Professional Documents
Culture Documents
Geely Automobile
Engine ....................................................................................................................................... 1
No.001 Engine shuts off abnormally when driving..................................................................... 1
No.002 Engine surging .............................................................................................................. 3
No.003 Over idle speed when warm-up .................................................................................... 5
No.004 Idle speed fluctuation .................................................................................................... 7
No.005 Idle speed unstable or engine shut-off when opening AC or steering ........................... 9
No.006 Engine shuts off intermittently ..................................................................................... 11
No.007 Poor accelerating performance in cold condition ........................................................ 13
No.008 Spark plug non-sparking ............................................................................................. 15
No.009 Low idle speed during engine heating in cold condition .............................................. 17
No.010 Canister oil leaking...................................................................................................... 19
No.011 Fuel smells in vehicle .................................................................................................. 20
No.012 Engine vibration when operating................................................................................. 22
No.013 Engine noise over normal level ................................................................................... 24
No.014 Water temperature over normal value after AC activated............................................ 26
No.015 Oil pan leak ................................................................................................................. 27
No.016 Distributor oil leaking................................................................................................... 29
No.017 JL376/378 engine shut-off when sliding at neutral gear.............................................. 30
No.018 High idle speed when sliding at neutral gear, MK ....................................................... 32
No.019 Engine vibration .......................................................................................................... 33
No.020 Exhaust pipe pours black smoke ................................................................................ 34
No.021 Engine idle speed decreases when activating head beam or fan ............................... 36
No.022 Exhaust pipe blows water ........................................................................................... 38
No.023 Engine shuts off when accelerating ............................................................................ 39
No.024 Oil indicator is always on ............................................................................................ 41
No.025 Water temperature is over normal value when engine running with large load ........... 42
No.026 Canister electromagnetic valve sounds abnormal....................................................... 44
No.027 Engine fails to start ..................................................................................................... 45
No.028 Hard to start in cold condition...................................................................................... 47
No.029 Hard to stard engine when heating ............................................................................. 49
No.030 Idle speed unstable..................................................................................................... 51
Common Malfunction Diagnosis Flow of Geely Automobile
No.091 Malfunction code: P0336 “crankshaft position sensor signal with unreasonable
malfunction” ............................................................................................................. 143
No.092 Malfunction code: P0340 “Phase sensor signal malfunction”.................................... 144
No.093 Malfunction code: P0342 “circuit voltage of phase sensor too low”........................... 144
No.094 Malfunction code: P0343 “circuit voltage of phase sensor too high” ......................... 145
No.095 Malfunction code: P0443 "Malfunction of control circuit of driver stage of canister
control valve" ...........................................................................................................146
No.096 Malfunction code: P0444 "voltage of control circuit of driver stage of canister control
valve too low" ........................................................................................................... 146
No.097 Malfunction code: P0445 "voltage of control circuit of driver stage of canister control
valve too high" .........................................................................................................147
No.098 Malfunction code: P0480 "malfunction control circuit of cooling fan relay of AC
condenser"............................................................................................................... 148
No.099 Malfunction code: P0500 "unreasonable malfunction of speed signal" ..................... 148
No.100 Malfunction code: P0506 "idling speed lower than target speed value" .................... 149
No.101 Malfunction code: P0507 "idling speed higher than target speed value"................... 149
No.102 Malfunction code: P0508 "voltage of control circuit of idling speed governor too low"
................................................................................................................................. 149
No.103 Malfunction code: P0509 "voltage of control circuit of idling speed governor too high"
................................................................................................................................. 150
No.104 Malfunction code: P0511 "malfunction control circuit of idling speed governor"........ 150
No.105 Malfunction code: P0560 "unreasonable system voltage signal" .............................. 150
No.106 Malfunction code: P0562 "system voltage too low" ................................................... 151
No.107 Malfunction code: P0563 "system voltage too high" ................................................. 151
No.108 Malfunction code: P0601 "error of check code of electronic control unit".................. 152
No.109 Malfunction code: P0602 "error of identification code of diagnosis data of electronic
control unit" .............................................................................................................. 152
No.110 Malfunction code: P0645 "malfunction of relay control circuit of AC compressor"..... 152
No.111 Malfunction code: P0646 "voltage of relay control circuit of AC compressor too low" 153
No.112 Malfunction code: P0647 "voltage of relay control circuit of AC compressor too high"
................................................................................................................................. 154
No.113 Malfunction code: P1508 "voltage of control circuit of idling speed governor too high"
................................................................................................................................. 155
No.114 Malfunction code: P1651 "malfunction of control circuit of engine malfunction lamp
(SVS)" ...................................................................................................................... 155
Common Malfunction Diagnosis Flow of Geely Automobile
No.115 Engine not running or slowly running while startup ................................................... 157
No.116 While startup, engine running, but unable to start ..................................................... 158
No.117 Difficult to start for hot startup.................................................................................... 159
No.118 Difficult to start for cold startup .................................................................................. 160
No.119 Difficulty startup at any time though with normal speed ............................................ 161
No.120 Normal startup with instable idling speed at any time ............................................... 162
No.121 Normal startup, with instable idling speed during warming up .................................. 163
No.122 Normal startup, with instable idling speed after warming up ..................................... 164
No.123 Normal startup, idling speed is instable or the vehicle will flame out when partially
loaded (such as: when air conditioner is on) ............................................................ 165
No.124 Normal startup, the idling speed is too high .............................................................. 166
No.125 Unable to rotating speed or flameout while accelerating........................................... 167
No.126 Slow reaction while accelerating ............................................................................... 168
No.127 Weak with poor performance while accelerating....................................................... 169
No.128 Malfunction code with EOBD system ........................................................................ 170
No.129 Malfunction code without EOBD system ................................................................... 174
Electrics ...............................................................................................................................263
No.189 CD-player disk boot malfunction (without MP3) ........................................................ 263
No.190 CD-player fails to work when activating .................................................................... 265
No.191 CD-player keeps soundless under all modes............................................................ 265
No.192 CD-player/radio gains no power................................................................................ 267
No.193 A loudspeaker of CD-player/radio is soundless......................................................... 268
No.194 Onboard hand-free phone has no sound output (MK)............................................... 269
No.195 CD-player/radio button out of control ........................................................................ 271
No.196 CD-player/radio button indicator malfunction ............................................................ 271
No.197 CD-player/radio memory function malfunction .......................................................... 273
No.198 CD-player/radio no signal ......................................................................................... 273
No.199 CD-player/radio sound distortion at large volume ..................................................... 274
No.200 CD-player/radio tuner can’t stop ............................................................................... 275
No.201 CD-player/radio has noise when receiving signal ..................................................... 276
No.202 CD-player fails to insert disk ..................................................................................... 277
No.203 CD-player fails to popup disk .................................................................................... 279
No.204 CD-player with poor vibration resistance performance ............................................. 280
No.205 USB interface of CD –player malfunction (U-disk) (MK) ........................................... 281
No.206 CD-player burns out when connecting power source................................................ 283
No.207 CD-player consists back drop ................................................................................... 284
No.208 Cassette stuck or failed to popup.............................................................................. 286
No.209 Cassette speed abnormal, turned over automatically and chewed ........................... 287
No.210 Poor timbre, low volume or noise jump when playing CD ......................................... 289
Common Malfunction Diagnosis Flow of Geely Automobile
No.277 The sun sensor is in poor condition.(code display 05) .............................................. 378
No.278 The fan governing module is in poor condition; (code display 06).......................... 378
No.279 The high speed relay is in poor condition; (code display 07) .................................... 379
No.280 The rear defrosting function is invalid ....................................................................... 379
No.281 The display screen has no display ............................................................................ 380
No.282 The internal and external circulation regulation is invalid.......................................... 380
No.283 The wind direction adjustment is abnormal ............................................................... 381
No.284 The blower is in poor operation................................................................................. 381
No.285 Vehicle interior air conditioning is in poor condition................................................... 382
No.286 Vehicle interior central heating is in poor condition ................................................... 383
No.287 Night light regulation function of the a/c controller is invalid...................................... 383
No.288 The compressor is out of service .............................................................................. 384
No.289 Effect of the air conditioning is in poor condition (check it per the content in the
following table) .........................................................................................................384
No.290 Installation and Commissioning of the Air Conditioning ............................................ 386
No.291 Line inspection of "EPS" indicating lamp (the "EPS" indicator does not light up when
the ignition switch is opened) ................................................................................... 397
No.292 Inspection to "EPS" indicator line ("EPS" indicator does not light up or keep on lighting
up when the cross-line connection is made between the diagnoses switch terminal and
the ground terminal)................................................................................................. 398
No.293 Main line of DTC11 torque sensor (the main line is broken or short circuit) .............. 398
No.294 DTC13 torque sensor (there is big difference between the auxiliary line outputs of the
main line and the torque sensor).............................................................................. 398
No.295 DTC14 torque sensor (power supply voltage of the torque sensor is too high or too low)
................................................................................................................................. 399
No.296 Auxiliary line of DTC15 torque sensor (the auxiliary line is disconnected or short circuit)
................................................................................................................................................. 399
No.297 DTC22 engine speed signal (no engine signal input)................................................ 399
No.298 Vss line(Vss line is disconnected or short circuit) ........................................................................401
No.299 DTC41 motor (the motor voltage is too high or too low)............................................ 401
No.300 DTC51 clutch line (the clutch line is disconnected or short)...................................... 401
No.301 Power circuit of DTC54 control module (low voltage of the battery) ....................... 402
No.302 DTC52 and DTC55 control modules (failure of control module)................................ 402
No.303 Voltage inspection.....................................................................................................402
Common Malfunction Diagnosis Flow of Geely Automobile
Engine
No. 001 Engine shuts off abnormally when driving
Malfunction Cause Solution
Check the injection volume and the atomization of the injector, whether they are
normal, clean or replace the injector when necessary.
Low fuel pressure or
injector blockage Check fuel pressure. When idling the value shall correspond to 265~304 kPa, when
accelerating the value shall increase approximately 50 kPa. If fuel pressure is too
low, check fuel pressure controller, electric fuel pump and fuel filter etc.
Check engine ignition timing. When idling, the ignition advance angle shall be
Improper ignition
10~12°. Otherwise, shall adjust engine initial advance angle. When accelerating,
timing, engine shuts
the ignition advance angle shall over 20~30°, automatically adjusted. Otherwise,
off sometimes
shall replace ECU or maintain ignition controlling system.
Check valve clearance, whether it is too small. When heating, the clearance of air
Valve clearance too intake and exhaust valve shall be 0.20±0.05mm, otherwise, adjust it to prescribed
small or throttle body value according to maintenance manual.
too dirty Check throttle body, whether it is too dirty. Clean throttle body and idle speed
controller when necessary.
When applying poor quality fuel, the fuel pipe must be cleaned then replace
Fuel quality problem
standard gasoline, 93# or above.
Spark plug Check spark plug resistance, whether the value is 5~8KΩ, as well as the clearance,
malfunction whether the value is 0.8~1.0mm. Otherwise, shall adjust or replace them.
Ignition coil Check ignition coil, the initial winding shall be 0.4~0.6Ω, and the 2nd winding shall be
malfunction 11~15Ω. Otherwise, shall replace ignition coil.
Spark plug wire If there is short or open circuit in spark plug wire, then shall replace it.
Idle speed control
Engine shuts valve or stepper motor When stuck, shall clean or replace it.
off in normal malfunction
driving, such
as geared Check the relay by multimeter, whether it is connected, as well as the coil
Fuel pump relay burnt
driving or resistance, whether the value is 75~90Ω. Replace when necessary.
cornering Determine whether it is valve gumming, according to local and gasoline using
condition. Generally, the malfunction appears in cold condition, and will disappear
Valve gumming
after vehicle heated. It is recommended that driver shall clean engine without
components removing, meanwhile, replace qualified gasoline.
ECU harness pin poor Check ECU, whether it is poor contact, which results signal deviation when idling,
contact as well as abnormal shut-off. Fasten wire connector again, when necessary.
Three way catalytic Check three way catalytic converter, whether it is free-flowing, as well as the
converter damaged or housing, whether there is collision mark. Replace the converter assembly when
blocked necessary.
Temperature sensor part (pin disconnected) pin 1# and 2#: the rated resistance at
20℃ is 2.5KΩ±5%, and the value shall decrease when temperature raising.
Pressure sensor part (pin connected): black pen connects to earth; red pen
Pressure temperature
connects with pin 3# and 4# respectively. In idle condition, the reference voltage on
sensor malfunction
pin 3# shall be 5V, and the voltage on pin 4# shall be approximately 1.3V
(determined by vehicle). If the value abnormal, then the pressure temperature
sensor is damaged and shall be replaced.
Check main ECU wire harness connectors, whether they are fixed, as well as poor
connecting caused by rust and oxidation. Clean and fix it when necessary. Load
Poor ECU signal
data stream by K61 detector, and check the display value of ECU, whether it
coordinates to the standard. Replace ECU when necessary.
Check engine compression ratio and pressure, whether they are corresponding with
the standard value:
Insufficient engine
cylinder pressure 479Q 9.3: 1/1250kpa/250r/min; 479QA 9.8: 1/1440kpa/250r/min; 481Q9.4:
1/1360kpa/250r/min; JI376QE9.5: 1/1225kpa/350r/min; JL378QE 9.5: 1 /
1225kpa/350r/min; audit and maintain engine when necessary.
1
Common Malfunction Diagnosis Flow of Geely Automobile
Abnormal
Spark plug, ignition coil, spark plug wire
malfunction Replace
Normal Improper
Normal
Abnormal
Valve clearance too small or throttle body too dirty Adjust and clean
Normal
Abnormal
Normal Abnormal
Three way catalytic converter damaged or Replace
blocked
Normal Burnt
Normal Abnormal
Normal
Abnormal
Normal
Abnormal
Normal
Abnormal
Idle speed control valve or stepper motor Clean or replace
malfunction
Normal
Too low or bocked
Low fuel pressure or injector blockage
Check or replace
Normal
Abnormal
2
Common Malfunction Diagnosis Flow of Geely Automobile
3
Common Malfunction Diagnosis Flow of Geely Automobile
Engine surging
Blocked
Fuel fliter blockage
Clean or replace
Normal
Poor
Check the injector whether it is blocked or poor
atomized Clean or replace
Normal
Low
Low fuel pressure
Maintain
Normal
Leak
Intake system leaking
Maintain
Normal
Poor
Poor ignition
Maintain or replace
Normal
Abnormal
Charcoal canister
Replace
Normal
Abnormal
Engine valve clearance Adjust
Normal
Abnormal
Engine ignition timing
Adjust
Normal
Abnormal
Idle motor Clean or replace
Normal
Abnormal
Engine mechanical parts Check
4
Common Malfunction Diagnosis Flow of Geely Automobile
5
Common Malfunction Diagnosis Flow of Geely Automobile
Abnormal
Water temperature sensor malfunction
Replace
Normal
Abnormal
Oxygen sensor malfunction Replace
Normal
Abnormal
Intake system leaking Check
Normal
Stuck
Idle speed control valve or stepping motor stuck
Clean or replace
Normal
Abnormal
Incorrect fuel pressure Check
Normal
Abnormal
A/C control signal error
Check
Normal
Abnormal
Improper ignition time (too early)
Adjust
Normal
Abnormal
Throttle cable or damper malfunction Maintain
Normal
Abnormal
Replace
ECU inner malfunction
6
Common Malfunction Diagnosis Flow of Geely Automobile
7
Common Malfunction Diagnosis Flow of Geely Automobile
Stuck, dirty
Clean
Throttle is stuck and dirty
Normal
Abnormal
Adjust
Ignition maladjustment
Normal
Abnormal
Exhaust system malfunction Check or replace
Normal
Abnormal
Voltage unstable Check or replace
Normal
Abnormal
Sensor and executive unit malfunction
Replace
Normal
Abnormal
ECU malfunction Replace
Normal
Abnormal
Engine mechanical malfunction Check
8
Common Malfunction Diagnosis Flow of Geely Automobile
No. 005 Idle speed unstable or engine shut-off when opening AC or steering
Malfunction Cause Solution
AC compressor over load (for example, coolant over filling, tube blocked,
Compressor or booster
condenser is dirty, and etc.), belt over tensioned, compressor inner stuck, as well
pump malfunction
as booster pump inner rotor stuck and results over load.
When intake manifold leaking, repair or replace relevant component. When valve
Intake system abnormal
clearance disalignment, adjust it. When air filter blocking, replace it.
Replace oil pump, when it operates abnormally. Fuel filter blocked, replace it.
Oil line pressure abnormal Fuel pressure controller operates abnormally, replace it. Oil pump relay poor
contact, maintain or replace it.
9
Common Malfunction Diagnosis Flow of Geely Automobile
Abnormal
Compressor or booster pump failure
Check or replace
Normal
Abnormal
Normal
Abnormal
Oil line pressure abnormal Check or replace
Normal
Abnormal
AC switch or booster pump oil pressure sensor Replace
malfunction
Normal Abnormal
Clean or replace
Idle speed controller or stepping mortor malfunction
Normal Abnormal
Injector malfunction Clean or replace
Normal
Abnormal
Improper ignition timing or weak jump-spark power Adjust or replace
Normal Abnormal
ECU malfunction Replace
Normal Abnormal
10
Common Malfunction Diagnosis Flow of Geely Automobile
11
Common Malfunction Diagnosis Flow of Geely Automobile
Abnormal
Improper fuel pressure
Maintain or replace
Normal
Burnt
Fuel pump relay conducting point burnt
Replace
Normal
Abnormal
Idle speed control valve or stepping motor is dirty or
stuck Check or replace
Normal
Abnormal
Fuel pollution Replace
Normal
Abnormal
Ignition coil malfunction Replace
Normal
Abnormal
Canister oil leaking Check or replace
Normal
Blocked
Exhaust system blocked
Check or replace
Normal
Abnormal
Oxygen sensor malfunction
Replace
Normal
Abnormal
Improper valve clearance
Adjust
Normal
Abnormal
Crankcase venting device malfunction
Check
Normal
Abnormal
Fuel tank inner vacuum Check
Normal Abnormal
Replace
Spark plug and ignition wire malfunction
Normal Abnormal
12
Common Malfunction Diagnosis Flow of Geely Automobile
Air filter blocked Check air filter, whether it is blocked, clean or replace it when
necessary.
Check cylinder pressure, whether there is carbon deposit at
intake valve, as well as valve leaking and cylinder wearing
Low cylinder pressure
malfunction. Maintain or replace then according to the
malfunction.
Idle speed controlling valve or
Clean or replace idle speed control valve or stepping motor
stepping motor operates abnormal
Poor accelerating Check throttle body, whether it is stuck, clean or replace it
performance in cold Throttle malfunction
when necessary.
condition,
particularly in low Check ignition coil, wire and spark plug, whether they are
Ignition system malfunction
speed and middle malfunction, replace them when necessary.
speed.
Pressure sensor malfunction. Check the resistance and
Intake temperature pressure sensor voltage, whether the value is in normal range. Replace the
sensor when necessary.
Check oxygen sensor, whether the heating function is normal.
Oxygen sensor malfunction As well as the voltage signal, whether it varies between 0.1V
and 0.9V.
Check the vacuum, whether the value is in normal range.
Intake manifold leaking Check the connecting condition of each vacuum hose, as well
as intake/exhaust manifold gasket, whether it is damaged.
Check tachometer sensor signal and ignition datum, whether
Ignition timing maladjustment
they are normal.
Check ECU, whether it is malfunction. Check connecting wire,
ECU and connecting circuit
whether it is of poor contact. Maintain or replace it when
malfunction
necessary.
13
Common Malfunction Diagnosis Flow of Geely Automobile
Lack
Improper gasoline quality or low gasoline Check or replace
pressure
Normal
Blocked
Air filter blockage Clean
Normal
Low
Low cylinder pressure
Check
Normal
Stuck
Idle speed valve or throttle malfunction Check
Normal
Abnormal
Ignition system malfunction Check or replace
Normal
Abnormal
Intake temperature pressure sensor Replace
Normal
Abnormal
Oxygen sensor malfunction
Replace
Normal
Abnormal
Intake manifold leaking
Check
Normal
Abnormal
Ignition timing maladjustment Check and adjust
Normal
Abnormal
ECU and connecting wire malfunction Check or replace
14
Common Malfunction Diagnosis Flow of Geely Automobile
15
Common Malfunction Diagnosis Flow of Geely Automobile
Abnormal
Ignition coil malfunction Replace
Normal
Abnormal
Spark plug malfunction Adjust or replace
Normal
Abnormal
Distributor cover or distributor arm malfunction
Replace
Normal
Abnormal
Ignition wire malfunction Replace
Normal
Abnormal
Tachometer sensor failure or the Hall sensor in Replace
distributor malfunction
Normal
Abnormal
ECU malfunction
Replace
Normal
Abnormal
Ignition control system circuit malfunction Check
Normal
Abnormal
Engine anti-thief control system malfunction Replace
16
Common Malfunction Diagnosis Flow of Geely Automobile
No. 009 Low idle speed during engine heating in cold condition
Malfunction Cause Solution
Check ignition coil, wire and spark plug, whether they are normal. Adjust or
Weak ignition spark
replace them when necessary.
Crankcase venting Check PCV valve, whether it is normal. Replace crankcase venting device when
device fails necessary.
Measure vacuum, check the connecting condition of manifold gasket, throttle
Intake system leaking
gasket, and all vacuum pipes.
Check thermostat, whether it is leaking, which results warm-up period over
Thermostat malfunction
normal value. Replace thermostat when necessary.
Measure the resistance (UAES idle speed valve 17.6Ω, Delphi motor 53Ω,
Idle speed valve
Polarsun motor 48±2.4Ω) and voltage of idle motor, whether they are normal.
(steeping motor)
Check idle speed motor, whether it is dirty and stuck. Maintain and replace it
maladjustment
when necessary.
Adjust valve clearance: on 4-cylinder engine, the intake valve clearance shall
Improper valve be 0.20±0.05 mm, the exhaust valve clearance shall be 0.30±0.05mm. On
clearance 3-cylinder engine, the intake/exhaust valve clearance shall be 0.20±0.05mm
when warming-up, and 0.12±0.04mm in cold condition.
Check engine compression ratio and pressure, whether they are in accordance
Low idle speed with standard value. 479Q 9.3: 1/1250kpa/250r/min; 479QA 9.8:
during engine 1/1440kpa/250r/min; 481Q 9.4: 1/1360kpa/250r/min; JI376QE 9.5:
heating in cold Low cylinder pressure
1/1225kpa/350r/min; JL378QE 9.5: 1 / 1225kpa/350r/min; Inspemction the
condition cause, whether valve leaking or piston ring and cylinder wearing. Disassembly
and maintain the engine when necessary.
Check the resistance of water temperature sensor in cold condition (UAES
2.5kΩ, at 20℃; Delphi 3.56~2.26kΩ, at 20~30℃; Polarsun 2.5kΩ, at 20℃),
Water temperature
whether they are in accordance with standard. Or measure the temperature of
sensor damaged
cold vehicle by scanner, whether it is in accordance with actual engine
temperature. Replace coolant fluid temperature sensor when necessary.
Check injector, whether it is blocked or stuck. Check atomization and implement
Injector malfunction
leak test. Clean or replace injector.
Check heat-type oxygen sensor heater resistance (UAES 1~6Ω, Delphi 12Ω,
Polarsun 13.2Ω±10%), as well as heater voltage, 12V, and signal voltage,
Oxygen sensor
0.1~0.9V, whether they are in normal range. Check sensor surface, whether it is
malfunction
dirty and results voltage over normal value, as well as the fuel-air mixture is too
thin.
Check ignition time and calibrate ignition timing, in idle condition: on 4-cylinder
Ignition timing
engine, the ignition advance angle shall be 10°~12° before top dead center. On
maladjustment
3-cylinder engine, the value shall be 12°±3.75° before top dead center.
ECU malfunction Check connecting conditions of ECU and all wires.
17
Common Malfunction Diagnosis Flow of Geely Automobile
Abnormal
Weak ignition spark Check and replace
Normal
Abnormal
Crankcase venting device failure Check
Normal
Damaged
Replace
Water temperature sensor damaged
Normal
Abnormal
Replace
Thermostat failure
Normal
Abnormal
Normal
Abnormal
Check
Intake system leaking
Normal
Abnormal
Ignition timing maladjustment
Check
Normal Low
Check
Low cylinder pressure
Normal Abnormal
Normal
Abnormal
Oxygen sensor malfunction Replace
Normal
Abnormal
ECU malfunction Replace
18
Common Malfunction Diagnosis Flow of Geely Automobile
Damaged
Check valve damage, on fuel tank Replace
Normal
Damaged
Fuel tank cover damage
Replace
Normal
Damaged
Controlling canister malfunction
Replace
Normal
Blocked
Pipe blocked, on top of canister
Check
Normal
Damaged
Canister control valve malfunction
Replace
Normal
Abnormal
ECU malfunction
Replace
19
Common Malfunction Diagnosis Flow of Geely Automobile
Engine operates abnormal Check engine operation, whether there is unavailable cylinder.
Measure the voltage of sensor, whether it is too low, as well as the
Oxygen sensor
fuel-air ratio, whether it is over normal value.
20
Common Malfunction Diagnosis Flow of Geely Automobile
Leak
Fuel pipe leakage
Check
Normal
Leak
Fuel tank leakage Replace
Normal Abnormal
Normal Leak
Injector leak Check
Normal
Abnormal
Engine oprates abnormal Check
Normal
Abnormal
Ignition timing maladjustment Check
Normal Abnormal
Normal
Abnormal
Canister pipe malfunction Replace
Normal Abnormal
21
Common Malfunction Diagnosis Flow of Geely Automobile
22
Common Malfunction Diagnosis Flow of Geely Automobile
Unavailable cylinder
Engine operates with unavailable cylinder Check
Normal Abnormal
Incorrect ignition timing Check
Normal Abnormal
Check
Fuel pressure abnormal
Normal Abnormal
Normal Abnormal
Check
Cylinder gasket damage
Normal
Abnormal
Engine fuel grade doesn't in accordance with Replace
standard
Normal Abnormal
Engine mounting bracket deformed
Check
Normal
Abnormal
Check
Crank link mechanism malfunction
Normal
Abnormal
Normal
Abnormal
Gearbox or vehicle transmission accessories
Check
damaged
23
Common Malfunction Diagnosis Flow of Geely Automobile
24
Common Malfunction Diagnosis Flow of Geely Automobile
Leaking or block
Exhaust system leaking or block
Check and replace
Normal
Abnormal
Engine operates abnormal Check
Normal
Abnormal sound
Generator water pump, booster pump etc. Check and replace
sound abnormally
Normal
Abnormal sound
Water tank fan and AC fan sound abnormally Check and replace
Normal
Abnormal Check
Water temperature over normal value
Normal Interferen
Engine interferences with relevant accessories Check
25
Common Malfunction Diagnosis Flow of Geely Automobile
Lack
Normal
Poor
Radiator fan operates abnormal Check and replace
Normal
Over normal value
Too much refrigerant Drain
Normal
Failure
Condenser fan malfunction Check and replace
Normal Poor
Poor cooling water recycles
Check
Normal
Abnormal
ECU failure
Replace
Normal Abnormal
26
Common Malfunction Diagnosis Flow of Geely Automobile
Oil leak at rear end of Oil pan bolt loose Tighten oil pan retaining bolt or replace damaged bolt.
oil pan after vehicle Oil pan damaged or deformed Maintain or replace oil pan.
parked.
Oil pan retaining bolt adjust to 4.9NM, evenly.
Irregular assembly procedure
Coat sealant with proper quantity, otherwise, the gasket may slid and
move.
Unplug or replace gas exhaust system (PCV valve)
Inner engine pressure over
normal value Engine cylinder, piston ring and piston worn out. Maintain or replace
relevant component when necessary.
Crankshaft rear oil seal ageing Replace crankshaft rear oil seal.
or damage
27
Common Malfunction Diagnosis Flow of Geely Automobile
Too much
Fill oil according to standard
Too much oil
Normal
Damage
Oil pan gasket damage Replace
Normal
Irregular
Irregular assembly procedure
Remount
Normal
Damage
Oil pan damaged
Replace
Normal
Abnormal
Rear end panel deformed or seal gasket failure
Check and replace
Normal
Blocked
Rear oil pipe capping leaking Check and replace
Normal
Loose
Oil pan bolt loose
Tighten
Normal
Over normal value
Inner engine pressure over normal value Check
Normal Abnormal
Replace
Cranksahfe rear oil seal ageing or damage
28
Common Malfunction Diagnosis Flow of Geely Automobile
Y
Drain spare oil
Too much oil
N
Damage
Normal
Loose
Check
High inner engine pressure
Normal
Loose
Normal
Wearing
Distributor rotating shaft loose Replace
Normal
Over normal value
Distributor rotor gear wearing Replace
Normal
Poor
Blow hole or crack on distributor
Replace
29
Common Malfunction Diagnosis Flow of Geely Automobile
30
Common Malfunction Diagnosis Flow of Geely Automobile
Improper
Improper spark plug and valve clearance Adjust
adjustment
Normal
Stuck
Fuel circuit stuck (when steering) Check
Normal
Abnormal
Idle speed controller (stepping motor) Clean and replace
Normal Abnormal
Normal
Abnormal
Distributor failure Replace
Normal
Leak
Intake system leaking
Maintain
Normal
Fuel contains
Fuel contains in vaccum pipe Maintain
Normal
Low
Low cylinder pressure Check
31
Common Malfunction Diagnosis Flow of Geely Automobile
Fails to return
Throttle body or cable fails to return Check and replace
Normal
Abnormal
Improper ignition timing
Check and adjust
Normal
Leak
Intake system leaking
Check
Normal
Abnormal
Improper valve clearance
Adjust
Normal
Operates poorly
Electric injection unit operates poorly
Check and replace
Normal
Abnormal
ECU software failure or inner damage
Replace
32
Common Malfunction Diagnosis Flow of Geely Automobile
Engine vibration
Check
Engine oprating with unavailable cylinder
Check
Normal
Low
Low fuel pressure
Check
Normal
Deform
Engine bracket or vehicle body deformed
Check and replace
Normal
Abnormal
Clutch system malfunction Check and replace
Normal
Damage
ECU damaged
Replace
33
Common Malfunction Diagnosis Flow of Geely Automobile
34
Common Malfunction Diagnosis Flow of Geely Automobile
Blocked
Clean or replace
Air filter blocked
Normal Abnormal
Normal Low
High oil pressure
Check and replace
Normal
Abnormal
Unavailable cylinder Check and replace
Normal
Abnormal
Improper ignition timing Adjust
Normal Abnormal
Oxygen sensor voltage abnormal Check
Normal
Leaking
Valve leaking Check and replace
Normal Abnormal
Normal
Abnormal
ECU failure Replace
Normal
Abnormal
Injector leak or atomization abnormal Clean or replace
Normal Abnormal
35
Common Malfunction Diagnosis Flow of Geely Automobile
No. 021 Engine idle speed decreases when activating head beam or fan
Malfunction Cause Solution
Fuel quality is not in
Apply unleaded clean fuel, 93# or above.
accordance with requirement
Generator belt loose Adjust belt tension to 50NM, when pressuring downwards, and the
deflection shall be 10MM.
Earth lead loose Check gearbox, body earth lead and instrument earth lead, whether
they are loose. Tighten them when necessary.
Generator operates abnormal Check the electrical energy of generator, whether it is beneath 9V.
Replace generator voltage controller when necessary.
Battery open circuit Check the gravity of battery electrolyte, maintain or replace battery
Engine speed assembly when necessary.
decreases, with
vibration, when Idle speed controlling valve or Clean idle speed control valve or stepping motor. Replace it when
activating head stepping motor malfunction damaged.
beam or fan
Grouped switch short circuit Maintain grouped switch and relevant harness.
The power of head beam or the Check head beam, whether it applies the bulb requires the power over
load of fan is over normal value. standard value. Replace standard power bulb when necessary.
Replace fan motor or maintain the circuit.
Low generator charging current
Replace generator assembly, which supplies 90A charging current.
(75A)
Poor ECU signal Measure the voltage among terminals and wire connecting condition.
Maintain or replace them when necessary.
Engine operates abnormal Maintain engine
36
Common Malfunction Diagnosis Flow of Geely Automobile
Loose
Generator belt loose Adjust
Normal
Low
Earth lead loose Check
Normal
Open circuit
Generator operates abnormal
Check or replace
Normal
Normal
Idle speed controlling valve or stepping motor Abnormal
failure Clean and replace
Normal
Short circuit
Combined switch short circuit
Check and replace
Normal
Over load
The power of head beam or the load of fan is over normal value
Replace
Normal Poor
Replace
Poor ECU signal
Normal Abnormal
Check
Engine operates abnormal
37
Common Malfunction Diagnosis Flow of Geely Automobile
Water log
Water log in silencer Check
Normal
Damage
Gasket damage Replace
Normal
Crack or blow hole
Crack or blow hole in cylinder head
Replace
Normal
Crack or blow hole
Replace
Crack or blow hole on clinder wall
38
Common Malfunction Diagnosis Flow of Geely Automobile
39
Common Malfunction Diagnosis Flow of Geely Automobile
Lack
Fuel tank lacks of fuel Fill
Normal
Poor quality
Poor fuel quality
Replace
Normal
Blocked
Air filter blocked
Clean or replace
Normal
Low
Low intake vaccum
Check
Normal
Blocked
Exhaust system blocked
Check and replace
Normal
Abnormal
Ignition maladjustment Check
Normal
Decrease
Fuel pressure decrease when accelerating Replace
Normal
Positive electrode of oxygen sensor short or Abnormal
open circuit Replace
Normal Abnormal
Check
Low cylinder pressure
40
Common Malfunction Diagnosis Flow of Geely Automobile
Low
Low oil quantity results low oil pressure
Fill
Normal
Deteriorate
Low oil viscocity or oil deteriorated Replace
Normal
Damage
Oil pressure switch damage
Replace
Normal
Short circuit
Grouped instrumernt inner short circuit Replace
Normal
Low
Low oil pressure
Check
Normal
Large clearance
Large engine liner clearance, which results low oil pressure
Check
Normal Leak
Oil pipe leaking Check
41
Common Malfunction Diagnosis Flow of Geely Automobile
No. 025 Water temperature is over normal value when engine running with large load
Malfunction Cause Solution
Lack of coolant fluid
Fill non-standard anti-freeze fluid Replace standard anti-freeze fluid
Fuel grade against requirement Apply specified fuel
Thermostat shall be fully opened when water temperature
Low thermostat open travel
reaches 82℃, otherwise, replace it.
Water pump belt loose Adjust tension rate
Water Radiator is too dirty inside or outside, and results
temperature Clean radiator, the dirt and water mark, replace water
low cooling performance, as well as water
is over normal tank when necessary.
temperature increased.
value when
diving in high Radiator fun operates abnormal (low speed or
Maintain fan circuit and replace fan.
speed, and is fails to work sometimes)
normal in low
Improper ignition timing Adjust timing
speed.
Engine water pipe rust Clean rust
Engine oxygen sensor damaged and results mixed gas
Engine mixed gas is too thick
viscosity misadjusted.
Low cylinder pressure, maintain it. Low clearance often
Improper piston fit clearance caused by applying non-standard piston, replace and
reassemble with proper piston.
Cylinder bolt loose or cracked
42
Common Malfunction Diagnosis Flow of Geely Automobile
Poor
Low cooling performance of rediator
Check and replace
Normal
Poor
Fan operates abnormal
Check and replace
Normal
Abnormal
Improper piston fit clearance
Check
Normal
Too thick
Engine mixed gas is too thick
Adjust
Normal
Too small
Low thermostat open travel
Replace
Normal
Loose
Water pump belt loose Adjust
Normal
Rust
Engine water pipe rust Clean
Normal
Against
Fuel grade againsts requiremen
Replace
43
Common Malfunction Diagnosis Flow of Geely Automobile
Dirt
Canister electromagnetic valve is dirty inside
Clean and replace
Normal
Damage
Canister electromagnetic valve retaining rubber seat
Replace
damage
Normal
Vaccum
Serious fuel tank inner vaccum Maintain
Normal
Over normal value
Over adjustment of canister solenoid valve inner tube Adjust
Normal
Wearing
Serious canister solenoid valve wearing Replace
44
Common Malfunction Diagnosis Flow of Geely Automobile
45
Common Malfunction Diagnosis Flow of Geely Automobile
N
No fuel
Fill
Y
Lack
Low battery voltage
Charge
Normal
Abnormal
Starter failure Check and replace
Normal
Abnormal
Ignition switch open circuit and wire failure Check and replace
Normal
Abnormal
Electric control system failure
Check and replace
Normal
Abnormal
Improper ignition timing or weak spark voltage
Check
Normal
Abnormal
Spark plug failure Replace
Normal
Error
Incorrect valve timing Check
Normal
Blocked
Air filter blocked
Clean
Normal
Abnormal
Fuel system failure
Maintain
Normal
Low pressure
Low cylinder pressure Maintain
Normal
Abnormal
Exhaust system blocked Unplug
Normal
Abnormal
Injector failure
Clean and replace
Normal
Abnormal
Engine signal plate loose or moved Check or replace
Normal Abnormal
Replace
ECU inner short circuit
46
Common Malfunction Diagnosis Flow of Geely Automobile
47
Common Malfunction Diagnosis Flow of Geely Automobile
Abnormal
Low engine speed when driven by starter
Check
Normal
Abnormal
Electric controlling system short or open circuit
Check
Normal
Abnormal
Cooling fluid temperature sensor failure Replace
Normal
Poor
Spark plug operates abnormally Adjust and replace
Normal
Low
Low fuel pressure Check
Normal
Abnormal
Normal
Abnormal
Injector blocked or fuel atomized abnormally Clean and replace
Normal
Blocked
Air filter blocked Clean
Normal
Over carbon deposit
Over carbon deposit in intake mainfold or valve; exhaust Check
pipe blocked
Normal
Lack
Low cylinder pressure Check
Normal
Abnormal
ECU malfunction Replace
48
Common Malfunction Diagnosis Flow of Geely Automobile
49
Common Malfunction Diagnosis Flow of Geely Automobile
Low
Low starter speed or sliding Check and replace
Normal
Abnormal
Electric controlling system failure Check and replace
Normal
Abnormal
Spark plug failure Replace
Normal
Abnormal
Normal
Abnormal
Normal
Abnormal
Injector failure
Clean and replace
Normal
Abnormal
Fuel quality problem Replace
Normal
Over fitted
Engine fit pressure is over normal value Check
Normal
Abnormal
Speed sensor output signal abnormal Replace
Normal
Blocked
Normal
Lack
Normal
Abnormal
Intake pressure temperature sensor operates Replace
abnormally
Normal Abnormal
Replace
ECU inner malfunction
50
Common Malfunction Diagnosis Flow of Geely Automobile
51
Common Malfunction Diagnosis Flow of Geely Automobile
52
Common Malfunction Diagnosis Flow of Geely Automobile
Improper adjusted
Normal
Blocked
Idle speed by-pass pipe blocked Clean
Normal
Abnormal
Idle speed control valve or stepping motor failure Clean and replace
Normal
Abnormal
Replace
Electric controlling system failure
Normal
Leak
Intake pipe leak Check
Normal
Abnormal
Voltage abnormal Check
Normal
Abnormal
Injector failure Clean and replace
Normal Blocked
Normal
Abnormal
Replace
Intake temperature sensor failure
Normal
Low
Normal
Cracked
Normal
Abnormal
Normal
Fail
Canister valve failure Replace
53
Common Malfunction Diagnosis Flow of Geely Automobile
54
Common Malfunction Diagnosis Flow of Geely Automobile
Non-idle speed
Blocked
Normal
Abnormal
Ilde speed stepping motor failure Clean and replace
Normal
Abnormal
Improper throttle cable or thorttle position sensor adjustment Clean and replace
Normal
Abnormal
Electric controlling system failure
Check
Normal
Abnormal
Cooling fluid temperature sensor failure Replace
Normal
Fails to work
Indicidual cylinder fails to work Check
Normal
Abnormal
Engine voltage abnormal Check
Normal
Leak
Intake system leaking
Check
Normal Error
Normal
Abnormal
Circuit failure Check
Normal
Abnormal
Engine ECU failure
Replace
55
Common Malfunction Diagnosis Flow of Geely Automobile
Idle speed over Check water temperature sensor, whether it can send
normal value temperature signal to ECU correctly. In normal condition,
the coolant temperature is applied to adjust fuel injecting
quantity, sc. mixture gas viscosity. In low temperature,
ECU controls injector to inject more fuel to increase
Cooling fluid temperature sensor
mixture gas viscosity, as well as idle speed. Check water
malfunction
temperature sensor, if it fails to measure temperature as
normal. In different temperatures, the resistance of
cooling temperature sensor shall vary according to
regulated standard. Otherwise, replace coolant
temperature sensor.
Check intake manifold pressure temperature sensor,
Intake pressure sensor malfunction
replace it when abnormal.
Measure oxygen sensor, if the voltage is low, beneath
0.5V, then will cause incorrect ECU order, which results
Oxygen sensor malfunction
mixture gas viscosity increase, as well as idle speed.
Replace oxygen sensor when necessary.
Pull out engine ECU pin and measure the resistance
between each terminal of ECU, whether the value is
Engine ECU malfunction
accordance with technical requirements. Replace engine
ECU when abnormal.
56
Common Malfunction Diagnosis Flow of Geely Automobile
Improper
Normal
Over normal value
Normal
Abnormal
Idle speed stepping motor failure Clean and replace
Normal
Leak
Intake system leaking Check
Normal
Abnormal
Electric controlling system failure
Check
Normal
Abnormal
Temperature sensor failure Replace
Normal
Abnormal
Normal
Abnormal
Oxygen sensor failure Replace
Normal
Abnormal
Engine ECU failure Replace
57
Common Malfunction Diagnosis Flow of Geely Automobile
Air filter blocked Check intake system, whether it is leaking. Measure intake manifold vacuum, the
value shall above 30kPa when idling. Otherwise, the intake system is leaking. Shall
check connectors and all hoses and vacuum pipes carefully.
Improper adjustment Press accelerate pedal fully, and check whether the throttle fully opens. Adjust
of throttle cable or throttle cable or pedal, if it fails to open fully.
throttle position Check throttle position sensor. During throttle varies from full close to full open, the
sensor, which results resistance between signal terminal and earth terminal shall increase constantly,
throttle fail to fully without interruption. Adjust or replace the sensor according to regulation, when
open. abnormal.
Check ignition timing. When idling, the ignition advance angle shall be 10º~12º.
Improper ignition Otherwise, shall adjust the primary ignition advance angle. When accelerating, the
timing or weak spark angle shall increase to 20º~30º automatically. When abnormal, shall check ignition
energy. controlling system, including ignition coil, spark wire and spark plug etc., alternative
replace ECU.
Check fuel pressure. When idling, fuel pressure shall in accordance with regulation,
265~304kPa. When accelerating, fuel pressure shall increase about 50kPa. If fuel
Low fuel pressure
pressure is too low, then shall check fuel pressure controller, electric fuel pump, fuel
filter and etc.
Injector blocked or Remove injector and check injecting quantity and atomization quality, whether they
poor atomization are normal. When abnormal, clean or replace the injector.
Check battery voltage, whether it is normal. If the value is too low, when will cause
Low battery voltage fuel injecting quantity decrease, which results low engine power, as well as
Engine accelerating delay. In this case, shall check charging system or replace battery.
accelerates
abnormal Check coolant temperature sensor. In different temperatures, the resistance of the
Coolant temperature
sensor shall vary in accordance with regulated standard. Otherwise, shall replace
sensor malfunction
the sensor.
Intake pressure Check intake manifold pressure temperature sensor. Replace it when abnormal.
sensor malfunction
Clutch sliding Replace driven plate of clutch.
Low engine cylinder Measure the compressing pressure of engine cylinder. If it is too low, then shall
pressure adjust valve clearance, or disassemble and inspect engine.
In case of low power and accelerating performance, caused by poor flywheel and
Poor flywheel signal
signal wheel signal, shall replace flywheel assembly.
Crankshaft position In case of ECU order delay and low accelerating performance, caused by the sensor
sensor malfunction fails to indicate crankshaft position correctly, shall replace the sensor.
Incorrect engine valve Check engine valve timing, whether it is correct. Adjust it when incorrect.
timing
Check the operating condition of each cylinder, such as individual cylinder
Individual cylinder operating, whether it is abnormal. Particularly the spark plug, spark wire and cylinder
fails to work pressure etc. Determine the malfunction cause and maintain or replace relating
parts.
Check 3 way catalytic converter, whether it is blocked. The reverse interfere caused
Exhaust system
by blockage will result poor engine accelerating performance. In this case, replace
blocked
3-way catalytic converter.
Oxygen sensor It results indiscernible mixture gas rate, as well as low power.
malfunction
58
Common Malfunction Diagnosis Flow of Geely Automobile
Blocked
Air filter blocked Clean
Improper adjusted
Normal
Normal Abnormal
Normal
Low
Low fuel pressure
Check
Normal
Blocked
Injector blocked
Clean and replace
Normal
Low
Low battery voltage
Charge
Normal
Abnormal
Cooling fluid temperature sensor failure
Replace
Normal
Abnormal
Intake pressure sensor failure Normal
Normal Sliding
Normal
Low
Low engine cylinder pressure
Check
Normal
Poor
Poor flywheel signal Check
Normal
Abnormal
Crankshaft position sensor failure Replace
Normal
Error
Incorrect engine valve timing Check and adjust
Normal
Fails to work
Individual cylinder fails to work Check
Normal
Blocked
Exhaust system blocked Check and replace
Normal
Abnormal
Oxygen sensor failure Replace
59
Common Malfunction Diagnosis Flow of Geely Automobile
60
Common Malfunction Diagnosis Flow of Geely Automobile
Water overheat
Insufficient
Insufficient coolant Fill
Normal
Failure
Water temperature gauge and sensor fails Replace
Normal
Abnormal
Thermostat can not open normally Replace
Normal
Water leaking
Water leakage in water Check
tank
Normal
Abnormal
Water pump trouble Replace
Normal
Water leaking
Water leakage in water pipe Replace
Normal
Water leaking
Water leakage in water tank of fan Replace it
heater
Normal
Radiator cooling fan can not run normally Overhaul and replace it
Normal
Normal
Normal
61
Common Malfunction Diagnosis Flow of Geely Automobile
Oil appears in the water Check whether cylinder head or cylinder block is
tank during engine Cylinder head or cylinder block deforming
deformed, if any, repair or replace it;
operation
62
Common Malfunction Diagnosis Flow of Geely Automobile
63
Common Malfunction Diagnosis Flow of Geely Automobile
During engine repairing, there is water mixed into crankcase, oil mixes with water
Man-made
and color changes after the engine operates to normal water temperature. This
malfunction
malfunction can be eliminated by changing oil;
Cylinder head gasket is slightly damaged or not pressed tightly, after the engine
starts, water enters into crankcase through cylinder head gasket. In case of this
Malfunction of
malfunction , disassemble the engine to check cylinder head and its gasket, cylinder
cylinder head gasket
block surface, repair or replace it and then tighten it in accordance with standard
torque;
There is water in
the engine oil
There is crack on cylinder head, and the crack is enlarged once heated, therefore
There is crack on the
water enters into crankcase through it. In this case, check carefully that there is any
cylinder head
crank on the cylinder head, use instrument if necessary, if any, replace it;
There is crack on cylinder block, and the crack is enlarged once heated, therefore
There is crack on the
water enters into crankcase through it. In this case, check carefully that there is any
cylinder block
crank on the cylinder block, use instrument if necessary, if any, replace it;
Normal
Normal
Normal
64
Common Malfunction Diagnosis Flow of Geely Automobile
65
Common Malfunction Diagnosis Flow of Geely Automobile
Poor
Poor oil quality Replace
Normal
Blocked
Oil filter blocked Replace
Normal
Normal
Bend
Crankshaft bending Replace
Normal
Wearing
Main bearing shell is ablated and worn Replace
seriously
Normal
Abnormal
Abnormal pressure of oil pump Check
Normal
Too large
Thrust clearance between thrust Check
washers too large
Normal
Normal
Loose
Bolt on the cover of main bearing Check
shell is loose
66
Common Malfunction Diagnosis Flow of Geely Automobile
When engine accelerates Abnormal pressure of oil Check oil pressure, abnormality will also cause abnormal sound, if
suddenly, obvious clear pump necessary, replace oil pump;
and short knocking is
produced and becomes Check the clearance between connecting rod bearing shells, the
louder as the loading value is 0.020mm-0.063mm, if the clearance exceeds limit 0.1mm, it
increases; creaking can be Shell clearance too large is necessary to select connecting rod bearing shell again according
heard by shaking throttle to measured connecting rod bearing diameter and technical
slightly; the noise does not requirements. (empirical value);
change obviously when
engine temperature
changes. Check that there is any peeling, wearing, ablation or other
Shell wearing excessively,
abnormality on the surface of connecting rod bearing shell, if the
loosing or breaking etc.
bearing shell fails, it should be changed;
If connecting rod bearing shell is just loose, tighten the bolt by torque
Connecting rod bolt is loose
specified;
67
Common Malfunction Diagnosis Flow of Geely Automobile
Normal
Normal
Normal
Normal
Normal
Normal
68
Common Malfunction Diagnosis Flow of Geely Automobile
Worn
Engine with high water temperature Repair
Normal
Not good
Engine oil with poor quality Replace
Normal
blocked
Oil filter blocked Replace
Normal
Burnt
Normal
Abnormal
Pressure of oil pump abnormal Repair
Normal
Stiffness
Hardness of internal spring of the Repair
gear not enough
Normal
Too large
Fit clearance between camshaft and wall Replace
Normal
Abnormal
Cam worn Replace
69
Common Malfunction Diagnosis Flow of Geely Automobile
Camshaft driving Hardness of internal spring of the gear not Replace the spring or assembly;
gear with enough
abnormal sound Check inlet filter screen of oil pump is blocked; if so, clean or
replace;
Engine oil pressure too low Check clearance between drive gear and driven gear of oil
pump. And check relief valve is blocked; if so, repair or replace;
Check lubricating system is leaking, and mainly check clearance
of connecting rod tile; if leaking, eliminate it;
check driving gear is with obvious metal damaging traces,
Driving gear worn
causing noises; if so, replace it;
Improper
Improper Reassemble
assembling
Normal
Normal
Unusual
Matching angle under stress not even Replace
Normal
Not matching
Fit clearance of gears not Repair
matching
Normal Stiffness
insufficient
Hardness of internal spring of the gear not
enough Replace
Normal
Too low
Engine oil pressure too Repair
low
Normal Worn
Replace
Driving gear worn
70
Common Malfunction Diagnosis Flow of Geely Automobile
71
Common Malfunction Diagnosis Flow of Geely Automobile
Cylinder knocking
sound
Normal
Normal
Too early
Ignition time too early Adjust
Normal
Normal
Normal
Large clearance
Clearance of connecting rod tile Repair
too large
Normal
Normal
Normal
72
Common Malfunction Diagnosis Flow of Geely Automobile
Insufficient
Engine oil not sufficient Add
Normal
Poor
Engine oil with poor Replace
quality
Normal
Blocked
Filter screen blocked Clean
Normal
Normal
Normal
Normal
Sounding
Driving gear of oil pump Repair
sounding
Normal
Sounding
Driving chain Replace
sounding
73
Common Malfunction Diagnosis Flow of Geely Automobile
Insufficient
Engine oil not sufficient Add
Normal
Normal
Too large
Engine oil with too low pressure Repair
Normal
Worn
Crankshaft and thrust piece severely worn Replace
Normal
Normal
Large clearance
Thrust clearance too Repair
large
74
Common Malfunction Diagnosis Flow of Geely Automobile
Too large
Valve clearance too large Adjust
Normal
Normal
Deformed
Cylinder cover Replace
deformed
Normal
Poor
Engine oil with too low pressure, poor lubrication Repair
causing unusual noise
Normal
Worn
Camshaft worn Replace
75
Common Malfunction Diagnosis Flow of Geely Automobile
76
Common Malfunction Diagnosis Flow of Geely Automobile
Normal
Leaking
Intake system leaking Repair leaks
Normal
Normal
Normal
Normal
Too low Repair
Fuel pressure too
low
Normal
Abnormal
Remove, clean oil
ejector Replace oil injector
Normal
Normal
Normal
Unusual
Intake manifold pressure temperature Replace intake manifold pressure
sensor malfunction
Normal
No changes
77
Common Malfunction Diagnosis Flow of Geely Automobile
Idling speed too large or too Eliminate one by one according to idling speed-related malfunction
78
Common Malfunction Diagnosis Flow of Geely Automobile
79
Common Malfunction Diagnosis Flow of Geely Automobile
Habit problem
Driving habit problem Drive correctly
Normal
Abnormal
Oxygen sensor Replac
malfunction e
Normal
Improper
Normal
Poor sealing
Oil ejector obstructed or poor sealing Clean
Normal
Repair
Cylinder poorly operating Repair
80
Common Malfunction Diagnosis Flow of Geely Automobile
Normal
Abnormal
Cooling liquid temperature sensor Replace
malfunction
Normal
blocked
Air filter blocked Clean
Normal
Poor
Poor fuel quality Replace
Normal
Unusual
Tire obviously worn or pressure severely insufficient Repair or replace
Normal
Slipping
Clutch slipping Replace
Normal
Abnormal
Temperature control system malfunction Repair
causing large oil consumption
Normal
Leaking
Fuel pipe leaking Repair
Normal
Normal
Normal
Damaged
Canister control non-return valve Replace
damaged
Normal
Abnormal
Inlet pressure and temperature sensor damaged
Replace
Normal
Open circuit
Throttle valve position sensor with open Replace
circuit
81
Common Malfunction Diagnosis Flow of Geely Automobile
Blocked
Three-way catalyzer blocked Replace
Normal
Not working
Individual cylinders not Repair
working
Normal
Incorrect
Incorrect valve timing of the engine Repair
Normal
Too low
Cylinder pressure too low Repair
Normal
Abnormal
Idling speed too large or too small
Repair
Normal
Abnormal
Water temperature abnormal l Repair
82
Common Malfunction Diagnosis Flow of Geely Automobile
83
Common Malfunction Diagnosis Flow of Geely Automobile
Intake tempering
Improper
Improper ignition timing Check and adjust
Normal
Not well closed
Valve not well closed Repair
Normal
Poor atomization
Oil ejector blocked or with poor Clean
atomization
Normal
Abnormal
Inlet pressure sensor malfunction Replace
Normal
Unusual
Throttle valve position sensor malfunction Replace
Normal
Too thin
Gas mixture too thin Repair
Normal
Error
Engine valve timing error Repair
Normal
Abnormal
Malfunction of oil injection control
program within ECU Replace
84
Common Malfunction Diagnosis Flow of Geely Automobile
Improper
Improper ignition timing Repair
Normal
Leaking
Oil injector leaking Clean
Normal
Error
Engine valve timing error Repair
Normal
Unusual
Oil ejection control program malfunction
Replace
85
Common Malfunction Diagnosis Flow of Geely Automobile
86
Common Malfunction Diagnosis Flow of Geely Automobile
Engine knocking
Poor quality
Fuel with low grade and poor quality Replace
Normal
Piston and cylinder wall severely worn, with too large clearance Worn
Repair
Normal
Too early
Ignition time too early Repair
Normal
Too low Repair
Oil pressure too low
Normal
blocked
Oil ejector blocked Clean
Normal
Too much
Carbon deposit within the Repair
cylinder too many
Normal
Normal
Not working
Individual cylinders not Repair
working
Normal
Abnormal
Replace
Intake manifold pressure temperature sensor
invalid
Normal
Leaking Repair
Intake manifold leaking
Normal
Abnormal
Repair
Cooling system
malfunction
Normal
Abnormal
Program malfunction within Replace
ECU
87
Common Malfunction Diagnosis Flow of Geely Automobile
Invalid
PCV valve invalid Replace
Normal
Abnormal
Valve oil seal malfunction Repair
Normal
Too much
Engine oil too much Discharge
Normal
Poor
Engine oil with Replace
poor quality
Normal
Abnormal
Piston ring, piston and
Repair
cylinder malfunction
88
Common Malfunction Diagnosis Flow of Geely Automobile
Leaking
Normal
Abnormal
Normal Icing
Normal
Cracks
Cylinder cover with cracks Replace
Normal
Cracks
Cylinder body with cracks Replace
89
Common Malfunction Diagnosis Flow of Geely Automobile
Insufficient
Insufficient lubricating oil Add
Normal
Too small
Oil viscosity too small Replace
Normal
Damaged
Oil pressure sensor or indicator lamp Repair
damaged
Normal
Too large
Clearance of connecting rod tile too large, Repair
causing oil leaking
Normal
Too large
Replace
Clearance of crankshaft tile too large, causing oil leaking
Normal
Blocked or leaking
Main oil duct blocked or leaking Repair or
replace
90
Common Malfunction Diagnosis Flow of Geely Automobile
Power source:
Power supplied by the battery continuously via 18# pin; Power supplied while main relay is
turned on via 37# pin; power supplied while ignition switch is turned on via 27# pin. Earthing:
2#, 10#, 14#, 19#, 24#, 30#, 48# pin. Malfunction diagnosis interface:
55# pin, engine data K line. Call out malfunction information records within ECU via K line, or
manually input some instructions, such as clear malfunction information records, make idle
speed actuator self-learning, etc;
General causes:
1. Invalid caused by burnt and damaged parts and components within ECU due to electrical
overload of externally connected device;
2. ECU entered with water causing circuit board rusty, etc; Maintenance precautions:
1. Before removing ECU, remove battery cell firstly;
2. For welding on the vehicles, cut off ECU power source;
3. Close ignition switch firstly while startup with externally connected power source or as
externally connected power source;
4. Radio speaker could not approach the controller; Simple measuring method:
1 (connect the connector) Read engine malfunction records via engine data K line, and make
comparison based on engine system data and normal vehicle data, find out differences and
continue in-depth inquiry;
2 (Remove the connector) check ECU connections are complete, and mainly check ECU power
supply, earthing lines are normal;
3. Check external sensor is working normally, output signal is reliable, and its lines are complete;
4. Recommend the ECU replaced to be assembled in the normal vehicle, and simulate
malfunction malfunction, and further confirm the malfunction;
91
Common Malfunction Diagnosis Flow of Geely Automobile
92
Common Malfunction Diagnosis Flow of Geely Automobile
4. Check when the engine is running at 20001Vm, and switch on N Till malfunction elimination instructions
head lamp, air conditioner, voltage value of battery cell is higher than
15V?.
Function: provide idling-speed bypass air route, and control air quantity by changing
cross-section of the route, realizing closed-loop control over rotating speed while the engine is
under idling-speed condition; principle: one permanent magnet rotating freely on the shaft within
idling-speed governor is rigidly connected with one rotating slide block, and could rotating driven
by the coil, making slide block also rotating. Angular position of slide block determines opening of
bypass duct, and thus adjusting bypass air quantity. Angular position of slide block is controlled
by duty ratio of electrical pulse output by electronic controller;
93
Common Malfunction Diagnosis Flow of Geely Automobile
Function: this sensor is for providing engine knocking information to electronic controller ECU for
knocking control.
Principle: knocking sensor is a vibration acceleration sensor, which is installed at engine cylinder
body. Only one or several sensors installed is ok. Its sensitive element is a piezoelectric crystal,
to which vibration of cylinder body is transferred via mass block within the sensor, and which will
generate voltage at two pole faces due to pressure generated from vibration of mass block, and
transforms vibration signal into voltage signal;
94
Common Malfunction Diagnosis Flow of Geely Automobile
95
Common Malfunction Diagnosis Flow of Geely Automobile
Function: provide idling-speed bypass air route, and control air quantity by changing
cross-section of the route, realizing closed-loop control over rotating speed while the engine is
under idling-speed condition;
Principle: stepper motor is actuall a miniature motor, and its stator is polyphase coil winding and
rotor is permanent magnet, through which one spiral axis is threaded, and these two are
contacted with thread. When stator coil is switched with current, the rotor will rotate towards
corresponding directions. As rotor and spiral axis are contacted with thread, angular
displacement of rotor is transformed into linear displacement of spiral axis. Bypass cross-section
could be changed by front and rear moving of spiral axis. If the rotor rotates fixed angle each
time, spiral axis will move a certain displacement, i.e. one step. Electronic controller could control
moving steps of stepper motor by changing coil energization phase to obtain corresponding
bypass air flow.
96
Common Malfunction Diagnosis Flow of Geely Automobile
97
Common Malfunction Diagnosis Flow of Geely Automobile
Maintenance precautions:
1. Do not apply any forces axially to press down or take out the axle;
Before idle speed governor with stepper motor is installed within throttle valve body, the axle
must be at completely holdback position;
3. Pay attention to cleaning of bypass air route;
4. After removing battery cell, manually trigger self-learning function of stepper motor duly by
using K line for malfunction diagnosis for earthing with three times, and earthing time equaling to
and larger than 2.5s each time, or self-learning by using diagnosis instrument;
Simple measuring method:
1. (Remove the connector) place digital multimeter to ohm position, and two pens are
respectively connected into AD, BC pins of regovernor, and rated resistance under 25℃ is
53±5.3Ω; otherwise, replace it;
2. (Connect the connector) Start the engine, and make it rotate under idling speed; put hands
slightly against stepper motor, and you feel slight vibration at this point;
3. Read amount of step of idle speed stepper motor out of engine parameter with diagnosis
instrument, and start the air conditioner, and amount of step will increase. If rotating speed of the
engine is kept at 3000rpm for a certain time, check amount of step will continue to rise, till to
maximum opening value, which indicates that stepper motor is working normally;
4. If you cannot make judgment, recommend malfunction recurrence testing on malfunction-free
vehicle;
98
Common Malfunction Diagnosis Flow of Geely Automobile
3. Check control lines of stepper motor are with the following conditions? Y
Socket connector is tightly inserted or loosening; open circuited; shorted
to ground or shorted to voltage source; joint of stepper motor falls out. Repair
Y
N
Y 6. Check joint terminal and earthing resistance is larger than
10000ohm?
7. Clean idling speed bypass opening with compressed air gun; drive
stepper motor with idling-speed initialization function of diagnosis Y
instrument, making valve stem slide to clean pollutants with compressed
air; confirm repairs are completed.
99
Common Malfunction Diagnosis Flow of Geely Automobile
100
Common Malfunction Diagnosis Flow of Geely Automobile
Low-voltage side: 1# connected with ECU20# earthing channel of No. 1 coil primary winding;
2# connected with ECU1# earthing channel of No. 2 coil primary winding;
3# and 4# connected both to power source (+);
High-voltage side: 1, 2, 3, 4 respectively connected with spark plug of engine cylinder of same
numbering;
Simple measuring method:
1. (Remove the connector) place digital multimeter to ohm position, and two pens are
respectively connected to two pins of primary winding, resistance is 0.41-0.53Ω for Type ROV,
and 0.42-0.58Ω for Type 2X2 under 20℃; and for secondary winding, resistance is 7-9kΩ for
Type ROV, and 11.2-14.8kΩ for Type 2X2;
2. Take out spark plug within the engine, and connect with high voltage line, and make its casing
earthed; start the starting motor and observe flashover of spark plug;
3. Ignition switch closed; remove joint of ECU and ignition coil; and check ECU
Y
and ignition coil is shorted circuited to voltage source?
7. Replace ECU
Completed
101
Common Malfunction Diagnosis Flow of Geely Automobile
Function: this sensor is for providing information about outer corner of throttle valve to ECU,
based on which, ECU could obtain information related to engine load, condition (such as startup,
idling speed, dragging, partial load, full load) and acceleration and deceleration.
Principle: this sensor is actually corner potentiometer with linear output characteristics. Rocker
arm of potentiometer is installed with throttle valve at the same axis; when throttle valve rotates,
it will make rocker arm slide to certain position; potentiometer will output voltage signal
proportional to throttle valve position.
102
Common Malfunction Diagnosis Flow of Geely Automobile
Y 2. Close ignition switch; take out sensor joint; ignition switch switched on. Y
N Y
3. Check signal circuit of the sensor (53-3) is shorted circuited or shorted to
earth with B+?
5. Check signal circuit of the sensor (53-3) is open circuited, shorted to earth Y
or shorted to B+?
Y
6. Check earth circuit of the sensor (30-2) is open circuited, shorted to earth
or shorted to B+?
N 8. Ignition switch turned on; measure voltage between earth circuit (terminal
Repairs
2) and reference voltage (terminal 1) is 5V with the voltmeter?
103
Common Malfunction Diagnosis Flow of Geely Automobile
Function: this sensor is for measuring absolute pressure and inlet temperature of intake manifold,
and providing information related to engine load and inlet temperature. Principle: piezoelectric
transducer is for measuring inlet pressure, and will provide "load signal" to the controller
according to difference between atmospheric pressure and intake manifold pressure; provide 5V
via controller and feed 0-5V to the controller according to difference of inlet pressure. Type NTC
(negative temperature coefficient) sensor is for measuring inlet temperature, and resistance
changes by inlet temperature, and this sensor will transfer one voltage indicating changes of inlet
temperature to the controller.
immediately (specific value related to vehicle model), and then reduced to about 1.5V (specific
value related to vehicle model).
Diagnosis flowchart for inlet pressure temperature sensor (inlet temperature sensor)
1. Ignition switch closed; remove ECU joint and check earth circuit (30-1) of sensor
Y
is open circuited or shorted to B+?
2. Check signal circuit (44-2) of sensor is open circuited, shorted to earth or shorted
to B+? Y
Y
N
3. Plug in ECU joint, and take out sensor plug, ignition turned on. Check socket
connector terminal (2-1) has reference voltage of 5V?
N
Repairs
5. Replace ECU
Completed
105
Common Malfunction Diagnosis Flow of Geely Automobile
Diagnosis flowchart for inlet pressure temperature sensor (inlet pressure sensor)
1. Any following conditions occur?
---Vacuum booster or fuel pressure-regulating valve hose loosening or
Y
damaged
--- Intake manifold vacuum leaking and throttle valve leaking
Y
2. Disconnect sensor joint, and connect diagnosis instrument, and ignition
turned on. Observe absolute pressure displayed on diagnosis instrument is
Y
N 3. Check lines between ECU terminal 7 of signal circuit of sensor and sensor
terminal 4 is shorted circuited to B+?
106
Common Malfunction Diagnosis Flow of Geely Automobile
Function: this sensor is for providing information about engine cooling liquid temperature, so that
the controller could correct oil injection and ignition accordingly.
Principle: this sensor is a heat variable resistor of negative temperature coefficient (NTC), with its
resistance value reduced as the temperature rises, but not as linear relationship. This resistor is
installed within copper heat guiding sleeve.
107
Common Malfunction Diagnosis Flow of Geely Automobile
2. Check signal circuit of sensor (1-45) is open circuited, shorted to B+ or shorted to ground? Y
3. Plug in ECU joint, turn on ignition and check there is 5V reference voltage between two
N terminals of sensor joint? Repairs
5. Replace ECU
Completed
108
Common Malfunction Diagnosis Flow of Geely Automobile
Function: for controlling flow of regenerated air flow of fuel evaporation control system.
Principle: canister of fuel evaporation control system could absorb oil vapor of oil tank, till
saturation. After canister control valve by electronic controller is opened, fresh air and fuel vapor
saturated in the canister will form regenerated air flow, and reintroduce to engine inlet pipe. And
electronic controller will change duty ratio of impulse signal transferred to magnet coil of canister
control valve according to engine’s different conditions, thus controlling over flow of regenerated
air flow. In addition, this flow is affected by pressure difference at two s ides.
109
Common Malfunction Diagnosis Flow of Geely Automobile
Y
2. Check lines between main relay terminal 87 and canister control valve are
open circuited, shorted to ground or to power source?
N
3. Check resistance of canister control valve is 5-50Ω?
N 4. Ignition switch closed: remove ECU joint: check lines between ECU and Y
Repairs
canister control valve are open circuited, shorted to ground or to power
source?
Repairs
110
Common Malfunction Diagnosis Flow of Geely Automobile
1. O ring
2. Filter screen
3. Ejector body with electric
plug
4. Coil
5. Spring
6. Valve needle with coil
• Function: fuel injector ejects fuel within specified time according to instructions of ECU, and
provides fuel to the engine and make it atomized.
• Principle: ECU supplies power to coil of fuel injector, forming magnetic field force; when this
force increases enough to overcome resultant of pressure of release spring, gravity of needle
valve and friction force, needle valve starts to rise, and fuel injection starts. When injection
impulse stops, pressure of release spring will make needle valve re-closed.
• Mounting position: Intake manifold close to inlet valve.
Malfunction: Poor idling speed, poor acceleration, unable to startup (difficult startup), etc.
General causes: Colloid deposit within fuel injector due to lack of maintenance, causing it
ineffective.
Maintenance precautions: 1. There are many types of fuel injectors, and those with the same
appearance and which could be installed may not be the proper one. Part number for injector
during repairs must be the same with that of original injector. Do not mix up; 2. To ensure
convenient installation, apply clean silicon-free oil at surface of upper O ring connected with fuel
distribution pipe. Do not pollute inner of oil injector and jet orifice; 3. When removing and
reassembling fuel injector, replace O ring; do not damage sealing surface of fuel injector; 4. If
fuel injector has two slots, make it correct when installing clamps by referencing mounting
position of original parts; 5. Do not remove, and clean or replace filter screen without permission;
6. After removing, make sure fuel injector seat is clean. Avoid foreign substances entering to the
cylinder.
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Common Malfunction Diagnosis Flow of Geely Automobile
Y
2. Repair earthing, short circuit and open circuit between main relay, oil
pump relay, oil ejector
3. Check lines between oil ejector and ECU terminal (17-2) are open Y
circuited, shorted to ground or to power source? Repairs
4. Close ignition switch, and remove joint of oil ejector: measure resistance
N of each oil ejector is lower than 15.95Ω one by one with ohmmeter?
Y 5. Connect oil ejector joint of each cylinder and ground with ohmmeter;
measure resistance between each oil ejector and ground is larger than
1MΩ?
7. Replace ECU
Completed
112
Common Malfunction Diagnosis Flow of Geely Automobile
Low
High
level
level
UV UV
UA output voltage
UV input voltage
113
Common Malfunction Diagnosis Flow of Geely Automobile
5. Connect all joints, and clear malfunction code; as road testing, N Troubleshooting tip
malfunction code is displayed?
Y
6. Replace hall sensor, and confirm malfunction code still exists
after repairs are completed?
114
Common Malfunction Diagnosis Flow of Geely Automobile
• Function: Transfer fuel from oil tank to the engine, and provide sufficient fuel pressure and rich
fuel.
• Principle: Fuel pump is vane pump driven by DC motor, and placed within oil tank and
immerged by fuel, using fuel for heat emission and lubrication. The battery supplies power to
electric fuel pump through oil pump relay, which will only switch on lines of electric fuel pump
when started and the engine is running. When the engine stops running due to accidents, fuel
pump will stop running automatically.
• Mounting position: Within fuel tank.
Malfunction: Large running noise, poor acceleration, unable to startup (difficulty startup), etc.
General causes: Due to uses of poor quality fuel, it will cause: 1. formation of insulating layer due
to colloid accumulation; 2. locking of oil pump bushing and armature; 3. corrosion of oil level
sensor elements, etc.
Maintenance precautions: 1. according to needs of the engine, electric fuel pump is with different
flows. Even mountable fuel pump with the same appearance is not proper. For maintenance,
number of part of fuel pump shall be consistent with original one; 2. to prevent damages of fuel
pump, do not operate it under dry condition for a long time; 3. if fuel pump is to be replaced,
clean fuel tank and pipes and replace fuel filter.
Simple measuring method:
(remove the connector) Place digital multimeter to ohm position, and two pens are respectively
connected to two pins of fuel pump, and measure internal resistance, which shall not be zero or
infinite (i.e. non-short-circuited, off state).
(connect the connector) for oil return system, connect the fuel pressure gauge at oil sucker, and
start the engine, making it operate at idling speed status. Fuel pressure of the engine shall be
around 260kPa at this time; take out vacuum tube of fuel pressure regulator, and fuel pressure
shall be around 300kPa at this time.
115
Common Malfunction Diagnosis Flow of Geely Automobile
N 2. Close inigtion and remove fuel pump relay: ignition switched on, and
voltage of terminal 85, 30 of relay is larger than 10.7V?
Y
N
4. Measure resistance between ECU terminal 3 and ground is infinitely
large?
Y
N 6. Check lines between fuel pump and fuse, and oil pump relay are
normally connected?
Y
7. Replace ECU and confirm repairs are completed.
Y
10. Repair short circuit of lines between relay and ECU, and confirm
repairs are completed?
Y
11. Replace oil pump reay, and confirm repairs are completed? Repairs
116
Common Malfunction Diagnosis Flow of Geely Automobile
• Function: For oil return system, fuel pressure regulator is used for regulating fuel pressure of
fuel system, making difference with pressure of intake manifold kept at a constant value.
• Principle: This pressure regulator is diaphragm type overflow valve. when system fuel pressure
is increased, oil pressure within oil inlet exceeds resultant force of pre-tightening force of the
spring and air pressure within spring chamber, the diaphragm will be jacked, and valve will be
opened. Fuel is returned to fuel tank through oil return port in center of pressure regulator, and
fuel pressure dropped, till the valve is closed.
• Mounting position: Installed at fuel distribution pipe for oil return system.
Malfunction: Fuel pressure too low or too high, difficult to startup, etc.
General causes: Due to uses of poor quality fuel, it will cause: 1. blocked filter screen; 2. foreign
substances causing large leakage. In addition, manually mechanical damages, etc. Maintenance
precautions: during maintenance: 1. do not impact diaphragm element by high pressure gas; 2.
do not clean it with strong corrosive liquid; 3. deformation is not allowed due to outside force.
Simple measuring method: For oil return system, connect fuel pressure gauge at oil sucker, and
start the engine, making it operate at idling speed status. Fuel pressure of the engine shall be
around 260kPa at this time; take out vacuum tube of fuel pressure regulator, and fuel pressure
shall be around 300kPa at this time.
117
Common Malfunction Diagnosis Flow of Geely Automobile
N Y
3. Check two lines connecting oxygen sensor (10-3; 28-4) are with
REPAIR
open circuit, shorted to ground or shorted to voltage source?
5. Remove joint of oxygen sensor, and its voltage is lower than 0.35V
Y
with the diagnosis instrument? To troubleshooting tip
Completed
118
Common Malfunction Diagnosis Flow of Geely Automobile
(connect the connector) under idling speed status, when oxygen sensor reaches working
temperature of 350℃, place digital multimeter to DC voltage position, and two pens are
respectively connected to 3# (grey, 4# (black) pins of sensor, and voltage shall fluctuate quickly
between 0.1-0.9V.
119
Common Malfunction Diagnosis Flow of Geely Automobile
Y 1. Connect the diagnosis instrument, and start the engine to water temperature >
80℃. Observe voltage of sensor signal is between 0.2-0.8?
N 2. Check two lines connecting oxygen sensor (sensor 4-ECU28, sensor 3-ECU10)
are with open circuit, shorted to ground or power source (>1.098V for shorted to Y
power source, <0.092 for shorted to ground)
3. Close ignition, and plug in controller. Connect voltmeter to two white conductors of N
oxygen sensor, and the engine is started and running at idling speed, and check
value displayed at voltmeter is between 12-14V?
6. Close ignition and take out controller plug. Remove connection of socket connector N
of oxygen sensor, and connect the multimeter, and check resistance of cathode
conductor is <0.5Ω?
Replace ECU
Completed
120
Common Malfunction Diagnosis Flow of Geely Automobile
Testing
Testing terminal Component, part check Preparations for testing conditions Rated value
step
Ignition closed, take out plug of controller, and intake pipe in front of throttle valve is sealed with
proper materials. Take out connecting pipe of canister control valve of throttle vavle body.
01 Sealing of intake system No generation of bulb
Apply compressed air, and make pressure within intake pipe as about 1-2bar. Check liquid
leaking, and check all sealing seams. After check, reassemble connecting pipe of canister
Ignition closed, take out plug of controller, and connect pressure gauge at fuel high-tension
loop. Take out fuel return pipe of the pressure regulator, and install auxiliary hose on the
02 Fuel device connector of pressure regulator. And auxiliary hose leads to one proper barrel (with capacity of
at least 2 liters). 46 and 3 pins on the controller are earthed at the same time, making oil pmp
rotate 30 seconds.
02.1 Oil supply of fuel pump Carry out same as step 02 700-1000ccm
Remove auxiliary hose, and connect return pipe to oil tank, and ignition is switched on, and 3
02.3 Oil return pipe and 46 terminals of controller plug are earthed (with auxiliary cable). Read out pressure of Max. 2.9—3.1 bar
pressure gauge, and disconnect earth connection, and ignition is closed.
After about 10 seconds, read pressure of the monograph again, and record dropped value of
02.4 pressure maintenance 0.2-0.3 bar
the pressure.
Ignition closed, and take out controller plug, and connect the voltmeter to plug of fuel pump,
02.6 Power supply of fuel pump and make 3 and 46 terminals of controller plug earthed at the same time (with auxiliary cable). Min. 10.7V
And fuel pump must be operating, and read out power supply voltage.
121
Common Malfunction Diagnosis Flow of Geely Automobile
02.9 Total value of voltage drop Values calculated based on 02.7 and 02.8. Max. 0.8V
Earth connection of
03.0 constant anode to Ignition closed, take out controller plug and connect multimeter
controller
122
Common Malfunction Diagnosis Flow of Geely Automobile
Close ignition, insert controller plug and connect voltmeter. Take out socket connector of
When replacing shading
ignition coil with ignition switch, and take out distributor cover. With ignition turned on, slowly
05.2 Hall sensor 1...2 Hall sensor signal rotor, one voltage larger
rotate belt pulley of engine crankshaft manually, and observe shading rotor of measuring
than 2V must be displayed
instrument and hall sensor.
Hall sensor based on To anode conductor
05.3 Close ignition, take out controller plug and connect the multimeter. <0.5Ω
terminal 12 and ECU connection of hall sensor
Pressure sensor terminal power supply from intake Ignition closed, and connect controller. Connect the voltmeter to plug of pressure sensor, and
06.1 约5
3...1 pipe pressure sensor ignition turned on
Pressure sensor terminal Power supply from intake Close ignition, connect controller plug, and take out connection of socket connector of pressure
07.1 About 5V
1...2 temperature sensor sensor, and connect voltmeter to plug of pressure sensor, ignition
Pressure sensor terminal Intake temperature sensor
07.2 Same as Step 07.1, connect plug of pressure sensor. Note: this value is related to temperature 0.5…3V
1...2 signal
Pressure sensor terminal Intake temperature sensor Close ignition, take out plug of pressure sensor. Connect multimeter of pressure sensor. Note:
07.3 At 20
1...2 resistance this value is related to temperature
123
Common Malfunction Diagnosis Flow of Geely Automobile
124
Common Malfunction Diagnosis Flow of Geely Automobile
heating element of oxygen conductor. The engine is started and running at idling speed. Note: this value is related to
sensor temperature.
10.4 Oxygen sensor Insulated resistance of Close ignition, disconnect socket connector of oxygen sensor. Measure signal line (black) and >30MΩ at -20℃; >10MΩ
heating element to signal cathode conductor (grey) of oxygen sensor and two white conductors one by one with at 350℃; > 100KΩ at
primary element multimeter. Note: this value is related to temperature. 850℃.
10.5 Oxygen sensor Reference voltage of Close ignition, plug in controller, and disconnect socket connector of oxygen sensor, and
controller terminal 10 voltmeter connected to black wire and central earthing, with ignition turned on.
10.6 Oxygen sensor Signal voltage of oxygen Close ignition, and connect socket connector of oxygen sensor. Connect voltmeter to black and Display slowly between
sensor grey cables of oxygen sensor. The engine is started and running at idling speed, and observe 0.2…0.8V
display of measuring instrument after several minutes.
10.7 Oxygen sensor Close-cycle control of Same as Step 10.6. When swinging at display, take out vacuum hose with fuel regulator and Display stable within short
oxygen sensor, seal it. After inspection, plug in hose at pressure regulator. time. Then re-swing.
interference identification
of signal voltage
10.8 Grey cable Cathode conductor signal Close ignition, take out controller plug, and disconnect socket connector of oxygen sensor, and
connection connect multimeter/
10.9 Oxygen sensor Anode conductor signal Same as Step 10.8; connect multimeter to black cable. After inspection, connect socket
Black cable connection connector of oxygen sensor.
11.1 Cooling liquid temperature Supply voltage of cooling Close ignition, and turn on controller plug. Take out plug of cooling liquid temperature sensor. About 5V
sensor liquid temperature sensor Connect voltmeter and turn on ignition.
11.2 Cooling liquid temperature Note: this value is related Same as Step 11.1, but connecting plug of cooling liquid temperature sensor.
sensor to temperature
11.3 Cooling liquid temperature Connection between Close ignition, take out controller, and take out plug of cooling liquid temperature sensor. <0.5Ω
sensor signal and controller Connect the multimeter.
conductor
11.4 Cooling liquid temperature Connection between Same as Step 11.3, with multimeter connected to another terminal. <0.5Ω
sensor cathode conductor and
controller conductor
12.0 AC ready and AC Close ignition, and take out controller plug. Open knife type panel of controller plug. Plug in
compressor input controller, with voltmeter connected to the following terminals.
12.1 18...41 AC ready to input The engine is started and running at idling speed. Close air conditioner. About 12V
12.2 18...41 AC ready to input Same as step 12.1, but with air conditioner turned on. About 0V
12.3 18...40 AC compressor input Same as step 12.1, with voltmeter connected to another terminal, and air conditioner closed About 12V
12.4 18...40 AC compressor input Same as step 12.3, but with air conditioner turned on. About 0V
13.1 Ignition coil Power supply from ignition Close ignition, and take out controller plug. Connect voltmeter. Ignition turned on. About 12V
coil (ignition switch)
125
Common Malfunction Diagnosis Flow of Geely Automobile
13.2 1...2 Ignition coil source input Same as Step 13.1, with voltmeter connected to another terminal. About 12V
13.3 Ignition coil connecting Power supply from ignition Close ignition, take out controller plug, and remove connecting conductor of ignition coil
conductor coil (with load) (ignition switch and terminal 1), and connect one load resistance to ignition switch and
connecting conductor of terminal 1. Make bridge connection at controller plug (from 2 to 1. )
13.4 B+… ignition coil Ignition coil voltage F drop Same as Step 13.3. with voltmeter connected to B+ and ignition switch (load resistance). <0.5V
(ignition switch)
13.5 ECU terminal 1 Cathode conductor Same as Step 13.3. with voltmeter connected to controller terminal 1. <0.5V
Ignition coil terminal 1 voltage drop of ignition coil
13.6 Ignition coil Close ignition, and connect connecting conductor of ignition coil. Connect controller plug, and Intense blue spark seen
remove conductor of ignition coil, and connect proper lightening distance, which is adjusted to during lightening
10mm. note: during inspection, do not hold or contact part 1 of ignition device with hands to
operate the starter.
14.1 Ignition coil Closed angle, closed Ignition “closed”, connect control plug. Connect conductor 4 of ignition coil. Turn on engine
angle control tester of ignition coil and adjust to closed angle for measurement. The engine is started and
running at idling speed. Read out closed angle (measured value of the tester).
14.2 Ignition coil Closed angle, closed Same as Step 14.1, but with rotating speed slowly increased to about 3000rpm. Display value becomes
angle selection larger
14.3 Ignition coil Voltage drop of ignition Same as Step 14.1, with engine tester converted to dynamic voltage drop for measurement.
final stage. Note: this
measurement is only valid
when using proper
measuring instrument.
14.4 Ignition coil Voltage drop of ignition Same as 14.2, but with engine slowly increased to about 3000rpm.
final stage. Note: this
measurement is only valid
when using proper
measuring instrument.
15.1 Ignition distributor Basic arrangement of Ignition “closed”, take out plug of hall sensor. The engine is placed at top dead center of the For basic adjustment, mark
distributor first cylinder (not rotating at camshaft). Take out ignition distributor cover, and evaluate marking on the distributor cover fit
position of distributor rotor. with distributor rotor center.
15.2 Ignition timing correction Distributor arrangement Ignition “closed”, connect plug of hall sensor, and install ignition distributor cover. optical disc Ignition time 6.75°
of distributor lamp of tong sensor is connected to ignition conductor of the first cylinder. crankshaft angle (mark)
Note: when engine tester is with dead center sensor, tong sensor is not needed to connect.
With the engine under hot running, temperature of cooling liquid is larger than 80℃. Connect
the diagnosis instrument, and choose ignition correction function, and at this point idling speed
could be increased to about 1500rpm. If with ignition correction line (terminal 51), it could be
selected. Ignition correction line (terminal 51) is earthed.
15.4 Ignition conductor of Digital idling-speed With the engine under hot running at idling speed, measure ignition advance angle. And When electric instruments
induction thong (the first stabilization function connect electric instruments as much as possible, such as heating pad, high beam. And are turned on, adjust
cylinder) or top dead observe ignition mark or ignition angle display of engine tester. ignition timing quickly.
126
Common Malfunction Diagnosis Flow of Geely Automobile
center sensor
16.1 Conductor connection of Close ignition, and take out controller plug. Remove fuse of oil pump and heating element of About 12V
oil injector of the first oxygen sensor. Bridge connection with terminal 14, 3 and 46. Connect 2 (-) and 17 (+) with
cylinder voltmeter.
16.2 Conductor connection of Same as 16.1, with voltmeter connected to 2 (-) and 16 (+). About 12V
oil injector of the second
cylinder
16.3 2...35 Conductor connection of Same as 16.1, connect 2 (1) and 35 (+) with voltmeter About 12V
oil injector of the third
cylinder
16.4 2...34 Conductor connection of Same as 16.1, connect 2 (1) and 34 (+) with voltmeter About 12V
oil injector of the fourth
cylinder
17.1 B+...+EVl Power supply under load Close ignition, and take out controller plug. Remove all plugs of oil injector. Connect load <0.5V
resistance to the first cylinder and terminal 14. voltmeter connects to positive connection of B+
and load resistance. Remove fuse of oil pump and heating element of oxygen sensor, with 2
bridge connected to 3 and 46.
17.2 B+...+EV2 Power supply under load Same as 17.1, switching with another terminal for load resistance and voltmeter to positive <0.5V
conductor (connecting plug for cylinder oil injector at cable side)
17.3 B+...+EV3 Power supply under load Same as above-mentioned, but for cylinder 3 <0.5V
17.4 B+...+EV4 Power supply under load Same as above-mentioned, but for cylinder 4 <0.5V
19.5 EV4+... Startup control Close ignition, and switch on controller plug. Connect closed angle tester to oil injector of fourth 25...35%
Note: this measuring cylinder with switching conductor. Remove fuse of oil pump. Remove conductor of ignition coil 10...20%
instrument could be used (ignition switch). Remove plug of cooling liquid temperature sensor and connect one resistance 5…8%
at each oil injector. with 30 thousand ohm to replace NTC. Operate starter for about 15 seconds, and observe
display of closed angle tester. Display when startup:
Display after startup for about 5 seconds:
Display after startup for about 10 seconds:
20.1 4...26 Internal resistance of Close ignition, take out controller plug, and connect the multimeter. Note: resistance is related 35…95 ohm
stepper motor to temperature.
20.2 21...29 Internal resistance of Close ignition, take out controller plug, and connect the multimeter. Note: resistance is related 35…95 ohm
stepper motor coil to temperature.
20.3 4… stepper motor Conductor connection Same as 20.1, take out plug of stepper motor, with the multimeter switched to corresponding <0.3ohm
terminal B terminal.
20.4 26… stepper motor Conductor connection Same as 20.1, take out plug of stepper motor, with the multimeter switched to corresponding <0.3ohm
terminal C terminal.
20.5 21… stepper motor Conductor connection Same as 20.1, take out plug of stepper motor, with the multimeter switched to corresponding <0.3ohm
127
Common Malfunction Diagnosis Flow of Geely Automobile
terminal D terminal.
20.6 29… stepper motor Conductor connection Same as 20.1, take out plug of stepper motor, with the multimeter switched to corresponding <0.3ohm
terminal A terminal.
20.7 Stepper motor Control Close ignition, turn on controller plug and turn on speed counter. Connect the tester to stepper About
motor with switching conductor. The engine is started and running at idling speed. Display on 850rpm
the speed counter: 60…80 step
Display on the closed angle tester:
20.8 Stepper motor Idling speed governing Same as 20.7, electric instruments such as heating pad shall be exact and turned on at the Rotating speed quickly
function same time. In case of servo steering, rotate to stopper and stop when the vehicle is at rest. reduced under the load,
Observe display on the speed counter and closed angle tester. then increased to starting
value
20.9 Stepper motor Basic governing of idling Same as 20.7, the engine is still warm, and close all current consumption instruments. Connect Adjusted value
speed diagnosis instrument and choose basic governing function. Choose maintenance connector
terminal. and make terminal 39 (controller) earthed. Observe display on the speed counter and
closed angle tester. Adjust bypass bolt. Running at idling speed.
21.1 51... Connection between Close ignition, take out controller plug and connect the multimeter. <0.5ohm
ignition correction
conductor to controller
(terminal 51) conductor
22.1 55... Connection between fuel Close ignition, take out controller plug and connect the multimeter. <0.50ohm
conductor to controller
(terminal 55) conductor
23.1 3...2 Fuel pump relay control, Ignition “closed”, take out controller plug. Take out casing of controller plug, and turn on About 12V
final stage controller plug, with voltmeter connected to terminal 1 and 2. “ignition” turned on, and starter
not started.
23.2 3...2 Fuel pump relay control, Same as 23.1, but engine started and running at idling speed. 0.5...2.0V
driver stage
128
Common Malfunction Diagnosis Flow of Geely Automobile
No.068 Diagnosis and solution of common malfunctions of JL376/378QE engine’s electric control system
Serial No. Malfunction Display by diagnosis instrument Analytic procedure Causes Measures
Oil pump relay is with closing sound, but Check fuse or lines from oil
8. Unable to start Without malfunction.
oil pump not working normally pump relay to oil pump
129
Common Malfunction Diagnosis Flow of Geely Automobile
2 Malfunction-free 11 - -
5 Condensing sensor 15 2 1
7 oxygen sensor 17 1 1
130
Common Malfunction Diagnosis Flow of Geely Automobile
21 Battery 38 2 0
24 Cylinder signal 43 2 0
Malfunction type: : “1” broken circuit or short circuited to ground or power source “2” signal
overrun
Malfunction lamp: : “1”ON “0” OFF
Steps for reading flashing code:
1. Switch on ignition switch of the engine, but unable to start the engine.
2. Connect K line (ECU-55# or OBDⅡ diagnosis connector -7#) to earth, and the time exceeds
2.5 seconds.
3. Malfunction stored in the malfunction memorizer is output in flashing mode through
malfunction indicating lamp.
4. Each flashing code is made up of 2 numbers, and each number is made up of 0 or 1-9.
5. Number 0 flashes ten times, and numbers 1-9 flash respectively 1-9 times; interval of two
numbers pauses (one second) when flashing, and neighboring malfunction code will pause for
long time (3 seconds).
6. The same malfunction code flashes continuously for 3 seconds. And all malfunction codes
flash continuously, till the engine is started or reading action of malfunction terminates.
7. If there is no malfunction stored within malfunction memorizer, then “without malfunction”
flashes, i.e. “11”.
131
Common Malfunction Diagnosis Flow of Geely Automobile
1 Switch on diagnosis instrument and commutator, and place ignition switch to “ON”. Next step
Observe “inlet pressure” of data flow, and check value is around 101kpa (specific Yes To step 5
2
value related to the air pressure at that time).
No Next step
Take out the connector of intake pressure sensor of the harness, and check voltage Yes To step 5
3
between 3# and 1# pins of this connector is around 5V with multimeter.
No Next step
Repair or replace
Yes
Check lines respectively between 17#, 33#, 37# pins of ECU and 1#, 3#, 4# pins of harness
4
sensor connector are shorted to ground.
No Next step
Start the engine and make it operate at idling speed. Step the throttle slowly to be
close to full opening, and observe changes of value of “inlet pressure” on the Yes Diagnosis help
5 diagnosis instrument, and values shall not be largely changed at this time; step the
throttle quickly to be close to full opening, and value shall reach above 90kpa
No Replace sensor
immediately at this time.
132
Common Malfunction Diagnosis Flow of Geely Automobile
1 Switch on diagnosis instrument and commutator, and place ignition switch to “ON”. Next step
Yes To step 5
Observe “inlet pressure” of data flow, and check value is around 101kpa (specific
2
value related to the air pressure at that time).
No Next step
Yes To step 5
Take out the connector of intake pressure sensor of the harness, and check voltage
3
between 3# and 1# pins of this connector is around 5V with multimeter.
No Next step
Repair or
Yes
Check lines respectively between 17#, 33#, 37# pins of ECU and 1#, 3#, 4# pins of replace harness
4
sensor connector are opened or shorted to power source.
No Next step
Start the engine and make it operate at idling speed. Step the throttle slowly to be Yes Diagnosis help
close to full opening, and observe changes of value of “inlet pressure” on the
5 diagnosis instrument, and values shall not be largely changed at this time; step the
throttle quickly to be close to full opening, and value shall reach above 90kpa
immediately at this time. Replace sensor
No
Observe “intake temperature” of data flow, and check it is equal to Yes To step 5
temperature within air inlet pipe (specific value related to engine
2
temperature at that time). Note: if value is -40℃ at this point, then
disconnection malfunction may occur to lines. No Next step
Take out connector of intake temperature sensor of the harness, and check Yes Next step
resistance between 1# and 2# pins of sensor is suitable to its temperature
3
with multimeter (for details, refer to related parts of this maintenance
manual). No Replace sensor
Take out connector of intake temperature sensor of the harness, and check Yes To step 5
4
voltage between 1# and 2# pins of this connector is around 5V.
No Next step
Repair or replace
Check lines between 17#, 40# pins of ECU and 1#, 2# pins of sensor Yes harness
5
connector are opened or shorted to power source.
No Next step
Start the engine, and make it operate at idling speed. Observe changes of
6
values of “intake temperature” on the diagnosis instrument, and values shall Yes Diagnosis help
rise as temperature of cooling liquid of the engine rises at this time
133
Common Malfunction Diagnosis Flow of Geely Automobile
No Replace sensor
Observe “intake temperature” of data flow, and check it is equal to Yes To step 5
temperature within air inlet pipe (specific value related to engine
2
temperature at that time). Note: if value is -40℃ at this point, then
disconnection malfunction may occur to lines. No Next step
Take out connector of intake temperature sensor of the harness, and check Yes Next step
resistance between 1# and 2# pins of sensor is suitable to its temperature
3
with multimeter (for details, refer to related parts of this maintenance
manual). No Replace sensor
Take out connector of intake temperature sensor of the harness, and check Yes To step 5
4
voltage between 1# and 2# pins of this connector is around 5V.
No Next step
Repair or replace
Yes
harness
Check lines between 17#, 40# pins of ECU and 1#, 2# pins of sensor
5
connector are shorted to ground.
No Next step
Take out connector of temperature sensor of cooling liquid of the harness, Yes Next step
and check resistance between 1# and 2# pins of sensor is suitable to its
3
temperature with multimeter (for details, refer to related parts of this
maintenance manual). No Replace sensor
134
Common Malfunction Diagnosis Flow of Geely Automobile
No Next step
Repair or replace
Yes
harness
Check lines between respectively 39#, 35# pins of ECU and 1#, 2# pins of
5
sensor connector are opened, or shorted to power source.
No Next step
Start the engine, and make it operate at idling speed. Observe changes of Yes Diagnosis help
values of “temperature of cooling liquid” on the diagnosis instrument, and
6
values shall rise as temperature of cooling liquid of the engine rises at this
time. No Replace sensor
Yes To step 6
Observe “temperature of cooling liquid” of data flow, and check it is equal to
engine temperature (specific value related to engine temperature at that
2
time). Note: if value is -40℃ at this point, then disconnection malfunction
may occur to lines. No Next step
Yes To step 6
Take out connector of temperature sensor of cooling liquid of the harness,
4
and check voltage between 1# and 2# pins of this connector is around 5V.
No Next step
Repair or replace
Check lines between respectively 39#, 35# pins of ECU and 1#, 2# pins of Yes harness
5
sensor connector are shorted to ground.
No Next step
Start the engine, and make it operate at idling speed. Observe changes of Yes Diagnosis help
values of “temperature of cooling liquid” on the diagnosis instrument, and
6
values shall rise as temperature of cooling liquid of the engine rises at this
time. No Replace sensor
135
Common Malfunction Diagnosis Flow of Geely Automobile
Repair or replace
Yes
Take out connector of throttle valve position sensor of harness, and check harness
5 lines between respectively 17#, 32#, 16# pins of ECU and 1#, 2#, 3# pins of
sensor connector are shorted to ground.
No Next step
Repair or replace
Yes
Take out connector of throttle valve position sensor of harness, and check harness
5 lines between respectively 17#, 32#, 16# pins of ECU and 1#, 2#, 3# pins
of sensor connector are opened, or shorted to power source.
No Next step
136
Common Malfunction Diagnosis Flow of Geely Automobile
Repair or replace
Check lines respectively between 36#, 18# of ECU and A# (opposed to Yes harness
3 grey connecting line of oxygen sensor), B# (opposed to black connecting
line of oxygen sensor) of sensor connector are shorted to ground.
No Next step
Start the engine, and make it operate at idling speed, till temperature of Yes Diagnosis help
cooling liquid reached normal value. Observe changes of value of “voltage
2
of oxygen sensor” on the diagnosis instrument, and the value shall be
changed quickly between 100mV~900mV at this time. No Next step
137
Common Malfunction Diagnosis Flow of Geely Automobile
Start the engine, and make it operate at idling speed, till temperature of Yes Diagnosis help
cooling liquid reached normal value. Observe changes of value of “voltage
2
of oxygen sensor” on the diagnosis instrument, and the value shall be
changed quickly between 100mV~900mV at this time. No Next step
Repair or replace
Yes
Check lines respectively between 36#, 18# of ECU and A# (opposed to harness
3 grey connecting line of oxygen sensor), B# (opposed to black connecting
line of oxygen sensor) of sensor connector are opened.
No Diagnosis help
Take out connector of oxygen sensor of harness, and check voltage Yes Next step
between C# (opposed to white connecting line of oxygen sensor), D#
2
(opposed to white connecting line of oxygen sensor) pins of this connector
is around 12V with multimeter. No To step 4
No Replace sensor
No Next step
Repair or replace
Check lines respectively between 1# pin of ECU, 87# pin of main relay and Yes harness
C# (opposed to white connecting line of oxygen sensor), D# (opposed to
5
white connecting line of oxygen sensor) of sensor connector are opened, or
shorted to power source or ground. No Diagnosis help
138
Common Malfunction Diagnosis Flow of Geely Automobile
Repair or replace
Check lines respectively between 36#, 18# pins of ECU and A# (opposed to Yes harness
4 grey connecting line of oxygen sensor), B# (opposed to black connecting
line of oxygen sensor) of sensor connector are shorted to power source.
No Next step
Check lines respectively between 36#, 18# pins of ECU and A# (opposed to
4 grey connecting line of oxygen sensor), B# (opposed to black connecting Yes Repair or replace
line of oxygen sensor) of sensor connector are shorted to power source. harness
139
Common Malfunction Diagnosis Flow of Geely Automobile
No Next step
Take out connector of one-cylinder oil injector of harness, and check Yes To step 4
2 voltage between 1# pin of this harness and cathode of power source is
around 12V.
No Next step
Repair or replace
Yes
Check lines between 1# pin of connector of one-cylinder oil injector and harness
3
main relay are opened or shorted to ground.
No Next step
Check voltage between 2# pin of one-cylinder oil injector connector and Yes Diagnosis help
5
cathode of power source is around 3.7V with multimeter.
No Next step
Repair or replace
Yes
Check lines between 2# pin of one-cylinder oil injector connector and 27# harness
6
pin of ECU are opened or shorted to power source or ground.
No Diagnosis help
Yes To step 4
Take out connector of two-cylinder oil injector of harness, and check voltage
2
between 1# pin of this harness and cathode of power source is around 12V.
No Next step
Repair or replace
Yes
Check lines between 1# pin of connector of two-cylinder oil injector and harness
3
main relay are opened or shorted to ground.
No Next step
140
Common Malfunction Diagnosis Flow of Geely Automobile
Repair or replace
Check lines between 2# pin of two-cylinder oil injector connector and 6# pin Yes harness
6
of ECU are opened or shorted to power source or ground.
No Diagnosis help
Take out connector of three-cylinder oil injector of harness, and check Yes To step 4
2 voltage between 1# pin of this harness and cathode of power source is
around 12V. No Next step
Repair or replace
Yes
Check lines between 1# pin of connector of three-cylinder oil injector and harness
3
main relay are opened or shorted to ground.
No Next step
Check voltage between 2# pin of three-cylinder oil injector connector and Yes Diagnosis help
5
cathode of power source is around 3.7V with multimeter.
No Next step
Repair or replace
Yes
Check lines between 2# pin of three-cylinder oil injector connector and 7# harness
6
pin of ECU are opened or shorted to power source or ground.
No Diagnosis help
Take out connector of four-cylinder oil injector of harness, and check voltage Yes To step 4
2 between 1# pin of this connector and cathode of power source is around 12V
with multimeter.
No Next step
Repair or replace
Yes
Check lines between 1# pin of connector of four-cylinder oil injector and main harness
3
relay are opened or shorted to ground.
No Next step
141
Common Malfunction Diagnosis Flow of Geely Automobile
Repair or replace
Yes
Check lines between 2# pin of four-cylinder oil injector connector and 47# pin of harness
6
ECU are opened or shorted to power source or ground.
No Diagnosis help
Yes To step 4
Take out oil pump relay, and place ignition switch at “ON”. Check power
2 supply terminal of oil pump relay, i.e. voltage between 30#, ,, , 86#
pins of relay and cathode of power source is around 12V.
No Next step
Repair or replace
Yes
Check lines at power supply terminal of relay are opened or shorted to harness
3
ground.
No To step 2
Repair or replace
Yes
harness
Check control terminal of relay, i.e. lines between 85# pin of relay and 69#
5
pin of ECU are opened or shorted to power source or ground.
No Diagnosis help
Check lines respectively between 1#, 2# of knock sensor connector and Repair or replace
3 Yes
19#, 20# of ECU are opened, or shorted to power source or to ground. harness
142
Common Malfunction Diagnosis Flow of Geely Automobile
No Next step
Repair or replace
Yes
Check lines respectively between 2#, 3# of speed sensor connector and harness
3
34#, 15# of ECU are opened, or shorted to power source or to ground.
No Next step
Repair or replace
Yes
harness
Check lines respectively between 2#, 3# of speed sensor connector and
3
34#, 15# of ECU are opened, or shorted to power source or to ground.
No Next step
143
Common Malfunction Diagnosis Flow of Geely Automobile
Replace signal
No
panel
Yes To step 4
Take out connector of phase sensor of the harness, and check voltage
2
between 3# and 1# pins of phase sensor connector is around 12V.
No Next step
Repair or replace
Yes
Check lines between 3# pin of phase sensor and 87# pin of main relay are harness
3 opened or shorted to earth;
Check 1# pin of phase sensor is poorly earthed.
No Next step
Yes To step 6
Check voltage between 2# pin of phase sensor connector and cathode of
4
power source is about 9.9V.
No Next step
Repair or replace
Yes
harness
check lines between 2# pin of phase sensor connector and 79# pin of ECU
5
are opened or shorted to power source or earth;
No Next step
Yes To step 4
Take out connector of phase sensor of the harness, and check voltage
2
between 3# and 1# pins of phase sensor connector is around 12V.
No Next step
Repair or replace
Yes
Check lines between 3# pin of phase sensor and 87# pin of main relay are harness
3 opened or shorted to earth;
Check 1# pin of phase sensor is poorly earthed.
No Next step
144
Common Malfunction Diagnosis Flow of Geely Automobile
Yes To step 6
Check voltage between 2# pin of phase sensor connector and cathode of
4
power source is about 9.9V.
No Next step
Repair or replace
Yes
check lines between 2# pin of phase sensor connector and 79# pin of ECU harness
5
are opened or shorted to power source or earth;
No Next step
Yes To step 4
Take out connector of phase sensor of the harness, and check voltage
2
between 3# and 1# pins of phase sensor connector is around 12V.
No Next step
Repair or replace
Yes
Check lines between 3# pin of phase sensor and 87# pin of main relay are harness
3 opened or shorted to earth;
Check 1# pin of phase sensor is poorly earthed.
No Next step
Yes To step 6
Check voltage between 2# pin of phase sensor connector and cathode of
4
power source is about 9.9V.
No Next step
Repair or replace
Yes
harness
check lines between 2# pin of phase sensor connector and 79# pin of ECU
5
are opened or shorted to power source or earth;
No Next step
145
Common Malfunction Diagnosis Flow of Geely Automobile
Yes To step 4
Take out connector of canister control valve of the harness, and check
2 voltage between 1# pin of this connector and cathode of power source is
around 12V with the multimeter.
No Next step
Repair or replace
Yes
Check lines at power supply terminal of canister control valve are opened or harness
3
shorted to ground.
No To step 2
Repair or replace
Yes
Check lines between 2# pin of connector of canister control valve and 46# harness
6
pin of ECU are open shorted.
No Diagnosis help
Yes To step 4
Take out connector of canister control valve of the harness, and check
2 voltage between 1# pin of this connector and cathode of power source is
around 12V with the multimeter.
No Next step
Repair or replace
Yes
harness
Check lines at power supply terminal of canister control valve are opened or
3
shorted to ground.
No To step 2
146
Common Malfunction Diagnosis Flow of Geely Automobile
Repair or replace
Yes
harness
Check lines between 2# pin of connector of canister control valve and 46#
6
pin of ECU are shorted to ground.
No Diagnosis help
Yes To step 4
Take out connector of canister control valve of the harness, and check
2 voltage between 1# pin of this connector and cathode of power source is
around 12V with the multimeter.
No Next step
Repair or replace
Yes
harness
Check lines at power supply terminal of canister control valve are opened or
3
shorted to ground.
No To step 2
Repair or replace
Yes
harness
Check lines between 2# pin of connector of canister control valve and 46#
6
pin of ECU are shorted to power source.
No Diagnosis help
147
Common Malfunction Diagnosis Flow of Geely Automobile
Yes To step 4
Take out cooling fan relay of AC condenser, and place ignition switch at
2 “ON”, and check voltage between power supply terminal of this relay, i.e.
30# and 85# pins of relay and cathode of power source is around 12V.
No Next step
Repair or replace
Yes
Check lines at power supply terminal of cooling fan relay of AC condenser harness
3
are opened or shorted to ground.
No To step 2
Repair or replace
Yes
harness
Check lines between 86# pin of control terminal of relay and 50# pin of ECU
5
are opened or shorted to power source or ground.
No Diagnosis help
Replace speed
No
sensor
148
Common Malfunction Diagnosis Flow of Geely Automobile
Repair or replace
Yes
harness
Check lines between sensor signal line and 59# pin of ECU are opened or
4
shorted to power source or ground.
No Diagnosis help
No.100 Malfunction code: P0506 "idling speed lower than target speed
value"
No.101 Malfunction code: P0507 "idling speed higher than target speed
value"
Serial No. Operation steps Results Follow-ups
149
Common Malfunction Diagnosis Flow of Geely Automobile
Repair or replace
Yes
Check lines among A, B, C D pins of idling speed governor and 65#, 66#, harness
3
67#, 64# pins of ECU are shorted to ground.
No Diagnosis help
Repair or replace
Yes
harness
Check lines among A, B, C D pins of idling speed governor and 65#, 66#,
3
67#, 64# pins of ECU are opened.
No Diagnosis help
150
Common Malfunction Diagnosis Flow of Geely Automobile
Repair or replace
Check lines among 44#, 45#, 63# pins of ECU and 87# pin of main relay Yes harness
3
are opened or shorted to ground.
No Next step
Start the engine, and check charging voltage of generator is between 9-16V Yes Next step
4
within different speed range.
No Replace generator
Repair or replace
Yes
harness
Check resistance of lines between 44#, 45#, 63# pins of ECU and 87# pin
3
of main relay are too large.
No Next step
151
Common Malfunction Diagnosis Flow of Geely Automobile
1 Switch on diagnosis instrument, and place ignition switch at “ON”. Next step
152
Common Malfunction Diagnosis Flow of Geely Automobile
Yes To step 4
Take out relay of AC compressor, and place ignition switch at “ON”. Check
2 voltage of power supply terminal of relay, i.e. 30# and 85# pins and cathode
of power source is around 12V.
No Next step
Repair or replace
Yes
harness
Check lines at power supply terminal of relay are opened or shorted to
3
ground.
No To step 2
Repair or replace
Yes
Check lines of control terminal of AC compressor relay, i.e. 86# pin of relay harness
5
and 70# pin of ECU are opened.
No Diagnosis help
Yes To step 4
Take out relay of AC compressor, and place ignition switch at “ON”. Check
2 voltage of power supply terminal of relay, i.e. 30# and 85# pins and cathode
of power source is around 12V.
No Next step
Repair or replace
Yes
Check lines at power supply terminal of relay are opened or shorted to harness
3
ground.
No To step 2
153
Common Malfunction Diagnosis Flow of Geely Automobile
Repair or replace
Yes
harness
Check lines of control terminal of AC compressor relay, i.e. 86# pin of relay
5
and 70# pin of ECU are shorted to ground.
No Diagnosis help
Yes To step 4
Take out relay of AC compressor, and place ignition switch at “ON”. Check
2 voltage of power supply terminal of relay, i.e. 30# and 85# pins and cathode
of power source is around 12V.
No Next step
Repair or replace
Yes
harness
Check lines at power supply terminal of relay are opened or shorted to
3
ground.
No To step 2
Repair or replace
Yes
harness
Check lines of control terminal of AC compressor relay, i.e. 86# pin of relay
5
and 70# pin of ECU are shorted to power source.
No Next step
154
Common Malfunction Diagnosis Flow of Geely Automobile
Take out connector of idling speed governor (EWD) of the harness, and Yes To step 4
2 check voltage between 2# pin of this connector and cathode of power
source is around 12V with the multimeter.
No
Next step
Repair or replace
Yes
Check lines at power supply terminal of idling speed governor (EWD) are harness
3
opened and shorted to ground.
No Next step
Repair or replace
Yes
harness
Check lines between 1# pin of connector of idling speed governor (EWD)
5
and 26# pin of ECU are shorted to power source.
No Diagnosis help
Carry out action testing on malfunction lamp of the engine via “actuator Yes Next step
2 action testing” of the diagnosis instrument, and observe it is at OFF status
or ON status.
No System normal
Repair or replace
Yes
Check lines at power supply terminal of malfunction lamp of the engine is harness
3
open circuited or shorted to ground.
No Next step
Repair or replace
Yes
Check lines between pin of control terminal of malfunction lamp and 28# pin harness
4
of ECU is open circuited or shorted to power source or the ground.
No Next step
155
Common Malfunction Diagnosis Flow of Geely Automobile
156
Common Malfunction Diagnosis Flow of Geely Automobile
Repair or replace
Yes
Remove startup motor, and check its working conditions. Mainly check it starting motor
3
is open circuited or jammed due to poor lubrication.
No Next step
Replace for
Yes lubricating oil with
If malfunction only occurs in winter, check resistance of startup motor is proper grade
4
too large due to improper selection of lubricating oil and gear case oil.
No Next step
Check internal
Yes resistance of
Check internal mechanical resistance of the engine is too large, causing engine
5
startup motor not running or slowly running.
No Diagnosis help
157
Common Malfunction Diagnosis Flow of Geely Automobile
Take out line of one cylinder, and connect spark plug, making spark plug
3 electrode about 5mm away from engine body. Startup the engine and
check there is high pressure spark.
Repair ignition
No
system
Eliminate
Yes
mechanical failure
Check pressure of each cylinder of the engine, and observe engine
4
cylinder is with insufficient pressure.
No Next step
158
Common Malfunction Diagnosis Flow of Geely Automobile
Repair lines or
Take out connector of cooling liquid temperature sensor, and start the Yes replace sensor
engine. Observe the engine is successfully started at this point. (or
3 connect one 300ohm resistance in series at connector of this sensor to
replace cooling liquid temperature sensor and observe the engine is
successfully started at this point.)
No Next step
No Next step
159
Common Malfunction Diagnosis Flow of Geely Automobile
Connect fuel pressure gauge (access point is front end of oil sucker of Yes Next step
1 fuel distribution pipe assembly), and start the engine, and check fuel
pressure is around 350kPa. Repai r oil supply
No
system
Take out line of one cylinder, and connect spark plug, making spark plug Yes Next step
2 electrode about 5mm away from engine body. Startup the engine and
check there is high pressure spark. Repair ignition
No
system
Take out connector of cooling liquid temperature sensor, and start the Repair lines or
Yes
engine. Observe the engine is successfully started at this point. (or replace sensor
3 connect one 300ohm resistance in series at connector of this sensor to
replace cooling liquid temperature sensor and observe the engine is No Next step
successfully started at this point.)
Clean throttle valve
Yes and idling speed
4 Step on the throttle lightly, and observe it is easily started. duct
No Next step
Replace
Remove oil injector, and check it is leaking or blocked with special Yes malfunctiony ones
5
cleaning and analysis instrument.
No Next step
Eliminate
Yes
mechanical failure
Check pressure of each cylinder of the engine, and observe engine
7
cylinder is with insufficient pressure.
No Next step
160
Common Malfunction Diagnosis Flow of Geely Automobile
No Next step
Connect fuel pressure gauge (access point is front end of oil sucker of Yes Next step
2 fuel distribution pipe assembly), and start the engine, and check fuel
pressure is around 350kPa. Repair oil supply
No
system
Take out line of one cylinder, and connect spark plug, making spark plug Yes Next step
3 electrode about 5mm away from engine body. Startup the engine and
check there is high pressure spark. Repair ignition
No
system
Repair lines or
Yes
Take out connector of cooling liquid temperature sensor, start the engine replace sensor
5
and observe it is successfully started at this time.
No Next step
No Next step
Replace
Yes
Remove oil injector, and check it is leaking or blocked with special malfunctiony ones
7
cleaning and analysis instrument.
No Next step
Eliminate
Yes
Check pressure of each cylinder of the engine, and observe engine mechanical failure
9
cylinder is with insufficient pressure.
No Next step
Connect commutator of electric injection system, and open ignition Yes Diagnosis help
11 switch, and check power supply of 12#, 13#, 44#, 45#, ,63# pins are
normal; check bonding of 3#, 51#, 53#, 61#, 80# pins are normal. Repair
No
corresponding lines
161
Common Malfunction Diagnosis Flow of Geely Automobile
Check throttle valve body and idling speed bypass air duct is with carbon Yes Clean
4
deposit.
No Next step
Replace
Yes
Remove oil injector, and check it is leaking or blocked, or flow with out of malfunction ones
5
tolerance with special cleaning and analysis instrument.
No Next step
Eliminate
Yes
Check pressure of each cylinder of the engine, and observe cylinder mechanical failure
7
pressure has too large differences.
No Next step
162
Common Malfunction Diagnosis Flow of Geely Automobile
Clean concerned
Yes
Remove idling speed regulator, and check throttle valve body, idling parts
3
speed regulator and idling speed bypass air duct are with carbon deposit.
No Next step
Repair lines or
Yes
Take out connector of cooling liquid temperature sensor, start the engine replace sensor
4
and observe the engine's idling speed is instable during warming up.
No Next step
Replace
Yes
Remove oil injector, and check it is leaking or blocked, or flow with out of malfunctiony ones
5
tolerance with special cleaning and analysis instrument.
No Next step
Eliminate
Yes
Check pressure of each cylinder of the engine, and observe cylinder mechanical failure
7
pressure has too large differences.
No Next step
Connect commutator of electric injection system, and open ignition Yes Diagnosis help
8 switch, and check power supply of 12#, 13#, 44#, 45#, ,63# pins are
normal; check bonding of 3#, 51#, 53#, 61#, 80# pins are normal. Repair
No
corresponding lines
163
Common Malfunction Diagnosis Flow of Geely Automobile
No Next step
Clean concerned
Yes
parts
Remove idling speed regulator, and check throttle valve body, idling
3
speed regulator and idling speed bypass air duct are with carbon deposit.
No Next step
Repair lines or
Yes
Take out connector of cooling liquid temperature sensor, start the engine replace sensor
4
and observe the engine's idling speed is instable during warming up.
No Next step
Replace
Yes
Remove oil injector, and check it is leaking or blocked, or flow with out of malfunctiony ones
5
tolerance with special cleaning and analysis instrument.
No Next step
Check fuel condition and observe malfunction is caused just after Yes Replace fuel
refueling.
6
No Next step
Eliminate
Yes
Check pressure of each cylinder of the engine, and observe cylinder mechanical failure
7
pressure has too large differences.
No Next step
164
Common Malfunction Diagnosis Flow of Geely Automobile
No.123 Normal startup, idling speed is instable or the vehicle will flame
out when partially loaded (such as: when air conditioner is on)
General malfunction part: 1. air conditioning system; 2、idling speed regulator; 3. oil injector.
General diagnosis flowchart:
Serial
Operation steps Results Follow-ups
No.
Clean concerned
Remove idling speed regulator, and check throttle valve body, idling speed Yes parts
1
regulator and idling speed bypass air duct are with carbon deposit.
No Next step
Yes To step 4
Observe output power of the engine is increased while air conditioner is on, i.e.
2 observe changes of ignition advance angle, oil injection pulse width and air input
with diagnosis instrument of electric injection system.
No Next step
Replace
Remove oil injector, and check it is leaking or blocked, or flow with out of tolerance Yes malfunction ones
5
with special cleaning and analysis instrument.
No Next step
165
Common Malfunction Diagnosis Flow of Geely Automobile
Yes Adjust
1 Check throttle cable is jammed or too tightening.
No Next step
No Next step
Remove idling speed regulator, and check throttle valve body, idling Yes Clean concerned parts
3
speed regulator and idling speed bypass air duct are with carbon deposit.
No Next step
166
Common Malfunction Diagnosis Flow of Geely Automobile
No Next step
Replace malfunction
Yes
Remove oil injector, and check it is leaking or blocked with special ones
6
cleaning and analysis instrument.
No Next step
167
Common Malfunction Diagnosis Flow of Geely Automobile
Connect fuel pressure gauge (access point is front end of oil sucker of Yes Next step
2 fuel distribution pipe assembly), and start the engine, and check fuel
pressure is around 350kPa during accelerating. Repair oil supply
No
system
Connect commutator of electric injection system, and open ignition Yes Diagnosis help
10 switch, and check power supply of 12#, 13#, 44#, 45#, ,63# pins are
normal; check bonding of 3#, 51#, 53#, 61#, 80# pins are normal. Repair corresponding
No
lines
168
Common Malfunction Diagnosis Flow of Geely Automobile
Check there are malfunctions such as clutch skidding, low tire Yes Repair
1 pressure, braking dragging, incorrect tire dimension, incorrect
positioning of four wheels, etc. No Next step
Repair air intake
Yes
2 Check air filter is blocked. system
No Next step
Connect fuel pressure gauge (access point is front end of oil sucker Yes Next step
3 of fuel distribution pipe assembly), and start the engine, and check
fuel pressure is around 350kPa during accelerating. Repair oil supply
No
system
Take out line of one cylinder, and connect spark plug, making spark Yes Next step
4 plug electrode about 5mm away from engine body. Startup the
engine and check strength of high pressure spark is normal.
No Repair ignition system
Check spark plug of each cylinder, and observe its type and Yes Next step
5
clearance conform to the specifications.
No Adjust or replace
Remove idling speed regulator, and check throttle valve body, idling Yes Clean concerned parts
6 speed regulator and idling speed bypass air duct are with carbon
deposit. No Next step
Remove oil injector, and check it is leaking or blocked with special Yes Replace malfunction
8
cleaning and analysis instrument.
No Next step
Check fuel condition and observe malfunction is caused just after Yes Replace fuel
9
refueling.
No Next step
Connect commutator of electric injection system, and open ignition Yes Diagnosis help
switch, and check power supply of 12#, 13#, 44#, 45#, ,63# pins
12
are normal; check bonding of 3#, 51#, 53#, 61#, 80# pins are
Repair corresponding
normal. No
lines
169
Common Malfunction Diagnosis Flow of Geely Automobile
Malfunction
NO Malfunction code Description
level
5 P0037 Short-circuit to earth of heating control circuit for downstream oxygen sensor 3
170
Common Malfunction Diagnosis Flow of Geely Automobile
28 P0171 Over-thin of self-learning of closed-loop control of air fuel ratio for off-line test 7
29 P0172 Lower cable inspection air/fuel ratio closed circuit self-adaptation too thick 7
34 P0261 Short circuit to earth of 1st cylinder fuel injector controlling circuit 3
35 P0262 Short circuit to power supply of 1st cylinder fuel injector controlling circuit 3
36 P0264 Short circuit to earth of 2nd cylinder fuel injector controlling circuit 3
37 P0265 Short circuit to power supply of 2nd cylinder fuel injector controlling t circuit 3
38 P0267 Short circuit to earth of 3rd cylinder fuel injector controlling circuit 3
39 P0268 Short circuit to power supply of 3rd cylinder fuel injector controlling circuit 3
40 P0270 Short circuit to earth of 4th cylinder fuel injector controlling circuit 3
41 P0271 Short circuit to power supply of 4th cylinder fuel injector controlling circuit 3
171
Common Malfunction Diagnosis Flow of Geely Automobile
51 P0327 Knock sensor signal circuit voltage lower than normal value 3
59 P0458 Canister valve controlling circuit voltage lower than normal value 3
61 P0480 Cooling fan relay controlling circuit open circuit (low speed) 5
62 P0481 Cooling fan relay controlling circuit open circuit (high speed) 5
172
Common Malfunction Diagnosis Flow of Geely Automobile
67 P0509 Stepping motor driving pin short circuit with power supply 3
78 P0647 Short circuit to power supply of A/C compressor relay controlling circuit 5
80 P0691 Short circuit to earth of cooling fan relay controlling circuit (low speed) 5
81 P0692 short circuit to power supply of cooling fan relay controlling circuit (low speed) 5
Air/fuel ratio closed circuit self-adaptation over upper limit (middle loading
82 P2177 11
area)
Air/fuel ratio closed circuit self-adaptation below lower limit (middle loading
83 P2178 11
area)
173
Common Malfunction Diagnosis Flow of Geely Automobile
84 P2187 Air/fuel ratio closed circuit self-adaptation over upper limit (low loading area) 11
85 P2188 Air/fuel ratio closed circuit self-adaptation below lower limit (low loading area) 11
86 P2195 Upper oxygen sensor ageing (signal deviation over upper limit) 3
87 P2196 Upper oxygen sensor ageing (signal deviation below lower limit) 3
Malfunction
NO Description
code
174
Common Malfunction Diagnosis Flow of Geely Automobile
21 P0444 Voltage too low, driver-stage control circuit of canister control valve
22 P0445 Voltage too high, driver-stage control circuit of canister control valve
28 P0509 short circuit to power supply of idle speed adjustor controlling circuit
35 P0630 Vehicle Identification Number (VIN) discode or mismatch - Electrical Control Unit
(ECU)
36 P0645 AC compressor relay controlling circuit failure
37 P0646 AC compressor relay controlling circuit voltage lower than normal value
175
Common Malfunction Diagnosis Flow of Geely Automobile
Transmission
No. 130 Transmission hard to put into gear
Gear shifting lever incorrectly adjusted 2. Check whether rubber pillar of support base is broken;
replace gear shifting lever assembly if so;
176
Common Malfunction Diagnosis Flow of Geely Automobile
Abnormal
Clutch not fully separated Adjust and repair
Normal
Abnormal
Shift bar incorrectly adjusted Adjust and repair
Normal
Abnormal
Transmission oil Check and replace
Normal
Normal
177
Common Malfunction Diagnosis Flow of Geely Automobile
Incorrectly
Gear cable incorrectly adjusted
Adjust
Normal
Ruptures
P-position locking device fails or broken Replace
Normal
Abnormal
Auto transmission malfunction
Repair
Gear indicator Check contact on A/T switch, and replace A/T switch if
lamp off A/T switch malfunction necessary; check earth wire is falsely connected; fix earth
sometimes wire.
178
Common Malfunction Diagnosis Flow of Geely Automobile
Abnormal
Combination instrument Replace
malfunction
Normal
Abnormal
A/T switch malfunction Replace
Abnormal
Line malfunction Repair
Oil filled between 2-4 holes of dip stick. Oil is too much, causing abnormal
sound with parts rotation. Oil too little, and each friction pair lack of
Oil quantity and quality lubrication, causing abnormal sound. Check idling speed is normal and
engine temperature is normal. For N-position, check oil level is normal,
and fill transmission oil if not sufficient. If dirty, replace transmission oil.
Auto transmission
Abnormal sound in middle, slow shifting, oil pressure insufficient. Check
with abnormal
Oil pump malfunction clearance between oil pump rotor and casing, plate, which shall be within
sound
standard range;
Check meshing mark of output shaft and gear ring is normal; replace
output shaft and gear ring if abnormal; check whether differential bearing
Out shaft axle differential with is loosening. Shaking with hands shall be without loosening sound, and
abnormal sound ball bearing track not flaked; replace differential bearing if abnormal;
check differential planet gear, shaft could grind step. Replace differential
assembly if worn.
179
Common Malfunction Diagnosis Flow of Geely Automobile
Abnormal
Oil quantity and quality Check or repair
Normal
Normal
Normal
Abnormal Repair
Planet gear mechanism
Normal
Abnormal
Outshaft axle differential Repair
with abnormal sound
180
Common Malfunction Diagnosis Flow of Geely Automobile
181
Common Malfunction Diagnosis Flow of Geely Automobile
Transmission shaking
during driving
Abnormal
Engine Repair
Normal
Normal
Normal
Normal
Abnormal
Within transmission Repair
182
Common Malfunction Diagnosis Flow of Geely Automobile
No. 135 Auto transmission case oil temperature rises, reverse gear fails
Malfunction Causes Solution
Normal
183
Common Malfunction Diagnosis Flow of Geely Automobile
1. Check throttle tie-line, and step to the end, and throttle shall at
maximum position. If not possible, adjust throttle tie-line;
184
Common Malfunction Diagnosis Flow of Geely Automobile
Abnormal
Throttle tie-line Adjust
Normal
Abnormal
Control valve plate Repair or replace
Normal
Abnormal Repair or replace
Governor valve
Normal
Abnormal
Friction disk skids Replace
Normal
Abnormal
Oil pressure insufficient Repair
Normal
Normal
Abnormal
Shifting valve Replace
Normal
Abnormal
Accumulator Replace
185
Common Malfunction Diagnosis Flow of Geely Automobile
Check auto transmission oil is too little, and oil level shall
Auto transmission oil be between 2-4 holes of dipstick; if too little, it will not
generate oil pressure, making it unable to upshift;
Abnormal
Auto transmission oil liquid Check and fill
Normal
Normal
Normal
Abnormal Repair
Auto shifting valve
Normal Abnormal
Replace
Accumulator
Normal
186
Common Malfunction Diagnosis Flow of Geely Automobile
Abnormal
Throttle tie-line Adjust
Normal
Abnormal
Control valve Repaiar or replace
Normal
Abnormal
Forced downshift switch
Replace
Normal
Abnormal
Forced-gear solenoid valve
damaged Replace
187
Common Malfunction Diagnosis Flow of Geely Automobile
Idling speed too low or clutch too low; Clean idling motor or replace, and adjust clutch height, or
throttle blocks replace throttle tie-line;
Clutch disk and flywheel locked or not fully Repair or replace parts and components; repair and separate
separated fully or replace damaged parts and components;
Abnormal
Idling speed too low or clutch too low; throttle Repair
blocks
Normal
Normal
Normal
Abnormal
Torque converter
Replace
188
Common Malfunction Diagnosis Flow of Geely Automobile
No forward gear
Unusual
Forward gear clutch Replace
Normal
Unusual
Forward gear brake Replace
Normal
Abnormal
Forward gear one-way clutch Replace
Normal
Abnormal
Control valve Replace
Normal
Abnormal
Governing valve Replace
189
Common Malfunction Diagnosis Flow of Geely Automobile
Oil level flush with lower plane of oil filler bolt; quality of
gear oil not good, and its quantity severely insufficient,
causing poor heat emission and excessive wearing of the
Transmission oil severely insufficient bearing. Mating surface of constant meshing gear falls out
due to high temperature causing transmission oil turning
black and deteriorating; replace damaged parts and
components and clean transmission, and replace gear oil;
Transmission oil Vent hole falls out, causing entry of dust and moisture
easily deteriorate Transmission vent hole falls out from the atmosphere, and turning transmission oil white or
dirty;
190
Common Malfunction Diagnosis Flow of Geely Automobile
Normal
Abnormal
Transmission oil quality problem Refill accordingly
Normal
Abnormal
Transmission oil severely insufficient Refill accordingly
Normal
Abnormal
Transmission vent hole falls out
Repair
Normal
Abnormal
Repair transmission
Transmission inner malfunction
Normal
Auto transmission
oil easily Check ablation of each clutch and brake within auto
deteriorate Transmission inner malfunction transmission, making auto transmission oil deteriorate;
replace clutch and brake friction disk;
191
Common Malfunction Diagnosis Flow of Geely Automobile
Normal
Abnormal
Transmission oil quality problem Replace
Normal
Abnormal
Torque converter inner Replace
Normal
Abnormal
Repaiar or replace
Transmission inner
Normal
Abnormal
Auto transmission heat-removal Repair
system
Shifting operation mechanism incorrectly Adjust shifting operation mechanism (gear shifting lever or shift
No reversing adjusted tie-line);
gear, reversing
not possible or Reversing locking mechanism worn, Check reversing shift fork is severely worn, or fails; if abnormal,
automatic damaged replace swing link support;
jump-out while
reversing
Reverse gear malfunction Check reverse gear ruptures or fails; if abnormal, replace gear;
192
Common Malfunction Diagnosis Flow of Geely Automobile
No reversing gear
Normal
Normal
Shift fork of third, fourth gear excessively worn Check shift fork shaft is deformed or worn; replace it if
(4-gear end face) abnormal;
193
Common Malfunction Diagnosis Flow of Geely Automobile
Abnormal
Shifting operation mechanism incorrectly
adjusted Adjust
Normal
Unusual
Synchronizer of third, fourth gear loosens Repaiar or replace
Normal
Abnormal
Shift fork shaft of third, fourth gear self-locked, interlocking Repair
mechanism poor
Normal
Abnormal
Shift fork of third, fourth gear excessively Replace
worn
Normal
194
Common Malfunction Diagnosis Flow of Geely Automobile
If any gear is sounding and park gear not sounding during driving,
check each bearing within transmission is worn or loosening, and
Bearing within transmission worn
bearing shall move stably without abnormal sound. Shaking with
hands shall be without loosening sound;
195
Common Malfunction Diagnosis Flow of Geely Automobile
Abnormal
Transmission oil quality, quantity Replace or add
poor
Normal
Abnormal
Bearing within transmission worn Replace
Normal
Abnormal
Gear worn Replace
Normal
Abnormal
Input shaft or bearing Replace
Normal
Normal
196
Common Malfunction Diagnosis Flow of Geely Automobile
Gear shifting lever loosens, shifting Check nylon cover of gear shifting lever is unusually worn; if
Gear shifting incorrect; so, replace it;
lever swinging,
hard to shift
Gap between shift ball head and swing lever
Check shift ball head and swing lever loosen; if so, replace it;
too large, shifting incorrect;
Normal
197
Common Malfunction Diagnosis Flow of Geely Automobile
No. 147 Sounding when releasing throttle of third, fourth gears and decelerating
Abnormal
Transmission oil quality, quantity Fill up accordingly
Normal
Abnormal
Gear clearance of third, fourth gear too Repair
large
Normal
Abnormal
Bearing with unusual noise Replace
Normal
Abnormal
Large play of one shaft Repair
Normal
Abnormal
Synchronizer malfunction Repaiar or replace
198
Common Malfunction Diagnosis Flow of Geely Automobile
199
Common Malfunction Diagnosis Flow of Geely Automobile
Abnormal
Shift lever Replace
Normal
Unusual
Transmission shift operation Repair
mechanism
Normal
Abnormal
Fifth-gear synchronizer Replace
Normal
Abnormal
Transmission input, output shaft Repair
fifth-gear
No. 149 Fifth gear, first gear blocks, relieved only when the vehicle stops
200
Common Malfunction Diagnosis Flow of Geely Automobile
Fifth gear, first gear blocks, relieved only when the vehivle
stops
Abnormal
Check gear shifting lever Replace
Normal
Abnormal
Clutch not fully separated Repair
Normal
Abnormal
Transmission inner malfunction Repair
No. 150 Hiss sound when put into gear during driving
Hiss sound when Check working face of fourth-gear shift shaft and
put into gear fork is vertical; if not, replace fourth-gear fork. Check
Fourth-gear shift shaft and fork malfunction
during driving working face of fork is worn unilaterally; if so, replace
fourth-gear fork;
201
Common Malfunction Diagnosis Flow of Geely Automobile
Abnormal
Check shift bar Repair
Normal
Abnormal
Fourth-gear shift shaft and fork Replace
Normal
Abnormal
Check fourth-gear synchronizer Replace
202
Common Malfunction Diagnosis Flow of Geely Automobile
Gear shifting lever deforms Gear shifting lever deformed causing gear abnormally or not well jointed;
1. If gear runout found at any gear, gear lever is switched to this gear,
then remove transmission cover and check gear meshing; if normal,
check locking mechanism of shift fork shaft;
Shift fork within transmission is 2. Push positioning device of shifting fork with hands; if poor, remove shift
excessively worn, self-locked fork shaft and check positioning ball and spring; if the spring is too soft or
spring breaks or too softens; broken, replace it. If groove of shift fork shaft is excessively worn, repair
During driving, replace self-locked spring and or replace it;
gear lever fork 3. Check screws of fixing plate of shifting fork are loosening, and
automatically clearance between fork end and gear groove is too large; correct it if
jumps to neutral shifting fork bends; if lower end of shifting fork is worn and sliding gear
position, which groove is too loosening, remove and repair it;
may occur when
driving at medium, Axle head of swing link support
high speed, load within transmission is
Weld up shaft end of swing link support, and grind it to stand dimension;
suddenly changes excessively worn, making all
or automotive is gears not well positioned
vibrating severely,
and most trip stop Bearing and shaft unusually Check abrasion of bearing and shaft; if the shaft is severely worn, bearing
during at high worn is loosening or shift shaft plays axially, then remove, repair or replace;
speed.
Spline clearance between
transmission clutch collar and
spline hub too large; clearance Check operation of synchronizer; if malfunction found, repair or replace it;
between clutch collar and tooth
of put gear too large
Soldered tooth bent or deformed, Check meshing of gear; if not fully meshed, check gear is worn or in
abrasion smaller taper; replace it if severely worn;
203
Common Malfunction Diagnosis Flow of Geely Automobile
Abnormal
Fixed bolt of transmission loosens
Fasten
Normal
Abnormal
Shift fork within transmission worn Replace
Normal
Abnormal
Swing link support within transmission Repair
Normal
Abnormal
Unusual abrasion of bearing and shaft Replace
Normal
Abnormal
Synchronizer clutch collar and spline hub
Replace
Normal
Abnormal
Soldered tooth bent, deformed, worn Replace
No. 152 Hiss sound when second, third, fourth gear upshift
Malfunction Causes Solution
204
Common Malfunction Diagnosis Flow of Geely Automobile
Normal
Normal
Abnormal
Check transmission Repair
Normal
Unusual
Check transmission lubricating oil Fill or replace
205
Common Malfunction Diagnosis Flow of Geely Automobile
Gap between spline hub and one shaft spline within clutch
Clutch malfunction friction disk is too large; replace clutch friction disk and one
shaft;
Lubricating oil malfunction check lubricating oil is insufficient; if not sufficient, fill up;
206
Common Malfunction Diagnosis Flow of Geely Automobile
Normal
Abnormal
Check transmission Repair
Normal
207
Common Malfunction Diagnosis Flow of Geely Automobile
208
Common Malfunction Diagnosis Flow of Geely Automobile
Normal
Normal
Normal
Abnormal
Adjust according to
Transmission cone bearing adjustment standard gap
Normal
209
Common Malfunction Diagnosis Flow of Geely Automobile
Transmission
with abnormal ① Toothed ring of synchronizer is excessively worn. Clearance on
sound while the gear pressed by synchronizer ring is no less than 0.5mm.
shifting Specified value is between 0.85-1.45. Area of joint face of fifth-gear
synchronizing ring and gear shall be larger than 80%; if lower,
replace synchronizing ring;
Synchronizer gear ring, hub, cover ② Check fit clearance of hub, cover, which shall be no obvious
excessively worn or clearance clearance while shaking from left to right. Hub shall be assembled
incorrectly within the cover freely. Joint part of cover and gear shall be
triangular. Replace synchronizer assembly if damaged, worn, or its
edge angle turning round;
③ Check height of slide block of synchronizer; if less than 5mm,
replace slide block;
210
Common Malfunction Diagnosis Flow of Geely Automobile
Normal
Abnormal
Check tightening torque at connection of Tighten
transmission lever accordingly
Normal
Abnormal
Check transmission synchronizer gear ring, hub, cover, slide block Replace
Normal
Abnormal
Check transmission gear, shaft and bearing, etc. Replace damaged
parts
Lock frame, pin of interlocks deformed or Replace interlock ball, pin and spring of
severely worn. transmission
211
Common Malfunction Diagnosis Flow of Geely Automobile
Gear disorder
Put into different gear. Hold gear lever Try to put into gear but Yes
with hands and shake around. Check cannot or try to shift down
swing angle of gear lever (automotive) but cannot?
No Malfunction caused
as shifting swing
Yes Swing or not lever falls out from
Put into two gears at fork groove, such as
the same time? No severely worn lever
No or groove
No
Yes
But swinging angle of
Malfunction caused by gear lever exceeds
broken or leaked normal range Malfunction caused by
location pin damaged locking
device, such as
severely deformed,
worn lock pin, frame
Malfunction caused by
loosening mating of location
pin and slot or severe abrasion
of ball head and seat
Interlocjing
End
212
Common Malfunction Diagnosis Flow of Geely Automobile
When the vehicle starts at low 1. Check if any large abrasion sound is heard
speed, release clutch gradually during rotation, even rotating resistance is
according to operation rules, and Driven disk or clutch plate deformed or larger?
slowly step down accelerator warped; end face of flywheel severely 2. A. Check cushion sheet on clutch plate is
pedal. Clutch could not jointed jumps broken, damping spring is fatigue or broken; B.
stably and cause shaking, even friction rivet on clutch plate is loosening;
buffeting to whole vehicle. Repair or replace it if malfunctions exist.
213
Common Malfunction Diagnosis Flow of Geely Automobile
214
Common Malfunction Diagnosis Flow of Geely Automobile
Chassis
No.159 Shaking startup
(1) Clutch pedal has too large free stroke, diaphragm spring
force fully or partially acting on operation mechanism, making
Adjust free stroke of clutch;
driven disk unable to well separated with flywheel and clutch
plate;
(3) Rivet on driven disk loosening or driven disk too thick; Clinch or replace driven disk;
Malfunction: while
startup, clutch
(4) Driven friction disk, clutch plate and flywheel’s working face Replace warped driven disk, clutch plate
could not be
warped, deformed; or flywheel;
jointed stably,
causing shaking.
(5) Spring annealing, diaphragm spring fatigue, with uneven
Replace clutch plate assembly;
and insufficient elastica, or broken;
(6) Fixed screws for clutch plate and flywheel loosening; Fasten bolt;
(7) Space between release bearing sleeve and its guide pipe
Clean guide pipe;
with oil sludge, dust or blocked, unable to return;
215
Common Malfunction Diagnosis Flow of Geely Automobile
216
Common Malfunction Diagnosis Flow of Geely Automobile
217
Common Malfunction Diagnosis Flow of Geely Automobile
1. Clutch drive mechanism deformed, Check drive mechanism is deformed or jammed; correct and
jammed; repair if so;
Feel heavy and 3. Clutch master cylinder damaged, Check clutch master cylinder is damaged, blocked; replace it
hard when blocked; if so;
stepping down
clutch pedal
4. Foreign substances or rust at pivoting of Check any foreign substances or rusts at pivot; clean them or
diaphragm spring of clutch plate; lubricate rusts if so;
Heavy clutch
Unusual
Clutch drive mechanism deformed, jammed Correct and repair
Normal
Unusual
Clutch tie-line jammed or fouling Clean or replace
Normal
Damaged
Clutch master cylinder damaged, blocked Replace
Normal
Damaged
Clutch wheel cylinder damaged, blocked Replace
Normal
Unusual
Foreign substances or rust at pivoting of diaphragm spring of clutch plate Clean or lubricate
218
Common Malfunction Diagnosis Flow of Geely Automobile
(1) Free stroke of clutch too large, diaphragm spring force fully or partially
acting on operation mechanism when stepping down the pedal, making
Adjust it;
diaphragm spring not fully compressed, and driven disk unable to well
separated with flywheel and clutch plate;
Malfunction: when
the engine is (2) Clutch plate diaphragm uneven, not within the same plane; Replace clutch plate;
operating at idling
speed, step on
clutch pedal, (3) Driven disk incorrectly installed, causing friction between driven disk
Reassemble;
impact sound of and flywheel;
gear occurs when
put into gear at (4) Driven disk warped, deformed, causing friction between driven disk
Correct driven disk;
original position, and flywheel or clutch plate;
and hard to put into
gear; if severe, replace driven disk of standard
engine will stall (5) Clutch driven disk too thick;
thickness;
(6) Spline hub of driven disk not flexibly moved at one shaft (output shaft)
of transmission, causing friction between driven disk and flywheel or Replace driven disk;
clutch plate, and making clutch not fully separated;
219
Common Malfunction Diagnosis Flow of Geely Automobile
220
Common Malfunction Diagnosis Flow of Geely Automobile
1. Fixed screws of clutch operation mechanism Check fixed screws of clutch operation mechanism are
loosening or damaged; loosening or damaged; fasten or replace it if any;
Abnormal sound
when stepping on 3. Torsion spring of clutch plate loosening or Check torsion spring of clutch plate is loosening or
clutch pedal broken; broken; replace it if any;
221
Common Malfunction Diagnosis Flow of Geely Automobile
Abnormal
Fixed screws of clutch operation mechanism loosening or damaged Fasten or replace
Normal
Abnormal
Clutch release bearing worn, damaged Replace
Normal
Abnormal
Torsion spring of clutch plate loosening or broken Replace
Normal
Abnormal
Spline hub of clutch plate worn, loosening Replace
Normal
Abnormal
Screws of clutch housing Fasten screws
loosening
222
Common Malfunction Diagnosis Flow of Geely Automobile
5. Spring too soft or broken; Check spring is too soft or broken; replace it if any;
223
Common Malfunction Diagnosis Flow of Geely Automobile
Normal
Fasten or
Fixed bolts loosening or damaged Abnormal replace
Normal
Damaged Replace
Upper and lower rubber covers damaged
Normal
Damaged
Buffer block aged, damaged Replace
Normal
Oil leaking
Oil leaking
Replace
Normal
Abnormal
Spring too soft or broken Replace
Normal
Abnormal
Internally worn, loosening, core axle warped, not straight, friction face warped, uneven Replace
224
Common Malfunction Diagnosis Flow of Geely Automobile
4. Pressure bearing of front wheel lack of Check pressure bearing of front wheel lacks of
lubricating oil or damaged; lubricating oil or damaged; lubricate or replace it if any;
225
Common Malfunction Diagnosis Flow of Geely Automobile
Abnormal
Front suspension bolt loosening or damaged? Fasten or replace
Normal
Loosening
Ball head of tie rod, lower swing arm loosening Replace
Normal
Normal
Abnormal
Pressure bearing of front wheel lack of lubricating oil or Lubricate or
damaged replace
Normal
Abnormal
Outer ball cage of front wheel worn, loosening Replace
226
Common Malfunction Diagnosis Flow of Geely Automobile
227
Common Malfunction Diagnosis Flow of Geely Automobile
228
Common Malfunction Diagnosis Flow of Geely Automobile
Steering wheel not 3. Pressure bearing lack of lubrication or Check pressure bearing is lack of lubricating oil or
well back to damaged; damaged; if so lubricate or replace it;
original position
4. Meshing clearance of steering gear too small; Check meshing clearance is too small; if so, adjust it;
229
Common Malfunction Diagnosis Flow of Geely Automobile
Too low
Tire pressure too low
Fill
Normal
Unusual
Lubricate or
Tie-rod ball head, and ball head of lower swing arm rusty, jammed replace
Normal
Unusual
Pressure bearing lack of lubrication or damaged Lubricate or replace
Normal
Too small
Meshing clearance of steering gear Adjust
too small
Normal
Damaged
Correct or
Steering column bent or blocked, cracked, too soft
replace
Normal
Unusual
Positional
Positional parameter of front wheel
adjustment
incorrect
230
Common Malfunction Diagnosis Flow of Geely Automobile
Too loosening
Power steering pump belt too loosening Adjust
Normal
Normal
Damaged
Power steering pump damaged Replace
Normal
Abnormal
Power steering gear clearance too large or damaged Adjust or replace
Normal
231
Common Malfunction Diagnosis Flow of Geely Automobile
1. Connecting screws of front suspension Check connecting screws of front suspension loosening or
loosening or damaged; damaged; if so, fasten or replace it;
2. Wheel and wheel parts abraded while Check wheel and wheel parts are abraded while steering; if
steering so, adjust and repair it;
Steering wheel
shaking while
steering during
driving 3. Steering gear looseningly installed; Check steering gear is looseningly installed; if so, fasten it;
4. Front wheel incorrectly positioned; Check front wheel is incorrectly positioned; if so adjust it;
1. Power-assisted steering pump belt too Check power-assisted steering pump belt is too
loosening or damaged; loosening or damaged; if so, adjust or replace it;
2. Lack of power steering oil; Check it is lack of power steering oil; if so, add it;
Steering wheel not 3. Power steering pump damaged; Check power steering pump is damaged; if so, replace
well back to it;
original position
4. Hydraulic booster system with air Empty the air inside the hydraulic booster system;
6. Power steering gear damaged; Check power steering gear is damaged; if so, replace it;
232
Common Malfunction Diagnosis Flow of Geely Automobile
Normal
Normal
Normal
1. Power-assisted oil insufficient Check power-assisted oil is insufficient; if so, add it;
233
Common Malfunction Diagnosis Flow of Geely Automobile
Lack
Power-assisted oil insufficient Add
Normal
Loosening
Fixed screws of power-assisted pump Fasten
loosening
Normal
Damaged
Power-assisted pump belt pulley loosening or Replace
worn
Normal
Damaged
Power-assisted pump belt loosening or worn Replace
Normal
Damaged
Power-assisted pump severely worn internally Replace
234
Common Malfunction Diagnosis Flow of Geely Automobile
(2) Front wheel’s radial circle or end face circle running Positional adjustment for tire, dynamic balancing of
out too large; the wheel
When the vehicle (6) Front beam or front suspension bent, distorted,
is running within Correct front body or replace front suspension
deformed;
certain low or high
speed range,
(7) Action of steering system and front suspension Correct toe-in; adjust tie-rod; replace tie-rod, ball
sometimes angular
interferes each other; head
oscillation occurs
around kingpin at
two front wheels, (8) Steering system’s rigidity too low (including
Replace steering tie-rod, lower swing arm;
as called front steering tie-rod, lower swing arm, etc.);
wheel yawing;
especially when (9) Meshing clearance of drive, driven parts or bearing
Adjust clearance;
yawing at high clearance of steering engine too large;
speed, two front
wheels are (10) Gear rack of steering engine matched
severely Adjust matching clearance;
looseningly;
pendulating left to
right, and hands
holding steering (11) Ball head of inner and outer steering tie-rods
Replace ball head;
gear feels sense of connected looseningly;
numbness, or even
whole nose is seen (12) Front support loosening or deformed; Fasten or replace front support
to be shaking from
the cab.
(13) Front wheel hub bearing loosening; Replace bearing
235
Common Malfunction Diagnosis Flow of Geely Automobile
236
Common Malfunction Diagnosis Flow of Geely Automobile
One of tire or hub of two front wheels deformed Replace deformed tire or hub;
One ball head of steering tie-rod loosening or jammed Replace loosening or jammed ball head;
One lower swing arm bent or lining loosening Replace lower swing arm assembly;
Automatically run to
Lower joist of front suspension deformed Replace lower joist of front suspension;
another side during
driving. Straight driving
only ensured with
hands forcibly holding Wheelbase of two sides of frames unqual Adjust wheelbase at two sides of frame;
steering wheel
Hub bearing or oil seal of two front wheels with unequal Adjust degree of tightness of hub bearing
degree of tightness or oil seal of two front wheels;
Wheels at two sides of front, rear axles with braking or Correct breaking of wheels at two sides
dragging at one side; of front, rear axle;
Front beam, rear axle tube or frame with bending with Correct front beam, rear axle tube or
horizontal plane; frame;
Camber of paving too large or with cross wind. Choose road for driving;
Electric power-assisted steering pitch sensor incorrectly Adjust or replace steering column
adjusted assembly;
237
Common Malfunction Diagnosis Flow of Geely Automobile
238
Common Malfunction Diagnosis Flow of Geely Automobile
(1) Tire pressure not conforming to requirements; Inflate or discharge to the standard
(2) Tire not changed for long time; Replace the tire
(8) Front wheel yawing; Fasten nuts of tie-rod ball head, replace the tire
(16) Often drive on the road with larger camber; Reduce driving on unfavorable road
239
Common Malfunction Diagnosis Flow of Geely Automobile
240
Common Malfunction Diagnosis Flow of Geely Automobile
No. 175 Normally when driving straightly, but with abnormal sound while turning
Normally when Outer cage of two front wheels without lubricating Check outer cage of two front wheels are with
driving straightly, oil or damaged; lubricating oil or damaged;
but with abnormal
sound while
turning Pressure bearing lack of lubricating oil or Check pressure bearing is lack of lubricating oil or
damaged; damaged; if so, lubricate or replace it;
Normal
Normal
Oil leaking
Pressure bearing lack of lubricating oil or
Lubricate or
damaged
replace
241
Common Malfunction Diagnosis Flow of Geely Automobile
(9) Brake shoe at single side and support pin closely Adjust clearance of brake shoe or remove
matched or rusty; dust
242
Common Malfunction Diagnosis Flow of Geely Automobile
243
Common Malfunction Diagnosis Flow of Geely Automobile
(1) Brake pedal without free stroke; Adjust free stroke of brake pedal
(3) Release spring of master cylinder piston ruptured or Replace release spring of master cylinder
with too small pretightening force; piston;
(4) Master cylinder piston, leather cup with too large length
Replace master cylinder piston, leather cup
or leather cup bloating, sticking;
After releasing brake (6) Leather cup of wheel cylinder bloating, sticking, or
Replace wheel cylinder leather cup
pedal, braking actions piston blocking;
on individual or all
wheels could not be
fully released, thus
(7) Release spring of brake shoe falling out, snapped off or
affecting re-startup, Replace release spring of brake shoe;
with too small pulling force;
accelerating driving or
free running of
vehicles.
(8) Brake shoe and support pin rusty; Repair brake shoe and support pin;
(11) While not braking, center hole of auxiliary cylinder Repair center hole of auxiliary cylinder
piston of supercharger could not be opened; piston of supercharger
(12) Brake hose distorted, deformed or partially obstructed Replace brake hose
244
Common Malfunction Diagnosis Flow of Geely Automobile
245
Common Malfunction Diagnosis Flow of Geely Automobile
Fixed screws for suspension connection of Check fixed screws for suspension connection of brake
brake system loosening or damaged; system are loosening or damaged; if so, fasten or replace;
Braking with
abnormal sound
Brake disk severely worn; Check brake disk is severely worn; if so, replace it;
while vehicle is
driving normally
Brake hub or disk severely worn with groove; Replace brake hub or disk;
246
Common Malfunction Diagnosis Flow of Geely Automobile
Braking with
unusual noise
Unusual
Normal
Abnormal
Normal
Abrasion
Brake disk severely worn Replace
Normal
Abnormal
Fixed bolt of front brake tongs loosening or with worn
lining Grind or replace
Normal
Abnormal
Brake hub or disk severely worn with Grind or replace
groove
Normal
Abnormal
Rubber cover of front and rear
Replace
suspensions loosening, aging
Normal
Abnormal
Check fixed screws for suspension connection of brake system are Fasten or replace
loosening or damaged;
247
Common Malfunction Diagnosis Flow of Geely Automobile
Tire worn smoothly Check tire is worn smoothly; if so, replace it;
Tire of the same axle not consistent Check tire of the same axle is consistent; if not, adjust it;
Check tire pressure is too low or too high; if so, adjust to specified
Tire pressure too low or too high
pressure;
While braking,
vehicle slips to one Brake shoe, brake disk with oil sludge; Check brake shoe, brake disk are with oil sludge; if so, clean it;
side or swerves
Air in the pipeline; Check air is in the pipeline; if so, empty it;
Pressure dividing valve incorrectly Check pressure dividing valve is incorrectly adjusted; if so, readjust
adjusted it;
Rubber cover of chassis suspension Check rubber cover of chassis suspension is loosening; if
loosening necessary, replace rubber cover;
248
Common Malfunction Diagnosis Flow of Geely Automobile
Replace
Abnormal
Check tire is worn smoothly
Normal
Abnormal
Check tire of the same axle is consistent Adjust or
replace
Normal
Abnormal
Check tire pressure is too low or too high Adjust
Normal
Abnormal
Check brake shoe, brake disk are with oil sludge Clean
Normal
Abnormal
Check air is in the pipeline Empty the air
Vacuum tube of vacuum booster with cracks, or air Check vacuum tube of vacuum booster is with cracks,
leakage or air leakage; if so, replace it;
Brake pipe obstructed Check brake pipe is obstructed; if so, unclog it.
249
Common Malfunction Diagnosis Flow of Geely Automobile
Abnormal
Check vacuum tube of vacuum booster is with Replace
cracks, or air leakage
Normal
Abnormal
Check non-return valve of booster is obstructed or Clean or replace
blocked
Normal
Abnormal
Check vacuum booster is damaged
Replace
Normal
Abnormal
Check machinery parts of brake pump are Repair
blocked
Normal
Abnormal
Check brake pipe is obstructed Unclog the pipe
250
Common Malfunction Diagnosis Flow of Geely Automobile
(5) Master cylinder leather cup, piston or cylinder Replace leather cup piston or replace brake master
severely worn; cylinder
While braking, the (8) Delivery valve, spill valve of master cylinder or
driver feels pretightening force of piston release spring too Replace master cylinder
deceleration small;
insufficient; while
emergency
braking, braking (9) Through hole at front end of master cylinder
distance too long. Replace master cylinder
piston obstructed or leather cup sticking, bloating;
(13) Brake pedal with too large free stroke; Adjust free stroke
251
Common Malfunction Diagnosis Flow of Geely Automobile
252
Common Malfunction Diagnosis Flow of Geely Automobile
When stepping (2) Leather cup of master cylinder severely Replace leather cup of master cylinder or eliminate oil
on brake pedal, ruptured or severe leakage of brake system; leakage
the vehicle is not
decelerating;
even with
stepping on (3) Brake hose or metal pipe ruptured; Replace brake hose or metal pipe;
continuously, not
obviously
decelerating.
(4) Connection between brake pedal and master
Repair brake pedal;
cylinder falls off.
253
Common Malfunction Diagnosis Flow of Geely Automobile
254
Common Malfunction Diagnosis Flow of Geely Automobile
(2) Connecting parts of steering gear and steering Adjust clearance of connecting parts of steering gear
shaft loosening; and steering shaft;
When the vehicle
keeps driving (3) Ball joint of steering gear loosening; Replace ball joint of steering gear;
straightly, shaking
steering gear to
and fro slightly, it
(4) Connecting part of tie-rod ball head loosening Fasten or replace tie-rod ball head;
feels play angle
very large.
Fasten or replace ball head of lower swing arm
(5) Ball head of lower swing arm loosening
assembly;
255
Common Malfunction Diagnosis Flow of Geely Automobile
256
Common Malfunction Diagnosis Flow of Geely Automobile
No. 184 Buzzing noise at rear wheel while driving at high speed
Normal
Abnormal
Positioning misadjustment of rear Positioning
wheel adjustment
Normal
Abnormal
Pressure of two rear wheels normal Adjust
257
Common Malfunction Diagnosis Flow of Geely Automobile
Braking force
insufficient
Leakage
Pipe with leakage Eliminate leakage
No
Poor
No
No
258
Common Malfunction Diagnosis Flow of Geely Automobile
Leaking
Vacuum connecting hose leaking Eliminate leakage
No
No
No
259
Common Malfunction Diagnosis Flow of Geely Automobile
Racially cracked,
Tire sidewall cord thread broken, Drive on favorable
7 stabbed or or even blown up if Tire stabbed (cut through) by sharp articles. road and avoid
cut through severe with bruising sharp articles
marks.
260
Common Malfunction Diagnosis Flow of Geely Automobile
Check mechanical
Local pattern of tire system of the
Unusual Caused by driving habit of mechanical system (caster
16 crown is worn as in vehicle, and avoid
abrasion angle too large, hub eccentric)
lumpy rapid steering,
braking, startup
261
Common Malfunction Diagnosis Flow of Geely Automobile
Surface layer between tire sidewall rubber and Tire rubber and sidewall not well bound
2 Joint slips off
rubber cracked during manufacturing.
Tire sidewall Side bulged out; foreign substances inside while Other substances mixed during
3
loosening dissecting. manufacturing
262
Common Malfunction Diagnosis Flow of Geely Automobile
Electrics
No. 189 CD-player disk boot malfunction (without MP3)
Malfunction Cause Solution
Inspect +B and GND, which normal value shall be 10V to 14V.
When ACC and GND ignition switch locating at ACC or ON, the
voltage shall be 10V to 14V. If it indicates no powers supply, then
Power source malfunction
check whether the fuse is burnt or not, and replace it if necessary.
In common condition, GND and vehicle earth lead shall be
conducted.
Check if the disk is inserted in wrong direction, and correct it if
CD inserted in wrong direction
necessary.
Firstly inspect the disk format, and change disk if necessary. Then
Wrong CD format or too dirty
check whether it contains dirt or scratch mark and replace it if
disk
necessary.
CD-player disk
CD not reset yet Press RESET button to reset CD-player
Boot malfunction
Shock proof screw not
Remove the shock proof screw on housing
removed
The laser head is too dusty and dirty, which affect reading ability of
the lens. And it needs to be cleaned. Clean method: clean with
The laser head of CD-player is special disk.
too dirty or aged and too high
resistance Laser head ageing, this results low laser power. That is, the beam
from laser head can not focus correctly, which causes reading
ability reduction or losing. Replace CD-player assembly.
Internal CD-player circuit
Replace CD-player assembly.
malfunction
263
Common Malfunction Diagnosis Flow of Geely Automobile
Normal
Normal
Normal
Normal
Inspect +B and GND, which normal value shall be 10V to 14V.
Abnormal When ACC and GND ignition switch locating at ACC or ON, the
Power source malfunction
voltage shall be 10V to 14V. Inspect and replace the fuse.
Normal
Abnormal
CD-player not reset Press RESET button to reset CD-player
Normal
Abnormal
CD inserts in wrong direction Correct the disk direction
Normal
Abnormal
Disk contains scrapes or deformation
Replace disk
abnormal
Normal
Not removed
Shockproof screw not removed Remove the shockproof screw on
housing
Normal
Abnormal
Internal CD-player malfunction Replace CD-player assembly
264
Common Malfunction Diagnosis Flow of Geely Automobile
Normal
Normal
265
Common Malfunction Diagnosis Flow of Geely Automobile
Abnormal
Normal
Check wires, connector and Abnormal
power source voltage. CD –player power Check and replace the fuse
source malfunction
Normal
Normal
Normal
266
Common Malfunction Diagnosis Flow of Geely Automobile
Abnormal
Vehicle ignition switch closed Turn to ON or ACC position
Normal
Abnormal
Fuse burnt
Replace with fuse of same specification
Normal
Abnormal
Power source output line loose Replace with fuse of same specification
Normal
Abnormal
Clean or replace connector with same
Dirt in connector conducting point
specification
Normal
Abnormal Replace connector with same specification
Connector wire core disconnected (open circuit)
Normal
Abnormal
Poor fuse contact (open circuit Replace connector with same specification
sometimes)
Normal
Abnormal
Replace connector with same specification
Connector earth lead open circuit
Normal
Short circuit
Internal CD-player/radio short circuit Replace CD-player/radio
assembly
267
Common Malfunction Diagnosis Flow of Geely Automobile
A loudspeaker of CD-player/radio is
soundless
Abnormal
Loudspeaker output line wrong Please refer to the connecting method shows on
connected nameplate
Normal Abnormal
Panel function setting inaptitude In SEL menu, on panel, BAL and FDA shall be set to 0
Normal Abnormal
Loudspeaker damaged Replace a new loudspeaker of same specification
Normal
Abnormal
Loudspeaker outputline Clear the oxide or replace with new outputline of
connection oxide same specification
Normal
Abnormal Clean the connector or replace it with a new one of
Dirts on connector conducting
point same specification
Abnormal
Normal
Connector wire core disconnected (open Replace with new connector of same specification
ciercuit)
Normal Disconnected
Internal CD-player/radio Replace CD-player/radio assembly
loudspeaker output
268
Common Malfunction Diagnosis Flow of Geely Automobile
269
Common Malfunction Diagnosis Flow of Geely Automobile
Abnormal
Low sound volume set Set it louder
Normal
Normal
Abnormal
Dirts on connector conducting point Clean or replace with new connector of
same specification
Normal
Abnormal
Cell phone or interface unmatch Replace with cell phone matching with
vehicle
Normal
Abnormal Check phone mute outputline external controlling circuit
Short circuit between phone mute outputline whether it is short circuit.normal
and earthlead
Normal
Abnormal
Controller wire core disconnected (open Replace with new connector of same
circuit) specification
Normal Normal
Abnormal
Internal CD-player failure Replace CD-player assembly
Normal
Abnormal
Onboard hand-free phone controller Replace onboard hand-free phone
failure controller
270
Common Malfunction Diagnosis Flow of Geely Automobile
Normal
Abnormal Press RST button by sticker to reset the player, then it will be
Improper operation recovered
Normal
Abnormal
Replace CD-player/radio assembly
CD-player/radio inner malfunction
271
Common Malfunction Diagnosis Flow of Geely Automobile
Normal
Normal
Abnormal
Lamp controlling switch fails or not Replace switch with same specification or turn lamp controlling
locates at ON position. switch to ON position.
Normal
Abnormal
Lamp controlling wire core Replace connector with same specification
disconnected (open circuit)
Normal
Abnormal
Dirts on connector conducting point
Clean or replace with new connector of same
specification
Normal
Abnormal
CD-player/radio inner circuit Replace CD-player/radio
short/open circuit assembly
272
Common Malfunction Diagnosis Flow of Geely Automobile
Normal
Normal
Abnormal
Replace CD-player/radio assembly
CD-player/radio inner memory short or
open circuit
273
Common Malfunction Diagnosis Flow of Geely Automobile
CD-player/radio no signal
Normal
Dirts on antenna cable conducting point Abnormal Clean conducting point with special cleaning solution
Normal
Abnormal
Antenna cable deformed and results poor contact Replace antenna assembly with same specification
Normal
Abnormal
Loudspeaker retaining screw loose
Tighten the screws
Normal
Abnormal
Loudspeaker damaged or disable to sustain
Replace loudspeaker or turn down the
high power
volume
274
Common Malfunction Diagnosis Flow of Geely Automobile
Abnormal
Antenna cable disconnected Connect antenna cable
Normal
Dirts on antenna cable conducting point Abnormal Clean or replace antenna cable with same specification
Normal
Normal
275
Common Malfunction Diagnosis Flow of Geely Automobile
Abnormal
Antenna cable earth lead loose or Replace antenna cable with same
poor contact abnormal specification
Normal
Normal
Abnormal
Check and maintain loudspeaker and circuit
Loudspeaker malfuction
Normal
Abnormal
Tighten the screws
Antenna retaining screw loose
Normal
Abnormal
CD-player/radio inner malfunction Replace CD-player/radio assembly
276
Common Malfunction Diagnosis Flow of Geely Automobile
①Another disk in CD-player ①Press popup button and insert another disk
CD-player fails to insert ⑤Don’t press two buttons at same time when
disk operating the panel, which may result CPU out of
⑤Function improper operated control sometimes. When it appears, press RST button
by sticker to reset CD-player and remove the
malfunction.
⑦Disk broken ⑦Broken disk can not be applied, please replace disk.
277
Common Malfunction Diagnosis Flow of Geely Automobile
Abnormal
Another disk remains in Press popup button and insert another disk
CD-player
Normal
Normal
Abnormal
Disk coating is too thin Replace disk
Normal
Normal
Normal
Normal
Normal
Abnormal
Shockproof screw not Remove the shockproof screw on
removed housing
Normal
Abnormal
CD -player inner circuit failure Replace CD-player assembly
278
Common Malfunction Diagnosis Flow of Geely Automobile
Disk with improper type Replace with disk of proper type, matching
CD-player
Sun or glare projectivity shines on CD hatch Don‘t operate CD-player when CD hatch exposures
directly under sun or glare projectivity.
Disk broken Broken disk can not be applied, please replace disk
Normal
Normal
Sun or glare projectivity Abnormal Don‘t operate CD-player when CD hatch exposures
shines on CD hatch directly under sun or glare projectivity.
Normal
Normal
Abnormal
CD –player inner circuit Replace CD-player assembly
malfunction
279
Common Malfunction Diagnosis Flow of Geely Automobile
①CD –player vibration resistance switch ①Press SEL button over 3 sec, until menu popup and
improper set select ESP 12/45, 45s is better.
CD –player vibration resistance Press SEL button over 3 sec, until menu popup and
switch improper set Abnormal select ESP 12/45, 45s is better.
Normal
Mounting bracket screws loose Abnormal Tighten retaining screws, as well as CD-player
normal
280
Common Malfunction Diagnosis Flow of Geely Automobile
②No MP3 music stores in U-disk ②Check music format on PC, whether it stores MP3 files.
281
Common Malfunction Diagnosis Flow of Geely Automobile
Normal
Abnormal
No MP3 music stores in U-disk Copy MP3 music to U-disk
Normal
Normal
Normal
Normal
Normal
Normal
Normal
Abnormal
CD-player inner program failure, Replace CD-player assembly,
which affects USB loading including USB
282
Common Malfunction Diagnosis Flow of Geely Automobile
CD-player power source or Check CD-player power source, whether the voltage is between 12V and
circuit malfunction 14V. If the voltage is over normal standard, then check generator and
external power source, whether they operating normally.
Check the resistance value between the positive pole of CD-player power
supply circuit and CD-player housing, with multimeter, whether the value is
between 5kOhm and 10kOhm. If the circuit is conducting and the resistance
value is 0, then it indicates there is short circuit between positive pole of
power source and CD-player housing.
CD-player burns CD-player short circuit
out when between housing and earth
Check CD-player inner stabilized voltage supply and all components of
connecting protective circuit, whether there is short circuit. The principle inspecting
power source points are as follows: the inductive choke of stabilized voltage supply end,
the dynatron of controlling switch power supply and protective diode.
Check the components above, whether they were burnt out, and replace
them or the CD-player when necessary.
Over load
Check CD-player power supply voltage Inspect and maintain
generator
Normal
Abnormal
Check the resistance value between the Inspect and maintain stabilitized
positive pole of CD-player inner power power source circuit
source and CD-player housing.
Normal
Normal
283
Common Malfunction Diagnosis Flow of Geely Automobile
CD-player consists
back drop when ⑦ Check the transfer switch between CD-player and
operating radio, whether it consists virtual link, or in place.
The alternation switch of CD-player and
Inspect the mechanical part of corresponding
radio not in place.
connection or replace CD-player assembly when
necessary.
284
Common Malfunction Diagnosis Flow of Geely Automobile
Abnormal
Check enigne high Check CD disk Replace disk
voltage wire or other
electric appliances
Normal
Normal
Normal
Normal
285
Common Malfunction Diagnosis Flow of Geely Automobile
Abnormal
Abnormal
Hatch mechanism stuck or contains
dirts Adjust or replace
Abnormal
Check hatch button “ EJECT”
Replace radio assembly
Abnormal
Check link mechanism of loader Replace radio assembly
286
Common Malfunction Diagnosis Flow of Geely Automobile
No. 209 Cassette speed abnormal, turned over automatically and chewed
①Check external power supply, whether the voltage is over load and
① Power supply malfunction results inner appliances operating unstably. The normal value shal
between 12V and 14V approximately.
Cassette speed
abnormal, ⑤Drive belt skid or dropped, that is, the friction reduced between belt
turned over and motor/flywheel, which results motor speed lowered and unstably.
⑤ Drive belt skid or dropped
automatically Check drive belt, whether it is loose or dropped, and replace recorder
and chewed assembly when necessary.
⑥Drive motor brush worn seriously and fallen graphite powder results
partly short circuit between the copper plates of commutator, and
⑥ Drive motor brush worn seriously. further causes motor speed lowered. Check the clearance and
wearing condition between brushes, and replace recorder assembly
when necessary.
287
Common Malfunction Diagnosis Flow of Geely Automobile
Normal
Abnormal
Power supply Maintain power supply
Normal
Abnormal
Cassette housing, damaged or not Replace cassette
Normal
Abnormal
Recorder button, damaged or not Inspect and replace
Normal
Abnormal
Drive gear wearing condition Replace recorder
Normal
Abnormal
Drive belt, loose or not Replace recorder
Normal
Abnormal
Drive motor wearing condition Replace recorder
Normal
Abnormal
Inspect guide pulley operating condition Inspect and replace recorder
Normal
Normal
288
Common Malfunction Diagnosis Flow of Geely Automobile
No. 210 Poor timbre, low volume or noise jump when playing CD
Poor timbre,
low volume or ⑤Check voltage of CD-player power supply, generally +B and
noise jump GND voltage shall between 10V and 14V. When ACC and GND
when playing ignition switch locating at ACC or ON position, the value shall
④ Power supply unstable between 10V and 14V.
CD
⑥Check CD-player laser head serve motor driving voltage,
whether it is in normal range. Maintain it when necessary.
289
Common Malfunction Diagnosis Flow of Geely Automobile
Abnormal
Check CD disk, whether it is too Replace CD disk
dirty
Normal
Abnormal
Check loudspeaker, whether it is
poor conducted Maintain, modify or replace
Normal
Abnormal
Check volume adjusting
knob Replace CD-player assembly
Normal
Abnormal
Check CD-player supply Maintain, modify
voltage
Normal
Abnormal
Check laser head, whether it is too
dirty or aging Clean or replace CD-player
assembly
Normal
Abnormal
Check the voltage between each pin of Inspect and maintain circuit or replace
power amplifier CD-player assembly
normal
290
Common Malfunction Diagnosis Flow of Geely Automobile
All or single
loudspeaker low
volume ④Check CD disk quality, whether it is piratic. Replace to
genuine CD disk.
CD disk damaged
⑤Check disk format or surface wearing level, and
replace timely when necessary.
291
Common Malfunction Diagnosis Flow of Geely Automobile
Abnormal
Replace loudspeaker
Loudspeaker poor performance
Normal
Normal
Abnormal
Normal
Abnormal
Volume controlling potentiometer damaged Replace volume
potentiometer
Normal
292
Common Malfunction Diagnosis Flow of Geely Automobile
Loudspeaker circuit poor contact ③Pull out the pins of CD-player and loudspeaker, measure the
resistance by multimeter, the value between both ends of circuit
shall be 0 Ohm, the resistance to earth shall be infinite, and the
resistance of loudspeaker shall be 4 Ohm. Inspect or replace when
necessary.
Large
loudspeaker
noise
⑤Check the filter of CD-player stabilized voltage, some may equips
with inductive choke filter, then shall check current leakage in
inductive choke. Replace CD-player when necessary.
CD –player stabilized voltage supply ⑥Check capacitor of circuit, whether it is damaged. Remove the
components malfunction capacitor and measure it by multimeter setting at voltage range,
survey value variation between straight polarity and reverse polarity.
If the variation range is too narrow, which indicates the capacitor is
damaged, then replace CD-player.
293
Common Malfunction Diagnosis Flow of Geely Automobile
Abnormal
Replace loudspeaker
Dirts in loudspeaker magnet
clearance or cone diaphragm
cracked.
Normal Abnormal
Maintain loudspeaker circuit
Normal
Abnormal Maintain modify replace
Normal
Abnormal
CD –player stabilized voltage supply Replace CD-player
components malfuction
Normal
Abnormal
CD –player voice short Replace CD-player
circuit or damaged
Normal
Abnormal
CD –player power Replace CD-player
amplifiying circuit short or
damaged
Normal
294
Common Malfunction Diagnosis Flow of Geely Automobile
295
Common Malfunction Diagnosis Flow of Geely Automobile
Loudspeaker susurrates
when pressing horn
Normal
Abnormal
Loudspeaker damage or screws
loose Maintain, tighten and replace
Normal
Abnormal
Replace loudspeaker
Loudspeaker short circuit
Normal
Normal
Abnormal
Normal
Abnormal
CD-player inner short circuit or burnt
Maintain and replace CD-player
296
Common Malfunction Diagnosis Flow of Geely Automobile
Lift vehicle with two-post lift, then turn shift lever to neutral
gear and set ignition switch at ON position. Rotate front
Speed sensor power supply circuit
wheel slowly, measure the voltage between pin 1 and pin 2
malfunction
by multimeter, the value shall between 0.5V and 9V.
Speedometer Otherwise, replace speed sensor.
non-display, sc.
odometer non-display
Lift vehicle with two-post lift, then start engine, geared, and
accelerate. Survey sensor pulse signal by oscilloscope, if
there is no pulse signal on display screen, then shall inspect
Speed sensor drive or driven gear speed sensor firstly. If it finds no damage in sensor
damaged inspection, then shall remove driven gear from speed sensor
rear end, as well as drive gear from gearbox output shaft,
and survey whether it appears gear hit and miss. Replace it
when necessary.
Open fuse box and check CLUSTER (10A) AM1 (30A) and
fuse MAIN (80A), whether they are burnt. Replace them
when necessary. Disconnect connector from grouped
LCD odometer power supply and
instrument assembly, measure the resistance between B7
instrument connecting circuit
(GND) and body (earth end) by multimeter, as well as the
malfunction
resistance between B8 (GND) and body (earth end), and the
value shall be 0 Ohm, sc. conducted. Otherwise, shall
maintain connecting circuit.
297
Common Malfunction Diagnosis Flow of Geely Automobile
Speedometer
non-display
Abnormal Normal
Abnormal Normal
Normal
Abnormal
Replace instrument
assembly
298
Common Malfunction Diagnosis Flow of Geely Automobile
No. 215 Freedom ship speedometer malfunction, indicates automatically when pressing horn
Battery positive pole wire poor ①Check battery positive pole pin, whether it is poor contacted. Clean
contact and tighten it when necessary.
②Set multimeter to voltage range, connect the red probe to terminal A11
on instrument panel pin, the black probe to body earth lead, turn ignition
switch to ON position, press horn button, and survey the variation of
voltage indicator. If the indicator swings greatly, which indicates short
circuit between speedometer and center integrated controlling circuit,
Instrument connecting cable short then shall implement maintaining work.
circuit
②Pull out instrument pin and center integrated controller pin, measure
the resistance between two ends of wire harness and earth lead, of
which value shall be infinite, sc. non-conducted. Otherwise, shall
maintain or replace wire harness.
299
Common Malfunction Diagnosis Flow of Geely Automobile
Check instrument connecting wire. Check center integrated controller inner circuit, Check horn button circuit and grouped
whether there is short circuit or damage switch.
Pull out instrument connector and center integrated Check center integrated controller, whether Disconnect center integrated controller and grouped switch
controller pin; inspect the harness by multimeter, it is burnt. connector, measure the resistance between A21 and A2,
whether there is short circuit. as well as A22 and A3, by multimeter.
Abnormal
Abnormal Inspect, maintain, replace
Inspect, maintain, replace Abnormal Inspect, maintain, replace
Connect multimeter to terminal A11 on instrument Connect multimeter to terminal A3 on center Measure the resistance between C6 and A21, C6 and
panel connector, set ignition switch to ON position, integrated controller, set ignition switch to ON A22, C6 and B11, C6 and B22, by multimeter, press
press horn button, and survey the variation of position, press horn button, and survey the horn button, and survey the variation of multimeter
voltage indicator. variation of voltage indicator. indicator.
Swing Swing
Inspect and maintain speedometer and Swing
center integrated
controller connecting wire, whether Replace grouped switch assembly
there is short circuit.
Replace center integrated controller
when necessary.
300
Common Malfunction Diagnosis Flow of Geely Automobile
301
Common Malfunction Diagnosis Flow of Geely Automobile
Incorrect indication of
speedometer
Abnormal Normal
Measure the voltage between terminals of speed sensor, place Check the rear connections of
igniting switch to ON and turn the wheel slowly; the voltage instrument panel and power supply
between #1 and #3 terminal of speed sensor should be varied of instrument
from 0.5 to 9 V
Yes
No
Normal Abnormal
Replace instrument
assembly
302
Common Malfunction Diagnosis Flow of Geely Automobile
No. 217 Kilometrage on LCD of odometer will accumulate automatically after the engine starts
Malfunction Cause Solution
303
Common Malfunction Diagnosis Flow of Geely Automobile
Replace instrument
With signal Without signal assembly
304
Common Malfunction Diagnosis Flow of Geely Automobile
Wrong connection of harness Check and sort out the harness connection again.
305
Common Malfunction Diagnosis Flow of Geely Automobile
Automatic movement of
odometer pointer after
start-up of engine
Remove plug of speed sensor; lift the vehicle with double props lifter, and
start up the engine; connect oscilloscope on A11 terminal of instrument
harness to view for signal
No Yes
Connect the
harness Replace speed sensor
again assembly
Replace instrument
assembly Normal Abnormal
Abnormal Normal
Abnormal Normal
306
Common Malfunction Diagnosis Flow of Geely Automobile
307
Common Malfunction Diagnosis Flow of Geely Automobile
Check power supply loop for Check tachometer coil for blow-out
instrument; measure voltage of B4 or break; check if hairspring blocks
instrument connector for normal with panel while rotating and if there
about 12 V with voltage grade of is break of hairspring of tachometer
multi-meter; check fuse for burn-out coil
Abnormal
Replace fuse of
instrument
Abnormal
Check, repair and
replace
Abnormal
Check, repair and
replace
Abnormal
Normal
308
Common Malfunction Diagnosis Flow of Geely Automobile
309
Common Malfunction Diagnosis Flow of Geely Automobile
Yes No
Yes No
Check fuel stabilizing circuit;
dismantle instrument panel and
Check bottom of tank for distortion and Replace fuel gauge then switch on igniting switch;
internal surface of tank for bulge or sensor check output voltage between
other blocking “+12V” and “-“ terminals of
instrument stabilizer
310
Common Malfunction Diagnosis Flow of Geely Automobile
311
Common Malfunction Diagnosis Flow of Geely Automobile
No indication of water
temperature gauge
Yes No
Yes No
Check power supply loop for instrument; open fuse unit
Check water temperature sensor with multi-meter and check fuse for burn-out; measure voltage of B4
Replace water temperature gauge or Abnormal
to measure resistances in different temperatures instrument connector for normal voltage of battery Replace
instrument assembly
fuse
Normal Abnormal
Check water temperature gauge stabilizing circuit; dismantle
instrument panel and then switch on igniting switch; check output
Check connecting wire of Replace water voltage between “+12V” and “-“ terminals of instrument stabilizer
water temperature sensor temperature sensor
or replace instrument
assembly
Abnormal
Replace water temperature Replace
gauge or instrument assembly stabilizer
312
Common Malfunction Diagnosis Flow of Geely Automobile
Abnormal
Switch of mirror damaged
Replace fuse
Normal
Abnormal
Poor contact, short-circuit or break of
Replace switch part
harness, connecting wire and connectors
Normal
Abnormal
Short-circuit or open circuit of power supply for Check, repair and replace
mirror
Normal
313
Common Malfunction Diagnosis Flow of Geely Automobile
Normal
Abnormal
Measure with multi-meter for
Malfunction of water resistance variation
temperature sensor
Normal
Abnormal
Malfunction of wire
Check, repair or replace electric
harness;
Normal
Abnormal
of Check if instrument is
Malfunction
broken
combined instrument
314
Common Malfunction Diagnosis Flow of Geely Automobile
Normal
Abnormal
315
Common Malfunction Diagnosis Flow of Geely Automobile
No. 225 Brake fluid level alarm indicator is always on or can’t alarm
Malfunction Cause Solution
Insufficient brake fluid results in always-on of brake
Fill sufficient brake fluid
fluid level alarm indicator
Short-circuit or open circuit of brake fluid level
Replace brake fluid level sensor
sensor
Short-circuit or open circuit of connection between
Failure of brake fluid level brake fluid level sensor and instrument results in Short-circuit of brake fluid level alarm indicator results in
alarm indicator is always always-on of brake fluid level alarm indicator always-on of its indicator.
on or can’t alarm
Break of circuit for brake fluid level alarm indicator or failure of
Brake fluid level alarm indicator can’t alarm
buzzer for alarm circuit
Internal fault of combined instrument Check, repair or replace combined instrument.
Fault of ABS system (indicated together with ABS
Repair ABS system
fault indicator)
Insufficient brake fluid Insufficient oil Check if oil is sufficient and fill sufficient brake fluid
Normal
Normal
Short-circuit or
break
Short-circuit or open circuit of
Repair the connection
connection between brake fluid
level sensor and instrument
Normal
Normal
Broken
Malfunction of ABS system Repair ABS system
316
Common Malfunction Diagnosis Flow of Geely Automobile
Insufficient
Insufficient lubricating oil
Fill lubricating oil
Normal
Blocked
Block of lubricating oil tube Repair
Normal
Blocked
Oil pressure sensor damaged Replace
Normal
Over-low
Check and repair
Over-low oil pressure
Normal
Abnormal
Break or short-circuit of connecting wire for oil Check and repair
pressure alarm indicator
Normal
Abnormal
Short-circuit of combined Replace combined
instrument instrument
317
Common Malfunction Diagnosis Flow of Geely Automobile
Burnt out
Broken fuse for headlight Replace
Normal
Burnt out
Headlight relay is broken Replace
Normal
Burnt out
Broken switch for headlight Replace
Normal
Abnormal
Broken harness or poor contact with bond Repair or replace
strap
Normal
Abnormal
Broken bulb or poor contact of lamp socket Repair or replace
Normal
Abnormal
Malfunction of centralized controller or Replace centralized controller or light
light controller controller
318
Common Malfunction Diagnosis Flow of Geely Automobile
Too low
Voltage of battery Charge or replace battery
Normal
Normal
Normal
Abnormal
Engine works abnormally Repair or replace
319
Common Malfunction Diagnosis Flow of Geely Automobile
Check if the coil of electromagnetic switch for starter is OK, and replace the
electromagnetic switch if the coil is broken;
Check the stator coil of starter for break or short-circuit, and replace starter assembly if
the coil is abnormal;
Starter can’t work Measure length of internal brush of starter with vernier caliper; the standard length of
brush should be 15.5 mm and the minimum worn length is 10 mm; if the brush is shorter
Internal than the minimum value, the brush or starter assembly should be replaced;
malfunction of
starter Check the condition of commutator: 1. Check with Ohm meter if it’s connected between
two commutators, and replace commutators or starter assembly if one of them is
disconnected. 2. Check the grounding situation of starter commutator; check connection
between armature coil and spindle with Ohm meter; it should be disconnected, if it’s
connected, the commutator or starter should be replaced. 3. Check if the undercutting
depth of commutator should be 0.60 mm and the minimum depth should be 0.20 mm. if
the depth is smaller than the minimum value, then the commutator or starter assembly
should be replaced. Check connecting condition of exciting coil: 1. Check with Ohm meter
if it’s connected between conductor and exciting coil brush, and replace starter assembly
if it’s disconnected. 2. Check the grounding condition of exciting coil; it should be
disconnected between end of exciting coil and magnetic pole armature frame measured
by Ohm meter, and replace starter assembly if it’s connected.
Internal
Check if the crankshaft of engine can be rotated normally, if it’s blocking or blocked, the
malfunction of
engine should be checked and repaired.
engine
320
Common Malfunction Diagnosis Flow of Geely Automobile
Normal
Normal
Normal
Open circuit or poor contact of connector loop for starter Abnormal Check and repair
starter loop
Normal
Normal
321
Common Malfunction Diagnosis Flow of Geely Automobile
Short-circuit
Short-circuit of internal contacts of electromagnetic Replace electromagnetic switch or
switch for starter starter assembly
Normal
Broken
Slipping or broken tooth of starter one-way clutch Replace one-way clutch
Normal
Loosing
Loosing of starter fastening bolt Tightening
Normal
Abnormal
Damage or loosing of ring gear for starter and flywheel Tighten or replace
flywheel
322
Common Malfunction Diagnosis Flow of Geely Automobile
Broken
Damage of one-way clutch bearing and pinion Replace one-way clutch
Normal
Over-low
Low voltage of battery Recharge or replace battery
Normal
Over worn-out of internal bearing bush for starter Abnormal Replace starter
Normal
323
Common Malfunction Diagnosis Flow of Geely Automobile
Over-high or 1. Check forward rectifying: Connect one probe of Ohm meter to positive pole
over-low recharging of rectifying diode, and the other probe to every end of rectifiers; changeover
voltage from the polarity of probes and repeat above procedure; the Ohm meter will show
generator conducting for one and cutoff for the other; if the conductivity is different from
above description, the rectifier or generator assembly should be replaced;
Malfunction of generator
rectifier 2. Check backward rectifying: Connect one probe of Ohm meter to negative
pole of rectifying diode, and the other probe to every end of rectifiers;
changeover the polarity of probes and repeat above procedure; the Ohm meter
will show conducting for one and cutoff for the other; if the conductivity is
different from above description, the rectifier or generator assembly should be
replaced.
Check internal plate of battery for sulfurization or short-circuit, which may result
Malfunction of battery in over recharging current and subsequent over recharging energy from
generator, thus the battery should be replaced;
324
Common Malfunction Diagnosis Flow of Geely Automobile
Normal
Normal
Normal
Normal
Sulfurization
Sulfurization or short-circuit of internal battery Replace battery
or
plate
short-circuit
325
Common Malfunction Diagnosis Flow of Geely Automobile
326
Common Malfunction Diagnosis Flow of Geely Automobile
Generator can’t
work
327
Common Malfunction Diagnosis Flow of Geely Automobile
Worn-out
Loosing or over worn-out of generator belt Replace generator
belt
Normal
Broken
Broken fuse of generator Change fuse
Normal
Abnormal
Generator regulator
Normalin poor operation
Replace generator
regulator
Normal
Abnormal
Generator rectifier
Normalin poor operation Replace rectifier or generator
assembly
Normal
Abnormal
Short-circuit or open circuit of charging indicator loop of Check or repair charging indicator
generator loop of generator
Normal
Abnormal
Short-circuit or open circuit of internal charging indicator of Replace
combined instrument combined
328
Common Malfunction Diagnosis Flow of Geely Automobile
329
Common Malfunction Diagnosis Flow of Geely Automobile
Abnormal
Loosing or over worn-out of generator belt Replace generator
belt
Normal
Abnormal
Broken fuse of generator Replace fuse
Normal
Abnormal
Generator regulator in poor operation Replace generator
regulator
Normal
Abnormal
Generator rectifier in poor operation Replace rectifier or generator
assembly
Normal
Abnormal
Short-circuit or open circuit of charging indicator loop of Check or repair charging indicator
generator loop of generator
Normal
Normal
Abnormal
Short-circuit or open circuit of internal charging indicator of Replace
combined instrument combined
330
Common Malfunction Diagnosis Flow of Geely Automobile
Malfunction of Adjust or
generator belt replace
331
Common Malfunction Diagnosis Flow of Geely Automobile
332
Common Malfunction Diagnosis Flow of Geely Automobile
Over-low
Over-low voltage for blower Charge or replace battery
Normal
Abnormal
Over-big resistance or short-circuit of blower coil Replace blower
motor
Normal
Abnormal
Replace blower
Blocking or unsmooth running of blower blades
assembly
333
Common Malfunction Diagnosis Flow of Geely Automobile
Over-low
Low voltage of battery Charg or replace battery
Normal
Break
Broken fuse of blower Replace blower fuse
Normal
Abnormal
Malfunction of blower relay Replace blower relay
Normal
Open circuit
Open circuit of blower speed governing Replace blower speed
resistance governing resistance;
Normal
Normal
Abnormal
Normal working of blower switch Replace blower
switch
Normal
Abnormal
Blocking or blocked blower fan Replace blower fan
Normal
Abnormal
Open circuit or poor contact of connector loop for blower Check and repair blower
loop
334
Common Malfunction Diagnosis Flow of Geely Automobile
Abnormal
Impurity enters into blower
Dismantle
blower
Normal
Abnormal
Loosing of internal blower blades Dismantle
blower
Normal
Abnormal
Internal brush and bearing for blower in poor Replace
operation blower
335
Common Malfunction Diagnosis Flow of Geely Automobile
Continuous
running of cooling
Leakage
Leaking or insufficient coolant Check cooling
system
Normal
Abnormal
No recirculation and heat dispersing Check, repair or
for coolant of radiator replace thermostat
Normal
Abnormal
Fan relay in poor operation Replace fan
relay
Normal
Abnormal
Water temperature sensor in poor Replace water
operation temperature
Normal
Abnormal
Short-circuit or break of fan loop Check and
repair fan loop
Normal
Abnormal
Engine ECU in poor operation Replace engine
336
Common Malfunction Diagnosis Flow of Geely Automobile
Blocked
Replace fan blades
Fan blades blocked due to contacting with fan guard
Normal
Open circuit
Broken fuse of fan Change fuse of fan
Normal
Normal
Abnormal
Water temperature sensor in poor operation Replace water
temperature sensor
Normal
Short-circuit or open circuit of cooling fan motor Abnormal Replace fan motor
Normal
Open circuit of cooling fan motor loop Break Check and repair fan motor
loop
Normal
Abnormal
Engine ECU Replace engine ECU
337
Common Malfunction Diagnosis Flow of Geely Automobile
Over-low
Low voltage of battery Charge or replace battery
Normal
Abnormal
Poor contact of fan fuse Replace fuse of fan
Normal
Abnormal
Poor power-on of fan relay Replace fan relay
Normal
Abnormal
Short-circuit of fan motor Replace fan motor
338
Common Malfunction Diagnosis Flow of Geely Automobile
Normal
Normal
Normal
Dropping-off of connection between wiper link and wiper motor Abnormal Check, repair or replace link
Normal
Short-circuit or open circuit of wiper loop Abnormal Check and repair wiper
loop
339
Common Malfunction Diagnosis Flow of Geely Automobile
Normal
Short-circuit or open circuit of wiper motor coil Abnormal Replace wiper motor
Normal
Normal
Normal
340
Common Malfunction Diagnosis Flow of Geely Automobile
Normal
Fuel pump relay in poor operation Abnormal Replace fuel pump relay
Normal
Open circuit
Open circuit of fuel pump loop Repair fuel pump loop
Normal
Abnormal
Main relay in poor operation Replace main relay
Normal
Open circuit or short-circuit of internal coil for fuel pump Abnormal Replace electric fuel
pump
Normal
341
Common Malfunction Diagnosis Flow of Geely Automobile
Leakage
Distortion or leakage of fuel pipeline Replace or repair
Normal
Abnormal
Malfunction of fuel pressure regulator Replace pressure
regulator
Normal
Abnormal
Internal pressure discharging or bad sealing Replace electric fuel
for electric fuel pump pump
Normal
Abnormal
Bad sealing of injector Replace injector
342
Common Malfunction Diagnosis Flow of Geely Automobile
Broken
Malfunction of venting check valve for fuel tank Replace
Normal
Abnormal
Malfunction of venting tube for fuel Replace
tank
Normal
Abnormal
Malfunction of fuel tank cover Replace
Normal
Normal
Abnormal
Malfunction of canister control Replace
valve
Normal
343
Common Malfunction Diagnosis Flow of Geely Automobile
344
Common Malfunction Diagnosis Flow of Geely Automobile
Failure of remote
controller
Is voltage of remote controller battery too low? Over-low Replace remote controller
battery
Normal
Normal
Normal
Normal
Mismatch
Is remote controller matched to centralized Coding
controller?
Normal
Normal
345
Common Malfunction Diagnosis Flow of Geely Automobile
Normal
Abnormal
Short-circuit or open circui of centralized controller Check and repair
loop centralized controller
loop
Normal
No signal from speed sensor to centralized controller Abnormal Repair speed sensor
Normal
Normal
Abnormal
Speedometer indication in poor operation Replace combined
instrument
Normal
346
Common Malfunction Diagnosis Flow of Geely Automobile
1. Malfunction of lockup unit 2. Check the lockup unit for blocking; it should be moved freely during
normal working; if it’s blocked, the lockup unit should be replaced;
3. Check motor of lockup unit and measure its resistance for short-circuit
Failure of central control or break; if so, it should be replaced;
either by manual control
4. Check fuse of central control for break; if so, the loop should be
or by remote control
checked for short-circuit, grounding and over-current; if so, the fuse
2. Malfunction of circuit should be replaced after repairing;
5. Check connector for loosing or dropping-off; if so, it should be
repaired;
6. Centralized controller is damaged internally; the centralized controller
3. Centralized controller
assembly should be replaced;
Abnormal
Loosing or dropping-off of the lockup unit Repair
Normal
Normal
Normal
Poor contact, short-circuit or open circuit of loop Abnormal Check and repair
Normal
347
Common Malfunction Diagnosis Flow of Geely Automobile
1. Malfunction of speed sensor 2. Lift front wheels and shift the gear; check speed sensor for signal;
replace it if necessary;
Flashing CGQ 3. Check speed sensor for dropping-off or poor contact; repair it if
alarm indicator for necessary;
speedometer during
2. Malfunction of drive assembly Check speedometer for blocking or damage, otherwise replace it if
driving
for speedometer necessary;
4. Check sensor combined instrument loop and all connectors for
2. Malfunction of circuit
short-circuit, open circuit or poor contact; otherwise repair it if necessary;
3. Malfunction of combined Check internal PCB of combined instrument for fault; otherwise replace
instrument it if necessary;
Abnormal
Speed sensor Replace
Normal
Abnormal
Drive assembly for speedometer Replace
Normal
Normal
348
Common Malfunction Diagnosis Flow of Geely Automobile
Centralized controller Check if connector of centralized controller is firm; if it's abnormal, it should be
checked and repaired;
Check centralized controller for normal working with displacement method, otherwise
replace it if necessary;
Normal
Abnormal
Malfunction of circuit Check and repair
Normal
Abnormal
Malfunction of lifter switch Check, repair or replace
Normal
Abnormal
Malfunction of lifter motor Check, repair or replace
Normal
Abnormal
Malfunction of centralized controller Check, repair or replace
349
Common Malfunction Diagnosis Flow of Geely Automobile
Malfunction of opener Check the lockup unit for blocking; it should be moved freely during normal working;
of Door lock if it’s blocked, the lockup unit should be replaced;
Check motor of lockup unit and measure its resistance for short-circuit or break; if
so, it should be replaced;
Check if the door is distorted and if there is sign of squeezing or bumping; if it’s
Door can’t be Door abnormal, the door should be calibrated;
opened due to
blocking latch Check if the blocking of internal mechanism of Door lock is because of
Over-abrading Door
over-abrading; if so, it should be replaced;
lock
Dislocation of Door Check Door lock for loosing; if so, adjust or replace it.
lock due to external
force Check Door lock for distortion; if so, replace it.
Dismantle internal decorating plate of door and check supporting bar for knob of
Supporting bar for
Door lock for blocking or distortion; if it's abnormal, it should be calibrated or
knob of Door lock
replaced.
Rusting or
blocking
Blocking or rusting of door latch Check, repair or
replace
Normal
Abnormal Check, repair or
Malfunction of door opener
replace
Normal
Distortion or
dislocation
Distortion or dislocation of door Check, repair or
replace
Normal
Worn-out
Over-abrading door latch Replacing
Normal
Blocking or
interference
Blocking or interference of door latch knob Checking and
repairing
350
Common Malfunction Diagnosis Flow of Geely Automobile
No
Yes
Blocking or damage of core of door lock Replace
No
Yes
Broken body of door lock Replace
No
Yes
Distortion of door Check, repair or replace
No
Yes
Distortion of door lock knob Replace
351
Common Malfunction Diagnosis Flow of Geely Automobile
No. 256 If four doors of vehicle are not closed, the anti-theft alarm will be activated automatically and
central control will be locked automatically
Malfunction Cause Solution
If four doors of vehicle Is triggering switch of door control Check if the triggering switch of door control is unable to return
are not closed, the broken? or blocked; repair or replace it according to condition;
anti-theft alarm will be
activated automatically Check if there is signal outputted from centralized controller;
Is centralized controller broken?
and central control will repair or replace it according to condition;
be locked Check loops among all doors for break, short-circuit or poor
automatically Malfunction of circuit contact, otherwise repair them;
If four doors of vehicle are not closed, the anti-theft alarm will be activated automatically and
central control will be locked automatically
No
No
352
Common Malfunction Diagnosis Flow of Geely Automobile
Normal
Normal
Normal
353
Common Malfunction Diagnosis Flow of Geely Automobile
Abnormal
Abnormal installation for sensor Adjust
Normal
Normal
Broken
Broken sensor or controller Replace
354
Common Malfunction Diagnosis Flow of Geely Automobile
No. 259 Sunroof can’t move, including malfunction of automatic closing and anti-nip
Malfunction Cause Solution
Broken fuse Check if fuse is burnt-out; if so, replace it;
Poor contact of switch Check switch for poor contact with multi-meter; if so, replace the switch;
Sunroof can’t Disordered memory for Check if the sunroof has functions such as automatic shutting and
move, including control module jam-preventing; if not, power-off the sunroof, and power-on again after 30 s to
malfunction of reset;
automatic closing
Malfunction of control
and anti-nip Check control module for burn-out; if so, the control module should be replace;
module
Reverse connection Connect the harness again;
Malfunction of motor Check motor for normal working; if it’s abnormal, replace the motor;
Sunroof in poor
operation
Burnt
Fuse burnt Change fuse
Normal
Normal
Power-off the sunroof, and power-on
Disordered memory for control again after 30 s to reset
module
Normal
Burnt
Control module burnt
Replace control module
Normal
Burnt
Malfunction of motor Replace motor
355
Common Malfunction Diagnosis Flow of Geely Automobile
With impurity
Impurity or blocking of sliding Clearing impurity and lubricating
groove
Normal
Normal
Over-low
Internal malfunction of motor Replace sunroof and
motor assembly
Normal
Distorted
356
Common Malfunction Diagnosis Flow of Geely Automobile
One side of the clearance between Too-big Adjust the clearance around
glass of sunroof and roof is too big glass of sunroof and roof evenly
Even
Unblocked
357
Common Malfunction Diagnosis Flow of Geely Automobile
Exceed or less opening of Replace expansion valve assembly, pump for vacuum and fill refrigerant;
358
Common Malfunction Diagnosis Flow of Geely Automobile
expansion valve
Malfunction of compressor Malfunction of compressor will resulting in failure of AC;
Short-circuit or break of loop
Check and repair loop and harness;
and harness
Malfunction of engine ECU Replace engine ECU;
359
Common Malfunction Diagnosis Flow of Geely Automobile
Abnormal
Dirt in system
Repair or clear
Normal
Abnormal
Malfunction of air duct Check, repair or replace
Normal
Abnormal
Undercharge or overdose of Check and
refrigerant repair
Normal
Abnormal Check and
Air or moisture in system
repair
Normal
Abnormal
Check and repair
Too much refrigerating oil or dirt in system
Normal
Abnormal
Malfunction of evaporator Check and repair
Normal
Abnormal
Electromagnetic clutch of compressor is slipping or belt is Check, repair or
loosing replace
Normal
Abnormal
Malfunction of blower Check, repair or
replace
Normal
Normal
Abnormal
Malfunction of temperature controller Check, repair or
or temperature wrap replace
Normal
Abnormal
Malfunction of Check, repair or
compressor replace
Normal
Short-circuit or circuit of circuit Abnormal Check and repair loop
and harness and harness;
Normal
360
Common Malfunction Diagnosis Flow of Geely Automobile
No. 263 Normal suction pressure and too high exhaust pressure for AC compressor
Malfunction Cause Solution
1) Air in system: Drain refrigerant and vent air out; pump vacuum and fill
Air in system
refrigerant again.
Too much refrigerant 2) Too much refrigerant: Discharge exceeding refrigerant.
Normal suction Condenser blocked 3) Clog-up of condenser: Clean or replace condenser; pump vacuum and fill
pressure and too refrigerant again.
high exhaust 4) Clog-up of drying reservoir: Replace drying reservoir; pump vacuum and
pressure for AC Drying reservoir blocked fill refrigerant again.
compressor while
running of vehicle Pipeline blocked 5) Clog-up of pipeline: Clear clog-up; pump vacuum and fill refrigerant
AC again.
Insufficient air amount of
6) Insufficient air amount of condenser fan: Replace fan.
condenser fan
High temperature of engine
7) High temperature of engine water tank: find the cause and remove it.
water tank
Normal
Abnormal
Too much refrigerant Discharge
Normal
Abnormal
Condenser blocked Check, repair or replace
Normal
Abnormal
Drying reservoir blocked Check, repair or replace
Normal
Abnormal
Abnormal
Pipeline blocked Check, repair or replace
Normal
Normal
Abnormal
High temperature of engine water tank Check, repair or replace
361
Common Malfunction Diagnosis Flow of Geely Automobile
No. 264 Too high suction pressure and exhaust pressure for AC compressor
Malfunction Cause Solution
Overdose of refrigerant 1) Overdose of refrigerant: Discharge exceeding refrigerant.
Malfunction of heat expansion
2) Malfunction of heat expansion valve: Replace heat expansion valve.
valve
Broken suction valve segment
3) Broken suction valve segment of compressor: Replace compressor.
of compressor
Too high Over-high temperature of inlet 4) Over-high temperature of inlet air for evaporator: Check if fresh air damper
suction air for evaporator is closed tightly; find the cause and remove it.
pressure and
Air in system 5) Air in system: Vent air in system out; pump vacuum and fill refrigerant again.
exhaust
pressure for Poor heat radiating for 6) Poor heat radiating for condenser: Check if fins of condenser are blocked by
AC compressor condenser dirt and if fins are bent or distorted; clean or replace them.
while running
of vehicle AC 7) Insufficient air amount of condenser fan: Check if fan circuit is in poor
Insufficient air amount of
contact, if the rotating speed of fan is normal and if there is too much dust on
condenser fan
fins of condenser; find out the cause and remove it.
8) Loose fixing of temperature wrap: The temperature wrap contacts badly with
Loose fixing of temperature outlet of evaporator or outer heat isolating part of temperature wrap is broken;
wrap fix the temperature wrap again to ensure good heat isolating and contact of
temperature wrap for heat expansion valve.
Too-high suction pressure and exhaust pressure for AC
compressor
Abnormal
Overdose of refrigerant Check and
repair
Normal
Abnormal
Fault of heat expansion valve Replace
Normal
Normal
Abnormal
Too-high temperature of inlet air for Check and
evaporator repair
Normal
Normal
Normal
Abnormal
Insufficient air amount of condenser fan Check, repair or replace
Normal
Abnormal
Loose fixing of temperature wrap Check and
repair
362
Common Malfunction Diagnosis Flow of Geely Automobile
No. 265 Too high suction pressure and normal exhaust pressure for AC compressor
Malfunction Cause Solution
1) Too high temperature of inlet air for evaporator: Check fresh air
Too high temperature of inlet
damper for leakage; the doors and windows should be closed to keep
air for evaporator
outside warm air away from carriage;
Too high suction
pressure and normal Malfunction of heat expansion 2) Malfunction of heat expansion valve: Replace heat expansion valve;
exhaust pressure for valve
AC compressor
Broken compressor 3) Broken compressor: Replace compressor;
while AC running
Loosing or bad heat isolating
4) Loosing or bad heat isolating of temperature wrap for heat expansion
of temperature wrap for heat
valve: Tighten it to ensure good contact and enhance isolating protection;
expansion valve
363
Common Malfunction Diagnosis Flow of Geely Automobile
No. 266 Too low suction pressure and exhaust pressure for AC compressor
Malfunction Cause Solution
Insufficient refrigerant in 1) Insufficient refrigerant in system: Check system for leakage; repair it and
Too low suction system supplement refrigerant again;
pressure and Malfunction of heat
exhaust pressure for 2) Malfunction of heat expansion valve: Replace heat expansion valve;
expansion valve
AC compressor
while running of 3) Moisture in system: Discharge refrigerant, replace drying filter and pump
Moisture in system
vehicle AC vacuum repeatedly (not less than 30 min) and fill refrigerant again;
Broken compressor 4) Broken compressor: Replace compressor;
Insufficient
Abnormal
Abnormal
Abnormal
364
Common Malfunction Diagnosis Flow of Geely Automobile
(3)The abnormal sound may be caused by the looseness of the mounting bolt between the
engine and the compressor bracket as well as untightening of the bolt when mounting the
compressor bracket; the bolt shall be checked and retightened to ensure its reliable
connection;
The compressor
has abnormal (4).The compressor is oil shortage that causes the piston seizure, the piston scraping and
sound also the abnormal sound: the refrigeration oil shall be added;
(5).Too much or too little refrigerant, which causes the malfunction or the liquid impact of the
compressor; the refrigerant must be refilled;
(7).Undersupply of the sedan generator battery that causes the insufficiency in the
compressor electromagnetic clutch coil suction resultant; the electromagnetic clutch is in
nearly sucking condition, which may cause the abnormal sound; the generator battery shall
be checked or replaced;
(1).The abnormal sound is generated owing to the mismatch of the thermo expansion valve
structure with the system; it normally occurred when opening or closing the air conditioning;
here opening of the thermo expansion valve can be lowered (clockwise fasten the set screw
by half turn to 3/4 turn; over low fastening has no effect and over high fastening will influence
the performance); replace the thermo expansion valve if the above method is invalid;
(2)Performance of the thermo expansion valve does not mate with the system. The thermo
The thermo expansion valve will have an abnormal sound under certain operation mode if the capacity of
expansion valve the thermo expansion valve is too large; replace into a thermo expansion valve of suitable
has abnormal capacity.
sound
(3).Resonance of the thermo expansion valve will be caused if the thermo expansion valve
structure does not mate with the system; the thermo expansion valve shall be replaced under
this condition;
(4). It is caused by the quality problem of the thermo expansion valve such as ultra low of the
spring force; the thermo expansion valve shall be replaced;
The air (1) abnormal sound of the blower, imbalance of the blower fan blade, abnormal sound
conditioning has caused by excessive wear of the blower motor: replace the blower;
other abnormal
sound (2) Looseness of the clamp or the knock during the operation: tighten the clamping stirrup,
eliminate the friction or the vibration between the hoses and other parts;
(3) There has chatter in the pressure line caused by overfilling of the refrigerant; surplus
refrigerant shall be discharged;
(4) There has hissing sound at inlet of the thermo expansion valve caused by inadequate
filling of the refrigerant; the refrigerant shall be supplied;
365
Common Malfunction Diagnosis Flow of Geely Automobile
Abnormal noise of the auto air conditioning reversing servomotor of generation II Vision and
Leading; replace the servomotor
Abnormal
Abnormal noise of the Overhaul or replace
compressor
Normal
Abnormal
Abnormal noise of the thermo Replace
expansion valve
Normal
Abnormal
Other abnormal sounds of the air Overhaul or replace
conditioning
No. 268 The air conditioning has no heating supply or the heating air is not warm
2). Air leak of the heating radiator shell or the blower shell: tighten the connection
Air leak of the heating radiator screw and replace the sealing gasket;
shell or the blower shell
The cooling fin of the hot-water
pipe inside the heating radiator is 3). Cooling fin of the hot-water pipe inside the heating radiator is squeezed and
squeezed and deformed. deformed, which blocks the wind passing through the heater: straighten the
The air cooling fin with a nipper pliers; it shall be replaced by a new heater in case that
conditioning the cooling fin is unable to be straightened.
has no
heating
supply or Hot air outlet is blocked by the 4). Hot air outlet is blocked by the heater felt gasket: readjust the felt gasket
the heating heating radiator felt gasket position;
air is not
warm
366
Common Malfunction Diagnosis Flow of Geely Automobile
Malfunction
The blower switch is out of Overhaul or replace
service
Normal
Air leakage
The heating radiator shell or the
blower shell is air leakage Overhaul or replace
Normal
Deformation
The cooling fin of the hot-water pipe
inside the heating radiator is Overhaul or replace
squeezed and deformed.
Normal
Block
Hot air outlet is blocked by the heating radiator felt Adjust
gasket
Normal
Improper adjustment
The mix air throttle is in improper Adjust
adjustment
367
Common Malfunction Diagnosis Flow of Geely Automobile
Malfunction
Cause Solution
symptom
A/c compressor Fuse, electric appliance relative fuse is blown, the electric appliance element is of poor contact, the relay
assembly fails to element and relay are coil is broken: check the service condition of each electric appliance element and
start when the malfunction replace damaged one;
a/c is in
operation The belt is over loose Readjust or replace the belt
Failure of low voltage Low temperature protection switch takes effect; when the environment
switch temperature is lower than 15oC, the low temperature protection switch will
automatically cut out the circuit controlling the compressor: check if the
environment temperature is lower than 15oC and if the low temperature protection
switch is in normal operation;
Water temperature is too Check and eliminate the failure of ultra high in water temperature;
high
The idle speed is too low Eliminate it per the preclusion method of too low idle speed of engine;
The temperature Performance parameter of the temperature controller is over proofed while the
controller is failure temperature inside the car is ultra high, but the temperature controller is incapable
of being switched on to operate the compressor: replace the temperature
controller;
The thermo sensitive The thermo sensitive resistance is damaged and incapable of sensing the
resistance is damaged temperature correctly: check and replace the thermo sensitive resistance;
High pressure switch The high pressure switch takes the protection effect so that the compressor fails to
start; check if the high pressure is too high and the system is blocked;
The electromagnetic The electromagnetic clutch can not be sucked together and is incapable of being
clutch can not be sucked operated along with the compressor: check if the clearance of the electromagnetic
together clutch is too large, replace the electromagnetic clutch;
The electromagnetic The electromagnetic clutch can’t work: check if the electromagnetic clutch coil is
clutch can’t work broken, replace the electromagnetic clutch;
The refrigerant is leaking The refrigerant is leaked to the set value of low pressure switch, the low pressure
protection switch takes effect so that the compressor fails to start: check the
system leaking position and eliminate it;
The compressor bearing The compressor bearing is damaged or oil shortage: replace the compressor and
is damaged or oil fill up the refrigeration oil as required;
shortage
Cylinder sticking of Cylinder sticking of compressor; there may have foreign materials inside the
compressor cylinder or the piston position maybe changed after long-term abrasion that causes
the seizure or the oil shortage: remove the compressor for replacement;
368
Common Malfunction Diagnosis Flow of Geely Automobile
Normal
Abnormal
Malfunction of low pressure Overhaul or replace
switch
Abnormal
Malfunction of temperature Replace
controller
Abnormal
High pressure switch Overhaul or replace
Leaking
The refrigerant is Overhaul
leaking
Damaged
The compressor bearing is damaged or oil Replace
shortage
Abnormal
The compressor is of piston Overhaul or replace
seizure
Abnormal
Short circuit of ECU Replace the ECU
assembly
369
Common Malfunction Diagnosis Flow of Geely Automobile
Malfunction
Cause Solution
symptom
Manipulating key of the control 1).Manipulating key of the control mechanism and rocker on the shell
mechanism and rocker on the shell body are heavy: spread lubrication oil at the sliding part of each
The A/C control body are heavy revolving member.
mechanism is
hard to operate
The air throttle is ineffective in
2).The air throttle is ineffective in rotation: repair the air throttle.
rotation
Normal
Blocked
The air throttle is ineffective in Overhaul
rotation
The thermo expansion 1).The thermo expansion valve is in abnormal operation: replace the
valve can’t work thermo expansion valve;
.Thermo sensitive
resistance of the 3). Thermo sensitive resistance of the temperature controller is
temperature controller is mounted in incorrect position, so it is incapable of sensing the surface
mounted in incorrect temperature of the evaporator. Install the resistance in correct position;
position
The A/C evaporator is 4). Thermo sensitive resistance of the temperature controller fails so
frosting during the operation Malfunction of thermo that the compressor can not stop; uninterrupted refrigeration will lower
sensitive resistance of down the surface temperature of the evaporator. when the temperature
the temperature is below 0 degree, water vapor in the air flowing through the evaporator
controller will be frosting on external surface of the evaporator: replace the
thermo sensitive resistance;
Temperature of the
5).Temperature of the temperature controller thermo sensitive
temperature controller
resistance is set so low, causing surface temperature of the evaporator
thermo sensitive
below 0 degree to frost: replace the thermo sensitive resistance;
resistance is set too low
370
Common Malfunction Diagnosis Flow of Geely Automobile
Abnormal
The thermo expansion valve is in
abnormal operation Replace
Normal
Deficient
The evaporator is deficiency in draught Overhaul
Normal
Incorrect
Thermo sensitive resistance of the
temperature controller is in incorrect Re-mount
mounting position
Correct
Abnormal
Thermostat of the temperature controller is out of Replace
service
Normal
Abnormal
Design temperature of the temperature
controller thermostat is over low Replace
371
Common Malfunction Diagnosis Flow of Geely Automobile
A/C relay 1).The contact is superficial charring; 1).Connection check: bridge a wire at the suction position
2).The relay coil is burnt out; of the relay. If the compressor or the fan is in normal
3).The spring leaf is damaged and incapable of operation after the bridging, it means there is failure in the
sucking; relay;
2) Displacement method check: replace into a new relay
of the same type and specification to make the judgment
of the original relay. When replacing the damaged relay, it
shall adopt the relay of the same model and specification
and the relay position shall not be changed randomly;
Compressor 1).Cylinder sticking and cylinder scoring of Replace into a new compressor of the same model;
compressor; the link rod is breakout; the pulley
does not rotate or is hard to rotate; there has
abnormal sound;
2).Valve leaf and valve plate of the compressor
is damaged and there has abnormal sound;
3).The compressor sealing gasket is breakdown
that result in coalition between high and low
pressures; high pressure is the same as the low
pressure;
4).The compressor shaft seal is leaked that
causes large leakage of the refrigerant;
5).Pulley bearing is damaged. Ultra large belt Replace the electromagnetic clutch and adjust the belt
tension will generate too much radial bearing tensioning force;
force, and the suction cup will be seized with the
pulley thus damage the bearing;
9). The electromagnetic clutch is slipping; Reason of insufficient suction and its preclusion method:
suction between the pulley and the suction cup (1).The electromagnetic clutch is insufficient in the power
is inadequate that causes the slippage; supply voltage: recharge the battery;
(2).A/C relay is in poor contact: check the relay and
replace it if anything wrong with it.
(3).There has too much refrigerant or the compressor is
of piston seizure that causes excessive load; discharge
the surplus refrigerant or replace the compressor;
(4).The electromagnetic clutch has slipping sound caused
by the belt slippage; re-tension the belt;
Evaporator 1).The evaporator is leaking that causes the Replace the evaporator assembly or the evaporator.
shortage of refrigerant or no refrigerant; the
result is that the evaporator is insufficient in the
cooling volume or does not refrigerate.
372
Common Malfunction Diagnosis Flow of Geely Automobile
3) The ice block is caused by the moisture in the system and the
dirty block is caused by the impurities such as the aluminium chips in
3)The evaporator assembly is the system; result of the ice block is that the evaporator is not cool
blocked sometimes, while the result of the dirty block is that the evaporator is
not cool or is inadequate in the cooling volume: eliminate the
moisture or the impurities.
Condenser
2).There is impurity blockage
on the condenser heat Purge them with compressed air;
emission fin;
The block reason is the pulverizing of the drier as well as too many
impurities in the system; the phenomena is that the high pressure is
1)Dry reservoir assembly is
increased and there has apparent temperature difference between
blocked;
inlet and outlet of the dry reservoir assembly: replace the dry
Dry reservoir reservoir;
Thermo expansion valve maybe blocked so that the a/c will not
2)Filter screen inside the dry
refrigerate: replace the dry reservoir and check the thermo
reservoir assembly is damaged;
expansion valve;
373
Common Malfunction Diagnosis Flow of Geely Automobile
2).The connection is loose; Retighten the connection or replace the hose assembly;
Pipeline assembly
3).The connection thread is
Replace the hose assembly;
damaged;
Replace O seal ring. The above failures will cause the refrigerant
4).O seal ring is damaged;
leaking;
Replace the condenser fan (the above failure will cause deficiency in
fan draught or no draught of the fan so that the high pressure will be
5).The fan blade is battered abnormally high; deficiency in the blower draught or no draught of
the blower will cause the evaporator to frost, deficiency in heating air
or no heating air);
374
Common Malfunction Diagnosis Flow of Geely Automobile
375
Common Malfunction Diagnosis Flow of Geely Automobile
Solution to auto a/c Constant malfunction: Auto air-conditioning system of Vision and Leading
models are provided with failure self-diagnostic function. Some basic failures can be checked by
the self checking function. In addition, we have enumerated some familiar failure symptoms and
treatment processes, according to which you can find out the failure reasons and help your
clients to solve the problems.
No.273 Vehicle temperature sensor is in poor condition
(code display 01)
Yes
Power on and test if the voltage between B3 and B2 is0.5V≤Vi≤4.8V
Pull out B plug behind the control panel The a/c controller is in poor condition
Test the ohmic value between B3 and B2 of B plug at the harness end with the meter
Vehicle interior temperature sensor
Yes
Is the ohmic value between 500 and
100K?
B2 B3 No
1. Harness or metal plug-in connected with B3 and b2 is in B3 and B2 metal plug-in card inside B plug are in
poor condition; poor contact with the controller socket;
2. The vehicle temperature sensor is in poor condition.
Yes
Power on and test if the voltage between A12 and A11 is 0.5V≤Vi≤4.8V
No
Pull out A plug Aehind the control panel The a/c controller is in poor condition
Vehicle exterior temperature sensor Test the ohmic value between A12 and A11 of A plug at the harness end with the
meter
Yes
Is the ohmic value between 500K and
100K?
A11 A12 No
1. Harness or metal plug-in unit connected with A12 and A11 is A12 and A11 metal plug-in card inside A plug are in
in poorcondition; poor contact with the controller socket;
2. The vehicle exterior temperature sensor is in poor
condition.
A/C controller
376
Common Malfunction Diagnosis Flow of Geely Automobile
Yes
Power on and test if the voltage between B4 and B1 is 0.5V≤Vi≤4.8V
No
Pull out B plug behind the control panel The A/C controller is in bad condition
Test the ohmic value between B4 and B1 of B plug at the harness end with the meter
Vehicle exterior temperature sensor
Yes
Is the ohmic value between 500 and
100K?
B3 No
B2 B3
1. Harness or metal plug-in unit connected with B4 and B1 is B4 and B1 metal plug-in card inside B plug are in
in bad condition; poor contact with the controller socket;
2. The evaporator temperature sensor is in bad condition.
A/C controller
No
Yes
Yes
Does the voltage value
The A/C controller is in bad
A/C controller remain constant?
condition
No
1. The temperature adjustment 1. B10, B9 and B13 wires inside B plug are in poor
performer is in bad condition; contact with the performer or broken;
2.The A/C controller is in poor condition 2. The temperature adjustment performer is in bad
condition or the mechanism is seized;
3. The A/C controller is in bad condition.
377
Common Malfunction Diagnosis Flow of Geely Automobile
Yes
Power on and test if the voltage between B2 and B5
is0.7V≤Vi≤4.85V
No
1. Pull out B plug behind the control panel; let the light sensitive
head fully exposed under the sun;
1.Pull out B plug behind the control panel; 2. Connect B5 pin at the harness end B plug with the digital
2.Cover the light sensitive head of the sun sensor
multimeter red pen and connect B2 (ground lead) with the black
with a light-tight object.
A/C controller pen.
Yes
Test the ohmic value between B2 and B5 of B plug at Test if the ohmic value between B5 and B2 is
the harness end with the meter reduced apparently?
No
Yes
Is the ohmic value less than 100K? The sun sensor is
in poor condition.
No
故障6-
No.278 The fan governing module is in poor condition;
(code display 06)
40A 800 power line (2)
GAUSE meter
3BW
Fan relay
Blower
speed regulation module
Test the voltage between B7 and B2 with a meter from gear 1 to gear 5. The normal
voltage shall be as follow: 3.9V at gear 1; 4.0V at gear 2 and 4.3V at gear 3; 4.5V at
gear 4; 4.8V at gear 5.
black
E
blue/brown
grey/brown
Yes
blue/black
No
A/c controller 1.The harness connected with 1The governing module is in poor
B7 and the plug-in unit are in condition;
poor condition; 2.The plug-in unit at DS end of the
2.The a/c controller is in poor governing module is in poor contact.
condition.
378
Common Malfunction Diagnosis Flow of Geely Automobile
No.279 The high speed relay is in poor condition; (code display 07)
Blue
M
Yes
Is voltage value at gear 5 or gear 6 close to 0V?
black No
E
1.The GAUSE meter wire is in bad condition;
grey/brown
blue/black
blue/brown
contact;
No 3. The high-speed relay is in bad condition.
A/c controller
1. The controller card connected with B6 1. The high-speed relay socket is in bad
at light on.
A3
A/C controller
1. The A3 plug-in unit is in bad contact with the 1. The rear defrosting relay socket is in bad
controller socket; contact;
2. The a/c controller is in bad condition;
2. The rear defrosting relay is in bad condition;
3. The rear defrosting heater and concerned
harness problem.
379
Common Malfunction Diagnosis Flow of Geely Automobile
380
Common Malfunction Diagnosis Flow of Geely Automobile
381
Common Malfunction Diagnosis Flow of Geely Automobile
382
Common Malfunction Diagnosis Flow of Geely Automobile
383
Common Malfunction Diagnosis Flow of Geely Automobile
1. There is too much air mixed in the system. Vacuumize again and refill the refrigerant.
1. There is insufficient refrigerant filled. Add the filling volume of the refrigerant.
Both high pressure and Make the leak check and replace the
low pressure are too low 2. The refrigerant is leaking.
leaked spare.
1. The expansion valve is in over size opening or is Adjust the opening of the expansion valve
damaged. or replace with a new expansion valve.
The high pressure is
normal and the low
pressure is too high 2. Too much refrigerant filled. Discharge the surplus refrigerant.
384
Common Malfunction Diagnosis Flow of Geely Automobile
1. The low pressure increase fast after the power off- the Replace with a new liquid storage
The high pressure is low system is ice blocked. drying bottle.
yet the the low pressure is
of negative pressure
2. The low pressure increase slowly after the power off -
Clean the system.
the system is blocked.
1. The evaporator temperature sensor is in poor Replace the sensing head or check if its
condition. position is correct.
4. Air capacity passing through the evaporator is Inspect if the fan rotation speed is
inadequate. normal.
385
Common Malfunction Diagnosis Flow of Geely Automobile
Vacuumizing
Leak Remain it for at least 72 hours after the vacuum degree is 745mmHg
detection
Close the manifold pressure gauge and watch for 5 minutes without felling back
being occurred
Fill in the refrigerant The liquid refrigerant can be filled from the high pressure side per the regulation
before the system start-up; gaseous refrigerant must be filled from the low
pressure side after the system start-up.
386
Common Malfunction Diagnosis Flow of Geely Automobile
Correct
387
Common Malfunction Diagnosis Flow of Geely Automobile
388
Common Malfunction Diagnosis Flow of Geely Automobile
Open Open
Fig 4-2 Structure of manifold pressure gauge
1 high pressure gauge 2 low-pressure gauge, 3 manual low pressure valve, 4 manual high-pressure valve, 5
valve body, 6 high pressure connection, 7 refrigerant vacuumizing connector
8 low-pressure connector
Usage of the refrigerant charging valve
A charging valve is installed on the inlet and the exhaust pipes of the sedan air conditioning compressor. Its
operating principle is identical to that of the valve core on the tire. During the usage, tighten the quick joint of
the charging hose into the port of the charging valve so that the needle is pressed open; the air-conditioning
system is connected with the detection used hose with the refrigerant flows into it; the charging valve can be
closed automatically when the detection used hose is removed.
Routine method to check the leakage of air conditioning refrigerant
Leak-detection methods generally used in the vehicle air conditioning refrigeration system are nitrogen
supercharging leak detection, vacuum leak detection, charging leak detection, instrument leak detection and
appearance leak detection.
1). Nitrogen supercharging leak detection: charging the nitrogen into the refrigeration system and apply the
soap water at the leak detection position. The soap bubble will be generated when there is the leakage. The
compressed air is strictly prohibited when the supercharging leak detection is adopted. This is because there is
moisture in the compressed air and will cause the ice block at the thermal expansion valve when the moisture
enters into the system along with the air. The industry nitrogen is non-corrosive, moisture-free and low in price,
yet bottle high pressure nitrogen gas must be provided with a decompression adjuster to adjust the air out
pressure. When the system reaches the specified 1.0 Mpa, apply the soap bath at each joints and welding
points of the system to observe the leakage carefully. There is tiny sound at large leakage area with big foam
and there is discontinuous small foam at small leakage area. The leak detection must be made carefully and
repeated for 3 to 5 times. The leaking position shall be marked and restored in time, then the leak detection
can be made at other joints until the leakage is eliminated totally. The leak-off-test shall be made after the
leakage is restored, i.e. the system is kept the pressure for more than 0.5 hours. The leak-off-test is accepted
when the pressure does not reduce; the leak detection must be made once again if the pressure reduces
greatly until the leaking area is found and restored.
Leak-off-test pressure of the refrigeration system is 1.5 ~ 1.7Mpa. Take care when checking the leak.
2). Vacuum leak detection: it shall be made adopting the vacuum pump. The vacuum pressure shall be lower
than 100Pa and constant. It is acceptable when the vacuum pressure is not increased remarkably during
relatively long time.
3). Filling leak detection: it can be made following the vacuum leak detection. The leak detection is carried out
by the electronic leak detector after little refrigerant is charged. The indicator will light up and give out an alarm
when the refrigerant is leaking.
4). Appearance leak detection: normally there is the refrigeration oil leaked out at the refrigerant leaking
389
Common Malfunction Diagnosis Flow of Geely Automobile
locations. A clean plain paper can be used to wipe it off or the hand can be used to inspect it directly. It means
the refrigerant leakage when the oil stain keeps on leaking.
Locations where air conditioning refrigerant leakage often occurs
Operating condition of the air conditioning is normally rough. Its refrigeration system keeps on vibrating along
with the vehicle operation, hence the pipeline is easy to be damaged and the joint is loose thus causing the
refrigeration leakage. The general leaking locations are shown as the following table.
Locations where air conditioning refrigerant leakage often occurs
Assembly Leaking parts
Connection of the condenser air inlet pipe and the liquid outlet pipe
Condenser
Welding of the condenser flat pipe and the collector pipe
Connection of the evaporator air inlet pipe and the liquid outlet pipe
Evaporator
Fusible plug
Liquid storage dryer
Connection of the evaporator liquid inlet pipe and the liquid outlet pipe
390
Common Malfunction Diagnosis Flow of Geely Automobile
391
Common Malfunction Diagnosis Flow of Geely Automobile
maintained. However, the refrigeration oil must be added when parts of the refrigeration system are replaced
and severe leakage of the system is precluded. There are two methods to fill the refrigeration oil as follows: (1)
Shut down the air conditioning and fill the refrigeration oil utilizing the filling port on the compressor; screw out
the filling port bolt and pour the required refrigeration lubrication oil into the filling port and then tighten the
filling port bolt.
(2) Detailed operation methods of charging the refrigeration oil when the vacuumizing is made are as follows:
Fig. 4-4 Filling the refrigeration lubrication oil with vacuumizing method
1- the manual low pressure valve is closed 2- the manual high pressure valve is opened
3- exhaust the air 4- vacuum pump 5- refrigeration lubrication oil
a. Select a graduated cylinder to contain the refrigeration oil of the volume more than required.
b. Screw down the hose connected with the low pressure charging valve from the manifold pressure gauge
and insert it into the measuring cylinder containing the refrigeration oil. As shown in Fig.4-4.
c. Startup the vacuum pump and open the manual high pressure valve on the manifold pressure gauge. Added
refrigeration oil will be sucked into the compressor through the suction pipe via the charging valve at the low
pressure side. Stop the suction of the vacuum pump and close the manual high pressure valve when the
refrigeration oil volume has reached the specified volume.
d. After the refrigeration oil is added per the vacuumizing method, the refrigeration system shall be vacuumized
and the refrigerant shall be added.
2) The following notices shall be taken care when the refrigeration oil is used: (1). The refrigeration oil is easy
in water absorption so the lid must be tightened right after the refrigeration oil is used
(2). Deteriorate turbid refrigeration oil is not allowed, or else it will influence the normal operation of the
compressor.
(3). Excess refrigeration oil is not allowed to be added into the system, or else it will influence the refrigerating
capacity of the vehicle air conditioning refrigeration system.
(4) The refrigeration oil must be of the grade specified in the compressor instruction of that model.
3) Correlation method and dripping method can be adopted to judge the quality of the refrigeration oil: (1).
Correlation method: put clean and standard refrigeration oil into a test tube as the standard oil and put the oil to
be checked into another test tube of the same size to make the comparison. Provided the oil to be checked is
of light yellow or of saffron yellow, it can be used, however the turbid solution of rufous color can not be used.
(2). Dripping method: drip one drib of the refrigeration lubrication oil to be checked on a clean plain paper and
watch its color. It means there is no impurity in the oil if its color is light and even; the oil can be used.
392
Common Malfunction Diagnosis Flow of Geely Automobile
Fig. 4-5 inspection to the refrigeration lubrication oil volume of the sedan air conditioning compressor
1- oil filling plug 2- Filling port 3- oil dipstick
Provided there is no oil filling plug hole in the compressor, the oil shall be poured into a measuring cup to
make the comparison with the oil charge volume specified in the instruction to judge if the compressor is
required to add the oil. Generally oil content in the compressor shall not be less than 1/3 oil charging volume
specified in the instruction, or else the oil shall be added. Compressor provided with the oil charging plug hole
can also adopt this method, but the compressor assembly must be removed from the air-conditioning system.
393
Common Malfunction Diagnosis Flow of Geely Automobile
effect of the condenser thus cause the condensing pressure and temperature over high, simultaneously low
pressure of the system is high that causes the refrigerating capacity of overall system being reduced, so that
air in the system shall be removed timely with the preclusion methods as follows:
1). Drain out the refrigerant inside the system.
2). Inspect the refrigeration system for any leakage and eliminate it.
3). Pump out the air in the system repeatedly with the vacuum pump.
How to dismount the sedan air conditioning compressor
When the air conditioning compressor is breakdown, most failure parts shall be dismounted to carry out the
repair or the replacement except very few failure parts can be maintained on the vehicle instead of
dismounting the compressor. The dismounting steps and requirements are as follows:
Steps of dismounting the compressor from the compressor frame:
(1). Dismount the connecting wire of the electromagnetic clutch.
(2) Drain out the refrigerant from the refrigeration system.
(3) Remove the hoses at intake and exhaust port of the compressor; the hose as well as intake and exhaust
ports of the compressor shall be covered to prevent the dust and the water vapor from being entered into the
system.
(4) Dismount the driving belt of the compressor.
(5) Remove the compressor fastening screw and the compressor from the compressor frame.
(6) Pour out the oil inside the compressor and measure the oil output with the measuring cylinder to judge if it
is required to add the oil and inspect the oil for any discoloration as well as any impurities in the oil.
Inspection to the air conditioning control system
The air conditioning control system can be checked according to the following methods: power→ ignition→
switch→ fuse cutout→ relay→ air conditioning switch ( fan switch, temperature detect switch)→temperature
control circuit→pressure switch circuit→electromagnetic clutch→fan→electric machine. After the ignition
switch is turned on, the current flows into the air conditioning switch through the fuse cutout and is branched.
One branch flows into the evaporator blower motor and the other branch flows into the compressor
electromagnetic clutch through the temperature controller and the pressure switch circuit. When malfunction
is found in the auto security protection, the fuse shall be checked first for any burn-out; If it is in normal
condition, control switch of the blower shall be turned on to inspect if the blower plug is in good contact, the
blower governing resistance is in open circuit and the blower motor is damaged; If the blower is in normal
operation, then finally check the control circuit of the electromagnetic clutch, the high and low pressure switch,
the temperature controller as well as the electromagnetic clutch for any failure; eliminate any failure existed.
How to inspect the vehicle air conditioning thermo expansion valve
Inspection steps of the vehicle air conditioning expansion valve (take F type thermo expansion valve as an
example) are as follows:
1). Eliminate the refrigerant in the system and remove the thermal expansion valve from the refrigeration
system.
2). Supply the nitrogen with certain pressure (e.g. 0.05Mpa) at the high pressure inlet side of the thermal
expansion valve. If there is no gas flowing out from the low pressure outlet side, it means the thermal
expansion valve is out of service.
3). Then immerse the thermo bulb of the thermal expansion valve into warm water and enhance the water
temperature; opening of the thermal expansion valve shall be increased (pressure at the low-pressure side is
increased, i.e. the gas flow rate is increased), or else it means media inside the thermal expansion valve power
head is leaked or the thermal expansion valve is blocked by impurities, then the thermal expansion valve shall
be replaced.
4) The blocked thermal expansion valve shall be disassembled to determine the impurity nature.
Other notices in repairing the vehicle air conditioning
1). Operation environment: cleanness and moistureproof shall be paid attention to when the air conditioning is
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Common Malfunction Diagnosis Flow of Geely Automobile
checked. Dirt, dust and moisture shall be prevented from entering into the air-conditioning system. Areas
around the assembling unit and the joint shall be cleaned out and rainy day maintenance shall be avoided.
2). Usage of the refrigerant: the refrigerant shall be stored in places of low temperature and dry when the
refrigerant cylinder is stored and transported. It shall not be brought into locations with open flame such as the
welding, nor exposed under the sunshine. Directly heating to the refrigerant cylinder or putting it into the hot
water over 40 Celsius degree is strictly prohibited. The protective glasses shall be worn when the refrigerant is
filled to avoid the eye frost damage. Please be noted that it shall not be contact with the skin. Provided the
refrigerant is contacted with accidentally, a great deal of fresh water shall be used to rinse the contact area
quickly to prevent the frost damage and ask for medical care as soon as possible. Manual high pressure valve
on the manifold pressure gauge is strictly prohibited to open when the engine is in operation. The refrigerant
will back flow into the refrigerant tank that cause the explosion. When the gaseous state refrigerant is charged
from the low pressure side during the engine running, the refrigerant cylinder is not allowed to upend to avoid
the compressor "cylinder slugging". The manifold pressure gauge shall be used to drain out the refrigerant
inside the system from the low pressure side. The refrigerant shall be exhausted slowly with the time interval
not less than 15 minutes to prevent the refrigeration oil from being drained out along with the refrigerant.
3). Operation to the refrigeration system pipeline: the pipeline or the joint shall be capped after the pipeline is
dismounted to prevent the moisture and the dust from entering into it. The bending radius shall be as large as
possible when the pipe is bent; the pipe orifice shall be remained leveling and clean when the pipe is cut and
scraps inside the pipe shall be cleaned out; The trichloroethylene liquid shall be used to clean the pipeline, and
the pipeline shall be dried sufficiently; The refrigeration oil shall be applied at the joint and the O-ring when the
pipeline is connected; two wrenches shall be used to tighten or unscrew the pipeline joint.
4). Operation to the control wire: the battery ground wire (negative wire) shall be dismounted when the repair
work is made to the air conditioning to prevent the circuit short circuit during the refrigeration system repair.
Replaced wires shall be fixed by the adhesive tape and the original fasteners; wires of original color and
original diameter shall be preferred; the wire is not allowed to close to high temperature objects such as the
engine.
There is several methods of judging the constant malfunction of the vehicle air conditioning as follows:
1). Hand feeling inspection: the failure is judged mostly by feeling the temperature of the parts by hand. High
pressure loop (from the compressor outlet, the condenser and the dry reservoir to the thermal expansion valve
outlet) shall be in a thermal behavior (50℃~ 70℃) when it is touched; if certain location is exceptionally hot or
there is apparent temperature difference between the inlet and the outlet, it means there is the blocking. The
low pressure loop (from the thermal expansion valve outlet, the evaporator and the compressor inlet) shall be
cool (0℃~ 5℃) when it is touched. Provided there is no apparent temperature difference between the high
pressure side and the low pressure side, it means there is the leakage in the system or the compressor is
broken down.
2). Visual examination: inspect each pipeline joint, compressor shaft seal, condenser and evaporator surface
for any oil stain; the system has the leakage if there is any oil stain.
3). Sight glass inspection: observe and inspect the refrigerant state via the sight glass installed on the dry
reservoir or the pipeline. The refrigerant shall be clear and bubble free, and the evaporator air outlet shall be
cold under normal condition. It means that the refrigerant is highly inadequate when it is clear and bubble free
yet the air outlet is not cold; is means that the refrigerant is inadequate when it is clear and has bubble in it, yet
the air outlet is not cold enough.
4). Leak detection made by the electronic leak detector: electronic leak detector is used to inspect each joint
of the overall system for any leakage.
5). Inspection made by the multi-meter: the multi-meter can be used to check out the air conditioning circuit
breakdown and judge the broken circuit or the short circuit.
6). Manifold pressure meter: connect the manifold pressure meter with the system high and low pressure
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Common Malfunction Diagnosis Flow of Geely Automobile
valves to judge the breakdown of the refrigeration system. The inspection shall be made when the air
temperature is between 30 ~35oC and the engine speed is 2000r/min. The fan wind speed is adjusted to the
high gear and the temperature is adjusted to the Max. refrigerating gear. The normal condition is that: the
pressure at the high-pressure side is 1.2Mpa ~ 1.8Mpa and that at the low-pressure side is 0.15 Mpa ~
0.20Mpa; the system may have a failure if it is out of this scope. 7). Other inspection methods
(1) Condenser: the thermometer is used for thermometer under normal operation. When the condenser air-in
temperature is about 35oC, the air-out temperature shall be about 55oC.
(2) Continual reduction of the air volume at the air outlet means the frosting on the evaporator surface.
(3) Dry reservoir: inconsistency of the temperature on upper and lower side of the dry reservoir shell means
there is the block inside the dry reservoir.
Are the main fuse and the line fuse in good condition Go to step 2 The main fuse and the line fuse is
1 or not ? broken
1. Turn on the ignition switch Go to step 3 “B/W” wire is broken or short circuit
2. Inspect the voltage between the terminal "A6"
2 and the module case earthing
3、Is it the battery voltage?
1. Check the voltage between the terminal "A8" and Go to step 4 "B/R" wire is broken or short circuit
the module case earthing
3 2. Is it the battery voltage?
1. Turn off the ignition switch and disconnect the Go to step 5 The bulb is burnt out or the "V/G" wire is
connector 8 from the control module broken
2. Disconnect the body ground terminal "A3" on the
connector "8" body
4 3. Turn on the ignition switch again, is the "EPS"
lamp light up?
1. Is the connection between the connector "8" and Terminal “A6”,“A7” Poor connection
the control module firm? " A3 " or " A8 " is in
poor contact; the
5 control module case
is in poor earthing;
"B" wire
+12V is broken
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Common Malfunction Diagnosis Flow of Geely Automobile
1. If terminal "A2" of the connector "9" is perfectly connected to Go to step 2 Poor contact
1 the control module
1. Earth the "A2" terminal by wire under the condition that the 1、The maintenance line Recheck it with replaced
connector is connected with the control module is broken control module
2 2. Turn on the ignition switch, is the "EPS" lamp flicking? 2、. "B/W" line is broken
or "B" line is in poor earth
No.293 Main line of DTC11 torque sensor (the main line is broken or
short circuit)
Step Operation Yes No
1、Remove the protective cover of the steering column hole 1. "W" wire is broken Go to step 2
2、 Turn on the ignition switch and put the steering wheel 2. Terminal "B5" is in poor
towards the right front direction of the vehicle, and check if connection
the terminal voltage of the torque sensor bar foot center "B5" 3. Recheck it with replaced
1 wire is about 2.5V. control module if the above
conditions are normal
1. Close the master switch and disconnect the torque sensor 1. "W" wire to the battery is The torque sensor has
rod head short circuit or earthed defects
2 2. Check the resistance between terminals "B5" and "B2" of 2. The torque sensor connector
the torque sensor is in poor contact with the line
3. Whether it is about 0.96kΩ
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Common Malfunction Diagnosis Flow of Geely Automobile
1 1)Remove the protective cover of the steering column hole Recheck it with replaced control Go to step 2
2)Turn on the ignition switch and check the voltage between module
"R" wire of the torque sensor connector and the terminal
ground
3)Is it about 5V?
2 1)Turn off the ignition switch and disconnect the torque 1) Terminal "B2" or "B3" is in The torque sensor
sensor connector poor connection is broken down
2) Check the resistance between "R" wire of the torque 2) Harness of the torque sensor
sensor connector and the terminal ground plug-in unit is in poor contact
3)Is it about 1.09 KΩ? 3) "R" or "G" line is disconnected
4) "R" or "G" line is grounded and
the battery are short
1)Remove the protective cover of the steering column hole 1)"B" wire is disconnected
2) Turn on the ignition switch and put the steering wheel to 2)Terminal "B4" is in poor contact
1 the front moving position of the vehicle; check the voltage of 3)Recheck it with replaced control Go to step 2
"B" terminal on the torque sensor connector. module if the above conditions
3)Is it about 5V? are normal
1 Does the tachometer display the engine speed Go to step 2 1)The connector is in poor
signal? connection or the line is
0-1V broken
2 ) There is no rotation
speed signal output in ECU
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Common Malfunction Diagnosis Flow of Geely Automobile
2 1 ) Remove the control module and connect the "A4" is in poor connection; "Br" line is broken
control module connector when the ignition switch is replace with a good control
off. module if the connection is
2)Check the voltage between "A4" terminal of the normal
control module and the earthing when the ignition
switch is on; check the resistance between "R" line of
the torque sensor connector and the terminal ground
3)Is it 8~12V?
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Common Malfunction Diagnosis Flow of Geely Automobile
DTC21Vss line (the engine runs at 2500 R.P.m or higher for continuous 60 seconds (the rotation speed is
4000 R.P.m or higher when the engine is started) and there is no vehicle high speed signal input)
DTC23Vss line (the engine runs at 2500 R.P.m or higher for continuous 60 seconds (the rotation speed is
4000 R.P.m or higher when the engine is started) and there is no vehicle high speed signal input)
DTC24Vss line (the engine is beyond the standard level for continuous 5 seconds/there is no vehicle speed
input)
DTC14 torque sensor (supply voltage of the torque sensor is too high or too low)
Step Operation Yes No
Does the speedometer display the speed 1)"A5" is in poor connection with "V" Replace with a good
signal? harness vehicle speed sensor
1 2)Replace the control module to recheck if
the connection is all right
No.299 DTC41 motor (the motor voltage is too high or too low)
1)Dismount the hole cover of the steering column Go to step 3 Motor failure
2)Disconnect the motor and the clutch connector
when the ignition switch is OFF
2 3)Check the conductivity between terminals of the
motor
4)Is it conductive?
3 1) Check the resistance between the motor and 1)"R" or "B" line is disconnected Motor failure
the clutch as well as the body ground 2)"R" or "B" line is short to
2) Is it infinite? ground
3 ) The connector is in poor
contact
4)Replace with a perfect control
module to recheck provided the
above phenomena are normal
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Common Malfunction Diagnosis Flow of Geely Automobile
1) Check the resistance between the 1)"B/B1" or "B/R" line is disconnected Clutch failure
motor and the clutch connector as well 2)"B/B1" or "B/R" to ground is short
as between the motor and the ground 3)The motor and the clutch connectors are in poor
2) Is it infinite? contact
2 4)"A9" and "A10" terminals are in poor contact
5)Replace with a perfect control module to recheck
provided the above phenomena are normal
1)Remove the control module and connect the control 1)"A7" terminal is in poor contact Battery failure
module connector when the ignition switch is off. 2) Replace with a perfect control
2)Check the voltage between "A7" terminal of the module to recheck provided the
1 control module and the ground when the ignition switch above phenomena are normal.
is ON.
3)Is it 10-14V?
Replace with a good control module and recheck; Inspection to the control module and its line: the control
module and its line can be inspected by measuring the voltage and the resistance of the module connector;
The multi-meter is strictly prohibited to measure the control module under the condition of disconnecting the
module connector.
1)Remove the control module from the body when the ignition switch is OFF
2)Connect the control module connector to the control module
3)Inspect each terminal voltage of the connector according to the following table
4)Voltage of the battery is confirmed to be 11V or higher when the ignition switch is in ON position
Terminal Line Normal voltage Malfunction symptom
A6 Voltage of the ignition switch control 10-14V Engine operates at idle speed
A5 Vss 0-1V and 4-6V The front left tire rotates greatly under the
condition of ignition switch being ON and the
front wheel being locked
B2 Power supply of the torque sensor About 5V Inspect the voltage between "B2" and B3 when
the ignition switch is ON
B1 Blank —— ——
A3 "EPS" failure indicating lamp 0-2V, 10-14V "EPS" lamp lights up or off when the engine
operates at idle speed
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Common Malfunction Diagnosis Flow of Geely Automobile
A9 Clutch plus 10-14 The engine operates at idle speed and the
steering wheel is fixed in straight ahead position
of the vehicle
A4 Engine signal —— ——
B4 Torque sensor plus About 2.5V The engine operates at idle speed, direct
moving direction, the voltage between "B4" and
"B3" terminals
B5 Torque sensor minus About 2.5V The engine operates at idle speed, direct
moving direction, the voltage between "B4" and
"B3" terminals
A11 Motor output plus 5-7V The engine operates at idle speed, the steering
wheel is fixed to direct moving position of the
vehicle
A12 Motor output minus 5-7V The engine operates at idle speed, the steering
wheel is fixed to direct moving position of the
vehicle
A1 Blank —— ——
1)The steering column assembly can not be disassembled. Provided any part is found to have defect, the
whole assembly shall be replaced.
2)It must be noticed not to cause the impact when the steering column assembly is replaced.
Chart of connector functions
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Common Malfunction Diagnosis Flow of Geely Automobile
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Common Malfunction Diagnosis Flow of Geely Automobile
No
Can it communicate?
Normal
End
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Common Malfunction Diagnosis Flow of Geely Automobile
Turn the ignition switch to "ON" (the engine is in stall state) and the ABS alarm lamp does not light up 1
The alarm lamp does not light off when the engine starts up 2
ABS is in operation when the brake pedal is stamped slightly (the vehicle is
ABS is in abnormal in stationary state)
3
operation
ABS is in operation when the brake pedal is stamped slightly (the vehicle is
in driving state)
There is no malfunction code output (communication with the malfunction diagnosis instrument is
6
unavailable)
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Common Malfunction Diagnosis Flow of Geely Automobile
Note:
The motor is incapable of being driven if the battery is of excess discharging, so the battery voltage must be
confirmed to be normal before the motor driving test is made. The vehicle must be at the stationary state
when the motor driving test is made.
Unplug the motor harness and connect
the battery power directly to the motor Abnormal
plug, does the motor still operate?
Replace the hydraulic control unit
Normal
Abnormal
Inspect the fuse and the ABS ECU joint Replace the fuse or the harness
Normal
No
Yes
Does the failure recur? Replace the electronic control unit
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Common Malfunction Diagnosis Flow of Geely Automobile
No.309 The malfunction codes are 00283, 00285, 00290 and 00287
(mechanical malfunction)
2 Malfunction codes: 00283, 00285, 00290 and 00287 (mechanical Possible cause
malfunction)
[Description] The malfunction code will appear when open circuit of the return z Miss installation of the sensor
can not be checked out and there is no signal output when the speed is above z Short of the sensing coil or the harness
20km/h. z Ultra big of the air gap between the
[Prompt] It may be caused by miss installation of the sensor, short of the sensor sensor and the tooth ring
coil or the harness, ultra large air gap between the sensor and the tooth ring, or the z Miss installation of the tooth ring
damage or the tooth ring. z Malfunction of ABS ECU
No
Is the sensor installation correct? Install it correctly
Normal
Normal
Abnormal
Inspect each sensor tooth ring
Replace ABS ECU Replace it
Normal
Normal
408
Common Malfunction Diagnosis Flow of Geely Automobile
[Description] The malfunction code will appear if the sensor signal is out z Intermittent poor contact or short of the
of tolerance when the speed is larger than 20km/h. sensing coil or the harness
[Prompt] The probability is that the weak sensor signal is cause by the z Ultra big or ultra small of the air gap between
intermittent poor contact or the short of the sensing coil or the harness, the sensor and the tooth ring
damage of the tooth ring teeth and ultra large of the air gap between the z Damage of the tooth ring teeth
tooth rings. z Ultra big of the bearing clearance
z Malfunction of ABS ECU
Incorrect
Is the sensor installation correct? Install it correctly
Correct
Inspect the sensor output voltage at Abnormal Inspect each wheel sensor Abnormal
the ABS25 core socket Replace
Normal
Normal
Abnormal
Inspect the tooth ring of each
Replace ABS ECU wheel sensor Replace
Normal
Normal
409
Common Malfunction Diagnosis Flow of Geely Automobile
[Description] The malfunction code wil appear when there are failures z Connector or coil of the sensor is of open circuit
such as the recognizable open circuit or short circuit existed in the z The sensing coil is short
sensor. z The sensor plug, the harness, the earth or the
[Prompt] It is likely that the sensor is in poor contact, the coil or the power is short
harness is short, or there is a failure in the sensor signal treatment circuit z Treatment circuit of ABS ECU sensor signal is
in ABS ECU. out of order
Normal Abnormal
Abnormal
Remove the ABS ECU plug Inspect the corresponding
Inspect if the resistence value sensor plug Repair the connector
between the following terminals of
ABS ECU meets the standard
value?
Standard value: 1.0 ~ 1.3 k Normal
Shake the sensor harness and the No Refer to the gist
Does the malfunction recur? of the incidental
joint simultaneously when trouble
measuring the resistance. maintenance
MK20 I:
Yes
Left front: 4 - 11
Right front: 3 - 18 Inspect the harness between
the sensor and ABS ECU
Left rear: 2 - 10
Right rear: 1 – 17
MK20 I/E:
Left front: 1 - 2
Right front: 19 - 20
Left rear: 5 - 6
Right rear: 22 – 23
Normal
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Common Malfunction Diagnosis Flow of Geely Automobile
[Description] The malfunction code will appear when the ECU software z Error of jumper connection in ABS harness
z Error of ABS ECU code
code is different from the hardware jumper connection of ABS harness.
Correct
[Description] The malfunction code will appear when there is no z Fuse of ABS system is blown out
z The battery voltage is over low or over high
voltage or over high voltage on the power supply terminal 30.
z Connector of ABS harness is damaged
z ABS ECU is damaged
411
Common Malfunction Diagnosis Flow of Geely Automobile
Normal
Abnormal Abnormal
Disconnect the connection between Inspect ABS harness connector Repair the
ABS harness and ECU, turn the
connector
ignition switch to "ON" and measure
the voltage between the following
terminals of ABS harness Normal
Terminals 8 and 9: 9.5 – 16.5V
Terminals 24 and 25: 9.5 - 16.5V Refer to the incidental trouble No Check the battery
MK20 I: Retry. Does the abnormal voltage
Terminals 8 and 23: 9.5 –16.5V condition recur?
MK20 I/E:
Terminals 8 and 4: 9.5 –16.5V
Yes
Normal
[Description] The malfunction code will appear when ABS is z High frequency electromagnetic
interfered by the high frequency electromagnetic wave or the interference
microprocessor regards the input speed signal as false. z The sensor or the sensor harness is
damaged
z ABS ECU is damaged
Abnormal
Abnormal
Inspect output voltage of the sensor Inspect the sensor Replace the sensor
Normal
Normal
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Common Malfunction Diagnosis Flow of Geely Automobile
[Description] ABS alarm lamp does not light up. It might be caused by the z The fuse is burnt
open circuit of the alarm lamp power return, burnt out of the bulb or damage z Bulb of ABS alarm lamp is
of the alarm lamp controller. burnt
z The power circuit is broken
z ABS alarm lamp controller is
damaged
Abnormal
Check the ABS alarm lamp fuse in
the central electric appliance box
Replace it
Normal
Abnormal
Inspect the fuse socket of the Repair the fuse socket
central electric appliance box
Normal
No
Normal
Abnormal
Yes Inspect the connector of the
alarm lamp power return and Repair the connector
the earth return
Replace the harness
Normal
No
See the maintenance
Does the failure recur? importance of
incidental trouble
Yes
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Common Malfunction Diagnosis Flow of Geely Automobile
No.316 The ABS alarm lamp is normally open after the engine starts
2 The ABS alarm lamp is normally open after the engine is started. Possible cause
[Description] The possible cause is that ABS alarm lamp controller is z The alarm lamp controller is damaged
damaged or the ABS alarm lamp return is open. z Return of ABS alarm lamp controller is open
z ABS ECU is damaged
Note: this failure mode confines to the condition of the system being capable of communicating with the failure
diagnosis instrument (power supply of ABS ECU is normal) and no malfunction code appeared.
No
Normal
[Description] This problem is closely related to the driving condition z The sensor is of improper installation
and the road surface, therefore the failure diagnosis is difficult to be z There is something wrong with the sensor harness
made. However the following inspections can be made provided there z The sensor is damaged
is no malfunction code memory. z The tooth ring is damaged
z The sensor is stained with foreign materials
z The wheel bearing is damaged
z ABS HCU (hydraulic unit) is damaged
z ABS ECU (electric control unit) is damaged
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Common Malfunction Diagnosis Flow of Geely Automobile
Yes
Abnormal Abnormal
Inspect each sensor
Inspect output voltage of the sensor Replace it
Normal
Abnormal
Normal
Inspect each sensor tooth ring Replace it
Normal
No Refer to the
Does the failure recur? maintenance gist
of incidental
trouble
Yes
415
Common Malfunction Diagnosis Flow of Geely Automobile
[Description] Visually inspect if there is any exterior z The braking fluid is leaked
leakage or mechanical failure. Check if there is air in the z The normally closed valve is leaked
system by the air exhausting method. Check if the normally z There is air in the system
closed valve is leaked with the function test of failure z The brake disc is of heavy wear
diagnosis hydraulic unit. z The hand braking is improper adjusted
Abnormal
Visually inspect if the hydraulic pipe joint is leaked Tighten the pipe joint as required
Normal
Normal
Normal
Abnormal
Air exhaust inspection Carry out the air exhaust again
Normal
416
Common Malfunction Diagnosis Flow of Geely Automobile
[Description] Inspect the stroke of the booster and the brake pedal with conventional z There is something wrong with the
method. Failure of the normally open valve can be inspected with the function test of the booster
failure diagnosis hydraulic pressure unit. z There is something wrong with the
normally open valve
Normal
6 There is no malfunction code output (communication with the failure Possible cause
diagnosis instrument is unavailable)
[Description] ABS ECU power return or the diagnostic line return is open z The fuse is burnt
z The diagnostic line is broken or the joint is
when the communication with the failure diagnosis instrument is unavailable.
loose
z ABS ECU is damaged
z There is something wrong with the failure
diagnosis instrument
417
Common Malfunction Diagnosis Flow of Geely Automobile
Is the failure diagnosis instrument There is something wrong with the failure diagnosis
capable of communicating with MK20 No instrument
ABS ECU on other vehicles Carry out the inspection after the repair
Yes
Abnormal
Inspect ABS power fuse
Replace it
Normal
Yes
Conductive
418
Common Malfunction Diagnosis Flow of Geely Automobile
Terminal
Ignition switch
Inspection items Standard value Unit
gear
MK20 I MK20 I/E
Battery voltage
↑ 9 – 24 ↑
(electromagnetic valve) V
ECU connected
The alarm lamp lights
up, and lights off after Visual inspection
ON
1.7 seconds
419
Common Malfunction Diagnosis Flow of Geely Automobile
420
Common Malfunction Diagnosis Flow of Geely Automobile
Note: there must have the vacuum acting on the vacuum booster when the following inspections are made.
421
Common Malfunction Diagnosis Flow of Geely Automobile
Input relevant vehicle code at code input (see ABS elementary diagram MK20,
No.01901, and MK60, No.0004097)
End
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Common Malfunction Diagnosis Flow of Geely Automobile
Dry HECU
When equipped with dry HECU, after replacing HECU, not only implement fluid filling and air exhaust
according the requirements of normal brake system, but also implement air exhaust to 2nd circuit of HECU. The
procedures when operating with diagnosis scanner are as follows:
Implement fluid filling and air exhaust, until there is no bubble in transparent
pipe.
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Common Malfunction Diagnosis Flow of Geely Automobile
Press brake pedal 10 times and tighten the air drain screws on left and right
brake caliper, press ↑
Teilentlüftung beendet…
Screen display, air exhaust finished, press → and return to function select
menu.
End
424
GEELY INTERNATIONAL CORPORATION
Address: No.87 Qianyang Road, Shanghai, P.R.China
Webside: www.geely-globe.com