolant in the tank was added to the MIN to MAX range.
9
install the radiator cap and Repeat ③～⑧more than twice with
until the engine coolant level no longer drops.
10
Run engine check cooling system for leaks.
3
）
Flush the cooling system
Caution:
■Be sure to clean the drain plug and install a new O-ring.
1
Disconnect the blower water outlet hose. Raise the hose as high as possible.
2
Add engine coolant to the radiator and reservoir and install the radiator cap.
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3
Reconnect and continue filling engine coolant when engine coolant
overflows warm air outlet hose.
4
Run the engine to preheat to normal working temperature.
5
Speed up the engine speed several times under no-load condition.
6
Turn off the engine and wait for cooling.
7
Drain water from the system. Refer to “Drain engine coolant”.
8
Repeat steps
①～⑦
until the radiator begins to drain clear water.
1.4.3 Water pump
1. Disassembly and installation
Caution:
■When removing the pump, be careful not to spill engine coolant on the drive
belt.
■The water pump cannot disintegrate and should be replaced as a whole.
■After installing the pump, connect the hose and fix it with a clamp, then use
the radiator cap leak detector to check for leakage.
1) Disassembly
1
Drain engine coolant from the radiator. Refer to “Engine coolant
replacement”.
2
Loosen the fixing bolt of water pump belt pulley.
■Tightening torque: (8.4±0.6) N·m.
3
Remove the elastic belt.
4
Remove the fixing bolt of water pump.
■Tightening torque: (8.4±0.6) N·m.
2) Inspection after disassembly
■Check the water pump assembly for serious corrosion, water seal leakage or
corrosion.
■Check for excessive end clearance resulting in poor work.
■Check whether the pump bearing is stuck or has other damage. Please replace it
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if necessary.
3) Installation
1
Clean the water pump sealing surface.
2
Install the water pump.
■Tighten each fixing bolt evenly and alternately.
3
Install the water pump belt pulley.
4
Install the drive belt and adjust it to the specified tension.
5
Fill the engine coolant.
2. Inspection after installation
■Use the radiator cap leak detector to check for leakage.
■Start and warm up the engine. Visually check engine coolant for leakage.
1.4.4 Thermostat assy.
1. Disassembly and installation
1) Disassembly
1
Drain engine coolant from the radiator water drain plug.. Refer to “Engine
coolant replacement”.
Caution:
■Be sure to operate after the engine is cooling.
■Do not let engine coolant splash on the drive belt.
2
Disconnect the radiator inlet and outlet pipes and short circle pipes on the
side of the thermostat housing
3
Disconnect the wire harness connector of the coolant temperature sensor and
the water temperature attention switch, and the fixing bolt of the fixing bracket of the
front and rear oxygen sensor wire harness connector and remove them.
4
Remove the fixing bolt of the warm air water return pipe and remove the
pipe.
5
Remove the fixing bolts of thermostat upper cover and remove the
thermostat.
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2
）
Inspection after disassembly
1
Thermostat
■Check the throttle valve opening
at
normal room temperature
The opening temperature of the
thermostat:
82C
（
open start
）
,95C
（
full open
）
.
Maximum lift of valve rod
：
≥8mm
The closing temperature of the thermostat
：
>77C
If the measured value exceeds the specified range, please replace the thermostat.
2
thermostat upper cover and thermostat housing
Check for cracks or other damage.
3) Installation
Please note the following items and install in the reverse order of disassembly.
1
Be careful not to spill engine coolant on the engine. Use a cloth to dry the
engine coolant.
2
Replace the "O" ring of water inlet pipe with the new "O" ring, and then
apply the coolant to the "O" ring so that they can be easily embedded in the water
pump and thermostat housing.
Caution:
■Do not apply engine oil or other oil substances to the “O” ring.
■The water pipe behind the thermostat housing must be securely installed.
3
When installing a thermostat, keep its jump valve in the highest position.
4
If the water temperature sensor is to be reused, the specified sealant should
be applied to its threads.
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■Specified sealant
：
Tonsan 1243 thread sealant.
2. Inspection after installation
■Use the radiator cap leak detector
to
check for leakage. Refer to
"Leakage
Inspection"
■Start and warm up the engine.
Visually
check engine coolant for leakage.
1.4.5 Water pipe assy.
1. Disassembly
1
Drain engine coolant from water drain plug at the bottom of the radiator
Refer to “Engine coolant replacement”.
Caution:
■Be sure to operate after the engine is cooling.
2
Remove the radiator upper and lower water hose
3
Remove warm water hose and short circle hose.
4
Remove the inlet pipe fixing bolt and remove the water inlet pipe from the
back end of the water pump.
Caution:
■Before disassembling, remove the battery negative terminal first
2. Installation
Please note the following items and install in the reverse order of disassembly.
1
）
Firmly insert each hose Install the clamp ring, and the clamp ring will not
clamp the boss of the pipe
2
）
Replace the "O" ring of water inlet pipe with the new "O" ring, and then apply
the coolant to the "O" ring so that they can be easily embedded in the water pump and
thermostat housing.
Caution:
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■Do not apply engine oil or other oil substances to the “O” ring.
■The water pipe behind the thermostat housing and water pump must be
securely installed.
3. Inspection after installation
1) Use the radiator cap leak detector to check for leakage.
2) Start and warm up the engine. Visually check engine coolant for leakage.
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1.4.6 Common fault analysis
Analysis of overheating
Symptoms Inspection items
C
o
o
li
n
g
s
y
st
e
m
c
o
m
p
o
n
e
n
ts
f
a
il
u
r
e
Bad cooling
Water pump
failure
Drive belt worn or
loose
—
Thermostat stuck
in closed position
The heat sink is
damaged
Dust or paper
jammed
Mechanical damage
Radiator cooling
tube blocked
Excessive foreign
matter (corrosion,
dirt, sand, etc.)
Insufficient air flow
Cooling fan does
not work
Fan assembly —
Fan rotation
resistance
is too large
Fan blades
damaged
Windshield damaged — — —
Incorrect mixing ratio
of coolant
— — —
Engine coolant
quality
is poor
—
Engine coolant is
viscous
Engine coolant is not
sufficient
Engine coolant
leakage
Coolant hose
Clamps
loose
Hose
ruptured
Water pump Poor sealing
Radiator cover
is loose
Poor sealing
Radiator
O-ring
damaged,
aged or
incorrectly
installed
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Radiator
Water tank
Belt
raptured
Radiator
core
cracked
Fluid reservoir
Fluid
reservoir
Damage
Kettle spill
Exhaust gas leaked
to the cooling
system
Cylinder
head aging
Cylinder
head
gasket
aging
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.
P
a
rt
s
o
t
h
e
r
t
h
a
n
c
o
o
li
n
g
s
y
st
e
m
m
a
lf
u
n
c
ti
o
n
— Engine overload Abnormal driving
Engine
speed is too
high under
no-load
conditions
Long time
driving
Over speed
driving
— —
Transmission
system failure
—
Incorrect size
wheels and tires
installed
—
Braking retardation
Ignition timing is
incorrect
Poor air circulation
Bumper vents
blocked
—
—
Radiator grille
blocked
Car cover installed
Dust or paper
jammed
Radiator jammed —
Condenser
clogged
Poor air circulation
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1.5 Engine emission control system
1.5.1 Fuel evaporation system
1. System description
Fuel evaporation system map
Fuel evaporation system theory map
The fuel evaporation system is used to reduce hydrocarbon emissions from the
fuel system into the atmosphere. Use activated carbon in EVAP tanks to reduce
hydrocarbon emissions. When the engine is not running or refueling to the tank, the
vapors from the sealed tank are guided into the EVAP tank with activated carbon and
stored there. When the engine is running, the fuel vapor in the EVAP carbon tank is
carried into the intake manifold through the clean line. EVAP Carbon canister
solenoid valve is controlled by ECM. When the engine is working, the steam flow
controlled by the EVAP carbon tank solenoid valve is adjusted proportionally to the
increase of air flow.
Air filter
Air
Tank
EVA
EVAP
Carbon
air
Fuel
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2. Fuel evaporation exhaust pipeline map
Fuel evaporation system map
1-Carbon can assembly 2-Engine oil inlet hose 3-Carbon canister solenoid valve tube
4-Carbon canister solenoid valve hose
5-Engine oil inlet pipe 6-Fuel filter
Caution:
Do not use soapy water or any cleaner when installing vacuum tubes or
cleaning tubing.
3. Component inspection
1
）
EVAP Carbon canister solenoid valve
Steam by-pass line opening of EVAP Carbon canister solenoid valve controls
airflow rate. According to the signal sent by ECM, the EVAP carbon canister solenoid
valve repeatedly opens/closes (ON/OFF), and the valve opening changes to achieve
the best engine control. The optimal value stored in the ECM is determined by the
different states of the engine. When the engine is running, the airflow rate of fuel
steam from EVAP carbon canister is adjusted with the change of air flow.
1
Component description
2
5
3
4
1
6
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The EVAP carbon canister solenoid valve uses the ON/OFF duty ratio to control
the flow rate of fuel steam out of the EVAP carbon canister. The EVAP carbon
canister solenoid valve is driven by an open /OFF (ON/OFF) duty ratio signal sent
from the ECM. The longer width of the (ON) pulse, the more fuel vapor will flow
through the valve.
2
Disassembly
a.Disconnect the vacuum hose of the EVAP carbon canister solenoid valve.
b. Disconnect the wire harness connector of the EVAP carbon canister solenoid
valve.
c.Take down the EVAP carbon canister solenoid valve from air inlet manifold
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bracket.
3) Oil filler cover
A vacuum relief valve is installed on oil filler cover When the pressure in the
fuel tank is high (more fuel vapor), the vacuum relief valve is closed to prevent the
fuel vapor from escaping into the atmosphere. When the pressure in the fuel tank is
low (negative pressure), the vacuum relief valve opens to allow the outside air to enter
the fuel tank.
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1.5.2 Crankshaft box force ventilation system
1、System instruction
Crankshaft box force ventilation system map
1-Air filter 2-air inlet hose 3-throttle valve body
4-purification can 5-PCV valve
6-PCV valve connecting hose 7-Air inler manifold 8-Injector
The crankcase forced ventilation system is designed to send the cylinder air back
to air inlet manifold
The crankcase forced ventilation valve(PCV) is designed to send the cylinder air
back to air inlet manifold. When the throttle of the engine is partially opened, the air
inlet manifold is sucked into crankshaft box air through the PCV valve. Normally, the
PCV valve has enough air volume to fully inhale the crankshaft box air and a small
amount of ventilation air. ventilation air is drawn into the crankshaft box from the air
inlet pipe In this process, the air passes through a hose that connects air inlet pipe to
the rocker chamber cover. When the throttle of the engine is fully opened, The
vacuum of the air inlet manifold is not sufficient to open the PCV valve and inhale the
crankshaft box air. The air will flow in the opposite direction through the connecting
hose. The PCV valve cannot meet the requirements in a vehicle with a particularly
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severe gas leakage. because in any case a portion of the gas will pass through the hose
to the air inlet pipe.
2
、
Component inspection
Inspect the PCV (Crankshaft box force ventilation) valve as follow:
1) Working principle:
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PCV valve working principle table
Engine working Out of action Engine working Idle or decelerate
PCV valve Not working PCV valve Fully open
Vacuum degree Limit Vacuum degree Slightly
Engine working Working normally Engine working Acceleration and
PCV valve Working normally PCV valve Working slowly
Vacuum degree Large amplitude Vacuum degree Very large
2) Disassembly
1
Disconnect the respirator vent tube from the head cover.
2
Remove the PCV valve from the cylinder cover guard side.
Vacuum is
Cylinder
No
Cylinder
No
Cylinder
High
Cylinder
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3) Inspection after disassembly
1
PCV valve
A normal working valve makes a hissing noise when airflow passes. When your
finger is at the entrance of the valve, you immediately feel a strong vacuum pressure.
2
Respirator ventilation tube
a.Check hoses and hose connections for leaks
b.Disconnect all hoses and clean with compressed air. If the plug in the hose
cannot be removed, replace it.
4) Installation
1
Install the PCV valve.
■
Tightening torque is about 4N; it cannot be too big.
2
Install the respirator air duct.
■
Pay attention to the direction of installation.
Connect
the PCV
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Chapter 2 Engine Electric Appliance
2.1 Ignition system
2.1.1 Ignition coil
1
．
Element
2
．Disassembly and installation
1）Disassembly
Note: Confirm that the start switch has been on OFF position.
1
Remove the engine intake manifold.
2
Disconnect the connection between the wire harness connector and the high
voltage ignition coil from the ignition coil.
3
Remove high voltage ignition coil bolts and remove high pressure ignition
coil.
■Tightening torque: (9±1) N·m
4
Use spark plug sleeve to remove spark plug
■Tightening torque:30~30N·m
Note: do not drop or shake spark plugs
2）Check after disassembly
1
High voltage ignition coil
■Check the primary coil resistance between the terminal, the primary coil
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resistance: 0.77～0.66Ω
2
Spark plug
Check spark plug.
a. Check whether or not the thread or insulator of the spark plug is damaged or
broken
b. Check the spark plug for carbon deposits, oil or oil deposits. Normal spark
plug porcelain heads are between white and yellowish, gray or brown
c. Check if the spark plug electrode is damage.
d. Check spark plug clearance with a plug gauge. Standard clearance:
0.8-0.8mm
e. Check arcing ability of spark plug.
Remove the spark plug and put it on the cylinder cover. Connect the high-voltage
wire to the spark plug terminal for arcing test. Peaking and blue light from spark plugs
indicates that they work well.On the contrary, it indicates that the spark plug is not
working well.
3
）
Installation
Follow the opposite sequence of the demounting sequence.
2.1.2 Common fault diagnosis
Fault symptoms Possible causes Solution
Engine can not be
started
or is hard to start
Ignition coil or switch
fault
Check or replace ignition coil
or ignition switch
Spark plug fault
Check and replace the spark
plug
The high-voltage line
is
disconnected or not
connected
Check high voltage line
Engine idling unstable
High voltage wire or
spark
plug malfunction
Check high voltage wire or
check and replace
the spark plug
Ignition coil malfunction Check or replace ignition coil
The engine is wheezing
or weak in acceleration
High voltage wire
malfunction
Check or replace high voltage
wire
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Spark plug fault
Check and replace the spark
plug
Poor fuel economy Spark plug fault
Check and replace the spark
plug
2.1.3 Maintenance parameters
Ignition coil
Primary coil
resistance
0.51Ω
～
0.66Ω
Spark plug Sparking plug gap 0.8-0.9mm
2.2 Starting and charging system
2.2.1 Storage battery
1.Method to prevent battery over-discharge:
1) Keep the battery surface (especially the top) clean and dry at all times.
2) The connection part of the port should be cleaned and tightened
3) If the car is not in use for a long time, the negative terminal of the battery
should be disconnected.
4) Check the charging status of the battery
2.Check
1) Visual inspection: check whether the battery terminal is damaged, whether
the electrolyte is leaking, if any, please replace it.
2) Voltage Inspection:
① If U>13.2V, please check the electrical system.
② If 12.5V<U<12.9V, system is normal.
③ If 11V<U<12.4V, please check the charging system.
④ If U<11V, it indicates that the battery is damaged or the charging system is out
of order. Please check the charging system and the battery.
3.Disassembly and installation
1) Disassembly
■The ignition switch should be switched to the "OFF" position.
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① Disconnect the negative terminal.
② Remove the battery positive terminal, the battery pressure plate fixing bolt,
take out the pressure plate.
③Take down storage battery.
④ Take down the battery tray.
2) Inspection after disassembly
① The battery tray.
■Check for corrosion Please clean it with clean hot water.
② Battery wire harness
■Check for wear and tear or damage. Replace it if necessary.
3) Installation
Follow the opposite sequence of the disassembly procedures.
Caution:
■When connecting, the positive terminal of the battery should be connected
first.
■After installation, mineral oil can be applied to each terminal post.
2.2 Starting system
1.Start system description: switch on → switch to turn on the switch screw (while
the fork will drive the gear to mesh with the flywheel) →
battery positive (+) terminal power supply, main current from the positive brush into
the commutator → rotor coil forming circuit (Return to the negative electrode
grounding) → Rotate the rotor under the action of a magnetic field → (drive the
planetary wheel to rotate) → The pinion moves forward along the drive shaft spline
→ The gear drives the flywheel to rotate → The engine starts to work.
2.Disassembly and installation
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1) Disassembly
① Disconnect the battery negative terminal.
② Disconnect the starter harness connector.
③ Remove the starter fixing bolts and remove the starter.
Note: Unplug the vehicle key before disconnecting the battery negative terminal.
2) Installation: Install in the reverse order of disassembly.
Note: Be sure to tighten the “B” end nut.
S
termi
M
termi
B
termi
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3. Failure mode
NO Fault model
1 Starting noise
2 The starter does not turn
3 Weak start of the starter
4 The starter turns non-stop
5 The starter is idling and slipping
6 Other faults
4.Troubleshooting and precautions
1) Abnormal sound
NO Sequence Inspection Precautions
1
Confirm the fault
phenomenon of the
customer
description
Start the vehicle and
confirm the abnormal
sound of the customer
description
Please confirm it in
a relatively quiet
environment.
2
Listen to the
start sound
Judgment:
1) Abnormal sound of
the starter gear
meshing with the
flywheel;
2) Abnormal sound of
the internal motor of
the starter
1) Abnormal sound of
the starter gear
meshing with the
flywheel
2) Replace it when
it is determined
that the abnormal
sound of the
internal motor of
the starter is
running.
3
Check the engine
flywheel
Visually inspect the
engine flywheel for
wear and missing teeth
Turn the flywheel
and check the tooth
flank and side of
the flywheel.
Replace if there is
wear or missing
teeth.
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4
Check the starter
gear
Visually inspect the
starter gear for wear
and missing teeth
Turn the starter
gear, one direction
is the lock
direction, the
other direction can
be rotated, check
the face and side.
Replace if there is
wear or missing
teeth.
5
Check the meshing
condition of the
starter gear and
the flywheel
When the one-way
device is not engaged
with the flywheel, it
operates when it comes
into contact with the
flywheel. The
distance between the
one-way device and the
flywheel is large, and
the axial distance
between the gear and
the flywheel should be
kept at 3 to 5 mm. (The
axial distance is too
close and too far will
produce abnormal
sound, gear damage)
Check if the starter
fixing screw is
loose, and the
mounting surface of
the engine and
starter should not
be rusted or
stained.
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2) The starter does not turn
NO Sequence Inspection Precautions
1
Confirm the fault
phenomenon of the
customer
description
Start the vehicle,
confirm the fault
phenomenon described
by the customer, and
confirm the frequency
and phenomenon.
Please pay
attention to
confirm the
previous
maintenance status
and maintenance
records.
2
Check the starter
S terminal wiring
Make sure the S
terminal plug that
connects the starter
to the car starter
switch is in place.
If the starter S
terminal plug is
found to be loose,
please re-plug and
re-start to
confirm.
3
Check battery
voltage without
starting
Check the battery
voltage, the general
voltage
is around 12.5~12.9V
Insufficient
voltage will make
the starter fail to
meet the design
output power.
Please charge or
replace the
battery.
4
Check the starter
terminal voltage
without starting
the vehicle
Check the voltage of
the starter terminal,
that is, the positive
pole B terminal of the
starter power supply
and the negative
voltage of the casing,
and the detection
voltage is equal to
the battery voltage.
If the detection
voltage is not equal
to the battery
voltage, please
check the battery
positive and
negative wiring,
and the generator B
terminal wiring
status.
5
Check battery
positive and
negative wiring,
starter B terminal
wiring status
Check the positive and
negative wiring of the
battery and the wiring
condition of the B
terminal of the
starter. There must be
no slack or rust.
Repair the battery
positive and
negative terminals
and the starter B
terminal wiring
status.
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6
Check the line for
damage and
grounding
Check harness damage,
grounding
The harness is
broken, grounded,
and the voltage
applied to both ends
of the starter is
insufficient,
causing the starter
to operate at low
voltage for a long
time.
7
Check if the
electromagnetic
switch part of the
starter is faulty.
When rotate the
ignition lock, there
is a suction sound:
this is normal!
When rotate the
ignition lock, there
is no suction sound:
this is abnormal!
Abnormal possible
causes: A.
Electromagnetic
switch part; B.
Ignition lock, start
relay, wiring part.
Unplug the ignition
harness from the S
terminal of the
starter
electromagnetic
switch and connect the
S switch of the
electromagnetic
switch to the battery:
(No suction sound, the
starter gear does not
extend. Judgment: A.
Part of the
electromagnetic
switch is faulty!
(There is a suction
sound, the starter
gear extends.
Judgment: A. The
electromagnetic
1) The
electromagnetic
switch is faulty,
please replace the
starter.
2) Ignition lock,
start relay, wiring
part failure
reasons.
Please continue to
find the fault
causes!
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switch is normal! B.
Ignition lock, start
relay, wiring part
failure!
8
Check if the motor
part of the
starter is faulty
Connect the starter M
terminal to the
battery:
1) Part of the motor is
running: this is
normal!
2) The motor part does
not run: this is
abnormal! Starter
internal failure
1) If the motor is
partially faulty,
please replace the
starter.
2) Confirm that the
newly replaced
starter is started
normally.
9
Detect the removed
starter again
Use the battery to
detect the removed
starter again:
1) Connect the S
switch of the
electromagnetic
switch to the battery
to detect the
electromagnetic
switch part of the
starter;
2) Connect the M
terminal of the
starter to the battery
and check the motor
part of the starter.
Test the removed
starter again
to prevent false
judgment.
3) Weak start of the starter
NO Sequence Inspection Precautions
1
Confirm the fault
phenomenon of the
customer
description
Start the vehicle,
confirm the fault
phenomenon described
by the customer, and
confirm the frequency
and phenomenon.
Please pay
attention to
confirm the
previous
maintenance status
and maintenance
records.
2
Check battery
voltage without
starting
Check the battery
voltage, the general
voltage
Insufficient
voltage will make
the starter fail to
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is around 12.5~12.9V meet the design
output power.
Please charge or
replace the
battery.
3
Check the starter
terminal voltage
without starting
the vehicle
Check the voltage of
the starter terminal,
that is, the positive
pole B terminal of the
starter power supply
and the negative
voltage of the casing,
and the detection
voltage is equal to
the battery voltage.
If the detection
voltage is not equal
to the battery
voltage, please
check the battery
positive and
negative wiring,
and the generator B
terminal wiring
status.
4
Check battery
positive and
negative wiring,
starter B terminal
wiring status
Check the positive and
negative wiring of the
battery and the wiring
condition of the B
terminal of the
starter. There must be
no slack or rust.
Repair the battery
positive and
negative terminals
and the starter B
terminal wiring
status.
5
Check the line for
damage and
grounding
Check harness damage,
grounding
The harness is
broken, grounded,
and the voltage
applied to both ends
of the starter is
insufficient,
causing the starter
to operate at low
voltage for a long
time.
6
Check the
condition of the
starter gear and
the flywheel
Visually inspect the
engine flywheel for
wear and missing teeth
Replace if there is
wear or missing
teeth.
7
Inspect the
meshing condition
Check if the one-way
pinion and flywheel
mesh are normal
When the meshing is
abnormal, please
confirm that the
axial distance
between the gear and
the flywheel should
be 3 to 5 mm.
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8
Check ignition
system and fuel
supply system
Please check the
ignition system and
fuel supply system
Repair or replace
9
Change to another
starter to test
Change to another
normal starter to test
the start:
1) Normal. The
original starter may
be damaged internally
and the performance is
low;
2) Abnormal. The
engine part may be
faulty and the
starting load is
large.
Before changing the
normal starter,
please compare the
original starter
with the normal
starter. Connect
the M terminal of
the starter to the
battery. If there is
a significant
difference between
the sound and the
speed, perform the
replacement test.
10 Engine inspection
If another normal
starter is used after
the test start, if the
speed is still slow
and the start is weak,
please check the
inside of the engine,
such as: injector
failure, engine lock,
etc.
If the engine is
heavily loaded, it
will cause the
starter to fail to
start the engine.
4) The starter turns non-stop
NO Sequence Inspection Precautions
1
Confirm the
fault
phenomenon
of the
customer
description
Start the vehicle, confirm
the fault phenomenon
described by the customer,
and confirm the frequency and
phenomenon.
Please pay
attention to
confirm the
previous
maintenance
status and
maintenance
records.
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2
A.
Electromagn
etic switch
part
detection
Use a multimeter to measure
the starter electromagnetic
switch B, M terminal, do not
turn the ignition lock:
1) The electromagnetic switch
B and M terminals are turned
on, the electromagnetic
switch contacts are
connected, and the starter is
faulty.
2) The electromagnetic switch
B and M terminals are not
conducting, then: the
starting part of the line is
normal; please check the
ignition lock, start relay,
line short circuit, etc.
NG after the
electromagnetic
switch contact is
connected,
indicating that
the starter has a
fault, please
replace the
starter.
3
B. Ignition
lock, start
relay,
wiring part
detection
Unplug the ignition harness
from the S terminal of the
starter solenoid switch and
measure the ignition harness
connector with a multimeter:
1) Turn the ignition lock and
the plug should be turned on;
2) The ignition lock is
returned and the plug should
not be turned on;
3) When an abnormal condition
is found, please check the
ignition lock start relay
line short circuit condition
The ignition lock
and the start
relay are stuck
and the return
fault is difficult
to reproduce.
Please test it
several times!
5) Idling and slipping
NO Sequence Inspection Precautions
1
Confirm the
fault
phenomenon of
the customer
description
Start the vehicle,
confirm the fault
phenomenon described by
the customer, and
confirm the frequency
and phenomenon.
The idling and
slipping of the
starter is a process of
gradually increasing
the frequency. At
first, there may be
idling and slipping
after several dozen
starts. In the future,
there may be one idling
and slipping after ten
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starts. Finally, there
may be one idling and
slipping several
times.
2
Confirm the
idling and
slipping
Confirm: Start the
starter and see the
meshing condition
between the starter and
the flywheel. If the
gear is found to be
engaged with the
flywheel after the
starter is energized,
the starter sound is
heard, but the gear does
not run on the flywheel,
it can be judged as the
starter idling and
slipping
Note: When starting
the machine
continuously and
repeatedly, pay
attention to stop for
30 seconds between two
times, let the starter
properly cool down, so
as to avoid frequent
starter overheating
and ablation.
3
Remove the
starter to
check the
idling and
slipping
Rotate the starter
gear: If both
directions can be
rotated, or both
directions cannot be
rotated, it can be
determined that the
starter one-way device
is idling and slipping;
if one direction can be
locked, the other
direction is not smooth
or stuck, it can be
determined that the
starter one-way device
is idling and slipping.
It can be carried out
by other normal parts
comparison inspection
methods.
6) Other faults
NO Sequence Inspection Precautions
1
Damaged
appearance
Check the starter switch
cover is broken, the
mounting end cover is
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broken, the gear shaft is
broken, the lead is
broken, etc.
2
Check to
confirm if
there is any
self-demoliti
on
Check whether the screws
of the starter are
screwed, the missing
parts (demolition marks),
whether the screws, nuts,
electromagnetic
switches, and one-way
gears are replaced with
different parts.
Please discern
carefully.
3
Check the
starter's
immersion
marks
The overall rust and mud
of the starter
Due to the use of the
environment, the
surface of the
starter is dusty and
oily. Please pay
attention to the
overall rust and
muddy phenomenon of
the starter. It may
be a long-term
immersion mark on
the starter.
2.2.3 Charging System
1. System description
the generator provide the direct current to the vehicle electric system and keep
the charging state of the battery. The output of the voltage is controlled by IC
regulator.
When the ignition switch is connected, the current flows into magnet exciting
coil, the magnet exciting coil is initially stimulated. After the generator is started, and
when the stator coil begins to generate, the magnet exciting coil outputs the current
stimulation through the stator coil. Terminal B provides the electricity to the vehicle
electric system, and provide the charging power supply to the battery. IC regulator
checks the input voltage at the S terminal, and control the output voltage through this.
If the exciting current enlarges, the output power of the alternating generator also
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enlarges, if the exciting current decreases, the output power of the alternating
generator also decreases. When the battery voltage (the voltage of the alternating
generator S terminal) reaches about 14.4V adjusting voltage, the exciting current is
cut down. When the battery voltage decreases under the regulating voltage, the
voltage regulator adjusts the output voltage through controlling the exciting current to
keep it the constant level.
1.W-engine speed line 2.IG-Excitation line 3.L-to indicator light 4.S-Signal
output terminal 5.B+—Connected generator battery
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2. Charging attention lamp
1）When the ignition switch opens and the engine does not start
the power supply goes through the inner fuse box to instrument charging
indicator lamp terminal to instrument terminal, through the generator L terminal to E
terminal grounding, the charging indicator lamp will light on in this time.
2）After starting the engine
when the generator can generate normally, the power supply terminal of the
charging indicator lamp is close to the voltage of the L terminal, the charging
indicator lamp lights off. If the charging indicator lamp still lights on when the engine
runs, it means that there is some faults.
If the generator produces no voltage or over-high voltage in working, the indication
function of the IC regulator will open and light on the charging indicator lamp.
3.Disassembly and installation
1) Disassembly
① Disconnect the battery negative terminal;
② Disconnect the generator harness connector;
③ Remove the elastic belt;
④ Loosen the generator fixing bolt and remove the generator from the vehicle.
2
）
Installation
■Install in reverse order of removal.
■Install the generator and install the elastic belt
"B" terminal nut tightening torque 10 ~ 12N · m
4. Common faults of charging system
■No electricity generating
■Generator charging indicator light is always on
■Charger voltage is too low
■Charger voltage is too high
■The generation voltage is unstable
■Abnormal sound
■Generator electric leakage
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5.Charging system inspection process
Caution:
■If the charging system fails but the test result is normal, check the "B" port
connection (check the tightening torque and voltage drop).
Check items as
follow:1. the
lamp bulb 2.
the lamp fuse
Ignition
switch ON
Charging
Disconnect
the joint and
ground the L
Charging
Charging
Charging
Check
items as
follow:1.
rotor
2.Rotor
IC regulator is
damaged;replac
e it
►Engine
starts,
rotation
speed is
Charging
Check
items as
follow:1.
drive
belt 2.
Generator
3.generat
Engine
idling
Charging
Norma
Charging
Charging Norma
Engine
rotation
speed is
2200
rpm,Measure
More than
IC
regulator
is
Less than
Check items as
follow:1.Rotor
2.Rotor
sliding ring
Damaged IC
regulator
or diode
assembly.Re
place it.
Attention lamp: the "charge" attention
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Chapter 3 Engine Electronic Control
System
3.1 Attentions
3.1.1 Common maintenance precautions
All the failures in electronic control system sensors, actuators, control circuits,
ECM and other components will have some impact on the operation of the engine.
Because the ECM has fault self-diagnostic capabilities, the computer tester can be
connected to the ECM for troubleshooting to identify the cause of the fault in the
electronic control system by reading the fault code or data flow.
In order to improve the reliability of the engine electronic control system work,
most of the system components are structurally designed to be sealed,
indecomposable, damaged and can not be repaired. The main task of electronic
control system maintenance is to find faulty parts of the system, and replace the faulty
parts.
When servicing the electronic control system, the following precautions must be
taken to avoid damage to the ECM or control components.
1. Only the use of automotive diagnostic tools can be taken to check the
electronic control system (such as digital multimeter, automotive oscilloscope and car
diagnostic, etc.).
2. Please use genuine JAC parts in maintenance operations, otherwise it can not
guarantee the normal work of the system.
3. Only unleaded gasoline can be used during maintenance and use.
4. Please follow the standard maintenance diagnosis process for maintenance
operations.
5. It is prohibited to operate the disassembly work on the system in the
maintenance process.
6. You must be very careful to pick and place electronic components (electronic
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control module, sensors, etc.) and do not let it fall.
7. Establish awareness of environmental protection, and effectively handle the
waste generated during the maintenance process.
8. Do not remove or plug in the ECM's harness plug when the ignition switch is
on, to prevent the inductive components in the electronic control system from
generating induced voltage during the power-off or power-on instant, causing damage
to the ECM.
9. The ECM harness connector should be securely connected, or the ECM may
be damaged.
10. When dismantling the battery or use an external battery across the start, you
must first turn off the ignition switch, and then you can make the folded or
cross-connect operation. Pay special attention to the battery that can not be connected
reversed.
11. When the battery connector is not tightened, never start the engine. Also do
not remove the battery cable while the engine is running. Otherwise it will make the
engine charging voltage too large, damaging the electronic control system
components.
12. When turning the engine to check the cylinder compression pressure, please
cut off the injector power or unplug all the injector harness connector to prevent the
fuel injected into the exhaust without examination, resulting in three-way catalytic
converter damage.
13 . When the ignition system is inspected , the spark detection shall be carried
out only if necessary , and the time shall be as short as possible , otherwise a large
amount of unburned gasoline will enter the exhaust pipe and damage the three-way
catalyst converter.
14. Do not allow the ECU temperature to exceed 80 ° C while performing
thermal condition simulations of faults and other maintenance operations that may
raise the temperature.
15. Removal of tubing and replacement of fuel filters should be carried out by
professional maintenance personnel in well-ventilated areas.
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16. Prohibit the use of piercing wire skin to detect the input and output
components of the electrical signal.
3.1.2 Diagnostic tool
■Tool name: electrospray system diagnostic instrument
Functions: read/clear the fault code of the electrical spraying system, observe the
data flow, test the action of parts, etc.
■Tool name: digital multimeter
Function: check the voltage, current, resistance and other characteristic
parameters in the electrospray system.
3.1.3 Engine OBD System Cautions
The Electronic Control Module (ECM) comes with an on-board diagnostic
system that lights up when there is mulfunction caused by the aging exhaust system.
■ Before performing any repair or inspection work, please turn the ignition
switch OFF and disconnect the battery negative terminal. Open or short circuits in
associated switches, sensors, and solenoid valves will cause the fault indicator to light
up.
■ After work, be sure to connect and reliably lock the connector. Loose
(unlocked) connectors may open the circuit and cause the fault indicator to light.
(Make sure no dirt such as water, grease and other dirt on the connector, and the
connector pins are without bending, fracture, etc.)
■ After work, be sure to arrange and fix the harnesses correctly. If the bracket
interferes with the harness, it may cause a short circuit , causing the fault lamp to light
up.
■After work, make sure the rubber hose is connected If the rubber hose is not
connected properly, the failure indicator light may be turned on due to the failure of
EVAP system and fuel injection system.
■ Before returning the vehicle to the customer, be sure to clear the useless fault
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information in the ECM (repair has been completed).
■ Be sure to use a 12V battery as the power source.
■Do not disconnect the battery while the
engine is running.
■ Before connecting or disconnecting the
ECM harness connector, turn the ignition
switch to the "OFF" position and disconnect
the negative battery terminal. Or it may
damage the ECM because the battery is still
energizing the ECM even when the ignition switch is turned "OFF".
■ Before removing the parts, turn
the ignition switchOFF and disconnect
the negative battery terminal.
■ Do not disassemble the ECM.
■If a battery cable is disconnected, the
memory is returned to the ECM initial value.
ECM will begin to control itself based on the
initial value. When the battery port is disconnected, the running of the engine will
change slightly. But that does not mean there is a failure. Don't change parts for minor
changes
■ When connecting the ECM harness connector, push the lever to the bottom to
lock the ECM securely.
■ When inserting the pin connector into the ECU or removing it from the ECU,
be careful not to damage the pin port (bend or broken). When connecting the pin
connector, make sure the ECM pin port is not bent or broken.
■ Securely connect the ECM harness connector. Poor connection can cause very
high (ripple) voltage on the coil and capacitor, causing damage to the ECU.
■ Keep the engine electronic control system components and harness dry.
■ Even a small leak in the air intake system can cause serious malfunctions, so do
not easily replace the air intake pressure sensor.
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■ Do not shake the camshaft position sensor (phase) or crankshaft position
sensor(location).
■ When measuring the ECM with a circuit tester, do not contact the two gauges
together. The probe is inadvertently touched, resulting in a short circuit and damage to
the ECM power transistor.
■When measuring the input/output voltage, do not use the ECM grounding port.
Otherwise, the transistor of ECM may be damaged. Grounding except the ECM port
should be used;
■Do not use the fuel pump when there is no fuel in the fuel pipe;
■Tighten the fuel hose clamp to the specified torque
■ Do not step on the accelerator pedal during start-up.
■ Do not immediately increase the engine speed after starting.
■Do not accelerate before closing the engine
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3.2 Structure Principle and Maintenance of the Engine Control
System
3.2.1 System description
The picture shows the control system diagram, such as sensor location and
physical discrepancies, please prevail in kind.
3.2.2 Electronic control system components
1.Fuel injection system
The timing and width of the fuel injection are controlled to provide the best
air/fuel mix ratio for the engine, which is suitable for changing engine operating
conditions. Oil injectors are installed at the inlet of each cylinder Fuel is pumped out
of the fuel tank by the fuel pump and distributed to each injector Under normal
circumstances,it will spray fuel to each cylinder every two revolutions of the
crankshaft. The working order of each cylinder is 1-3-4-2.
2.Ignition control system
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The ignition system consists of ignition switch, ECU and ignition coil,
The sensors related to ignition control include crankshaft position sensor, inlet
temperature and pressure sensor,
water temperature sensor, throttle position sensor and so on.
The main function of the ignition system is to control working of ignition coil,
thus to control ignition advance angle of engine, which is one of the main control
functions of the engine electronic control system. According to the engine speed,
throttle opening, coolant temperature, inlet temperature pressure, knock sensor and
other operating conditions measured by various sensors, ECU calculates and selects
the ignition angle which is most suitable for the current working condition, which
make it have high fuel economy and power performance, reduce emission pollution
and prevent deflagration.
The ignition advance angle is determined and controlled by ECU according to
the signals of various sensors.
Closing angle is the angle that the crankshaft or camshaft turns on during the
current conduction of the ignition coil. Closing angle control also known as ignition
coil electrification time control. For inductive energy storage type ignition system, the
induction voltage produced by the ignition coil depends on the current of the primary
coil passing through the coil at the moment of breaking. The higher the current value
of the primary coil, the higher the inductive voltage of the ignition coil. Because of
the inductive effect of the coil, under the condition of constant supply voltage, the
current flowing through the coil increases exponentially at the beginning of the
primary coil conduction, and it takes a certain time before the saturation current can
be reached. When the closing angle remains constant, the time of primary current
conduction will decrease with the increase of engine speed. In order to meet the
requirements of ignition voltage and ignition energy of gasoline engine, the closing
angle of ignition system is automatically controlled by ECM according to engine
speed. When engine speed increases, the closing angle will be increased appropriately
to ensure that the primary coil has enough conduction time, so that the current of the
primary coil can reach or approach the saturation current at the moment of
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disconnection, rising the inductive voltage. On the contrary, when engine speed is
reduced, ECM will properly reduce the closing angle, so as to prevent the primary coil
from overheating and excessive power consumption due to the excessive conduction
time of the primary coil current.
3.Air intake control system
Air intake system consists of air filter, throttle valve, intake manifold and related
pipe.
Air intake control system is to achieve idle control, variable valve control,
electronic throttle control, turbocharger control and other tasks through the
control of air intake,
so as to improve the stability of engine idling operation, or improve engine power,
reduce fuel consumption and emission pollution.
Idle speed control: the electronic control system has the function of automatic
control of engine idling speed. Through engine working temperature, load and other
factors measured by various sensors, to determine the optimal idle speed. Through
electronic throttle, the intake amount of idle speed when automatically controlled
idling, achieve the purpose of controlling idling speed. The engine has stable idle
speed under various conditions, to prevent idle speed instability or stall, and as far as
possible to reduce idle fuel consumption and emissions pollution.
Electronic throttle control: in the engine with electronic throttle valve, ECU
measures operating condition of accelerator pedal according to various sensors, also
calculates and confirms optimum opening degree of throttle valve according to engine
speed, vehicle speed and other factors, control opening degree of throttle valve by
electronic throttle valve actuator, and ensure the best fuel economy and improve
safety and comfort. In addition, the electronic control system of gasoline engine can
realize traction control and cruise control through electronic throttle valve.
Variable valve control: in engine with variable valve, ECU calculates and
confirms the optimal phase of valve distribution according to operating conditions
measured by various sensors. Through timing control of solenoid valve and other
actuators, change opening and closing time of intake and exhaust valve, so that the
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phase of engine valve and valve overlap angle change with the change of engine
speed and load, and keep the best at all times. Thus, the engine has good fuel
economy, power performance and running stability at any speed and load, and reduces
emission pollution.
4.Emission control system
The post-treatment of exhaust in three-way catalytic converters is an effective
way to reduce the concentration of harmful substances in the exhaust gas. Ternary
catalytic converters can reduce hydrocarbon (HC), carbon monoxide (CO) and
nitrogen oxides (NOx) by 98% or more, and convert them into water (H2O), carbon
dioxide (CO2) and nitrogen (N2). However, such high efficiency can only be
achieved within a narrow range of the engine's excess air coefficient
=1，
and the
goal of closed-loop control is to ensure that the mixture concentration is within this
range. The closed-loop control system can only act with oxygen sensors The oxygen
sensor at the side of the three-element catalytic converter monitors the oxygen content
in the exhaust gas. The dilute mixture ( 1) generates a sensor voltage of about
100mV. The thick mixture (1) generates about 900mV sensor voltage. When=1,
the sensor voltage has a jump. Closed-loop control responds to input signals
(1=Mixed gas is too thin1=Mixed gas is too thick) to modify the control variable
to produce a correction factor as a multiplier to modify the duration of the injection.
5.Crankshaft ventilation system
The function of fuel vapor recovery device is to recover the gasoline vapor from
the gasoline tank of vehicle to engine intake pipe,
so that it can burn into the engine cylinder with the fresh mixture, and prevent
gasoline vapor from being discharged into the atmosphere to pollute the environment.
The fuel vapor recovery unit consists of activated carbon canister, solenoid valve,
one-way valve and corresponding steam pipe and vacuum hose.
3.2.3 Vehicle diagnostic system
1.Instruction
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On-board Diagnostic System (OBD) is a diagnosis system integrated in engine
control system which can monitor the fault parts and the main function state of engine
which affect the exhaust gas emission. It has the function of identifying, storing and
displaying fault information through the self-diagnostic malfunction indicator light
(MIL).
2.Function introduction
The main functions of the diagnostic system are monitoring functions, memory
fault codes and warning functions, fail-safe functions
and data output functions.
（
1
）
Monitoring function
The target of the diagnosis system monitoring is the various sensors in the engine
electronic control system, actuator
and the control process of the electronic control system. The fault self-diagnosis
system continuously monitors the signal of the electronic control system during the
running of the vehicle, when a signal exceeds the preset range value, and the
phenomenon does not disappear in a certain period of time. The fault self-diagnosis
system determines that the corresponding circuit or component of the signal has
failed.
（
2
）
Store fault code and warning function. Once the fault self-diagnosis
system detects a fault in the electronic control system, it immediately lights the fault
warning light above the dashboard to remind the driver to promptly send the vehicle
to the repair shop for inspection and maintenance, so as to avoid any further damage.
The fault self-diagnosis system also detects that the fault is stored
in the memory of the ECM as a fault code. During maintenance, the inspector can
read out the fault code stored in the ECM by using a certain method to provide an
accurate basis for finding the fault location.
（
3
）
Failure protection function According to the different monitoring object,
the fault self-diagnosis system will take different failure protection measures when
finding fault.
（
4
）
Data storage output function. The cells that store data in ECU are ROM
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and RAM, respectively, memory ROM stored in the program is based on accurate
calculation and a large number of experimental data, the inherent program in the
engine work, constantly with the acquisition of the signals of each sensor to compare
and calculate, to achieve the control of the engine.
In the automotive electronic control system circuit has a dedicated diagnostic
socket, as long as the car ECM decoder and this diagnostic socket connection,
you can access the automotive ECM storage unit, read out the stored fault code.
In addition, the fault self-diagnosis system can also output the data flow
reflecting the working condition of the automobile electronic control system by
diagnosing the outlet outward.
3.Fault light description and control strategy
1) Engine fault indicator light (MIL): instructions required for emissions-related
components or system failures, MIL is generally a light that can be displayed on the
dashboard in compliance with regulatory standards.
2) The activation of the Mil led follows the following principles:
1
Ignition switch is in the "ON" state (non-start), MIL continues to light.
2
3 seconds after the engine starts, if there is no fault request in the fault
memory to turn on the MIL, the MIL goes off.
3
There is a fault in the memory required to light the MIL request, or outside
the ECM has a MIL request, MIL are lit.
4
When there is a flashing MIL request outside the ECM, or there is a
blinking MIL request due to a fire or there is a fault request in the memory that
flashes MIL, the MIL flashes at 1Hz.
4. Troubleshooting steps
1) For vehicles with OBD function, troubleshooting is generally followed by the
following steps:
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OBD Troubleshooting Steps Table
1. Connect the diagnostic test equipment to the
diagnostic connector and switch on the
diagnostic test equipment.
2. Connect the ignition switch.
3. Read fault related information (fault code,
frozen frame, etc.); check workshop manual to
confirm fault parts and types; making
maintenance plan according to fault related
information and experience.
4. Troubleshooting.
5. To clear the fault memory, the proper
operation of the vehicle and the operation
mode must meet the conditions of the
corresponding fault diagnosis; Read the fault
information to confirm that the fault has been
excluded.
2）Fault diagnosis common detection and diagnostic equipment
Compared with the mechanical system, the automobile electronic control system
has a fundamentally different overhaul mode. It is necessary to rely on the electronic
equipment and use the information of the self-diagnosis system to diagnose the fault.
The common equipment for overhaul of electronic control system includes
automobile computer tester and digital multimeter.
Connect the data cable of the computer detector to the diagnostic outlet on the
car to connect with the automotive ECM, accessing to the ECM memory of the fault
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diagnosis data, including fault code, data flow and so on, so as to understand the auto
fault diagnosis system monitoring results and the work of the electronic control
system, to provide a basis for quick troubleshooting. In addition, it can carry out the
action test and so on.
（
1
）
Read and Clear fault codes
By connecting the car's computer detector with the fault diagnosis seat on the car,
it is easy to read
the fault code stored in the ECM. The car's computer diagnostic device displays both
the fault and its meaning on the screen By reading the fault codes, maintenance
personnel can find out the short circuit, open circuit and other faults of most sensors
and their control circuits in the automotive electronic control system.
After troubleshooting, the computer tester can send instructions to the car
electronic control system to eliminate ECM stored fault code to turn off the the fault
warning light.
（
2
）
Read data stream
The car computer tester is connected with the electronic control system to read
the running status of the ECM
and the instantaneous data of various input and output electric signals (such as the
signal of each sensor, the calculation result of the ECM, the control mode, The control
signal issued by each actuator, etc.). Maintenance personnel can judge whether the
system is working normally according to the changes of various data or compare the
values of various signals with the standard values under specific working conditions
so as to accurately determine the type and location of the fault.
（
3
）
Action test
The motion test is to issue a work instruction to the ECM of the automotive
electronic control system through the computer tester to drive
or stop the work of some actuators to detect the working condition of the actuator and
find the faulty actuator or control circuit.
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3.2.4 Engine fault diagnosis
1. Engine control system troubleshooting overview
If the engine electronic control system components (sensors, ECM, injector, etc.)
failure, oil supply disrupts or it can't provide the correct fuel quantity for engine
different working conditions, will produce the following situations:
a.The engine is difficult to start or cannot start at all
b.Engine idling unstable
c.Poor driving performance
In case of any of the above situations, routine testing including basic engine
inspection (ignition system failure, correct engine adjustment, etc.) shall be conducted
first. Then the components of the engine electronic control system are checked by a
fault diagnosis instrument
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MT62.1 Common fault code list of ECU control system
1
Fault code
Fault code information
1
P0012 Air inlet VCP camshaft phase error is large
2
P0016 Intake VCP camshaft tooth learning deviation exceed range
3
P0026 Intake VCP hydraulic pressure control valve vised
4
P0031 Front oxygen sensor heater short circuit to low voltage
5
P0032 Front oxygen sensor heater short circuit to high voltage
6
P0033 Turbo pressure relief solenoid valve control line disconnection
7
P0034 Turbo pressure relief solenoid valve control line low voltage
8
P0035 Turbo pressure relief solenoid valve control line high voltage
9
P0037 Rear oxygen sensor heater short circuit to low voltage
10
P0038 Rear oxygen sensor heater short circuit to high voltage
11
P0068 Electronic throttle valve air flow fault
12
P0075 Intake VCP hydraulic pressure control valve coil disconnection
13
P0076 Intake VCP hydraulic pressure control valve coil low voltage
14
P0077 Intake VCP hydraulic pressure control valve coil high voltage
15
P0107 Intake pressure sensor circuit low voltage or open circuit
16
P0108 Intake pressure sensor circuit high voltage
17
P0112 Boosted intake air temperature sensor line low voltage
18
P0113 Boosted intake air temperature sensor line high voltage or open circuit
19
P0117 Coolant temperature sensor circuit low voltage
20
P0118 Coolant temperature sensor circuit high voltage or open circuit
21
P0122 Electronic throttle valve position sensor 1# circuit low voltage
22
P0123 Electronic throttle valve position sensor 1# circuit high voltage
23
P0130 Front oxygen sensor open circuit
24
P0131 Front oxygen sensor short circuit to low voltage
25
P0132 Front oxygen sensor short circuit to high voltage
26
P0133 Front oxygen sensor responds too slowly
27
P0134 Front oxygen sensor responds too slowly
28
P0136 Rear oxygen sensor open circuit
29
P0137 Rear oxygen sensor short circuit to low voltage
30
P0138 Rear oxygen sensor short circuit to high voltage
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31
P014C Front oxygen sensor responds too slowly
32
P014D Front oxygen sensor responds too slowly
33
P0171 Non-idle fuel system is too thin
34
P0172 Non-idle fuel system is too thick
35
P0222 Electronic throttle valve position sensor 2# circuit low voltage
36
P0223 Electronic throttle valve position sensor 2# circuit high voltage
37
P0230 Fuel pump relay fault
38
P0234 Turbo overcharge
39
P0237 Boost pressure sensor line low voltage or disconnect
40
P0238 Boost pressure sensor line high voltage
41
P023A Turbocharger intercooled water pump relay disconnected
42
P023B Turbocharger intercooled water pump relay low voltage
43
P023C Turbocharger intercooled water pump relay high voltage
44
P0243 Turbo bypass solenoid valve control line open circuit
45
P0245 Turbo bypass solenoid valve control line low voltage
46
P0246 Turbo bypass solenoid valve control line high voltage
47
P0261 1
st
cylinder fuel injector circuit low voltage fault
48
P0262 1
st
cylinder fuel injector circuit high voltage fault
49
P0264 2
st
cylinder fuel injector circuit low voltage fault
50
P0265 2
st
cylinder fuel injector circuit high voltage fault
51
P0267 3
st
cylinder fuel injector circuit low voltage fault
52
P0268 3
st
cylinder fuel injector circuit high voltage fault
53
P0270 4
st
cylinder fuel injector circuit low voltage fault
54
P0271 4
st
cylinder fuel injector circuit high voltage fault
55
P0299 Turbo is insufficient
56
P0300 Single cylinder or multi-cylinder miss fire
57
P0324 Knock control system failure
58
P0325 Knock sensor failure
59
P0335 Crankshaft position sensor circuit no signal
60
P0336 Crankshaft position sensor circuit signal interfere
61
P0340 Camshaft position sensor circuit no signal
62
P0340 Intake VCP camshaft position sensor state diagnosis
63
P0341 Intake VCP target wheel diagnosis fault
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64
P0341 Camshaft position sensor line signal interference
65
P0351 Ignition coil "A" disconnects (1 cylinder)
66
P0352 Ignition coil "B" disconnects (3 cylinder)
67
P0353 Ignition coil "C" disconnects (4 cylinder)
68
P0354 Ignition coil "D" disconnects (2 cylinder)
69
P0420 Catalystic converter is too inefficient
70
P0458
Carbon canister electromagnetic valve short circuit to low voltage or open
circuit
71
P0459 Carbon canister electromagnetic valve short circuit to high voltage
72
P0482 PWM fan failure
73
P0500 Speed signal source failure (speed signal comes from TCM/ABS/ESP through CAN)
74
P0504 Brake switch relativity fault
75
P0506 Idling engine speed too low
76
P0507 Idling engine speed too high
77
P0532 Air conditioning pressure sensor line low voltage or open circuit
78
P0533 Air conditioning pressure sensor line high voltage
79
P0557 Brake power vacuum pressure sensor short-circuit to low voltage or disconnect
80
P0558 Brake power vacuum pressure sensor short circuit to high voltage
81
P0562 System voltage is low
82
P0563 System voltage is high
83
P0564 Cruise control input line fault
84
P0565 Cruise“On/Off”signal interference
85
P0565 Cruise "On/Off" button signal embedded
86
P0566 Cruise“Cancel”signal interference
87
P0566 Cruise“Cancel”signal embedded
88
P0567 Cruise“Resume”signal interference
89
P0567 Cruise“Resume”signal embedded
90
P0568 Cruise“Set”signal interference
91
P0568 Cruise“Set”signal embedded
92
P0571 The switch state of the brake lamp has not changed during braking
93
P0601 ROM error
94
P0602 ECM programming error(Software version does not match)
95
P0606 ECM processor fault
96
P0606 ECM processor fault
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97
P0606 ECM processor fault
98
P0606 ECM processor fault
99
P0606 ECM processor fault
100
P060A ECM processor fault
101
P060A ECM processor fault
102
P060A ECM processor fault
103
P0616 Starter motor relay low voltage
104
P0617 Starter motor relay high voltage
105
P0633 The anti-theft alarm failed to learn
106
P0641 ETC reference voltage A# amplitude
107
P0646 Air conditioning clutch relay short circuit to low voltage or open circuit
108
P0647 Air conditioning clutch relay short circuit to high voltage
109
P0651 ETC reference voltage B# amplitude
110
P065B Intelligent generator line failure
111
P065C Intelligent generator mechanical error
112
P0685 Main relay fault
113
P0685 Main relay fault
114
P06E9 Starter damage
115
P0805 Clutch sensor line fault
116
P0831 Clutch line signal is often released
117
P0832 Clutch line signal is often pressed
118
P1167 Excessive thick when front oxygen decelerating and cutting off fuel
119
P1171 Excessive thin when front oxygen accelerating and concentrating
120
P1336 58 tooth gear wheel error not learning
121
P1515 The starter state input is disconnected
122
P1516 ETC drive steady state diagnosis fault
123
P1554 Brake vacuum booster pump relay shorted to low voltage or disconnected
124
P1555 Brake vacuum booster pump relay shorted to high voltage
125
P1556 Brake vacuum booster pump vacuum small leak
126
P1559 Brake vacuum booster pump vacuum big leak
127
P1565 Start-Stop switch signal interference
128
P1566 Start-Stop switch signal clamp
129
P1615 Start relays open
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130
P1616 Start relay bonding
131
P2101 ETC drive second order diagnosis fault
132
P2104 Engine forced idling
133
P2105 Engine forced stop
134
P2106 Engine function limited
135
P2110 Engine power management
136
P2119 Electronic throttle valve return fault
137
P2122 Electronic accelerator pedal position sensor 1# circuit low voltage
138
P2123 Electronic accelerator pedal position sensor 1# circuit high voltage
139
P2127 Electronic accelerator pedal position sensor 2# circuit low voltage
140
P2128 Electronic accelerator pedal position sensor 2# circuit high voltage
141
P2135 Electronic throttle valve position sensor 1#, 2# circuit related fault
142
P2138 Electronic accelerator pedal position sensor1#, 2# circuit related fault
143
P2187 Idle fuel system is too thin
144
P2188 Idle fuel system is too thick
145
P2300 Ignition coil "A" short circuit to low voltage (1 cylinder)
146
P2301 Ignition coil "A" short circuit to high voltage (1 cylinder)
147
P2303 Ignition coil "B" short circuit to low voltage (3 cylinder)
148
P2304 Ignition coil "B" short circuit to high voltage (3 cylinder)
149
P2306 Ignition coil "C" short circuit to low voltage (4 cylinder)
150
P2307 Ignition coil "C" short circuit to high voltage (4 cylinder)
151
P2309 Ignition coil "D" short circuit to low voltage (2 cylinder)
152
P2310 Ignition coil "D" short circuit to high voltage (2 cylinder)
153
P2A01 Rear oxygen sensor decelerating and breaking response too slowly
154
U0001 CAN network communication failure (C001)
155
U0028 LIN communication fault
156
U0073 CAN bus close(C073)
157
U012D Communication loss between ECU and intelligent generator
158
U0146 Communication loss between ECM and gateway
159
U0151 Communication loss between ECM and airbag controller
160
U0167 Anti-theft device is not responding (C167)
161
U0426 Anti-theft device authentication failed (C426)
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2.Faults diagnosis flowchart
Inspecti
3.Confirm the symptoms
Try to diagnose the
1. Get symptom information
and ask the customer for
details related to the
2.Inspect DTC
Check the DTC,
print the DTC and
freeze frame data,
4.Confirm symptoms
Try to diagnose the
5.Execute the DTC confirmation step 6.Perform basic
9.Check the system
failure through the
7. Run the fault diagnosis
and inspection mode
8. Check the fault parts
10.Check the defective
11.repair or replace faulty
12.Final check
Make sure no symptoms are detected
Perform the DTC confirmation step
again, and then make sure the
Inspection
The client
described the
symptoms and
The
client
did not
describe
The client
described
the
No use fault
Within
the
No
fault
components
Use fault
Beyond the range
Fault
Abnormal
(DTC
Abnormal (the
Nor
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Caution:
■Before disassembling and installing any components, read the fault code first
and then disconnect the negative terminal of the battery.
■Turn off the ignition switch before disconnecting the wiring harness from the
battery terminal. If the battery wiring harness is disconnected while the engine is
working or the ignition switch is turned on, ECM will be damaged.
■The wire harness between the ECM and the sensor shall be shielded by an
earth wire connected to the body to prevent the ignition system interference and
radio interference. If the shielding harness fails, the harness must be replaced.
■When checking the charging status of the generator, do not disconnect the
positive electrode of the battery to prevent ECM damage.
■When charging the battery with an external charger, disconnect the battery
connection to prevent damage to ECM.
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3.3 Structure Principle and Maintenance of the Engine Electric
Components
The electronic components covered in this section mainly include sensors,
actuators and ECM. This section mainly describes the working principle of electronic
components, structure, circuits and related maintenance.
The sensor's basic circuit generally has 3 wirings of power, signal and ground.
Some sensors do not need a power supply, or the power circuit is built into the ECM,
so that they only have the signal and ground two wirings. If they use the shell of iron,
there may be only one link to the ECM signal line, so that the circuit is very simple,
and some sensors circuit is very complex. The complexity of the sensor circuit
depends on the type and structure principle of the sensor, the main sensors in the
engine electronic control system are switch type, resistor type, pulse type, voltage
type and so on.
Switch-type sensor is a simple structure sensor, usually has two terminals. Its
circuit has the iron-and power-type two, of which the iron-type circuit is the end of
the switch to the grounding, and the power-type circuit switch to the end of the power
supply.
Resistive sensor is the most widely used sensor in electronic control system. Its
structure has variable resistor type, potentiometer, etc., generally using the principle
of DC circuit partial pressure to generate electrical signals. In order to ensure the
accuracy of the signal, the ECU provides a constant size of the reference voltage as its
operating voltage (generally 5V).
Variable resistance sensor has 2 terminals, generally the iron-type circuits, the
end of which is the signal end, the other end of the iron-end; the potentiometer sensor
has 3 terminals, respectively, the power supply end, signal end, and the iron end.
Pulse sensor has a variety of principles and structural forms, such as the
electromagnetic using electromagnetic induction principle, photoelectric using
photoelectric principle, hall-style using Hall-effect, and the magnetic resistance type
using principle of reluctance, etc., the circuit is very complex.
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The voltage sensor usually uses the electrochemical principle and the
piezoelectric effect to change the measured parameters into electromotive force. Most
voltage sensors do not require operating power.
Electronic control system actuators are mainly solenoid valves, motors, relays,
transistor switching circuits, lights and so on. Actuator circuit is usually relatively
simple. It is generally only the power and ground wiring. The ECM uses ground
control for most actuators. The power source for this actuator comes from the battery
and the ground wire to the ECM.
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3.3.1 Air inlet temperature pressure sensor
1.Elements instruction
1) MT62.1 electric injection system adopts velocity density air measurement
method to detect the amount of air entering the engine, so as to control the fuel
injection pulse width and accurately control the engine power output. The sensor is
composed of an inlet absolute pressure sensor and an inlet temperature sensor.
2) The inlet absolute pressure sensor (MAP) is a pressure-sensitive variable
resistance. Internal pressure diaphragm of air inlet pressure sensor and a magnet
placed inside the coil heart are linked together, when the intake pipe inlet pressure
change,the diaphragm will drive the core to move, the output voltage of the sensor is
changed, ECU can convert the air intake of the starting motor according to the output
voltage of the sensor, engine based on this signal, refer to other signals for engine fuel
injection quantity control. MAP sensors are also used to measure atmospheric
pressure at start-up and allow ECM to adjust automatically at different altitude under
certain conditions. The ECM provides a 5V voltage to the MAP sensor and receives
the voltage from the signal line. The sensor provides a circuit to ground through its
variable resistance. The MAP sensor input signal affects the ECM's control of fuel
output and ignition timing.
3) the inlet temperature sensor is a thermistor with a negative temperature
coefficient (NTC). The resistance decreases with the increase of inlet temperature.The
engine ECU monitor the change of inlet temperature through an internal comparison
circuit.
Working pressure range: 20kPa～250kPa
Working temperature: -40℃ ~ 125℃;
2. Sensor installation position
Install on the intake manifold.
3.Sensor circuit diagram
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Terminal 39: 5v power voltage signal
Terminal 43: manifold pressure sensor signal
Terminal 45: power grounding
Terminal 29: air inlet temperature sensor signal
Working voltage:5±0.1V
4. Installation precautions
■ Tightening torque of absolute pressure sensor self-tapping bolts: 6±0.5 N·m
■Make sure the sensor is fully attached to the intake manifold
■ Prohibit brutal disassembly.
5.Failure phenomenon and judgment
●Symptom: the fuel injection function of the ECM of the engine will be
abnormal. If the air mixture is too rich or too thin, the engine will not run normally or
accelerates idly and the exhaust pipe will emit black smoke and so on.
●General Fault Cause: The internal circuit of the sensor is disconnected, or the
dirt accumulates, and the air inlet pipe leaks that causes the incorrect signal.
●Inspection methods:
1）Exterior inspection
Check whether the sensor harness connector is well connected, solid and reliable.
Whether the appearance is good, and confirm that there is no impact marks.Check if
the sensor detection hole is blocked.
2）Circuit detection
1
Turn the ignition switch off and unplug the sensor end harness terminal.
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2
Turn the ignition switch on and measure the terminals of the sensor harness
connector separately with a digital multimeter.
3
Sensor power supply terminals should be measured as 5V reference voltage.
If the voltage value does not match, it indicates that the control circuit or ECM has
faulty, and it should be further tested.
4
When the sensor terminal is measured, the negative resistance between the
battery and the battery should be less than 3Ω, if abnormal, the ground line should
be repaired.
5
If the above check is not normal, turn off the ignition switch, unplug the
harness ECM connector, check the wiring harness between the sensor connector and
the ECM connector for the existence of disconnection, and the line phenomenon.
3.3.2 Coolant temperature sensor
1.Component description
Engine coolant temperature sensor detects engine coolant temperature and
transmits signal to ECM for start-up, idling, normal operation, injection timing and
fuel injection pulse width control, while providing water temperature signal to
instrument, for instrument water temperature display. It uses a thermistor with a
negative temperature coefficient, whose resistance decreases with temperature. The
ECM determines the temperature of the coolant by the output voltage of the sensor
and provides the engine with the best air-fuel ratio mixture.
2.Installation position
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3.Elements circuit diagram
Pin A: Output coolant temperature signal
Pin C: Ground
Pin B:Vain
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Resistance value (Ω)
The resistance between A and C varies with temperature
Temperature Standard resistance（Ω）
-10 16120
25 2795
85 283
115 115.7
4.Installation precautions
1
■ Thread sealing with thread sealant;
2
Tighten torque:20±4N·m；
3
Start and idle the engine,Visually check engine coolant for leakage.
5.Failure phenomenon and judgment
●fault phenomenon:When the water temperature sensor fails, the mixture
concentration will be affected.When the temperature signal sent to ECU by the water
temperature sensor is lower than the actual temperature of the engine, it will lead to
excessive mixing gas, exhaust black smoke, hot car idling instability, etc. when the
water temperature signal of water temperature sensor is higher than the actual
engine water temperature, will lead to mixed gas is too thin, cold start difficult, cold
car idling instability and other failures.When the water temperature sensor has a short
circuit or break fault, the fault self-diagnosis circuit of ECM will detect this fault, so
that the engine fault attention lamp is on, and ECM will start the failure protection
function.
●General fault reasons: Short circuit, open circuit, the output signal voltage and
the standard value does not meet.
●Inspection methods:
1
）
Exterior inspection
Check whether the sensor wiring harness plugs are connected well, solid and
reliable; whether the sensor installation is loose or off; whether the appearance is
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good. Make sure there is no impact traces.
2) Circuit detection
1
Turn the ignition switch off and unplug the sensor end harness terminal.
2
Turn the ignition switch on and measure the terminals of the sensor harness
connector separately with a digital multimeter.
3
Sensor power supply terminals should be measured as 5V reference voltage.
If the voltage value does not match, it indicates that the control circuit or ECM has
faulty, and it should be further tested.
4
When the sensor terminal is measured, the negative resistance between the
battery and the battery should be less than 3Ω, if abnormal, the ground line should
be repaired.
3
）
Performance Test
Unplug the sensor harness connector and remove the sensor. Place the sensor in
water, measure the resistance between the sensor terminals at different temperatures
when heating, if it is not corresponding to the standard value, the sensor should be
replaced.
3.3.3 Electronic throttle valve
1.Elements instruction
Electronic throttle valve assembly is one of the main components of intake
control management system in modern engine management system. It directly
controls the total intake of the engine, and then controls the engine speed and output
power.
The electronic throttle valve eliminates the mechanical control mechanism of the
mechanically controlled throttle body.Electronic throttle valve include drive motors,
drive gear mechanisms, necessary mechanical transmission components and more
powerful special throttle valve position sensors.
As one of the security guarantees of the system,The system is provided with a
double output throttle valve position sensor, and a throttle valve position sensor
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increases with the opening of the throttle valve body. The output voltage signal of
another throttle valve position sensor decreases with the increase of throttle valve
opening.
2.Installation position
Install on the intake manifold
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3.Elements circuit diagram
Definition Function
1 Throttle motor control（-）
2 Grounding
3 5V power supply
4 Throttle motor control
（
+
）
5 TPS2 signal
6 TPS1 signal
●Measuring range of throttle valve position sensor：Idle condition PS1 is 6%～
14%，TPS2 is 86%～94%；Full open condition TPS1 is 86%～94%.
●Throttle valve response time: ≤135ms (full open to close), ≤100ms (full close
to open)
4. Installation precautions
■Fastening torque: 10±2N·m;
■after re-installation, be sure to self-learning:
■ Prohibit brutal operation and damage to the shell and related sensors.
5.Failure phenomenon and judgment
Fault phenomenon: Throttle valve failure will cause that the engine idling
operation not normal (such as idle speed is too high or too low; idling is unstable,
easily engine off when idling) or engine acceleration is not normal (such as the
acceleration of the engine shaking, acceleration response delay, etc.), sometimes it
can lead to the engine in the process of intermittent jitter and other phenomena.
●Fault cause: The potentiometer in the sensor is open or shorted, the motor can
not normally open or close because of the fault, the throttle valve has too much carbon
deposit, and the control function of ECM is abnormal.
●Inspection methods:
1）Exterior inspection
Check whether the sensor wiring harness plugs are connected well, solid and
reliable; whether the sensor installation is loose or off; whether the appearance is
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good. Make sure there is no impact traces. Slide valves to check whether the rotation
is smooth, with or without catching phenomenon. Check whether there is too much
carbon deposit in throttle valve.
2) Circuit
1
Turn the ignition switch off and unplug the sensor end harness terminal.
2
Open the ignition switch, measure the position sensor harness wire harness
plug terminals with a digital multimeter;
3
Sensor power supply terminals should be measured as 5V reference voltage.
If the voltage value does not match, it indicates that the control circuit or ECM has
faulty, and it should be further tested.
4
When the sensor terminal is measured, it should be the conduction state
between the battery and the battery , if abnormal, the ground line should be repaired.
3
）
Position sensor resistance detection
Sensor resistance can be detected with an electronic multimeter.The detection
method is as follows:
1
Turn the ignition switch off and unplug the sensor end harness terminal.
2
Use a multimeter to measure the total resistance of the potentiometer on the
sensor harness socket.If there is short circuit, broken circuit or resistance value does
not meet the standard, that means the potentiometer is faulty.
3
Measure the resistance of the potentiometer sliding contact to the ground
terminal. The resistance should change smoothly with the opening or closing of
throttle valve, otherwise the potentiometer is faulty.
3.3.4 Hall sensor
1.Component description
The camshaft position sensor and crankshaft position sensor are hall
sensors,work with the signal wheel on the camshaft and crankshaft.The signal wheel
corresponds to a specific position of the engine.ECU uses the sensor's digital voltage
signal to determine engine operating conditions and implement one-to-one control.
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2.Installation position
They are respectively installed near the camshaft and crankshaft.
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3.Elements Circuit
Sensor Crankshaft position sensor Camshaft phase sensor
Elements Circuit
A: Power B: Ground C:
Output
A: Output B: Ground C:
Power
Working
temperature
-40～150℃ -40～150℃
System input
voltage
5.0V (powered by the
controller)
5.0V (powered by the
controller)
Working clearance 0.5-1.5mm 0.5-1.5mm
Installation
precautions
Installation
clearance
0.5～1.5mm 0.5～1.5mm
Fastening torque 7
～
9N·m 6
～
10N·m
Re-installation
Be sure to conduct
self-learning
Be sure to conduct
self-learning
4.Failure phenomenon and judgment
●Fault phenomenon：If the hall position sensor is input error signal, it can not
inject fuel in order, which is easy to cause engine flameout, idling instability and
acceleration weakness.
●General failure reason：The internal component of the sensor is damaged, or the
internal circuit is broken or short-circuit, unable to generate signals;The external
circuit of the sensor is broken or short-circuited;The installation position of the sensor
is not correct, and the gap between the sensor and the rotor is too large, resulting in
abnormal output signal.
●Inspection methods:
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1
）
Exterior inspection
Check whether the sensor harness connector is well connected, solid and reliable.
Whether the distance between the Hall element and the signal wheel meets the
standard requirements, whether there is dirt or iron between them, if so, they should
be removed.
2
）
Circuit detect: The hall sensor must be able to produce a signal when the
power is in normal condition, so please check its power circuit and the ground circuit
first.
1
Turn the ignition switch off and unplug the sensor end harness terminal.
2
Turn the ignition switch on and measure the terminals of the sensor harness
connector separately with a digital multimeter.
3
Measure the sensor power terminal with 5V reference voltage.If the voltage
value does not match, it indicates that the control circuit or ECM has faulty, and it
should be further tested.
4
When the sensor terminal is measured, it should be the conduction state
between the battery and the battery , if abnormal, the ground line should be repaired.
5
If the above check is not normal, turn off the ignition switch, unplug the
harness ECM connector, check the wiring harness between the sensor connector and
the ECM connector for the existence of open circuit.
3.3.5 Oxygen sensor
1.Component description
The oxygen sensor is used to provide information on whether the fuel injected
into the engine cylinder has excess oxygen after it is completely burnt in the air
inhaled. ECU can make use of this information with infinite loop control of the fuel
quantity, has resulted in a three main engine exhaust of toxic ingredients can get
maximum conversion and purification in three-way catalytic converter.
Its sensing component is a ceramic pipe with pores, the outside of the pipe wall
is surrounded by the engine exhaust, and the inside opens to atmosphere. The sensor
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indirectly calculates the pulse width of fuel injection according to the difference of
oxygen concentration on the inside and outside, and sends it to the ECU, which
controls the injection again. At the same time, the output data of the oxygen sensor
are detected, and the data of the oxygen sensor before and after are compared within
the ECU to monitor whether the work of ternary catalysis was good.
The operating voltage of oxygen sensor fluctuates between 0.1-0.9v, and it
should change 5-8 times in 10 seconds. If the frequency value is lower than this, the
sensor is aging and needs to be replaced,it can noi be repaired.
2.Installation position
The front (upstream) oxygen sensor is installed on the exhaust manifold before
the three-element catalytic converter, and the back (downstream) oxygen sensor is
installed after the three-element catalytic converter.
3. Elements circuit diagram
A: Signal to ground B:
Signal
output C: Heating end-
D:
Heating end+
4. Installation precautions
■Plug the installation hole of oxygen sensor with hairless cotton yarn to prevent
sundries or oil and water from entering the exhaust manifold.
■Fastening torque: 50±10N·m;
■It is forbidden to drop oxygen sensor or collide with hard surface.
■Carbon dioxide, silicone oil, engine oil, lead, paint, or other organic
contaminants, which are released from the engine, are forbidden to pollute the sensor.
■Do not pull the wire when installing.
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■Do not knot, pinch, or otherwise damage the sensor harness wire.
■Do not use grease, detergent or other impurities on the connector
3.Failure phenomenon and judgment
●Fault phenomenon: once the oxygen sensor and its connecting line malfunction,
it will not only make the emission exceed the standard, but also worsen the working
condition sometimes, cause the idle speed to be unstable or turn off, exhaust pipe to
emit black smoke and so on.
●Common failure reasons: oxygen sensor poisoning, surface area carbon deposit,
oxygen sensor internal circuit breakage, heater failure and so on.
●Inspection methods
1
）
Measure heating resistance of oxygen sensor
Turn ignition switch to “OFF”, disconnect wiring harness connector of oxygen
sensor, use multimeter to measure resistance between C, D terminal of oxygen sensor.
The resistance should accord with standard value（about 9.6Ω）.
2
）
Check voltage of oxygen sensor heater
Turn on the ignition switch and test the heating power supply voltage of the
sensor with a multimeter. The standard value should be 12V.
3
）
Check whether the connection of several wires on the sensor is good,
whether there is short-circuit, open-circuit , etc.
3.3.6 Fuel injector
1.Component description
Fuel supplied from the fuel pump is stored and distributed through the oil
pressure guide rail assembly,It provides a stable pressure environment for the fuel
system, for the fuel system to provide a relatively stable pressure environment, make
each cylinder oil pressure and oil balance, smooth engine operation. The fuel injector
sprays the fuel according to the signal sent by ECM, and the amount of fuel injection
is determined through the opening time of the solenoid valve of the injector.
2.Installation position
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Install it on the fuel rail.
■Standard resistance between two terminals: 11~16Ω
3.Installation precautions
■The installation of the oil injector is done by hand. It is forbidden to hit the oil
injector with hammer or other tools.
■When disassembling and reinstalling the injector, the o-ring must be replaced
and the sealing surface of the injector must not be damaged;
■After disassembly, the injector seat should be cleaned to avoid pollution.
4.Failure phenomenon and judgment
■ Fault phenomenon: engine power down, idling shaking, starting difficult or
even no start.The engine is high in fuel consumption and will emit black smoke when
serious
●General fault reason：The carbon deposits of the fuel injector result in leakage
or poor injection conditions, and the solenoid coil is damaged and cannot work.The
injector leaks oil.
●Inspection methods
1
）
Electromagnetic coil detection
The electromagnetic coil resistance is measured with a multimeter, 11 ~ 16 Ω
resistance.
2
）
Exterior inspection
Check whether or not the fuel injector has carbon deposition and other
phenomena.
3
）
Control signal detection
Connect the positive and negative poles of the light-emitting diode test lamp to
the power line and the ECM connection line of the fuel injector respectively. When
the engine is running, the light-emitting diode test lamp should be shining. If it is not
shining, it indicates that the control circuit of the fuel injector is malfunctioning, and
the control circuit should be further overhauled. If there is an electric pulse in the
control circuit during measurement but the injector does not spray oil, that means the
injector is faulty.
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4
）
Control circuit detection
1
Turn on the ignition switch and unplug the fuel injector wire bundle. The
power ends supply voltage should be 12V.Otherwise, it indicates that the power
circuit of the fuel injector is broken, and it should further check whether or not the
power fuse is burnt out 、the main relay of the electric control system of the engine is
faulty.
2
If the fuel injector does not spray oil under the normal condition of the
power circuit, check whether the line from the fuel injector to ECM is broken. When
checking, the ignition switch should be closed first, the wire bundle plugs of each fuel
injector should be removed, and the circuit between each fuel injector and ECM
should be measured with a multimeter according to the circuit diagram.
3.3.7 Knock sensor
1.Component description
2.The knock sensor is installed on the side of the cylinder block, generally
between 2 and 3 cylinders, which is conducive to the engine detonation balance,The
ECU uses the vibration frequency signal outputted by the detonation sensor to filter
through the internal ECU, so as to judge whether the engine has a knock or not.When
the knock signal is detected, the
ECU
gradually reduces the ignition advance
Angle
until no knock occurs, and then
gradually
recovers until the knock edge, so
repeatedly.
Installation position
It is installed on the side of the
cylinder
block, generally between 2, 3 cylinders.
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3.Elements Circuit Diagram(see right)
1 - signal ground terminal
2 - signal output terminal
4.Installation precautions
■Tightening torque: (20±4) N·m
■Do not drop or damage the sensor.
5. Failure phenomenon and judgment
●Fault phenomenon: noise and engine power weakening.
●General fault reason: The knock sensor is damaged, there are the short circuit,
broken circuit, fastening bolts are not tightened as required.
●Inspection methods
1) Exterior Inspection
Check whether or not the fastening bolts are tightened as required, whether or
not there is any sundries on the sensor and cylinder joint surface.
2) Circuit inspection
Close the ignition switch, unplug the wire harness plug of the knock sensor, and
check whether or not there is short circuit or open circuit between the signal wire and
ECM terminals by comparing the circuit diagram. If abnormal, it should be repaired.
3
）
Performance check
Disconnect the cord plug of the detonation sensor and tap with a small hammer
on the cylinder body of the detonation sensor attachment,At the same time measure
the voltages between the signal output end and the iron end of the sensor with the
millivolt of the digital multimeter.If the voltage is generated during tapping, that
means the sensor is good, otherwise it should be replaced.
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3.3.8 Continuously variable CAM phase regulator and control valve
1.Component description
Continuously variable CAM phase regulator is used to change the timing of the
gas distribution mechanism. It can continuously adjust the phase relationship between
camshaft and crankshaft according to the needs of the control system and realize the
control of gas distribution phase.
VVT pressure regulating control valve is a four-way pulse width control solenoid
valve that can move in both directions.The oil flow can be controlled by the axial
movement of the plunger valve. The engine ECU changes the oil flow to both sides of
the rotor blade through the duty ratio signal regulated by pulse width, thus controlling
the timing and phase of the CAM relative to the crankshaft.
2.Installation location (see below)
3.Element Parameters
■VCP operating conditions
Items Value
Input voltage 10－16V
Average working current
while holding position
1.0A
Maximum current In the case of 100% duty ratio, -40ºC, 15.5v;2.5A
Environment temperature -40 to 150ºC
Cover interior temperature -40 to 150ºC
Solenoid valve temperature -10 to 150ºC
■OCV valve operating conditions
Type Engine oil pressure control solenoid
valve
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Coil resistance Standard:5.78Ω(-30 ºC)
7.2 Ω (20 ºC)
10.6 Ω (150 ºC)
Minimum current required for full
stroke of plunger valve
1.2A
Input voltage (through the coil) Standard:13±14V
Min：10.0V
Max: 16.0V
Starting response under normal input
voltage
<50Ms T coil temperature<65ºC
Close the response <50Ms T coil temperature<65ºC
4.Installation precautions
■OCV Bolts’ tightening torque: (6±1) N·m
■During installation, apply a proper amount of lubricating oil on the o-ring of
OCV before installing OCV.
5.Failure phenomenon and judgment
●Fault phenomenon: when the valve timing control system fails, the actual valve
timing will not match the target valve timing of ECM, which will affect its power
performance and emission performance.
●General failure reasons: OCV valve electromagnetic coil open circuit , short
circuit, valve core clamping stagnation,etc.
●Inspection methods
1) Measure the resistance of solenoid coil of OCV valve
Use a multimeter to measure the resistance between the two terminals of the
OCV to 6~9Ω.
2) Dynamic check
Power the OCV valve terminal by 12V to check whether or not the slide of the
OCV mid-column slide valve is stuck.
3.3.9 Carbon canister solenoid valve
1.Component description
The gasoline vapor produced in the fuel tank is piped into the activated carbon
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canister, which can absorb the gasoline molecules in the gasoline vapor. Another
outlet hose on the activated carbon canister communicates with the engine intake
manifold. The carbon canister solenoid valve in the middle of the hose controls the
opening and breaking of the line When the engine is running, if the solenoid valve
opens, under the action of vacuum suction within the inlet pipe, air enters beneath the
canister, pass the activated carbon from the upper outlet through the hose into the
engine inlet pipe, revaporize the gasoline molecules attached to the surface of the
activated carbon,The air is sucked into the engine to burn, allowing the fuel to be fully
used.At the same time, it can restore the adsorption capacity of activated carbon in the
carbon canister, and it will not be invalidated due to too long use.
2.Installation position
Install on air inlet manifold bracket. (see below)
3.Installation precautions
■Avoid water, oil and other liquids entering the valve during maintenance.
■Pay attention to the direction of installation.
4.Failure phenomenon and judgment
●fault phenomenon：The first is the failure, that is, the fuel vapor in the fuel tank
cannot be recovered, there is a fuel smell in the car during the summer driving;Second,
the work is abnormal, such as when the fuel vapor recovery work in the engine idle
speed, results in too much mixture or influence the engine idle speed stability.
●General fault reason：The solenoid valve is not working normally, it is closed
continuously, the solenoid valve is often opened, and the solenoid valve is blocked.
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●Inspection methods:
1
）
Measure the resistance
Measure the resistance between the two pins of charcoal canister solenoid valve
by multimeter and the resistance is 19~22Ω（20℃）.
2
）
Performance check
Unplug the solenoid valve harness and blow the air into the solenoid valve. The
solenoid valve should not be ventilated. Connect the 12V power supply to the two
terminals of the solenoid valve and blow the air into the solenoid valve. The solenoid
valve should be ventilated. If there is any abnormality, it indicates that the solenoid
valve is out of order.
3.3.10 Ignition coil
Ignition coil picture
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1. Overview
This engine adopts the independent electric control ignition system,
the secondary coil of the ignition coil is directly connected with the
spark plug. In this ignition system, each ignition coil is connected with
ECM to calculate the ignition advance angle according to the signals of
various sensors, and the piston positions of each cylinder are measured
according to the crankshaft position sensor. According to the working
order of each cylinder, the ignition signal is sent out to each ignition
coil in turn. According to the ignition signal of ECM, the ignition coil
of each cylinder controls the conduction and disconnection of the primary
winding current of each ignition coil, so that the secondary high voltage
is generated, which is directly sent to the spark plug for ignition.
The ignition coil consists of two sets of coils, primary coils and
secondary coils, the main function of which is to turn the low voltage
of the vehicle into high voltage.
2.Working principle
Ignition coil consists of primary winding resistance, secondary
winding and iron core, shell, etc. When some primary resistance grounding
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is connected, the primary resistance is charged. Once the primary
resistive circuit is cut off by ECU, the charge is suspended and a high
voltage is induced in the secondary resistance to discharge the spark
plug.
3、Installation position
Ignition coil is installed on engine cylinder head cover.
4. Installation precautions
The high voltage connecting rod can not be removed during packing,
transport and assembly process.
Fastening torque: M6 8~10N.m
Be sure to disconnect the battery negative electrode before
installation and disassembly
5. Technical parameters and pin definitions
Working voltage: +12V
Primary coil resistance: 0.75Ω
Pin definition:
Pin 1: Ground
Pin 2——Power supply
Pin 2——ECU control signal
6. Failure phenomenon and diagnosis method
General fault reasons: short circuit or open circuit inside the
coil, leakage of the coil, cracks in the shell, insufficient
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ignition energy caused by the ageing of the coil, and breakdown
of the coil;
Fault phenomenon: ignition coil failure causes spark plug no fire
or fire weak, cause engine work difficult to start, can not start
or shake.
Inspection methods
When there is a failure of individual cylinders to ignite, the
ignition coil can be exchanged to determine the cause of component damage
or electric has fault. If all cylinders do not ignite, the cause of failure
should be in the control circuit, sensor or ECU, and it is unlikely that
all ignition coils will be damaged at the same time. Therefore, as long
as the control circuit is detected, the fault range can be determined.
4）Control circuit detection
Disconnect wire harness plug of the ignition coil, turn on the
ignition switch, and the measuring power supply terminal shall be 12V
battery
voltage. If is 0V, indicating that the power circuit failure, should be
further overhaul.
Measure grounding terminal of wiring harness connector, resistance
between it and negative electrode of the battery should be less than 3Ω.
If abnormal, it should be repaired.
Measure the signal terminal of the wire harness plug with a light
emitting diode test lamp. When starting the engine, the test lights should
flicker, otherwise the ECU does not send a ignition signal to the ignition
coil. The crankshaft position sensor may be malfunctioning, or the ECU
may not work and should be further overhauled.
5）Performance check
Remove the ignition coil, attach the spark plug and make it grounding.
Start the engine and check whether there is high pressure spark in the
spark plug electrode.
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3.3.11 Spark plug
1. Overview
The role of the spark plug is to send the ignition coil to the pulse
high voltage discharge, to break through the air between the two
electrodes of the spark plug, and to produce an electric spark to ignite
the mixed gas in the cylinder.
2.Working principle
The main parts of spark plug are insulator, shell, connection screw
and electrode. Spark plug electrode consists of center electrode and side
electrode, and the spark gap is between them. The high voltage current
from the ignition coil passes through the central electrode and then
discharges at the bottom end of the discharge gap.
3.Technical characteristics of the parameters
Ignition clearance: 0.8~0.9mm
Spark plug heat value: 7
Resistance value between shell and connecting column: 5±2.5kΩ
4. Installation precautions
During installation, hammers and other tools are prohibited
Spark plug tightening torque: 34 ± 4N.m;
5、Failure phenomenon and judgment
General failure reasons: spark plug ablation and so on.
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Fault phenomenon: it is difficult to start and shake.
Inspection methods:
Observe color:
Normal working spark plug, its insulator skirt is russet and
relatively clean. If the spark plug shows the following symptoms, it
indicates that the engine or spark plug is not working properly.
4
Spark plug electrode melts and the body is white. This indicates
that the high temperature in the cylinder causes spark plug ablation,
which may be due to excessive carbon accumulation in the cylinder, too
small valve clearance, too late ignition time, and too thin and damaged
spark plug sealing ring. The spark plug failed to tighten according to
the required torque, engine heat dissipation and so on.
5
Spark plug electrodes become round and insulator scarring. The
reason is that the ignition time is too early, the octane number of
gasoline is too low, and the heat value of spark plug is too high.
6
The top of the spark plug insulator is broken. This shows that
the engine detonation combustion, instantaneous high pressure shock wave
will break the insulator. The reason is that the ignition time is too early,
the octane number of gasoline is low, the combustion chamber is serious
carbon deposit and the temperature is too high.
7
The top of the spark plug insulator has gray and black stripes.
This shows that the spark plug has cracked and leaked gas.
8
There are oily deposits between the tip of the spark plug
insulator and the electrode. This indicates that the lubricating oil has
entered the cylinder to participate in combustion. If only individual
spark plugs have deposits , it is due to failure of single cylinder valve
oil seal etc . If all spark plugs have carbon deposition , a systematic
lubrication system and crankcase ventilation device will be considered.
9
There are black deposits between the tip of the spark plug
insulator and the electrode. This indicates that the mixture does not burn
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well, mainly because the mixture is too dense, leaving the black soot layer
on the spark plug.
10
There are gray deposits between the top of the spark plug
insulator and the electrode, which is usually due to the gasoline quality
does not meet the requirements, gasoline additives after combustion
products, this type of sediment will reduce the spark plug ignition
performance.
11
The flame-plug insulator skirt and electrode are moist and oily.
This means that high voltage wire of the cylinder has no
power supply or weak electric energy.
3）Spark-over test:
Remove the spark plug, install it on the ignition coil, make the shell
of the spark plug iron with the cylinder head, turn on the ignition switch,
turn the engine with the starting device, and see if the spark plug is
igniting. Generally speaking, as long as spark plug jump out of the spark
is blue white or purple white, and
in the fire at the same time
issued a "patter" sound,
indicating that the spark plug
fire is stronger.
4）Measuring electrode gap:
The electrode gap of spark plug was measured with thick gauge or
circular gauge; the standard value is 0.8-0.9mm.
3.3.12 Turbocharger pressure control valve
1. Overview
The turbocharger pressure control valve is used to control the opening
and closing of the turbocharger bypass valve to control the boost pressure
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of the engine.
2.Working principle
The ECU calculates the intake air amount and the intake manifold
pressure from the throttle opening degree to obtain the target boost
pressure, and then calculates the duty ratio opening degree of the current
wastegate valve according to the external characteristic maximum boost
pressure and the base boost pressure of the booster. The solenoid valve
receives the duty cycle signal from the ECM to adjust the opening of the
wastegate valve.
3.Technical parameters
Working voltage: 12V
Resistance value: 23 ± 1.2Ω
4. Installation precautions
The air pipe is well connected and there is no air leakage or misassembly.
ECU E
IRC1
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5. Failure phenomenon and judgment
General causes of failure: water ingress corrosion, foreign matter stuck,
poor sealing, coil ablation
Fault phenomenon: abnormal supercharging pressure, vehicle
acceleration and weakness
Detection method:
1
Measure the resistance between the two pins of the boost pressure
control valve: 23±1.2Ω.
2
The control valve is powered on: the channel is open.
3
The control valve is powered off: the channel is closed.
3.3.13 RCV valve
1. Overview
The RCV valve only works when the throttle is quickly closed, avoiding
excessive pressure resistance from the surge and the compressor to
throttle line.
2.Working principle
When the throttle is quickly closed, the flow through the compressor
is small but the pressure ratio is very large. In this case, the noise
of the engine and the abnormal noise of the supercharger are adversely
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affected, and the speed of the supercharger is rapidly decreased, so that
the response speed after cycling the throttle in the next step is slow.
At this point, the RCV valve opens and vents pressure to the line before
pressurization to avoid surge noise.
3.Technical parameters
Working voltage: 8～16V
Coil resistance: 13±1Ω
4. Installation precautions
Make sure the seal is intact and not damaged before installation to avoid
bad air leakage.
Fixing bolt torque: 8-10N.m.
5. Failure phenomenon and judgment
General causes of failure: internal corrosion, stagnation, seal breakage or
loss
Fault phenomenon: engine surge abnormal noise, throttle reaction delay,
acceleration weakness
Detection method:
1
Measure the resistance between the two pins of the RCV valve: 13 ±
1 Ω.
2
The RCV is powered on: the channel is open.
3
The RCV is powered off: the channel is closed.
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3.3.14 ECM
ECM is the control center of the electronic control system. This
system is Delphi MT62.1. Its main functions are as follows:
1.Receive signals from various sensors to obtain engine operating
parameters and provide the basis for the control of engine systems.
2.According to the various operating parameters of the engine
provided by the sensor, according to the set program and control strategy,
the control signals are output to the actuators such as the injector and
the ignition coil to realize the control of each system of the engine.
3.Monitor sensors, control circuits, actuators and other signals of
the electronic control system. When the signal is abnormal, light up the
fault warning lamp to issue an alarm in time. At the same time, store the
fault code in the memory of ECU, and start failure protection function
to maintain the engine operation. In addition, the maintainer can trigger
self-diagnosis function of ECU through specific steps, and read the fault
code and data stream stored by ECU through the fault diagnosis connector,
which can provide the basis for fault diagnosis.
Besides, ECU also has the function of controlling the power supply
of the electronic control system and providing stable reference voltage
for some sensors.
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Electrical schematic map
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3.4 Engine Control System Common Fault Diagnosis
3.4.1 Electronic control system common failure and main causes
1. ECM failure
Under normal circumstances, ECM has a good reliability, and will not fail in
normal use. Most failures of ECM are by not properly used or caused by improper
maintenance. Main reasons of ECM failure are the following:
1
The ECM power circuit is faulty, causing ECM not to work.
2
Unplug the ECM harness connector while the power is on, causing ECM
damage due to momentary high voltage.
3
The operation due to water or damp, resulting in ECM internal circuit short
circuit or electronic components damaged; or the plug in the terminal is poor contact
because of the oxidation.
4
The ECM interior is damaged. When the ECM is completely out of service
due to damage and power failure,the engine failure warning light on the instrument
platform won't light up when the ignition switch is turned on.The engine cannot start
because it is not ignited and sprayed with oil.
5
If there is some damage to the control program of ECM or some of its input
and output circuits are damaged, some of the functions of the electronic control
system will be abnormal. For example, individual cylinders will not inject fuel and
idling automatic control will fail.
2. Sensor failure
Sensor failures are in the following forms.
1
Internal sensor failures, such as the internal circuit open circuit, short circuit
or internal components aging, damage and other failures.
2
External sensor control circuit failure, such as the sensor power circuit,
ground circuit, the signal circuit of the short circuit, open circuit and so on.
3
Sporadic failures internal or external the sensor, such as poor contact of
internal components or plugs, and occasional malfunctions at work.
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When the sensor internal or external circuit is open or short circuit fault, the
sensor signal value will exceed the normal range, this failure is easily measured by
ECM self-diagnostic system. The ECM immediately lights the engine fault warning
light on the dash and notes the fault code in memory and starts fail-safe control to
maintain the engine running.
When the sensor internal components have aging damage, the signal value,
although not beyond the normal range, does not meet with the actual parameters
detected. This failure is sometimes not detected by ECM self-diagnostic system and
fails to initiate fail-safe control, which can result in abnormal engine operation.
3.Actuator failure
Actuators containing both electronic components and mechanical parts inside, is
the most prone to failure components in electronic control system. When an actuator
fails, the ECM control commands will not be executed properly, causing the engine to
malfunction. Common causes of failure are the following:
1
The electronic components in the actuator are damaged or the internal circuit
is short-circuit, open-circuit or other hardware failure.
2
The mechanical parts in the actuator can not work normally due to wear and
jamming.
3
Aging and other reasons in the electronic components or mechanical parts in
actuator lead to slow response.
4
Actuator internal electronic components exist virtual connection or
mechanical parts exist with the abnormal gap; the actuator occasionally malfunctions
due to temperature or other external factors.
4. Control circuit failure
The abnormal control circuit between ECM and sensor, actuator, power supply
and iron can also make the sensors, actuators and ECM of the electronic control
system not work properly, and cause various faults of the engine. The main reasons of
the common control circuit fault are as follows:
1
Power fuse due to bad contact, overload fuse and other reasons causes the
system power circuit failure.
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2
The grounding wire of a sensor, actuator, or ECM is poorly pitched,
resulting in failures of sensor, actuator, or ECM abnormal operation.
3
The connector in the control circuit has been disassembled for many times,
causing the plug or terminal to loosen、oxidate ,results in improper contact of the plug;
4
Connecting wire aging, internal fracture or skin rupture, resulting in open
circuit or short circuit fault.
3.4.2 Electronic control system common fault diagnose
1.Engine can not be started
When ignition switch is ON, the starter can drive engine to turn normally, but
can not start, and there is no sign of starting vehicle. Then it must be at least one of
ignition control system, fuel control systems or ECM in engine electronic control
system is completely disabled. If starter can drive engine to normal rotation, and there
is a slight sign of starting vehicle, but can not start. It indicates that although function
of ignition system, fuel control system and ECM is abnormal, but it is not completely
functional. The reasons for this failure are that the high pressure spark is too weak or
the ignition time is not correct, the mixture is too thin, the mixture is too thick, and the
cylinder pressure is too low. The reasons for the failure of engine can’t start are
usually the followings:
1
The fuel pump does not work.
2
Fuel injector does not work.
3
Ignition system does not ignite.
4
Fuel pressure is too low;
5
Ignition advance angle is incorrect.
6
High pressure spark is too weak.
7
Injector leaks oil.
8
ECM does not work.
Check Steps:
1
To failure of engine can not start, generally should first check fuel storage
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situation of fuel tank. if there is no fuel in the tank, it should be refueling.
2
Read fault code, according to the fault code to find the corresponding fault
cause. The main components that may affect engine starting are crankshaft position
sensor, coolant temperature sensor, inlet temperature pressure sensor and so on.
3
Check ignition system. If engine does not ignite, engine can not also start.
Therefore, ignition system should be checked whether there is failure before further
inspection.Refer to engine electrical equipment for specific operation
4
Check whether or not the injector is working properly.
5
Check whether fuel pump is working properly. Make electric fuel pump run
artificially (temporarily supply it with a specified voltage). You should be able to hear
the sound of fuel pump running or to feel the pressure pulsation of fuel when you hold
the inlet pipe with your hand.
6
Check fuel pressure. The standard value should be around 350KPa.
2. Engine hard to start
Difficulty in starting the engine means that the starter can drive the engine to
rotate at the normal speed, there is obvious sign of the car, but it can't be started; or it
needs to be started several times in order to get on the car; or it needs to be driven by
the starter for a long time to drive; or it turns off immediately after starting and cannot
operate normally. Main reason for hard starting are in the followings:
1
The fuel pressure is too low, making the mixture too thin when starting.
2
Coolant temperature sensor failure, resulting in the mixture is too thin or too
thick.
3
The injector leaks oil,resulting in bad spray atomization
4
Fuel injector is blocked, making the fuel injection amount is less or no,
leading to the difficulty of starting.
5
Ignition timing is abnormal or poor performance of spark plug or ignition
coil in ignition system.
6
There is failure in ECM starting control circuit.
7
The pressure of the cylinder is too low. The combustible mixture in the
cylinder has poor combustion conditions and is not easy to fire.
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Check Steps:
1
Read fault code, check fault code related components.
2
Check whether there is leaking in intake system. Check carefully to see if the
relevant intake pipe is broken, the coupling clamps are loose, and the crankcase
ventilation system hose is well connected.
3
Check whether idling related component is working properly.
4
Check fuel pressure, if the pressure is too low, check if fuel pump is working
properly or the gasoline filter is blocked.
5
Check if the mixture is too thick during starting (black smoke, sharp
unburned gasoline, etc.). If the mixture is too thick, check the fuel pressure, coolant
temperature sensor, intake pressure sensor, etc.
6
If the mixture is normal, focus on the ignition system. Remove spark plug,
check whether there is aging, serious carbon deposition or spark plug gap is too large
in spark plug, these conditions may affect the starting performance. Check ignition
control circuit to see if there are open circuit, short circuit and so on. Do fire test, if
necessary.
7
Check the cylinder pressure. If the cylinder pressure is lower than 1.1Mpa,
the engine should be disassembled and inspected for mechanical failure.
If all above are normal, try to replace ECM.
3. Engine idling unstable
If engine starts normally, its idle speed is unstable, the engine has obvious jitter
and miss fire easily, regardless of whether it is cold or warm. This phenomenon may
be caused by the following reasons:
1
Fuel pressure is low.
2
Poor atomization、oil leakage or blockage of the injector;
3
Spark plug working not well.
4
Air inlet temperature pressure sensor failure.
5
Charcoal canister solenoid valve works at idle speed.
6
Cylinder pressure is too low or cylinder pressure difference is too large.
Check Steps:
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1
Read fault code and repair according to the fault code.
2
Check whether there is air leakage or pipe connections are connected
properly in air intake system.
3
Check whether there is stuck, carbon deposit, oil or excessive dust when
throttle valve working.
4
Do cylinder breaking test, cut off one cylinder one by one in idle speed , and
check whether engine speed drop is equal. If engine speed of some cylinder is
basically unchanged when the cylinder is broken, it indicates that the cylinder is not
working well or not work. Check whether there is fault in cylinder ignition coil, spark
plug or fuel injector, and whether there are faults in the related control circuit. Check
cylinder pressure, if the cylinder pressure is abnormal, further check the valve
clearance, cylinder wear and valve sealing.
5
Check fuel pressure, if abnormal please check the oil pump and related fuel
lines.
6
Check air inlet temperature pressure sensor signal.If not normal, proceed to
the next step.
4. Idling engine speed too high
Electric control system can let engine run in a faster speed when vehicle is cold,
and let engine returned to normal idle speed when vehicle is warm. If engine still
keeps high idle speed after warming vehicle, that is, the idle speed is too high, it
usually has the following reasons.
1
Throttle failure or air leakage in intake pipe.
2
Accelerator pedal failure.
3
Coolant temperature sensor fault
4
Carbon canister solenoid valve failure
Check Steps:
1
Read fault code and repair according to the fault code.
2
Check whether there is stuck, carbon deposite in electronic throttle valve.
3
Check water temperature sensor.
4
When A/C switch is ON, if engine speed does not change, check whether the
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relevant vehicle control signal is normal.
5
Tighten hose connected to intake manifold, if engine speed decreases, it
indicates that there is air leakage in the crankcase ventilation system or the carbon
canister solenoid valve, so the pipeline and solenoid valve of carbon canister should
be further checked.
5. Idling engine speed fluctuating too much
If engine speed fluctuates continuously during idling, it may be engine fuel
system, ignition system or electronic throttle valve related failure. It can be considered
from the following points.
1
Poor atomization or blockage of the injector;
2
Spark plug bad ignition.
3
Wrong water temperature sensor signal.
4
Oxygen sensor failure.
5
Electronic throttle valve or other control circuit failure.
Check Steps:
1
Read fault code Pay special attention to coolant temperature sensor, inlet
temperature pressure sensor, oxygen sensor.
2
Whether there is electronic throttle - related fault code or not, if there is,
check the corresponding sensors, actuators and their control circuits.
3
Disconnect each cylinder ignition coil or fuel injector wiring harness
connector one by one during idling, check whether the engine cylinders work steadily.
If engine speed drop is not obvious when disconnecting some cylinder ignition coil
or fuel injector wiring harness connector, it indicates the cylinder work normally,
should check spark plug, high voltage wire and fuel injector.
4
Measure resistance of coolant temperature sensor at different temperatures,
and check whether accord with the standard value.If it is abnormal, the water
temperature sensor should be replaced.
5
Check inlet temperature pressure sensor.
6. Easy to miss fire when idling
Main reasons for easy to miss fire when idling are the followings.
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1
Ignition system is not working properly, it is easy to miss fire during engine
running.
2
Fuel system works abnormally, such as low fuel pressure, abnormal fuel
pump working, fuel injector blockage, and so on.
3
Idle speed instability or idling engine speed too low;
4
Electronic throttle valve fault;
5
Bad contact in wiring harness connector of control system circuit.
Check Steps:
1
Read fault code and check related parts according to the fault code.
2
Check whether there is lack power during driving, if there are acceleration
weakness、 acceleration slow reaction; check fuel pressure, if it is abnormal, check
fuel system related components.
3
If idle speed is unstable, or even flameout during idling when A/C is on,
check whether or not there is failure in A/C switch, there is failure in ECU connecting
circuit.
4
If all the above checks are normal,check whether there is bad contact in
engine control wire harness.
7. Power not enough
Lack power means that vehicle accelerates slow, accelerator pedal is still
insufficient, rotating speed is hard to increase or the power climbing slope is weak, etc.
Main reasons for the failure include the following points:
1
Air filter blocked or inlet system pipe connection loosen;
2
Electronic throttle valve fault;
3
Fuel pressure is too low;
4
Poor atomization or blockage of the injector;
5
Water temperature sensor fault;
6
Temperature pressure sensor failure;
7
wrong ignition timing or high pressure spark is too weak.
8
Abnormal cylinder pressure.
Check Steps:
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1
Check whether there is blockage in air filter, whether air intake system
connection is normal. If abnormal, should be handled.
2
Read the fault code and check the components associated with the fault
code.Sensors and actuators that affect dynamic include water temperature sensor, air
inlet temperature pressure sensor, spark plug, fuel injector, ignition coil, etc.
3
Check spark plug and ignition coil.
4
Check ignition timing.
5
Check fuel pressure,If pressure is too low, further check fuel pump, fuel line
and so on.
6
Check the injector,See if there are serious problems such as carbon
deposition.
7
Measure cylinder pressure.
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3.5 Engine Control System Fault Diagnosis Process
3.5.1 Diagnose according to the fault code
1.Instruction
1) The following overhaul would be carried out only it has been confirmed as the
current steady-state failure , otherwise will cause the diagnosis to be wrong.
2) The following "multimeter" occasion refers to the the digital multimeter;
prohibit the use of pointer multimeter on the electronic control system line inspection.
3) check vehicles with anti-theft system, if ECM replacement occurs in "next
steps", pay attention to matching after ECM replacement.
4) If the fault code shows that the voltage of a circuit is too low, it means the
circuit may be shorted or open to ground. If the fault code shows that a circuit voltage
is too high, it means that the circuit may have a short circuit to the power supply. If
the fault code shows a circuit fault, it means there may be a circuit break in the circuit
or there are multiple line faults.
2. Fault diagnosing assist
1) If the fault code can not be cleared, the fault is a steady-state fault; if it is an
occasional fault, check the harness connector for looseness.
2) In the overhaul process, do not neglect the impact of car maintenance,
cylinder pressure, mechanical ignition timing and so on to the system.
3. Fault code diagnosis
■ Related ECM pins mentioned below refer to actual wiring harness diagram.
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Fault code P0012 Intake VCP camshaft phase is large
Set up emergency control
Turn on the fault lights until the fault is gone
Wire connection
MT62.1
VCP Normal
Variable timing
11 B 0
～
1000mV
Main relay: \ A 12V
Judging condition Possible causes
Referred failure
troubleshooting
Engine running
failure duration time
﹥2 seconds
1. Connectors are not plugged in
2. Variable timing control signal
circuit has open circuit
3. Variable timing control signal
circuit has short circuit to ground
4.Main relay circuit fault
5. Sensor damaged
6.Failure of timing control signal
input interface on ECM
1.Connect the
connector again
2.Repair the wire
harness
3.Repair the wire
harness
4.Repair the wire
harness
5.Replace the sensor
6.Replace ECM
Fault code P0026 Intake VCP hydraulic pressure control valve vised
Set up emergency control
plan:
Turn on the fault lights until the fault is gone,close
air inlet VCP hydraulic pressure control valve.
Wire connection
MT62.1 VCP control
Normal
Main relay: \ A
12V
Variable timing
11 B
0-12V square
Judging condition Possible causes
Referred failure
duration time﹥2
seconds
1. Hydraulic control valve drive
circuit has short circuit to the
system power anode
2. Hydraulic control valve is
damaged 3.
ECM fault
1. Repair wire harness
2. Replace control
valve 3.
Replace ECM
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Fault code P0107
Intake pressure sensor circuit low voltage or open
circuit
Set up emergency control
plan:
Turn on the fault lights until the fault is gone
When the engine stops：100kPa
When the engine is idle：≈32kPa
when engine is running:The manifold pressure
changes with the throttle opening
Wire connection
terminal:
MT62.1
Pressure
Sensor
Normal
measuring
signal
5V reference voltage: 39 2 5V
Manifold pressure
signal: 43 1 0.5
～
4.5V
Sensor signal ground: 45 4 0V
Judging condition Possible causes
Referred failure
troubleshooting
engine running
No TPS fault
MAP
﹤
14.017KPa
RPM
﹤
1050 rpm
TPS
﹥
18.75 %
fault duration time
﹥
2.5 seconds
1. The connector is not solid
2. Pressure signal circuit open circuit
3. Pressure signal circuit has short
circuit to earth
4. 5V reference voltage circuit open
5. Sensor signal ground circuit open
6. 5V reference voltage is opposite
the reference ground
（
This failure
may cause sensor damage
）
7. Sensor damage
8. MAP signal input interface fault
on ECM
1. Plug again
2. Repair wire
harness 3.
Repair wire harness
4. Repair wire
harness
5. Repair wire
harness 6.
Repair wire harness
7. Replace sensor
8. Replace ECM
Fault code P0108 Intake pressure sensor circuit high voltage
Set up emergency control
plan:
Turn on the fault lights until the fault is gone
When the engine stops
：
100kPa
When the engine is idle
：
≈32kPa
when engine is running:The manifold pressure
changes with the throttle opening
Wire connection
terminal:
MT62.1
Pressure
Sensor
Normal
measuring
signal
5V reference voltage: 39 2 5V
Manifold pressure
signal: 43 1 0.5
～
4.5V
Sensor signal ground: 45 4 0V
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Judging condition Possible causes
Referred failure
troubleshooting
Engine running
no TPS fault
MAP﹥98.117kPa
TPS﹤19.141%
fault duration﹥2.5seconds
1. The constrained
pressure signal circuit is
short-circuited to the 5V
reference voltage or
power positive pole
2. Sensor is damaged
3. Pressure signal input
interface fault on ECM
1. Repair wire harness
2. Replace sensor
3. Replace ECM
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Fault code P0112 Intake temperature sensor circuit low voltage
Set up emergency control
plan:
Turn on the fault lights until the fault is gone
The air inlet temperature is equal to the coolant
temperature，but is no more than 44.25 C.
Wire connection
terminal:
MT62.1
Temperat
ure
Sensor
Normal
measuring
signal
Air inlet temperature
29 3 0.5～4.5V
Sensor signal ground: 45 4 0V
Judging condition Possible causes
Referred failure
troubleshooting
Engine running
time﹥120 seconds
MAT﹥-38.25C
fault duration time
﹥2.5 seconds
1. The connector is not solid
2. The temperature signal circuit
open 3. Sensor signal
ground open
4. The temperature signal circuit is
short-circuited to the positive pole
of the power supply
5. Sensor damage
6. signal input interface fault on
ECM
1. Plug again
2. Repair wire
harness 3.
Repair wire harness
4. Repair wire
harness 5.
Replace sensor
6. Replace ECM
Fault code P0113 Intake temperature sensor circuit high voltage
Set up emergency control
plan:
Turn on the fault lights until the fault is gone
The air inlet temperature is equal to the coolant
temperature
，
but is no more than 44.25 C.
Wire connection
terminal:
MT62.1
Air inlet
temperatu
re sensor
Normal
measuring
signal
Air inlet temperature
signal: 29 3 0.5～4.5V
Sensor signal ground: 45 4 0V
Judging condition Possible causes
Referred failure
troubleshooting
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Engine running time
﹥
60 seconds
MAT
﹥
148.5C
fault duration time
﹥
2
seconds
1. Temperature signal circuit is
short-circuited to earth
2. Sensor is damaged
3. Pressure signal input
interface fault on ECM
1. Repair wire harness
2. Replace sensor
3. Replace ECM
Fault code P0117 Coolant temperature sensor circuit low voltage
Set up emergency control
plan:
Turn on the fault lights until the fault is gone
Start with air inlet temperature, after increasing to
79.5 degrees over time
Fix it
Wire connection
terminal:
MT62.1
Coolant
temperature sensor
Normal
measuring
signal
Coolant temperature
signal: 20 A 0.5
～
4.5V
Sensor signal ground: 46 C 0V
Judging condition Possible causes
Referred failure
troubleshooting
Engine running
time
﹥
10 seconds
CTS
﹤
-38.25C
fault duration time
﹥
2 seconds
1. 1. The connector is not solid
2. The temperature signal circuit
open 3. Sensor signal
ground open
4. The temperature signal circuit is
short-circuited to the positive pole
of the power supply
5. Sensor damage
6. signal input interface fault on
ECM
1. Plug again
2. Repair wire harness
3. Repair wire harness
4. Repair wire harness
5. Replace sensor
6. Replace ECM
Fault code P0118
Coolant temperature sensor circuit high voltage or
open circuit
Set up emergency control
plan:
Turn on the fault lights until the fault is gone
Start with air inlet temperature, after increasing to
79.5 degrees over time
Fix it
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Wire connection
terminal:
MT62.1
Coolant temperature
sensor
Normal
measuring
signal
Coolant temperature
signal: 20 A 0.5
～
4.5V
Sensor signal ground: 46 C 0V
Judging condition Possible causes
Referred failure
troubleshooting
Engine running
time
﹥
2 seconds
CTS
﹥
135C
fault duration time
﹥
2 seconds
1. Temperature signal circuit is
short-circuited to earth
2. Sensor is damaged 3.
Pressure signal input interface
fault on ECM
1. Repair wire harness
2. Replace sensor
3. Replace ECM
Fault code P0122
ETC throttle valve position sensor
１＃
circuit low
voltage
Set up emergency control
plan:
Turn on the fault lights until the fault is gone
Idle ，set throttle valve position sensor opening 0%；
other opening changes with rotating speed
throttle valve position sensor auto-zero function
stops clear function stops
Wire connection
terminal:
MT62.1
Throttle valve
position sensor
Normal
measuring
signal
5V reference voltage: 39 A 5V
Throttle valve
position 1 signal: 14 D 0.5
～
4.5V
Sensor signal ground: 45 F 0V
Judging condition Possible causes
Referred failure
troubleshooting
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Engine running，
rotate speed﹤
3000rpm
no MAP fault，and
MAP﹤70kpa
fault duration time
﹥2 秒
1. sensor signal circuit is
short-circuited to to power
positive pole or reference voltage
circuit 2.
Sensor is damaged 3.
Pressure signal input interface
fault on ECM
1. Repair wire harness
2. Replace sensor
3. Replace ECM
Fault code P0123
ETC throttle valve position sensor 1＃ circuit high
voltage or open circuit
Set up emergency control
plan:
Turn on the fault lights until the fault is gone
When idling, set throttle valve position sensor
opening to 0%: other opening changes with rotating
speed throttle valve position sensor auto-zero
function stops clear function stops
Wire connection
terminal:
MT62.1
Throttle valve
position sensor
Normal
measuring
signal
5V reference voltage: 39 A 5V
Throttle valve
position 1 signal: 14 D 0.5～4.5V
Sensor signal ground: 45 F 0V
Judging condition Possible causes
Referred failure
troubleshooting
Duration time﹥2
seconds
1. The connector is not solid
2. sensor signal circuit open
3. Sensor signal has short circuit
to ground 4.
Sensor damage
5. signal input interface fault on
ECM
1. Plug again
2. Repair wire harness
3. Repair wire harness
4. Replace sensor
5. Replace ECM
Fault code P0131 Front oxygen sensor short circuit to low voltage
Set up emergency control
plan:
Turn on the fault lights until the fault is gone and
turn off the ignition switch System
closed - loop working time delayed
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Wire connection
terminal:
MT62.1
Heating
oxygen
sensor
Normal
measuring signal
System main power: \ D 12V
Heating drive: 41 C 0V
Oxygen sensor high
signal: 22
B
0～1000mV
fluctuation
Oxygen sensor low
signal: 46
A
0V
Judging condition Possible causes
Referred failure
troubleshooting
Duration time﹥1
seconds
1. Fuel filter heater drive circuit is
short circuited to the power supply
positive
2. Sensor damage
3. Signal output interface fault on
ECM
1. Repair wire
harness 2.
Replace sensor
3. Replace ECM
Fault code P0132 Front oxygen sensor short circuit to high voltage
Set up emergency control
plan:
Turn on the fault lights until the fault is gone and
turn off the ignition switch System
closed - loop working time delayed
Wire connection
terminal:
MT62.1
Heating
oxygen
sensor
Normal measuring
signal
System main power: \ D 12V
Heating drive: 41 C 0V
Oxygen sensor high
signal: 22
B
0～1000mV
fluctuation
Oxygen sensor low
signal: 46
A
0V
Judging condition Possible causes
Referred failure
troubleshooting
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No main relay
failure duration
time﹥1 seconds
1. The connector is not solid
2. The heating drives the circuit
open 3. Heat drive
line to ground short circuit
4. Sensor damage
5. signal input interface fault on
ECM
1. Plug again
2. Repair wire
harness 3.
Repair wire harness
4. Replace sensor
5. Replace ECM
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Fault code P0133 front oxygen sensor responds too slowly
Set up emergency control
plan:
Turn on the fault lights until the fault is gone and
turn off the ignition switch System
closed - loop working time delayed
Wire connection
terminal:
MT62.1
Heating
oxygen
sensor
Normal measuring
signal
System main power: \ D 12V
Heating drive: 41 C 0V
Oxygen sensor high
signal: 22
B
0～1000mV
fluctuation
Oxygen sensor low
signal: 46
A
0V
Judging condition Possible causes
Referred failure
troubleshooting
No main relay
failure duration
time﹥1 seconds
1. The connector is not solid
2. The heating drives the circuit
open 3. Heat drive
line to ground short circuit
4. Sensor damage
5. signal input interface fault on
ECM
1. Plug again
2. Repair wire
harness 3.
Repair wire harness
4. Replace sensor
5. Replace ECM
Fault code P0137 Rear oxygen sensor short circuit to low voltage
Set up emergency control
plan:
Turn on the fault lights until the fault is gone and
turn off the ignition switch System
closed - loop working time delayed
Wire connection
terminal:
MT62.1
Heating
oxygen
sensor
Normal measuring
signal
System main power: \ D 12V
Heating drive: 13 C 0V
Oxygen sensor high
signal: 42
B
0～1000mV
fluctuation
Oxygen sensor low 49 A 0V
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signal:
Judging condition Possible causes
Referred failure
troubleshooting
Duration time﹥1
seconds
1. Fuel filter heater drive circuit is
short circuited to the power supply
positive
2. Sensor damage
3. Signal output interface fault on
ECM
1. Repair wire
harness 2.
Replace sensor
3. Replace ECM
Fault code P0138 Rear oxygen sensor short circuit to high voltage
Set up emergency control
plan:
Turn on the fault lights until the fault is gone and
turn off the ignition switch System
closed - loop working time delayed
Wire connection
terminal:
MT62.1
Heating
oxygen
sensor
Normal measuring
signal
System main power: \ D 12V
Heating drive: 13 C 0V
Oxygen sensor high
signal: 42
B
0～1000mV
fluctuation
Oxygen sensor low
signal: 49
A
0V
Judging condition Possible causes
Referred failure
troubleshooting
No main relay
failure duration
time﹥1 seconds
1. The connector is not solid
2. The heating drives the circuit
open 3. Heat drive line
to ground short circuit
4. Sensor damage
5. signal input interface fault on
ECM
1. Plug again
2. Repair wire
harness 3.
Repair wire harness
4. Replace sensor
5. Replace ECM
Fault code P0222
ETC throttle valve position sensor 2＃circuit low
voltage
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Set up emergency control
plan:
Turn on the fault lights until the fault is gone
When idling, set throttle valve position sensor
opening 0%: other opening changes with rotating
speed throttle valve position sensor auto-zero
function stops clear function stops
Wire connection
terminal:
MT62.1
Throttle valve
position sensor
Normal
measuring
signal
5V reference voltage: 39 A 5V
Throttle valve
position 2 signal: 16 E 0.5～4.5V
Sensor signal ground: 45 F 0V
Judging condition Possible causes
Referred failure
troubleshooting
Engine running,
rotate speed﹤
3000rpm
No MAP fault and
MAP﹤70kpa
fault duration time
﹥2 seconds
1. sensor signal circuit is
short-circuited to to power
positive pole or reference voltage
circuit 2.
Sensor is damaged 3.
Pressure signal input interface
fault on ECM
1. Repair wire harness
2. Replace sensor
3. Replace ECM
Fault code P0223
ETC throttle valve position sensor 2＃ circuit high
voltage or open circuit
Set up emergency control
plan:
Turn on the fault lights until the fault is gone
When idling, set throttle valve position sensor
opening 0%: other opening changes with rotating
speed throttle valve position sensor auto-zero
function stops clear function stops
Wire connection
terminal:
MT62.1
Throttle valve
position sensor
Normal
measuring
signal
5V reference voltage: 39 A 5V
Throttle valve 16 E 0.5～4.5V
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position 2 signal:
Sensor signal ground: 45 F 0V
Judging condition Possible causes
Referred failure
troubleshooting
Duration time﹥2
seconds
1. The connector is not solid
2. sensor signal circuit open
3. Sensor signal has short
circuit to ground
4. Sensor damage
5. signal input interface fault
on ECM
1. Plug again
2. Repair wire harness
3. Repair wire harness
4. Replace sensor
5. Replace ECM
Fault code P0325 Knock sensor failure
Set up emergency control
plan:
Turn on the fault lights until the ignition switch is off
Adopt safe ignition advance angle table
Wire connection
terminal:
MT62.1 Knock sensor
Normal
measuring
signal
Knock signal high: 25 0-1V
Knock signal low: 37 0V
Judging condition Possible causes
Referred failure
troubleshooting
Engine rotate
speed﹥2000rpm
MAP﹥50kPa
fault duration time
﹥5 seconds
1. 1. The connector is not solid
2. The knock signal circuit open
3. Sensor signal ground short
circuit 4.
Knock signal other circuit short
circuit
5. Sensor damage
6. Signal output interface fault on
ECM
1. Plug again
2. Repair wire
harness 3.
Repair wire harness
4. Repair wire
harness 5.
Replace sensor
6. Replace ECM
J
A
C
-
2
0
0
5
0
1
2
4
江淮汽车 部门：客户服务部
Electronic
Control System
193
Fault code P0336 Crankshaft position sensor circuit signal interfere
Set up emergency control
plan:
Turn on the fault lights until the fault is gone
Wire connection
terminal:
MT62.1
Crankshaft position
sensor
Normal
measuring signal
Sensor signal : 33 A
>400mV sine
wave (with
sensor B)
Voltage signal: 38 C
>400mV sine
wave
（
with
sensor A
）
System ground wire: 46 B 0V
Judging condition Possible causes
Referred failure
troubleshooting
Engine running
The number of
teeth entering
ECM for 5
consecutive cycles
is not equal to 58
1. The signal line is badly shielded
2. There are metal objects in the
58x gear ring
1. Use shield wire
2. Clean 58x gear ring
Fault code P0337 Crankshaft position sensor circuit no signal
Set up emergency control
plan:
Turn on the fault lights until the fault is gone
the engine failed to start
Wire connection
terminal:
MT62.1
Crankshaft
position sensor
Normal
measuring signal
Sensor signal : 33 A
>400mV sine
wave (with
sensor B)
Voltage signal: 38 C
>400mV sine
wave
（
with
sensor A
）
System ground wire: 46 B 0V
Judging condition Possible causes
Referred failure
troubleshooting
J
A
C
-
2
0
0
5
0
1
2
4
江淮汽车 部门：客户服务部
Electronic
Control System
194
Start engine
No engine speed
signal MAP
reduces 2.9509kPa
System voltage
drops 0.8V
speed<4km/h
Duration time﹥2
seconds
1. The connector is not solid
2. The signal is reversed high and
low 3. Signal circuit
open 4.
Signal circuit other short circuit
5. Sensor damage
6. Signal input interface fault on
ECM
1. Plug again
2. Repair wire
harness 3.
Repair wire harness
4. Repair wire
harness 5.
Replace sensor
6. Replace ECM
Fault code P0341 Camshaft position sensor reasonable fault
Set up emergency control
plan:
Turn on the fault lights until the fault is gone
he injection sequence has a 50% chance of 360
degrees of dislocation
Wire connection
terminal:
MT62.1
Camshaft
position
sensor
Normal
measuring
signal
5V reference voltage: 39 C 5V
Camshaft signal: 21 A
0-5V square
wave
Sensor signal ground: 45 B 0V
Judging condition Possible causes
Referred failure
troubleshooting
Engine running
1. The connector is not
solid 2.
reference voltage circuit
open 3.
signal ground open
4. Camshaft signal open
5. Sensor damage
6. interface fault on
ECM
1. Plug again
2. Repair wire harness
3. Repair wire harness
4. Repair wire harness
5. Replace sensor
6. Replace ECM
Fault code P0340 Camshaft position sensor no signal
Set up emergency control
plan:
Turn on the fault lights until the fault is gone
The injection sequence has a 50% chance of 360
degrees of dislocation
Wire connection MT62.1 Camshaft position Normal
J
A
C
-
2
0
0
5
0
1
2
4
江淮汽车 部门：客户服务部
Electronic
Control System
195
terminal: sensor measuring
signal
5V reference voltage: 39 C 5V
Camshaft signal: 21 A
0-5V square
wave
Sensor signal ground: 45 B 0V
Judging condition Possible causes
Referred failure
troubleshooting
Engine running
1. The connector is not solid
2. reference voltage circuit open
3. signal ground open
4. Camshaft signal open
5. Sensor damage
6. interface fault on ECM
1. Plug again
2. Repair wire harness
3. Repair wire harness
4. Repair wire harness
5. Replace sensor
6. Replace ECM
J
A
C
-
2
0
0
5
0
1
2
4
江淮汽车 部门：客户服务部
Electronic
Control System
196
Fault code P0351 1# ignition coil malfunction
Set up emergency control
plan:
Turn on the fault lights until the fault is gone
Stop spraying oil on 1 cylinder
The target idling is raised to 1200rpm
Wire connection
terminal:
MT62.1 Ignition coil
Normal
measuring
signal
System main power: \ 12V
1 cylinder drive: 35
0-12V
approximate
square wave
signal induction
peak>300V
Judging condition Possible causes
Referred failure
troubleshooting
Duration time
﹥
1.25 seconds
1. 1 cylinder drive circuit and
power positive short circuit
2. Ignition coil is damaged
3. ECM fault
1. Repair wire harness
2. Replace ignition
coil 3. Replace
ECM
Fault code P0352 2# ignition coil malfunction
Set up emergency control
plan:
Turn on the fault lights until the fault is gone
Stop spraying oil on 1 cylinder
The target idling is raised to 1200rpm
Wire connection
terminal:
MT62.1 Ignition coil
Normal
measuring
signal
System main power: \ 12V
2 cylinder drive: 48
0-12V
approximate
square wave
signal induction
peak>300V
J
A
C
-
2
0
0
5
0
1
2
4
江淮汽车 部门：客户服务部
Electronic
Control System
197
Judging condition Possible causes
Referred failure
troubleshooting
Duration time﹥
1.25 seconds
1. 2 cylinder drive circuit and
power positive short circuit
2. Ignition coil is damaged
3. ECM fault
1. Repair wire harness
2. Replace ignition
coil 3. Replace
ECM
J
A
C
-
2
0
0
5
0
1
2
4
江淮汽车 部门：客户服务部
Electronic
Control System
198
Fault code P0353 3# ignition coil malfunction
Set up emergency control
plan:
Turn on the fault lights until the fault is gone
Stop spraying oil on 1 cylinder
The target idling is raised to 1200rpm
Wire connection
terminal:
MT62.1 Ignition coil
Normal
measuring
signal
System main power: \ 12V
3 cylinder drive: 36
0-12V
approximate
square wave
signal induction
peak>300V
Judging condition Possible causes
Referred failure
troubleshooting
Duration time﹥
1.25 seconds
1. 3 Cylinder drive circuit and
power positive short circuit
2. Ignition coil is damaged
3. ECM fault
1. Repair wire harness
2. Replace ignition
coil 3. Replace
ECM
Fault code P0354 4# ignition coil malfunction
Set up emergency control
plan:
Turn on the fault lights until the fault is gone
Stop spraying oil on 1 cylinder
The target idling is raised to 1200rpm
Wire connection
terminal:
MT62.1 Ignition coil
Normal
measuring
signal
System main power: \ 12V
4 cylinder drive: 47
0-12V
approximate
square wave
signal induction
peak>300V
Judging condition Possible causes
Referred failure
troubleshooting
Duration time
﹥
1.25 seconds
1. 4 cylinder drive circuit and
power positive short circuit
2. Ignition coil is damaged
3. ECM fault
1. Repair wire harness
2. Replace ignition
coil 3. Replace
ECM
Fault code P0458
Carbon canister electromagnetic valve short circuit
to low voltage
J
A
C
-
2
0
0
5
0
1
2
4
江淮汽车 部门：客户服务部
Electronic
Control System
199
Set up emergency control
plan:
Turn on the fault lights until the fault is gone
close charcoal canister solenoid valve
Wire connection
terminal:
MT62.1
Carbon canister
solenoid valve
Normal
measuring
signal
System main power: \ B 12V
Solenoid valve drive: 03 A
0-12V square
wave
Judging condition Possible causes
Referred failure
troubleshooting
Duration time
﹥
2
seconds
1. Solenoid valve drive circuit has
short circuit to the system power
positive
2. Solenoid valve damage
3. ECM fault
1. Repair wire
harness
2. Replace control
valve 3.
Replace ECM
Fault code P0459
Carbon canister electromagnetic valve short circuit
to high voltage
Set up emergency control
plan:
Turn on the fault lights until the fault is gone
close charcoal canister solenoid valve
Wire connection
terminal:
MT62.1
Carbon canister
solenoid valve
Normal
measuring
signal
System main power: \ B 12V
Solenoid valve drive: 03 A
0-12V square
wave
Judging condition Possible causes
Referred failure
troubleshooting
Duration time﹥5
seconds
1. The connector is not solid
2. Solenoid valve drive circuit has
short circuit to the system power
negative pole 3.
Solenoid valve drive circuit open
4. the circuit connected with
system main power circuit open
5. Solenoid valve damage
6. fault on ECM
1. Plug again
2. Repair wire harness
3. Repair wire harness
4. Repair wire harness
5. Replace solenoid
valve 6.
Replace ECM
J
A
C
-
2
0
0
5
0
1
2
4
江淮汽车 部门：客户服务部
Electronic
Control System
200
Fault code P0482 PWM fan failure
Set up emergency control
plan:
Turn on the fault lights until the fault is gone
Fan does not working (open circuit); The high speed
fan starts and works constantly when the water
temperature rises to 98 degrees（short circuit to
ground）
Wire connection
terminal:
MT62.1 Cooling fan relay
Normal
measuring
signal
Battery: \
Instructions
provided by car
factory 12V
Low speed fan relay
drive:
04
Instructions
provided by car
factory
0V
(working),12V
(stopping)
High speed fan relay
drive:
05
Instructions
provided by car
factory
0V
(working),12V
(stopping)
Judging condition Possible causes
Referred failure
troubleshooting
Duration time﹥3
seconds
1. The connector is not solid
2. Relay drive circuit has short
circuit to the system power
negative pole 3.
Relay drive circuit open
4. The circuit connected with
battery is open
5. Relay damage
6. ECM fault
1. Plug again
2. Repair wire harness
3. Repair wire harness
4. Repair wire harness
5. Replace relay
6. Replace ECM
Fault code P0562 System voltage is low
Set up emergency control
plan:
Turn on the fault lights until the fault is gone
The system stopped spraying oil
Wire connection
terminal:
MT62.1 Ignition switch
Normal
measuring
J
A
C
-
2
0
0
5
0
1
2
4
江淮汽车 部门：客户服务部
Electronic
Control System
201
signal
Ignition switch: 26
Refer to electrical
system instructions
12V
Judging condition Possible causes
Referred failure
troubleshooting
Turn on ignition
switch
system voltage﹤
7.6V duration
time>5seconds
1. The generator regulator is
damaged 2. Wrong
usage of low voltage battery
1.Replace the damaged
generator regulator 2.
Use correct battery
Fault code P0563 System voltage is high
Set up emergency control
plan:
Turn on the fault lights until the fault is gone
The system stopped spraying oil
Wire connection
terminal:
MT62.1 Ignition switch
Normal
measuring
signal
Ignition switch: 26
Refer to electrical
system instructions
12V
Judging condition Possible causes
Referred failure
troubleshooting
Turn on ignition
switch
system voltage〉
17.2V duration
time〉5seconds
1. The generator regulator is
damaged 2. Wrong
usage of high voltage battery
1.Replace the damaged
generator regulator 2.
Use correct battery
Fault code P2122
Electronic accelerator pedal position sensor 1#
circuit low voltage
Set up emergency control
plan: Turn on the fault lights until the fault is gone
Wire connection
terminal:
MT62.1
Accelerat
or
position
sensor 1
Normal
measuring
signal
J
A
C
-
2
0
0
5
0
1
2
4
江淮汽车 部门：客户服务部
Electronic
Control System
202
5V reference voltage: 51 2 5V
Accelerator pedal
signal 1: 35 4 0.5
～
4.5V
Sensor signal ground: 50 3 0V
Judging condition Possible causes
Referred failure
troubleshooting
Engine running
Failure duration time
﹥
2.5 seconds
1. Accelerator position
sensor signal circuit is
short-circuited to the 5V
reference voltage or
power positive pole
2. Sensor is damaged
3. Pressure signal input
interface fault on ECM
1. Repair wire harness
2. Replace sensor
3. Replace ECM
Fault code P2123
Electronic accelerator pedal position sensor 1#
circuit high voltage
Set up emergency control
plan: Turn on the fault lights until the fault is gone
Wire connection
terminal:
MT62.1
Accelerat
or
position
sensor 1
Normal
measuring
signal
5V reference voltage: 51 2 5V
Accelerator pedal
signal 1: 35 4 0.5
～
4.5V
Sensor signal ground: 50 3 0V
Judging condition Possible causes
Referred failure
troubleshooting
J
A
C
-
2
0
0
5
0
1
2
4
江淮汽车 部门：客户服务部
Electronic
Control System
203
Engine running
Failure duration time
﹥
2.5 seconds
1. 1. The connector is not solid
2. Sensor signal circuit open
3. Sensor signal has short circuit
to ground
4. 5. Sensor damage
5. Signal input interface fault
on ECM
5. fault
1. Plug again
2. Repair wire
harness
3. Repair wire
harness
4. Replace
sensor 5.
Replace ECM
Fault code P2127
Electronic accelerator pedal position sensor 2#
circuit low voltage or open circuit
Set up emergency control
plan: Turn on the fault lights until the fault is gone
Wire connection
terminal:
MT62.1
Accelerat
or
position
sensor 2
Normal
measuring
signal
5V reference voltage: 37 1 5V
Accelerator pedal
signal 2: 61 6 0.5～4.5V
Sensor signal ground: 49 5 0V
Judging condition Possible causes
Referred failure
troubleshooting
Engine running
Failure duration time﹥
2.5 seconds
1. Accelerator position
sensor signal circuit is
short-circuited to the 5V
reference voltage or
power positive pole
2. Sensor is damaged
3. Pressure signal input
interface fault on ECM
1. Repair wire harness
2. Replace sensor
3. Replace ECM
Fault code P2128
Electronic accelerator pedal position sensor 2#
circuit high voltage
Set up emergency control
plan: Turn on the fault lights until the fault is gone
J
A
C
-
2
0
0
5
0
1
2
4
江淮汽车 部门：客户服务部
Electronic
Control System
204
Wire connection
terminal:
MT62.1
Accelerat
or
position
sensor 1
Normal
measuring
signal
5V reference voltage: 37 1 5V
Accelerator pedal
signal 1: 61 6 0.5
～
4.5V
Sensor signal ground: 49 5 0V
Judging condition Possible causes
Referred failure
troubleshooting
Engine running
Failure duration time﹥
2.5 seconds
1. 1. The connector is not
solid 2.
Sensor signal circuit open
3. Sensor signal has short
circuit to ground
4. Sensor damage
5. signal input interface
fault on ECM
1. Plug again
2. Repair wire
harness
3. Repair wire
harness
4. Replace
sensor 5.
Replace ECM