UAES 473F Engine Electronic Fuel Injection Section PDF

M1 Service Manual
(UAES 473F Engine Electronic Fuel Injection Section)
After-sales Service Department of Chery International Company
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Table of Contents
CHAPTER 1 REMOVAL & INSTALLATION OF ELECTRONIC FUEL INJECTION SYSTEM ................ 4
1. Removal & Installation of Electronic Fuel Injection System Component .................................... 4
CHAPTER 2 PRINCIPLE OF ELECTRONIC FUEL INJECTION SYSTEM ............................................. 6
І. System Component Overhaul...................................................................................................... 6
1. Intake Pressure & Temperature Sensor ............................................................................... 6

2. Engine Tachometer............................................................................................................... 8
3. Phase Sensor ..................................................................................................................... 10
4. Water Temperature Sensor ................................................................................................ 11
5. Knock Sensor ..................................................................................................................... 12
6. Electronic Throttle Body ..................................................................................................... 13
7. Oxygen Sensor................................................................................................................... 14
8. Fuel Pump Assembly.......................................................................................................... 17
9. Fuel Injector........................................................................................................................ 19
10. Ignition Coil ......................................................................................................................... 21
11. Spark Plug .......................................................................................................................... 23
12. Control of Carbon Canister Solenoid Valve........................................................................ 25
13. Electronic Accelerator Pedal .............................................................................................. 26
14. Three-way Catalytic Converter........................................................................................... 27
15. Fan Control ......................................................................................................................... 27
16. Dual-Brake Pedal Position Sensor..................................................................................... 29
17. Clutch Position Sensor ....................................................................................................... 29
18. Air Conditioner Control ....................................................................................................... 30
CHAPTER 2 BASIC DIAGNOSIS PRINCIPLE FOR ELECTRONIC INJECTION SYSTEM............... 31
1. Fault Information Record.................................................................................................... 31

2. Fault Status......................................................................................................................... 31
3. Fault Type ........................................................................................................................... 31
4. Fault Frequency Counter.................................................................................................... 31
5. Limp Home ......................................................................................................................... 32
6. Fault Alarm.......................................................................................................................... 32
7. Fault Reading Out .............................................................................................................. 32
8. Clearance of Fault Information Record .............................................................................. 32
9. Faultshooting ...................................................................................................................... 33
10. Fault Code Table ................................................................................................................ 33
11. Steps for Fault Diagnosis According to Fault Information Record ..................................... 38
11.1 Electronic Throttle Valve Fault ............................................................................... 38
11.2 Fault of Knock Sensor............................................................................................ 39
11.3 Faults of Air Pressure Sensor ................................................................................ 39
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11.4 Faults of Upstream Oxygen Sensor....................................................................... 40
11.5 Faults of Post Oxygen Sensor ............................................................................... 41
11.6 Faults of Coolant Temperature Sensor .................................................................. 42
11.7 Faults of Driving Stage of Fuel Injector.................................................................. 43
11.8 Faults of Driving Stage of Carbon Canister Control Valve..................................... 44
11.9 Faults of Driving Stage of Fault Indication Lamp (MIL).......................................... 45
11.10 Fault of Driving Stage of Step Motor’s Coil 1# and 2#........................................... 46
11.11 Fault of Camshaft Position Sensor ........................................................................ 47
11.12 Fault of Crankshaft Position Sensor ...................................................................... 48
11.12 Ignition Coil Fault ................................................................................................... 49
11.13 Fault of Position Sensor of Accelerator Pedal ....................................................... 50
11.14 Dual-Brake Switch.................................................................................................. 51
11.15 Anti-Theft System Fault.......................................................................................... 52
12. Steps for Fault Diagnosis According to Engine Symptom.................................................. 53
12.1 Primary inspection shall be conducted at first before steps for
fault diagnosis according to engine symptom........................................................ 53
12.2 Engine doesn’t rotate or rotation is slow during startup......................................... 55
12.3 Engine can be rotated by traction but cannot start successfully during
starting.................................................................................................................... 56
12.4 Difficult hot-start ..................................................................................................... 58
12.5 Start is still difficult to start even though speed is normal ...................................... 59
12.6 Start is difficult when engine is cool ....................................................................... 61
12.7 Idle speed is not stable anytime............................................................................. 63
12.8 Unstable idle speed during warming-up ................................................................ 65
12.9 Unstable idle speed after warming-up ................................................................... 66
12.10 Unstable idle speed or shut-down on load (air conditioner etc.) ........................... 68
12.11 Unstable periodicity (must conduct self-learning after ECU is power-off) ............. 69
12.12 Too high idle speed (self-learning must be carried out after ECU is power-off) .... 70
12.13 Speed cannot rise or misfire during accelerating................................................... 71
12.14 Slow response during accelerating........................................................................ 73
12.15 Poor performance and weak acceleration during accelerating ............................. 75
12.16 Not reach maximum speed during accelerating .................................................... 77
12.17 Loosen accelerator after acceleration and engine gets unstable idle
speed instantly even misfire................................................................................... 78
12.18 Air conditioning system fault .................................................................................. 79
13. Safety Cautions for System Maintenance .......................................................................... 80
13.1 Safety Cautions for Diagnosis and Maintenance of Electronic
Gasoline Injection Control System......................................................................... 80
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Chapter 1 Removal & Installation of Electronic Fuel Injection
System
1. Removal & Installation of Electronic Fuel Injection System

Component
1. Removal & installation of engine-control ECU
2. Position & removal of intake pressure sensor
3. Position & removal of camshaft position sensor
4. Remove fixing clamp of intake hose
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5. Remove four fixing bolts of electronic throttle body. Pull
out connector and take out electronic throttle body
6. Use screwdriver to press and hold the fixing clip of fuel

throttle connector, Pull out the connector
7. Use screwdriver to press and hold the fixing clip of knock

sensor’s connector, pull out the connector
8. Water temperature senor is behind thermostat base
9. Pull out the connector of ignition coil’s primary coil by

hand
10. Pull out the connector of engine’s tachometer by hand
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Chapter 2 Principle of Electronic Fuel Injection System
І. System Component Overhaul
1. Intake Pressure & Temperature Sensor
1.1 Sensor Function:

Detect intake pressure and temperature of intake manifold, send it to ECU as main load signal of engine.
ECU will calculate width of fuel injection pulse according to the signal.
1.2 Sensor Principle:

The intake pressure & temperature sensor is the sensor which integrates the intake pressure sensors
and intake temperature sensor into a whole. The absolute pressure sensing component of intake
manifold is comprised of a piece of silicon chips. A pressure membrane is etched on the silicon chip.
There are four piezoresistances on the pressure membrane and these piezoresistances consists of a
Wheatstone bridge as strain component. Besides the pressure membrane, signal processing circuit is
integrated into a silicon chip as well. The silicon chip consists of a sealed reference space with a metallic
housing and the absolute pressure of air in the reference space is approximate to Zero. This forms a
microelectronic mechanical system. The silicon chip’s active surface endures a pressure approximate to
0 and its back endures an absolute pressure of intake manifold to be measured being led in through a
connection tube. The thickness of silicon chip is just few microns (µm). So, the change of intake
manifold’s absolute pressure will cause mechanical deformation of silicon chip, four piezoresistances will
also deform and their resistance value will change. After processing of silicon chip’s signal processing
circuit, a voltage signal which has linear relationship with pressure is formed. The sensing component for
intake temperature is a resistance with negative temperature coefficient (NTC) and its resistance value
changes with intake temperature. This sensor transmits a voltage indicating change of intake
temperature to controller.
进气压力温度传感
Intake pressure &
temperature sensor
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Profile of the sensor for intake manifold’s absolute pressure and intake temperature
1 Seal ring; 2 Stainless bushing; 3 PCB board; 4 Sensing component; 5 Housing; 6 Pressure bracket; 7 Welding
connection; 8 Binder connection
1.3 Technical Characteristics & Parameters

This sensor is designed to be installed on the plane of vehicle engine’s intake manifold. The pressure
connection tube and temperature sensor are together projecting in the intake manifold and use a O ring
to seal air.
It ensures that no condensate water will be occurred on the pressure-sensitive component in case
suitable method is adopted to install the sensor on vehicle (obtain pressure from intake manifold, slope
pressure connection tube downward etc.).
The drilling hole and fixing on the intake manifold must be conducted according to supplier drawing in
order to ensure long-term seal and protect against corrosion of medium.
Besides the impact from the joints of part and component, reliable contact of joint’s electrical connection
is related to the material mass and dimensional accuracy of the joint on harness.
1.4 Fault Symptom and Judgment Method

● Fault symptom: shut down, bad idle speed etc.
● General fault cause:
1. Abnormal high pressure or large reverse current occurs during operation;
2. Vacuum component is damaged during service.
● Caution for service: high-pressure air is prohibited to impact vacuum component during service;
check if output voltage and current are normal during replacement of sensor in case fault is found.
● Simple measuring method:
1.4.1 Temperature Sensor Part:

(Remove joint) Turn the multimeter to Ohm position. Connect two probes to sensor’s pin 1# and 2#
respectively. The rated resistance at 20°C is 2.5kΩ±5% and other corresponding resistance value can
be measured through above characteristic curve. Simulating method can be used during measuring, this
is: use a hair dryer to blow sensor (do not get too close), observe change of sensor’s resistance and the
resistance value shall go down now.
1.4.2 Pressure Sensor Part

(Connect joint) Turn the multimeter to DC Volt position. Ground black probe and connect red probe to pin
3# and 4# respectively. Under idle speed status, the pin 3# shall have reference voltage of 5V and the
voltage of pin 4# is about 1.3V (specific value is related to vehicle model); under no-load status, open
throttle valve slowly, the voltage of pin 4# changes very little; open throttle valve fast, the voltage of pin
4# can reach about 4V (specific value is related to vehicle model) instantly and go down to about 1.5V
(specific value is related to vehicle model).
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2. Engine Tachometer

The tachometer is one of the most important sensors of engine. It provides signals to ECU such as
engine speed, acceleration and crankshaft’s striking angle, etc. ECU will calculate width of fuel injection
pulse, injection time and ignition timing through these signals, it also provides engine speed signal to
instruments.
2.2 Operation Principle of Sensor

The inductive tachometer matches with pulse disc and is used to provide information about engine
speed and top dead center (TDC) of crankshaft in non-distributor ignition system. The pulse disc is a
fluted disc with original 60 teeth, but there are 2 teeth position absent. The pulse disc is installed on
crankshaft and rotating with crankshaft. When tooth tip passing top of inductive tachometer closely, the
pulse disc made of ferromagnetic material cuts magnetic line of permanent magnet in the inductive
tachometer and creates induced voltage in coil which is output as rotational speed signal.
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Tachometer
1 Shielding cable 2 Permanent magnets
3 Sensor housing 4 Installation bracket
5 Core 6 Coil
7 Air gap 8 Tooth coil
2.3 Technical Characteristics and Parameters
Value
Parameter Unit
Min. Typical Max.
Resistance at ambient temperature of 20°C 774 860 946 Ω
Inductance 310 370 430 mH
Output voltage at crankshaft rotating speed
>1,650 mV
of 416 rpm
2.4 Cautions for Installation

● Tachometer
The inductive tachometer can be taken out from package only if it is going to be installed on vehicle
or test device.
● The inductive tachometer shall be pressed to be installed but not being hammered.
● It is recommended to use seal bolt M6×12 to fix inductive tachometer.
● Tightening torque shall be 8±2Nm.
● The air gap between inductive tachometer and tooth tip of pulse disc: 0.8 to 1.2mm.
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Dimension d (see following figure): 4.7mm.
Installation of tachometer
● Symptom: not start etc.
● General fault cause: man-made fault.
● Cautions for service: the inductive tachometer shall be pressed to be installed but not being
hammered during service.
1. (Remove joint) Turn the multimeter to Ohm position. Connect two probes to sensor’s pin 2# and
3# respectively. The rated resistance at 20°C is 860Ω±10%.
2. (Connect joint) Turn the multimeter to AC volt position. Connect two probes to sensor’s pin 2#
and 3# respectively. Start engine and a voltage shall be output now (suggest to use automobile
oscilloscope for inspection).
Test Waveform
3. Phase Sensor

Provide phase signal to ECU and help engine’s crankshaft position sensor to judge if it is on
compressing TDC or exhaust TDC.
3.2 Operational Principle of Sensor

The phase sensor consists of a Hall generator installed on the cover of the valve chamber and the signal
disc mounted on intake camshaft. When camshaft rotating, the signal wheel changes magnetic flux
passing through Hall generator to create changing Hall signal.
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Grounding point
Phase sensor
Main relay87#

● Symptom: excessive emission, fuel consumption increasing etc.
● Normal fault cause: man-made fault.
(Connect joint) switch on ignition switch and not start engine. Turn multimeter to DC Volt position.
Connect two probes to pin 1# and 3# respectively and ensure the reference voltage is 12V. Start engine
and check the signal on pin 2# by automobile oscilloscope, check if it is normal.
4. Water Temperature Sensor

The water temperature sensor provides water temperature signal to ECU and instrument simultaneously.
ECU calculates and adjusts the width of fuel injection pulse and the ignition advance angle. Additionally,
ECU can control start and stop of cooling fan through water temperature to prevent engine from
overheating and damage
4.2 Operational Principle of Sensor:

The water temperature is a NTC resistance sensor that resistance value will go down with temperature’s
rising. But temperature rising is not linear with reduction of resistance.
Coolant
temperature
sensor
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(1) Limit Data
Parameter Value Unit

Rated voltage Can be operated by ECU only
Resistance at 20°C 2.5±5% kΩ
Operating temperature range -30 to +130 °C
Max. measured current through sensor 1 mA
Acceptable vibration acceleration 600 m/s2

The coolant temperature sensor is installed on the cylinder and the coppery heat-conducting sleeve shall
be inserted into coolant. The sleeve has thread and the coolant temperature sensor can be screwed into
the threaded hole on cylinder conveniently by the hexagon head on the sleeve. The acceptable
maximum tightening torque is 15Nm.

● Symptom: difficult start and etc.
● General fault reason: man-made fault.
(Remove joint) Turn the multimeter to Ohm position. Connect two probes to sensor’s pin 1# and 2#
respectively. The rated resistance at 20°C is 2.5kΩ±5% and others can be measured through the
characteristic curve on above figure. Simulation method can be used during measuring, this is: put the
sensor’s working area into boiled water (immersing time shall be sufficient), observe changing of
sensor’s resistance and its value shall go down to 300Ω~400Ω (specific value depends on temperature
of boiled water) now.
5. Knock Sensor

The knock sensor provides knock signal to ECU. When engine is knocking, ECU will control and reduce
ignition advance angle step by step to eliminate knock. When no knocking occurs in some strokes, ECU
will increase ignition advance angle step by step to make engine obtain maximum torque.
5.2 Operational Principle of Sensor:

The knock sensor is a vibrating accelerometer installed on engine’s cylinder. It can be one or more. The
sensitive component of sensor is a piezoelectric component. The vibration of engine’s cylinder is
transferred to piezoelectric crystal through mass block in sensor. Due to the pressure caused by
vibration of mass block, the piezoelectric crystal produces voltage on two pole surfaces and changes the
vibration signal into alternative voltage signal to output. Its characteristic curve of frequency response is
shown below. Because the frequency of vibration signal caused by engine knock is much higher than
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that of engine’s normal vibration signal, ECU can distinguish knock and non-knock signal after
processing the signal from knock sensor.

The knock sensor is fixed on the cylinder by a M8 bolt through a hole in the middle. For the cylinder
made of aluminum alloy, 30mm long bolt shall be adopted; for the cylinder made of cast iron, 25mm long
bolt shall be adopted. Tightening torque is 20±5Nm. The sensor shall receive vibration signal from all
cylinders at installation position. The optimum installation position shall be confirmed through modal
analysis of engine. Generally, for 4-cylinder engine, knock sensor shall be installed between the 2nd and
3rd cylinders; for 3-cylinder engine, it shall be installed in the middle of the 2nd cylinder. Do not make
sensor contact any liquid such as lubricant, coolant, brake fluid and water, etc. Do not use any type of
gasket. The sensor’s metallic surface must cling to cylinder. When wiring signal cables of sensor, it shall
be noted not let signal cable produce resonance to avoid breakage. Switching on high-voltage power
between pin 1# and 2# of sensor is prohibited, because this may damage piezoelectric component.

Symptom: bad acceleration and etc.
● General fault reason: corrosion on sensor due to long-time contacting with various liquids such as
like lubricant, coolant, brake fluid and water etc.
● Caution for service: (refer to the Caution for Installation)
● Simple measuring method: (remove joint) Turn multimeter to Ohm position. Connect two probes to
sensor’s pin 1#,2# and 1#, 3# respectively and its resistance value shall be more than 1MΩ under
normal temperature. Turn the multimeter to mV position, use a small hammer taping around knock
sensor and a voltage signal shall be output now.
6. Electronic Throttle Body
6.1 Function:
The electronic throttle body can open or close throttle valve automatically according to driver’s opinion
on stepping on accelerator pedal to make engine operating under corresponding working condition. The
electronic throttle cancels the traditional throttle cable and the opening of throttle is controlled by ECU
according to signal of accelerator pedal and other signals (e.g. air conditioner, power steering, motoring
and gear shifting etc.) through the step motor inside electronic throttle body. The traditional idle by-pass
and idle step motor are canceled. Additionally, the electronic throttle body has throttle position sensor
used to feedback opening of throttle. This throttle position sensor is different from ordinary throttle
position sensor and 2 sets of throttle position sensors are set up inside the electronic throttle body to
monitor reasonability of its signal. If one signal fails, ECU can use the other set of signal to continue
work.
6.2 Operational Principle:

The throttle valve driving motor is a micro-motor comprising of a rotor and multiple stators being
arranged in a circle; each steel stator is rolled with a coil; rotor is a permanent magnet with a nut in
middle. All stator coils are always powered all the time. If current direction of any coil is changed, rotor
will rotate with a angle. When each stator changes current direction in proper sequence, a rotating
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magnetic field will be formed and the rotor made of permanent magnet will rotate toward a definite
direction. The principle is just a DC micro-motor.
The motor drives a set of particular gear reduction mechanism and a bidirectional spring. When system
is powered off, this mechanism can ensure the opening of throttle’s valve plate keeping at a safe position
beyond idle but not too high and ensure vehicle can continue to work. If engine’s electrical control
system enters into this fault mode, the valve plate of electronic throttle body will no longer take action
when stepping on accelerator pedal.
Electronic throttle valve
6.3 Symptom Diagnosis

ECU can monitor short-circuit and circuit break of throttle valve driving motor, also lighten the engine
fault indicator when such a fault occurs, then engine enters into fault mode. At present, engine cannot
accelerate; driving performance is very bad and need to be repaired immediately.
7. Oxygen Sensor

Oxygen sensor is one of the most important sensors of modern vehicle and feedback concentration of
mixed gas through detection of oxygen content in exhaust gas. ECU modifies mixed gas according to
the signal fed back by oxygen sensor. It means that mixed gas is always kept near ideal air-fuel ratio
(14.7:1) through control of fuel injection pulse width.
7.2 Operational Principle of Sensor

The sensing component of oxygen sensor is a ceramic tube with small opening. Outside of tube wall is
enclosed by engine’s exhaust gas and its inner side is connected to atmosphere. The sensing ceramic
tube wall is a solid electrolyte with electric heating pipe inside (see figure below).
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1 Cable
2 Disc spring
3 Insulation bushing
4 Protective sleeve
5 Clamping joint for
heating component
6 Heating rod
7 Contact shim
8 Sensor base
9 Ceramic probe
Profile of Oxygen Sensor
10 Protective tube
output voltage
excessive air coefficient 2
Oxygen Sensor’s Characteristic Curve under 600°C
The operation of oxygen sensor is realized by changing the concentration difference of oxygen ion
between inside and outside of sensing ceramic tube into voltage signal to output. When temperature of
sensing ceramic tube reaches 350℃, it will get characteristic of solid electrolyte. Due to particularity of its
material, the oxygen ion can pass through ceramic tube freely. By this characteristic, concentration
difference can be changed into potential difference and forms an electric signal to be output. If
concentration of gas mixture is relatively high, the concentration difference of oxygen ion between inside
and outside of ceramic tube and the potential difference will be high, and a lot of oxygen ion will move to
outside from inside and output voltage will be relatively high (approximate to 800mV-1,000mV); if
concentration of gas mixture is thin, the concentration difference of oxygen ion between inside and
outside of ceramic tube and the potential difference will be relatively low, only a few oxygen ion will move
from inside to outside and output voltage will be low (approximate to 100mV). The signal voltage will
change around theoretically equivalent air-fuel ratio (λ=1). See above figure.
main relay
oxygen sensor
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Oxygen sensor has cables. The other end of cable is electric joint. All the oxygen sensor’s electric joints
produced by our company have 4 pins:
Pin 1# connects to heating power’s positive pole (white);
Pin 2# connects to heating power’s negative pole (white);
Pin 3# connects to signal’s positive pole (gray);
Pin 4# connects to signal’s negative pole (black).

● Requirement on exhaust pipe: exhausting pipe in frontal area of oxygen sensor shall be heated
quickly. If possible, the exhaust pipe shall be designed to slope downward to avoid condensate
water accumulating in front of sensor.
● Do not improperly heat the metallic cable-holding ring aside oxygen sensor. Particularly after engine
stopped.
● Do not use cleaning fluid, oily liquid or volatile solid on the connector of oxygen sensor.
● Thread of oxygen sensor is M18×1.5.
● Dimension of oxygen sensor’s hexagon spanner is 22-0.33.

Tightening torque of oxygen sensor is 40 ~60Nm.
7.4 Symptom and Judgment

● Fault symptom: bad idle speed, bad acceleration, excessive emission and high fuel consumption
etc.
● General fault reason:
1. Humid vapor come into inside of sensor, temperature changes suddenly and probe is broken.
2. Oxygen sensor is “poisoned”. (Pb, S, Br, Si)
Cautions for service: forbid using cleaning fluid, oily liquid or volatile solid on oxygen sensor during
service.
1. (Remove joint) Turn multimeter to Ohm position. Connect two probes to sensor’s pin 1# (white)
and 2# (white) respectively and its resistance value shall be 1~6Ω under normal temperature.
2. (Connect joint) Under idle speed condition, when oxygen sensor reaches its working
temperature of 350℃, turn multimeter to DC Volt position, connect two probes to sensor’s pin
3# (gray) and 4# (black) respectively and voltage shall be quickly fluctuating at 0.1~0.9V at
present.
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8. Fuel Pump Assembly
8.1 Function of Fuel Pump:

Fuel pump transfers the fuel in fuel tank to engine at definite pressure for combustion, it also adjusts oil
pressure (no oil return) timely according to requirement of system pressure. Generally, the system
pressure provided by fuel pump is about 3.5~4bar.
8.2 Operational Principle of Fuel Pump

Electric fuel pump consists of DC motor, paddle pump and end cover (integrate non-return valve, relief
valve and anti-EMI component) (see figure below).
The pump and motor shall be installed on the same shaft and enclosed in the same housing. The
gasoline is sufficiently filled around pump and motor in housing and used for eliminating heat and
lubrication. The battery supplies power to electric fuel pump through fuel pump relay and the relay can
switch on circuit of electric fuel pump only if engine is started or operating. When engine is stopped due
to accident, fuel pump will stop operation automatically.
The maximum output pressure of electric fuel pump is subject to relief valve and it is between
450~650kPa. Because this system adopts non-oil-return system, the pressure of whole fuel system is
subject to fuel pressure adjustor. Generally, it is about 400kPa.
According to the requirement of the engine, the electric fuel pump has various flows. For convenience of
production, the EKP13 series of electric fuel pumps with identical structure adjust rotating speed of the
motor through adjusting turn number of coil to adjust flow. So, electric fuel pump for one vehicle model
cannot be used to other vehicle models arbitrarily.
1 End cover of fuel pump

2 Motor
3 Oil lead
4 Paddle pump
Profile of Electric Fuel Pump

The flow of electric fuel pump under definite fuel pumping pressure is proportional to voltage. The fuel
pump adopted by various manufactures is different.
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The EKP13 series of electric fuel pump is only applicable for fuel tank. The filter screen of oil inlet agreed
by customers or that mesh dimension is not greater than 60µ shall be installed during installation of fuel
pump. The oil ejected from vent hole shall not be ejected into the filter screen of oil inlet, fuel pump
bracket or oil tank wall. Moving fuel pump shall be careful. Firstly, protect filter screen from load and
impact. Fuel pump shall be taken out from plastic package carefully only if it is going to be installed.
Protective cover shall be taken away only if fuel pump is going to be installed immediately. Do not take
away filter screen of oil inlet because foreign bodies will enter into fuel pump’s oil inlet or filter screen
may cause damage on fuel pump.

● Fault symptom: loud operational noise, bad acceleration and cannot start (hard to start) etc.
● General fault reason: due to using inferior fuel:
1. Insulation layer is formed by accumulation of colloid;
2. Blocking of fuel pump’s bushing and armature;
3. Corrosion on component of oil-level sensor, etc.
● Cautions for Service:
1. According to requirement of engine, electric fuel pump can have different flows. The fuel pumps
with identical appearance and supposed to fit may be not suitable. The part No. of fuel pump
adopted in service must conform to original and cannot use wrong type.
2. For preventing unexpected damage on fuel pump, do not operate under dry state;
3. In case it is necessary to replace fuel pump, please take care of the cleaning of fuel tank and
pipeline and the changing of fuel filter.
● Simple Measuring Method:
1. (Remove joint) Turn multimeter to Ohm position, connect two probes to both pins of fuel pump
respectively, and measure internal resistance. The resistance value shall not be 0 or ∞ (i.e. not
in short circuit and circuit break conditions).
2. (Connect joint) Connect fuel pressure gauge at feed pipe, start engine, observe if fuel pump is
operating; if no operation, check if pin “+” has supply voltage; if operating, check if fuel pressure
is around 400kPa under idle condition.
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9. Fuel Injector
9.1 Function of Fuel Injector

ECU controls coil of fuel injector through pulse to open or close fuel injector and inject proper fuel into
intake tube to be mixed with air in proper time.
9.2 Operational Principle

ECU sends electric pulse to coil of fuel injector to form magnetic field force. When magnetic field force
rise enough to overcome resultant force of return spring’s pressure, needle valve’s gravity and friction
force, needle valve begins to rise and fuel injection process start up. When fuel injection pulse cuts off,
pressure of return spring will re-close needle valve.
1. O-ring
2. Filter screen
3. Fuel injector body with electric connector
4. Coil
5. Spring
6. Valve needle with armature coil
7. Valve base with orifice plate
Profile of Electromagnetic Fuel Injector
Connect to No. 87 pin of

main relay
No. 1 cylinder No. 2 cylinder No. 3 cylinder No. 4 cylinder
Fuel injector
Circuit Diagram of Electromagnetic Fuel Injector
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Value
Parameter Unit
Min. Typical Max.
Working Condition (Pressure Difference) 350 kPa
Resistance of Fuel Injector under 20℃ 11 16 Ω
Acceptable Fuel:
Fuel injector can use the fuel complying with GB 17930-1999 Vehicle Unleaded Gasoline of China
National Standard and the GWKB 1-1999 Control Standard on Hazardous Substance of Vehicle
Gasoline of National Environmental Protection Standard only, also clearing agent is required to be added
into gasoline. Particularly, gasoline will deteriorate if being stored too long. Also, the taxis using dual-fuel
engine for LPG & gasoline always use LPG as fuel but using gasoline for startup, it makes daily
consumption of gasoline very low. But the fuel tank’s temperature is extremely high due to long-time
operation of fuel pump. If gasoline is stored in the fuel tank of such a vehicle, it will deteriorate by
oxidation easily and may cause jam even damage to fuel injector.

● A fuel injector must use matched connector and can not be mixed.
● For convenience of installation, suggest painting clean non-silicon lubricant on the surface of upside
O-ring connecting with fuel distribution pipe. Do not make lubricant contaminate inside and orifice of
fuel injector.
● Install fuel injector on its base vertically and fix fuel injector on base with clamp. Note:
① Clamp of fuel injector falls into two types according to positioning method: axial and radial
positioning clamp. Misapplication shall be avoided.
② For installation of axial positioned fuel injector, ensure the bayonet in middle of clamp being
snapped into slot of fuel injector completely and the slots on both sides of clamp being snapped
into external jacket of fuel injector base.
③ The fuel injector with axial and radial positioning requirements both shall use axial-radial
positioning clamp when installing, also the positioning block and the locating pin of fuel injector
base shall be positioned in corresponding slots on positioning clamp respectively.
④ In case fuel injector has two slots, do not snap into wrong location. Please refer to original
installation position.
● Install fuel injector by hand and forbid using tools like hammer to knock fuel injector.
● When remove and reinstall fuel injector, O-ring must be replaced. At present, sealing face of fuel
injector shall not be hurt.
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● Supporting washer of O-ring cannot be pulled out from fuel injector. Damage to oil inlet of fuel
injector, O-ring, support ring, orifice plate and electric connector shall be avoided during installation.
If damaged, it is prohibited to be used.
● After complete installation of fuel injector, leakage test for fuel distribution pipe assembly shall be
carried out. The one with no leakage will be accepted.
● Failure part shall be removed by hand. First, remove clamp of fuel injector, then pull out fuel injector
from its base. Cleanness of fuel injector base shall be ensured after removal to avoid contamination.

● Symptom: bad idle speed, bad acceleration and cannot start up (hard to start), etc.
● General fault reason: fuel injector fails due to lack of maintenance caused colloid accumulation
inside fuel injector.
● Cautions for service: (refer to Cautions for Installation )
(Remove joint) Turn multimeter to Ohm position, connect two probes to fuel injector’s two pins and its
rated resistance shall be 11~16Ω at 20℃.
Suggestion: use special cleaning & analysis instrument to clean and analyze fuel injector periodically.
10. Ignition Coil
10.1 Functions of Ignition Coil

Primary and secondary circuits are integrated into ignition coil. When ECU controls switch-on/-off of
primary coil’s current, a high voltage power reaching to thousands volt is formed in secondary coil and
the gas mixture in cylinder will be ignited by the spark formed through high-voltage line and spark plug.

The ignition coil ZS-K2×2 consists of two primary winding, two secondary winding, iron core and housing
etc. When grounding channel of one primary winding is connected, this primary winding will be charged.
Once ECU switches off circuit of primary winding, charging will be broken off and induce high-voltage
power in secondary winding simultaneously to make spark plug discharge. The difference to the ignition
coil with distributor is the both ends of ignition coil ZS-K2×2’s secondary winding connect to a spark plug
respectively and both of the spark plug will spark at the same time. Both of the primary winding will be
powered up and off alternatively. Correspondingly, both secondary winding will be discharged
alternatively.
21
Double spark ignition coil
Main relay No. 87
10.3 Technical Characteristics
Parameter Value Unit
Min. Typical Max.
Nominal Voltage 14 V
Resistance Value Primary Winding 0.42 0.5 0.58 Ω

(20 to 25°C)
Secondary Winding 11.2 13.0 14.8 kΩ
Inductance Value Primary Winding 3.4 4.1 4.8 mH

(20 to 25°C)
Secondary Winding 26.5 32.0 37.5 H
Value of Formed Load 50pF 30 kV

Voltage
Load 50pF//1MΩ 23 kV

● Fault symptom: cannot start up and etc.
● Fault cause: damage due to over current and external force, etc.
● Cautions for service: forbid using “short circuit method” to test ignition function during service in
order to avoid damage on electronic controller.
● Simple measuring method:(Remove joint) Turn multimeter to Ohm position, connect two probes to
primary coil’s two pins and its resistance value shall be 0.42-0.58Ω at 20℃; And the resistance value of
secondary coil shall be 11.2-14.8kΩ.
22
11. Spark Plug
The spark plug has a very tough working condition. It endures impact of high pressure and temperature.
Therefore it is a vulnerable part.
11.1 Outside View
Single Pole 3-Pole
11.2 Thermal Characteristic

The spark plug must be kept at proper temperature in order to make it operate well. Practice has proved
that the oil drop falling to spark plug’s insulator will burn up immediately and no carbon deposit will be
formed if temperature of insulator’s skirt is kept at 500~700℃. This temperature is called self-clean
temperature of spark plug. If it is lower than this temperature, spark plug is easy to get carbon deposit
and cause electric leakage and non-ignition; if it is higher than this temperature, when gas mixture
contacts hot insulator, it may get pre-ignition and cause knock, even combust in intake stroke and cause
backfire.
11.3 Fault Caused by Drop on Spark Plug’s Ignitability Easily

Hard to start up, unstable vehicle speed, engine shaking, black smoke coming out from exhaust pipe,
high fuel consumption and lacking for power.
11.4 Judge If Vehicle Condition Match to Spark Plug’s Type by Spark Plug’s Color
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Yellow, brown Normal Gas mixture’s ignition condition is normal
Black, with carbon deposit Carbon deposit Check if spark plug’s type is matched, change to the
spark plug with lower thermal value (slow radiating
speed)
Black, with stain Smoked If fuel injector nozzle is dirty, clean it.
If fuel-gas mixing ratio is too high, dilute it.
If high-voltage power is short, check ignition coil and
etc.
Black, with oil stain Lubricant ignited Check sealing condition of seal ring and if cylinder
wall has scratch, etc.
Off-white Over heat Check if spark plug’s type is matched, change to the
spark plug with higher thermal value (fast radiating
speed)
11.6 Periodic Change and Overtime Operation

Spark plug is a low value consumption good and with cheap price compared with other assemblies. But
its ignition performance can influence engine’s performance directly and therefore it needs to be
changed periodically. The spark plug used for our company’s engine is recommended to be used about
10~15 thousand km if single pole type is adopted and about 15~25 thousand km if multi-pole type is
adopted.
Due to reduction of spark plug’s ignition performance, fuel consumption is increased and power is
reduced. Unconsciously, economic loss caused by over-consumed fuel every day can be accumulated
to pay off more than hundred of new spark plug. Overtime operation of spark plug is bad for engine’s
working condition and may cause some damages to engine.
11.7 Inspection and Maintenance of Spark Plug

Inspection of spark plug mostly includes carbon deposition, electrode ablation, spark plug’s tightness
and jump-spark performance, etc.
Spark plug’s electrode gap shall be 0.7~0.9mm. If electrode gap is too small, breakdown voltage will be
reduced and spark intensity will be weakened; if electrode gap is too big, voltage required by spark plug
will be raised to cause misfire, particularly when ignition coil is aged and ignition system has unfavorable
maintenance.
Common faults of spark plug including tightness drops, air leakage exists and smoked mark is at
leakage location. The above faults can be judged and check by sealing test and spark over test. The
leakage test and spark over test can be executed on the clean tester for both spark plug.
It shall be pointed out that some drivers and maintenance staff remove spark plug from engine and place
it on cylinder cover and check if it is faulty with high-voltage power on vehicle, this method is unscientific.
Because spark plug’s electrode is under an atmosphere pressure in this test, but spark plug is under the
air pressure of more than 800kPa when it is working. So, spark plug taking jump-spark under
atmosphere condition is not equivalent to that it can take jump-spark reliably under high pressure
condition in cylinder.
24
To clean carbon deposit is required in spark plug’s service life when vehicle has been driven for 10~15
thousand km and spark plug’s gap needs to be adjusted. When cylinder temperature is rising, increase
electrode gap properly, i.e. turn up it in summer and turn down it in winter. When concentration of gas
mixture is high, turn up electrode gap properly and turn it down if in reverse. Turn down electrode gap in
plain area and turn it up in plateau area properly.
12. Control of Carbon Canister Solenoid Valve
12.1 Function:
Carbon canister solenoid valve is a device which lets fuel steam in fuel tank enter cylinder for flaming
through control of ECU. ECU realizes opening and closing of solenoid valve through duty cycle control
on solenoid.

Carbon canister control valve consists of solenoid coil, armature iron and valve etc. Filter screen is
equipped at entrance. The air flow through carbon canister control valve is related to the pressure
difference between entrance and exit of carbon canister control valve except being related to duty cycle
of electric pulse output by ECU to carbon canister control valve. When there is no electric pulse, carbon
canister control valve will be closed.
Main relay No. 87
Carbib canister
1 From fuel tank

2 Carbon canister
3 Atmosphere
4 Carbon canister
control valve
ΔP is difference between ambient 5 To intake manifold

pressure Pu and intake manifold Ps
6 Throttle valve
Installation Diagram of
Profile of Carbon Canister Carbon Canister Control Valve
Control Valve
25
Connection of carbon canister control valve to carbon canister and intake manifold are shown in the
installation diagram above.
● In order to avoid transfer of solid-borne sound, it is recommended that the carbon canister control
valve shall be hung on hose.
● Air flow direction must conform to regulation when installing.
● Proper measures such as filtration and purification must be used to prevent foreign bodies like
particle entering carbon canister control valve. Suggest installing a corresponding protective cleaner
(mesh dimension <50µm) on exit of carbon canister.

● Fault symptom: function failed and etc.
General fault reason: corrosion or bad tightness causing by foreign bodies enter valve interior.
● Cautions for Service:Air flow direction must conform to provisions during installation;
2. Check carbon canister’s condition when control valve is found failed due to black particles
inside valve body and need to be changed;Avoid liquids like water and oil entering into valve
during service;In order to avoid transfer of solid-borne sound, it is recommended that the
carbon canister control valve shall be hung on hose.● Simple measuring method:(Remove
joint) Turn multimeter to Ohm position, connect two probes to two pins of carbon canister control valve
and its rated resistance value shall be 26±4 Ω under 20℃.
13. Electronic Accelerator Pedal
13.1 Functions:
Electronic accelerator pedal cancels traditional accelerator drawing cables and feeds back position of
accelerator pedal to ECU through electronic signal. ECU controls action of electronic throttle through
calculation. This pedal integrates 2 sets of Hall sensors and ECU will compare and analyze these two
signals. If one signal is unreasonable, the other signal will be used timely and fault indicator will be
lightened.

This pedal is a Hall sensor. The stationary parts installed on the pedal’s fixing seat are Hall generator
and signal processing circuit. The two parts acting along with pedal are permanent magnets with magnet
sheets in different thickness. When pedal acts, magnetic flux through Hall generator will change along
with pedal and signal processing circuit will process these signals and send them to ECU.
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13.3 Detection:
The relationship between two signals of accelerator pedals is that the voltage of signal 1 is 2 times signal
voltage. On idle position, signal 1’s voltage is 4.59V and signal 2’s voltage is 4.30V. The voltages will get
minimum value when pedal is in the middle position and get maximum value when pedal is at both ends.
14. Three-way Catalytic Converter
14.1 Function:
The 3-way catalytic converter can convert the hazardous gas in exhaust gas into harmless gas like CO2
and H2O through chemical reaction. It has maximum conversion efficiency at 300~800℃. The
conversion efficiency is very bad if the temperature is less than this temperature and may burn up itself if
the temperature is higher than this temperature. The 3-way catalytic converter must show better
conversion efficiency when oxygen sensor is working. There are several protective modes for 3-way
catalytic convertor in control strategy of ECU. The 3-way catalytic converter will be protected through
adjustment of air-gas ratio and ignition advance angle.
15. Fan Control
15.1 Functions:
In order to cool engine system and condenser after turning on air conditioner, fan control is influenced by
the ECU signal transmitted by water temperature sensor. The fan will operate if water temperature is
high (higher threshold set by ECU) and be started with low speed when turning on air conditioner if water
temperature is low (lower than threshold set by ECU).
15.2 Composition:
DC double fans (high and low variable speed).
15.3 Installation Requirement:

The fan is installed between engine and back of radiator. During installation, it shall be noted that blades
and fins of fan shall not be damaged, otherwise operational noise of fan will be increased and may cause
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heavy drop of engine’s cooling efficient in case it is serious.
15.4 Fault Diagnosis:

Fan control circuit is short circuit to ground and broken;
Fan’s problem;
Fan’s noise is too high;
Fan’s power supply circuit is failed.
15.5 Troubleshoot
Firstly confirm if fault is caused by high-speed fan system or low-speed fan system. If it is caused by fan
control system, diagnostic apparatus can be used to confirm fault point and determine if control line is
short circuit or broken.
Fault symptom: water temperature of engine will rise and refrigeration of air conditioner will turn bad if
fan failed.
15.6 Fan Control:

Turn on fan’s low speed gear:
1. Engine coolant’s temperature is higher than 96℃

and lower than 102℃;
2. Air conditioner requests, start fan;

Main relay
3. Start fan’s high speed gear;
Start fan at high speed:

Fan high Fan low
speed relay speed relay
1. Engine’s coolant temperature sensor fails;
2. Air meter fails;
3. Engine’s coolant temperature is higher than

102℃;
Pins: Fan electric motor
1. High speed fan control (corresponding to

ECU50#) Fan control
schematic diagram
2. Low speed fan control (corresponding to
ECU68#)
Fan’s working condition after engine stopped:
1. Engine’s intake temperature sensor fails, time delay for 60s;
2. Engine’s coolant temperature sensor fails, time delay for60s;
3. Engine’s coolant temperature is higher than 100.5℃, time delay for 60s;
4. Engine’s coolant temperature is higher than 70.5℃, time delay for 60s;
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16. Dual-Brake Pedal Position Sensor
16.1 Function:
The brake switch sends brake signal to ECU.
16.2 Operational Principle:

There are two mutually independent switches inside brake switch, one is normal-close (NC) and the
other is normal-open (NO). When the accelerator pedal is step down, the NC switch will turn to NO and
the NO switch will turn to NC. These two signals will be sent to ECU for control of other system.
Whenever these two signals are inconsistent, ECU will enter fault mode, electronic throttle valve will
have no change if step on accelerator and engine will keep on idle condition.
Composition: dual-brake switch is installed on the bracket of the brake pedal with two independent
switches inside.
Installation requirement: assembly is installed on pedal and switch is equipped with thread adjusting
mechanism to adjust switch’s stroke and adjust brake switch’s effective stroke.
Main power
Long fire(30) supply (15)
Double brake switch
17. Clutch Position Sensor
17.1 Function:
Clutch position switch provides clutch position signal to ECU, but this signal just can distinguish clutch’s
separation and combination position.
17.2 Operation Principle

ECU provides a 12V power supply to clutch position switch. When clutch is on disengagement status,
power supply will be grounded and ECU will lose 12V high-potential signal. The position of clutch can be
detected in turn.
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Position of clutch switch
18. Air Conditioner Control
ECU controls operation of air conditioner’s compressor by receiving air conditioning signal of A/C switch.
Meanwhile, ECU receives signals from air conditioner’s high/low pressure switch and ensures security of
air conditioning system. When A/C switch sends signal to ECU through high/low pressure switch, ECU
will not receive A/C signal if low pressure switch is opened. In that way, the compressor will not work. If
the pressure on the air conditioning system is too high, high pressure switch is opened and make A/C
signal will not be sent to ECU, this will make ECU switch off compressor immediately. When system
pressure is normal or slightly higher (medium pressure), medium pressure switch will be closed. This will
make ECU control fan operate with high speed immediately to ensure system pressure is kept in normal
range.
Low pressure switch’s opening pressure: 0.12MPa
Medium pressure switch’s closing pressure: 1.6MPa
High pressure switch’s opening pressure: 3.2MPa

Medium pressure switch
High and low voltage switch
ECU can protect air conditioning system through temperature

sensor of air conditioning system’s evaporation tank to prevent
freezing in evaporation tank. If the temperature provided by
temperature sensor of evaporation tank is lower than 3.75℃, ECU
will switch off the compressor; if higher than this temperature,
ECU will switch on the compressor automatically to make it work.
A/C switch
30
Chapter 2 Basic Diagnosis Principle for Electronic Injection
System
1. Fault Information Record
Electronic controls unit constantly monitors sensors, actuators, relevant circuits, fault indicator lamps
and battery voltage etc., even itself. It also detects reliability of sensor’s output signal, actuator’s driving
signal and internal signals (e.g. close-loop control of oxygen, knock control, idle speed control and
battery voltage control). Once it finds a link fails or a signal value is unreliable, electronic control unit will
set up fault information record in the fault memory of RAM. Fault information record is stored in form of
fault code and is displayed according to fault’s occurrence sequence.
The fault can be divided into “steady-state fault” and “accidental fault” (e.g. caused by short-time break
on harness or connector has bad contact) according to its frequency of occurrence.
2. Fault Status
If duration of a detected fault is beyond set stabilizing time for the first time, ECU will be sure this is a
stable fault and store it as “steady-state fault”. If this fault disappears, it will be stored as “accidental fault”
and “non-existent”. If this fault is detected again, it is “accidental fault” yet but the “existing” historical fault
will not influence normal operation of engine.
3. Fault Type
Short circuit to power supply’s positive pole
Short circuit to ground
Circuit break (ECU will identify the break fault at input end as short circuit of input end to power supply’s
positive pole or that on ground when input stage has pull-up or –down resistance)
Signal unreliable
4. Fault Frequency Counter
For each detected fault, an independent value (Hz) of frequency counter will be set up.
The time for the fault information record keeping on being stored in memory after disappearance of
detected fault (fault being eliminated) is subject to the value (Hz) of frequency counter.
When detect a fault for the first time, Hz will be set to initial value of 40. If fault condition is not changed,
this value will be always kept.
Once detected fault has disappeared and holding for a definite time, Hz will be reduced by 1 once after
every successful startup (rotating speed beyond that when startup is finished) of engine. At present,
ECU will consider this fault has disappeared but fault information record will still exit.
31
If fault (e.g. caused by bad contact) appears and disappears frequently, Hz will be added by 1 but not
beyond the set upper limit value of 100.
If Hz value is reduced to 0, the fault information record in this fault memory will be cleared completely
5. Limp Home
For some detected important fault, when its duration beyond set stabilizing time, ECU will adopt proper
software countermeasures such as close some control functions like close-loop control of oxygen sensor
and etc, set up alternative value for those data considered being unreliable etc. At present, even though
engine’s working condition is relatively bad, but vehicle can be driven yet. The purpose for this action is
to drive vehicle home or to service station constrainedly to avoid embarrassment of vehicle being shut
down in high-way or countryside. Once detected fault has disappeared and Hz value has dropped below
40, normal data will be recovered and to be used again.
6. Fault Alarm
In electronic control system, when fault occurs in some important parts such as ECU, absolute pressure
sensor of intake manifold, throttle valve position sensor, coolant temperature sensor, knock sensor,
oxygen sensor, phase sensor, fuel injector, idle actuator, two driving poles of step motors, carbon
canister control value and fan relay, corresponding fault bit will be set and ECU will lighten fault indicator
lamp to alarm until this fault bit being reset.
7. Fault Reading Out
Fault information record can be invoked from ECU by using fault diagnostic tester. If fault is related to
function of regulator for fuel-air mixture ratio, engine must be operated for 4 minutes at least to read out
fault information record. Particularly for fault of oxygen sensor, data must be detected after engine is
operated to be warm.
Figure 3-1 ISO 9141-2 Standard Diagnostic Joint
8. Clearance of Fault Information Record
When fault is cleared, fault information record in memory shall also be cleared. Fault code can be
cleared through the following several ways:
When Hz value of frequency counter in ECU reaches 0, fault information record in fault memory will be
cleared automatically.
32
Use diagnostic tester to clear fault information record through instruction “reset fault memory”.
Remove joint of ECU or remove harness of battery to clear fault information record in external RAM.
9. Faultshooting
After fault information record is obtained through above methods, we just know probable position where
fault occurred, this doesn’t mean fault has been found. So, the reason of triggering fault information may
lie in damage of electrical component (e.g. sensor or actuator or ECU, etc.) or breakage of wires, may lie
in short circuit of wires to ground or to battery’s positive pole, even mechanical fault.
The fault is intrinsic. Externally presented results of internal fault are various symptoms. When symptom
is found, it firstly need to check if there is fault information record by using fault diagnostic tester or
according to flicker code and eliminate relevant fault information. Then search fault according to engine’s
symptom.
10. Fault Code Table
Sequence No. Fault Code Description Fault Level
1 P0016 Relative position of camshaft and crankshaft unreasonable class5
2 P0030 Fault of heating control circuit of upstream oxygen sensor class31
Too low voltage of heating control circuit of upstream oxygen

3 P0031 sensor class31
Too high voltage heating control circuit of upstream oxygen

5 P0105 Fault of intake pressure sensor signal class31
6 P0106 Signal of intake pressure sensor unreasonable class31
7 P0107 Too low voltage of signal circuit of intake pressure sensor class31
8 P0108 Too high voltage of signal circuit of intake pressure sensor class31
9 P0112 Too low voltage of signal circuit of intake temperature sensor class5
10 P0113 Too high voltage of signal circuit of intake temperature sensor class5
Too low voltage of signal circuit of engine’s coolant temperature

Too high voltage of signal circuit of engine’s coolant temperature

13 P0121 Signal of electronic throttle’s position sensor 1 unreasonable class34
Too low voltage of signal circuit of electronic throttle’s position

14 P0122 sensor 1 class34
Too high voltage on signal circuit of electronic throttle’s position

33
16 P0130 Upstream oxygen sensor’s signal unreasonable class31
17 P0131 Too low voltage of signal circuit of upstream oxygen sensor class31
18 P0132 Too high voltage of signal circuit of upstream oxygen sensor class31
19 P0134 Fault of signal circuit of upstream oxygen sensor class31
20 P0201 Fault of control circuit of cylinder 1’s fuel injector class5
24 P0219 Engine speed over maximum speed limit class5
25 P0221 Signal of electronic throttle’s position sensor 2 unreasonable class34
Too low voltage of signal circuit of electronic throttle’s position

Too high voltage of signal circuit of electronic throttle’s position

28 P0261 Too low voltage of control circuit of cylinder 1’s fuel injector class5
29 P0262 Too high voltage of control circuit of cylinder 1’s fuel injector class5
36 P0321 TDC signal of crankshaft unreasonable class33
37 P0322 Fault of speed signal class33
38 P0324 Fault of knock signal processing chip and its circuit class5
39 P0327 Too low voltage of signal circuit of knock sensor class31
40 P0328 Too high voltage of signal circuit of knock sensor class31
41 P0340 Fault of signal circuit of phase sensor class5
42 P0341 Phase sensor signal unreasonable class5
43 P0342 Too low voltage of signal circuit of phase sensor class5
44 P0343 Too high voltage of signal circuit of phase sensor class5
45 P0444 Fault of signal circuit of carbon canister control valve class31
34
46 P0458 Too low voltage of control circuit of carbon canister control valve class31
Too high voltage of control circuit of carbon canister control

47 P0459 valve class31
48 P0480 Fault (low speed) of relay control circuit of electronic cooling fan class5
Fault (high speed) of relay control circuit of electronic cooling

49 P0481 fan class5
50 P0501 Vehicle speed signal unreasonable class5
51 P0504 A/B signal of brake pedal unreasonable class5
52 P0506 Idle control speed lower than target idle value class5
53 P0507 Idle control speed higher than target idle value class5
Too low voltage of signal circuit of evaporator temperature

Too high voltage of signal circuit of evaporator temperature

56 P0560 System voltage signal unreasonable class33
57 P0562 System voltage signal too low class33
58 P0563 System voltage signal too high class33
59 P0571 Fault of signal circuit of brake pedal class5
60 P0601 Fault of EEPROM of ECU class33
61 P0602 ECU not programmed class33
62 P0604 Fault of RAM of ECU class34
63 P0605 Fault of ROM of ECU class34
64 P0606 Fault of security monitoring function of electronic throttle class34
65 P0627 Fault of control circuit of fuel pump relay class33
66 P0628 Too low voltage of control circuit of fuel pump relay class33
67 P0629 Too high voltage of control circuit of fuel pump relay class33
68 P0645 Fault of relay control circuit of air conditioner’s compressor class5
Too low voltage of relay control circuit of air conditioner’s

69 P0646 compressor class5
Too high voltage of relay control circuit of air conditioner’s

70 P0647 compressor class5
71 P0688 Output voltage of main relay unreasonable class33
72 P0689 Output voltage of main relay too low class33
73 P0690 Output voltage of main relay too high class33
35
Too low voltage (low speed) of relay control circuit of electronic
74 P0691 cooling fan class5
Too high voltage (low speed) of relay control circuit of electronic

Too low voltage (high speed) of relay control circuit of electronic

Too high voltage (high speed) of relay control circuit of electronic

78 P0704 Pedal signal of clutch unreasonable class5
79 P1336 Limited by security monitoring torque of electronic throttle class34
Deviation of electronic throttle’s actual and target position over

80 P1545 limit class34
81 P1558 Opening resistance force of electronic throttle too large class34
82 P1559 Fault of electronic throttle valve’s self-learning process class34
System voltage not meet electronic throttle valve ’s self-learning

83 P1564 condition class34
Lower limit position of electronic throttle initiates self-learning

84 P1565 fault class34
85 P1568 Return resistance of electronic throttle valve too large class34
86 P1579 Self-learning condition of electronic throttle valve insufficient class34
87 P1604 Self-learning fault of electronic throttle valve’s gain adjustment class34
88 P1610 Secret Key and Security Code not programmed class39
89 P1611 Fault of receiving of Security Code class39
90 P1612 Challenge request failed class36
91 P1613 Immo Code request failed class36
92 P1614 Error of Transponder verification class36
93 P1677 Too high voltage of control circuit of service light (SVS) class5
94 P1678 Too low voltage of control circuit of service light (SVS) class5
95 P1679 Fault of control circuit of service light (SVS) class5
96 P2106 Fault of driving stage of electronic throttle class34
Too low voltage on signal circuit of electronic accelerator’s pedal

97 P2122 position sensor 1 class34
Too high voltage of signal circuit of electronic accelerator’s

98 P2123 pedal position sensor 1 class34
99 P2127 Too low voltage of signal circuit of electronic accelerator’s pedal class34
36
position sensor 2
Too high voltage of signal circuit of electronic accelerator’s

100 P2128 pedal position sensor 2 class34
Signal of electronic accelerator’s pedal position sensor

101 P2138 unreasonable class34
Self-learning value of close-loop control of air-fuel ratio over

102 P2177 upper limit (medium load zone) class5

103 P2178 lower limit (medium load zone) class5

104 P2187 upper limit (idle zone) class5

105 P2188 lower limit (idle zone) class5

106 P2191 upper limit (large load zone) class5

107 P2192 lower limit (large load zone) class5
Main power
supply line
Engine theft proof

module Sketch of
Diagnostic Interface
Circuit 1
37
11. Steps for Fault Diagnosis According to Fault Information Record
11.1 Electronic Throttle Valve Fault

Fault Code: P0121 P0122 P0123 P0221 P0222 P0223 P1336 P1545 P1558 P1559
P1564 P1565 P1568 P1579 P1604
Inspection
Item Operation Steps Subsequent Steps
Result
1 Set ignition switch on “ON”. Next step
2 Remove joint of throttle valve position sensor from Yes Next step
harness, check if voltage between its pin 3# and 5#
No 5
are about 12V with a multimeter; if 5V voltage is
between pin 6# and 2#.
3 Check if resistance values among pin 1#, 4# and 6# Yes Next step
of sensor are about 0.5~1.6kΩ by multimeter
No Replace sensor
4 Meanwhile, check if there is short circuit or break Yes Replace sensor

among pin 1#, pin 4#, pin 6# of throttle valve
No Replace ECU
position sensor and pin 38#, pin 54#, pin 36# of
ECU, or rotate throttle valve blade to observe if its
resistance value is jumping and if the resistance
values among pin 1#, pin 4# and pin 6# have
relevant change with rotating of throttle valve.
5 Install adapter between ECU and harness, check if Yes Repair or change
there is break or short circuit among sensor’s pin 1#, harness
pin 2#, pin 6#, pin 4# and ECU joint’s pin 10#, pin
No Replace ECU
32#, pin 36#, pin 54#.
Note: This vehicle model adopts electronic throttle valve, cancels step motor originally used and the
functions of ordinary throttle valve body completed by step motor is wholly accomplished by throttle
valve driving motor. Electronic throttle valve cannot be repaired but throttle valve body has very low fault
rate and it just can be treated by changing assembly if damaged.
Particular Note: maintenance station cannot remove and repair electronic throttle valve body,
meanwhile self-learning of valve body shall be carried out after replacement of electronic throttle valve
body and otherwise engine may operate at unstable idle speed. Please refer to Chapter about electronic
throttle valve for specific learning plan. The maintenance of throttle valve body is similar to that of
common valve bodies.
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11.2 Fault of Knock Sensor
Fault Code: P0324 P0327 P0328
Inspection
Result
1 Turn off ignition switch and engine has no operation. Next step
2 Remove joint of knock sensor from harness, check if Yes Next step
resistance value between pin 1# and 2# of knock
sensor and that between pin 1# and shield pin No Replace with new
(sensor shielding) are higher than 1MΩ. sensor
3 Tap periphery of knock sensor with a small hammer, Yes Next step
check if there is AC signal output between sensor’s
pin 1# and 2# through multimeter. No Replace sensor
4 Connect to ignition switch and not start engine. Next step

5 Install adapter between ECU and harness, use Yes Repair or replace
multimeter to check if there is short circuit or break harness
among ECU’s pin 19#, pin 20# and sensor joint’s No Replace ECU
pin 1#, pin 2#.
Note: In general, knock sensor is hard to be destroyed. No contamination is allowed on the contact
surface of the sensor and engine body during removal and installation of knock sensor, no additional
shim is allowed to be added. The damage of this sensor will bring big influence on engine’s economy
and exhaust. Engine’s electric control system will lock ignition advance angle at a fixed ignition angle if
knock sensor is damaged, this will cause reduction of engine’s acceleration ability, also economy and
exhaust will be greatly influenced.
11.3 Faults of Air Pressure Sensor

Fault Code: P0102 P0103 P0112 P0113
Inspection
Result
1 Turn ignition switch to “ON”. Next step
2 Remove joint of intake pressure sensor from Yes 4
harness, use multimeter to check if there is 5V
voltage on pin 2# and pin 3# of this joint. No Next step
3 Use multimeter to check between ECU and harness Yes Repair or change
if there is short circuit or break among ECU’s pin harness
42#, pin 33# and sensor joint’s pin 1#, pin 2#, pin 3# No Next step
and pin 4#.
4 Change intake pressure & temperature sensor Next step
Note: If short circuit occurs between sensor and 5V or 12V power supply or ground, engine may not be
started and stop operation.
39
11.4 Faults of Upstream Oxygen Sensor
Fault Code: P0130 P0131 P0132 P0134 P0135
Inspection
Result
2 Remove joint of oxygen sensor from harness, use Yes Next step
multimeter to check if there is a battery voltage about 12V No 4
between this joint’s pin 1# (+) and pin 2# (-).
3 Use multimeter to check if resistance value between Yes Replace ECU
oxygen sensor’s pin 1# and pin 2# is about 2~5Ω at 23℃. No Replace sensor
4 Check if oxygen sensor’s heating circuit is normal Yes Next step
No Check circuit
5 Use multimeter to check if there is break or short circuit Yes Repair or change
between pin 2# of oxygen sensor’s joint and main relay’s harness
pin 87 and between oxygen sensor joint’s pin 1# and No Next step
ECU’s pin 1#.
6 Plug joint of oxygen sensor on harness, start engine on Next step
neutral gear, keep idle speed until coolant temperature
reaches normal value.
multimeter to check if there is an output voltage (after No Replace sensor
engine being warmed up) about 0.1~0.9V between pin 3#
(+) and pin 4# (-) of sensor.
8 Install adaptor between ECU and harness, use multimeter Yes Repair or replace
to detect if there are break or short circuit between ECU’s harness
pin 36# and sensor joint’s pin 3# and between ECU’s pin No Replace ECU
18# and sensor joint’s pin 4# respectively.
reach normal value.
10 Connect diagnostic tester special for Kylin, read part of Yes Next step
data flow of engine, observe if this part of data flow of No Replace sensor
oxygen sensor is fluctuating between 100~900mV.
11 Start engine and keep idle speed until coolant temperature Next step
reaches normal value.
12 Connect diagnostic tester special for Kylin, read part of Yes Check other parts
data flow of engine, observe this part of data flow of No Replace sensor
oxygen sensor, completely step on accelerator, then
loosen accelerator pedal and observe if output voltage of
oxygen sensor is below 100mV.
40
Note: When data flow of oxygen sensor is checked, engine’s operating condition must be taken care
and working temperature of engine must reach normal level, because oxygen sensor will only start
normal work at the temperature above 300℃.
11.5 Faults of Post Oxygen Sensor

Fault Code: P0136, 0137, 0138, 0036, 0037, 0038, 0054
Inspection
Result
multimeter to check if there is a battery voltage about
No 4
12V between pin 1# (+) and pin 2# (-) of the joint.
3 Use multimeter to check if resistance value between Yes Replace ECU

pin 1# and pin 2# of oxygen sensor is about 2~5Ω at
No Replace sensor
23℃.
4 Check if oxygen sensor’s heating circuit is normal Yes Next step
No Check circuit
5 Use multimeter to check if there is break or short circuit Yes Repair or replace
between pin 2# of oxygen sensor’s joint and main harness
relay’s pin 87 and that between pin 1# and ECU’s pin
No Next step
1# of oxygen sensor joint.

reach normal value.
7 Confirm if 3-way catalytic converter is working normally Yes Next step
No Replace 3-way
catalytic converter
8 Remove joint of oxygen sensor from harness, step on Yes Next step
accelerator pedal for several times in a moment, use
No Replace sensor
multimeter to check if there is an output voltage (after
engine being heated) about 0.1~0.9V between
sensor’s pin 3# (+) and pin 4# (-).
9 Install adaptor between ECU and harness, use Yes Repair or replace
multimeter to detect if there are break or short circuit harness
between ECU’s pin 36# and sensor joint’s pin 3# and
No Replace ECU
that between ECU’s pin 55# and sensor joint’s pin 4#
respectively.

reach normal value.
41
11 Connect diagnostic tester special for Kylin, read part of Yes Next step
data flow of engine, observe if this part of data flow of
No Replace sensor or
oxygen sensor is around 100 under standard idle
3-way catalytic
condition.
converter
12 Start engine and keep idle speed until coolant Next step
temperature reach normal value.
13 Connect diagnostic tester special for Kylin, read part of Yes Check other parts
data flow of engine, observe this part of data flow of
No Replace sensor
oxygen sensor, quickly step on accelerator pedal for
several times in a moment and observe if there is a
relatively large-scale fluctuations in output voltage of
oxygen sensor.
Note: Post oxygen sensor’s characteristic and operational principle are similar as that of prefix oxygen
sensor’s and they can be exchanged to use in particular condition. The unique difference is that the
installation positions (working environment) of prefix oxygen sensor and post oxygen sensor are different.
So, some inspection methods for prefix and post oxygen sensors shall be noticed during maintenance &
diagnosis process of vehicle.
11.6 Faults of Coolant Temperature Sensor

Fault Code: P0112 P0113
Item Operation Steps Inspection Subsequent Steps

Result
2 Remove joint of coolant temperature sensor from Yes Next step

hardness, use multimeter to check if voltage between this
No 4
joint’s pin 1# (+) and pin 2# (-) is 5V.
3 Use multimeter to check if resistance value between pin Yes Replace ECU
1# and pin 2# of sensor is matched to its temperature
No Replace sensor
(refer to relevant part in this service manual).
4 Use multimeter to check if there is break or short circuit Yes Repair or replace
between ECU’s pin 17# and sensor joint’s pin 2# and harness
between ECU’s pin 29# and sensor joint’s pin 1#
No Replace ECU
respectively.
5 Start engine and check if the voltage between two wires of Yes Next step
sensor is dropping following rising of engine’s water
No Replace sensor
temperature.
6 Start engine, open connector of water temperature sensor Yes Check other parts
and observe if engine’s cooling fan is started and
No Replace ECU or
operating with high speed.
circuit
42
11.7 Faults of Driving Stage of Fuel Injector
Fault Code: P0201 P0202 P0203 P0204 P0261 P0262 P0264 P0265 P0267 P0268
P0270 P0271

Result
1 Turn off ignition switch and engine doesn’t work. Next step
2 Remove all joints of electromagnetic fuel injector from Next step

harness in turn, connect two probes of multimeter to
pin 2# of this joint and engine earth respectively.
3 Turn ignition switch to “ON”. Observe if multimeter Yes Repeat step 2

displays battery voltage (mostly check if there is
Yes for all 6
power supply for fuel injector, this power is provided
by main relay) about 12V at the moment when ignition No Next step
switch is switched on.
4 Use multimeter check if there is break or short circuit Yes Repair or replace
between pin 87# of main relay’s output port of engine harness
and pin 1# of each electromagnetic fuel injector’s joint
No Next step
in turn.
5 Repair or replace relay of fuel pump, main relay and Yes Repair or replace
its circuit. harness
6 Install adaptor between ECU and harness, use No Next step

multimeter to check if there is break or short circuit
between ECU’s pin 27#, 7#, 47# or 6# and their
corresponding electromagnetic fuel injector joint’s pin
2#.
7 Use multimeter to check if there is a resistance about Yes Repeat step 7

12~16Ω between electromagnetic fuel injector’s pin
Yes for all Next step
1# and 2# (and resistance value of fuel injector) under
20℃. No Replace
electromagnetic fuel
injector
8 Re-plug all joints of electromagnetic fuel injector, start Yes Repeat step 8
engine on neutral gear and operate with idle speed.
No Replace ECU
Remove joint of each electromagnetic fuel injector
from harness in turn. Remove one joint each time,
observe if vibration of engine is intensified by this
mean (equivalent to misfire test)
Note: Damage rate of fuel injector is very low. Main fault is caused by carbon deposit at nozzle of fuel
injector. This will cause unfavorable atomization and spray of fuel injection and lead to unsteady idle
speed of engine. So, above content shall be paid high attention during inspection.
43
11.8 Faults of Driving Stage of Carbon Canister Control Valve
Fault Code: P0443, 0444, 0445

Result
1 Start engine and keep idle speed until coolant Next step
temperature of engine reach normal value.
2 Remove joint of carbon canister control valve from Yes Next step
harness, use multimeter to check if there is a battery No 5 (check live wire)
voltage about 8.6V between two pins of this joint.
3 Re-plug joint of carbon canister control valve on Yes Next step
harness, rise engine speed to 2,000rpm, touch valve No 7 (check ground
body by hand and check if there is slight vibration and wire)
impact (frequency control) on carbon canister control
valve.
4 Use multimeter check if resistance value between pin Yes Replace ECU
A and pin B of carbon canister control valve is around No Replace carbon
25Ω (20℃). canister control
valve
5 Use multimeter check if there is break or short circuit Yes Repair or replace
between pin 87# of main relay and pin B of carbon harness
canister control valve. No Next step
6 Repair or change main relay and its circuit.
7 Shut down engine, install adaptor between ECU and Yes Repair or replace
harness, use multimeter to check if there is break or harness
short circuit between ECU’s pin 46# and pin A of No Change ECU
carbon canister solenoid valve’s joint.
8 Turn ignition switch to “ON”, disconnect joint of Next step
carbon canister solenoid valve, use multimeter to
check pin A and B of solenoid valve on terminals.
9 Use multimeter to check if there is a battery voltage Yes Next step
about 12V between pin B and ground wire. No Check power supply
circuit
10 Use multimeter to check if there is a battery voltage Yes Check others
about 3.6V between pin A and ground wire. No Check ECU circuit
or replace ECU
Note: The carbon canister solenoid valve is used for emission control system and to protect environment
and prevent atmospheric pollution. This solenoid valve does not work under large load condition and at
idle speed. Unstable working condition of engine will be caused if malfunction occurs. These details shall
be noticed during service.
44
11.9 Faults of Driving Stage of Fault Indication Lamp (MIL)
Inspection
Result
2 Remove instrument panel, use multimeter to check Yes Check circuit

if there is break or short circuit among port 29# and
No Next step
30# of instrument panel and pin 62# and 81# of
ECU.
3 Replace instrument and check if instrument is Yes Next step

normal.
No Replace instrument
4 Replace ECU and re-check if it is normal Yes Change ECU
No Check others
5 Check if CAN circuit is grounded or has short Yes Replace harness

circuit.
No Check other parts
Note: Fault lamp is controlled by ECU. In case system fails, ECU will control lightening of fault lamp. The
fault lamp of this vehicle model has two types, engine fault lamp and EPC. But the engine fault lamp of
the instrument may be shielded in system. It means that the EPC lamp will be lightened when fault
occurs. This shall be noticed in service.
45
11.10 Fault of Driving Stage of Step Motor’s Coil 1# and 2#
Fault Code: P1682, 1683
Inspection
Result
1 Connect to ignition switch and not start engine. Next step
2 Remove butt joint of electronic throttle valve and Yes Next step
check if resistance between pin 5# and 3# of joint
No Replace electronic
is around 6.1Ω.
throttle valve body
3 Remove joint, use multimeter to check if there is an Yes Next step

alternative voltage about 12V between pin 5# and
No Check harness
3# of electronic throttle’s joint.
4 Use multimeter to check if there is a 12V voltage Yes Replace idle

on the joint of harness when the key is on “ON”. actuator
No Next step
5 Use multimeter to check between ECU and Yes Repair or replace

harness if there is break or short circuit between harness
pin 67# / 65# of ECU and pin 5# of joint and that
No Replace ECU
between 66# / 64# of ECU and pin 3# of joint.
Note: Other faults diagnosis have been instructed above.
46
11.11 Fault of Camshaft Position Sensor
Fault Code: P0016
Inspection
Result
2 Remove joint of camshaft position sensor from Yes Next step

harness, use multimeter to check if the voltage
No Check circuit and
between pin 1# of this joint and ground wire is around
main power supply
12V (battery voltage).

harness, use multimeter to check if the voltage
between pin 2# of this joint and ground wire is around
ECU
11.5V (supplied by ECU but less than battery voltage).
4 Use multimeter to check if there is break or short Yes Repair or replace

circuit between ECU’s pin 79# and sensor joint’s pin harness
2#.
No Next step

harness, use multimeter to check if the pin 3# of this
No Replace sensor
joint and ground wire is properly connected.
6 Plug connector of sensor and start engine Next step
7 Use oscilloscope to check if signal wire 2# has Yes Check other parts
square-wave signal outputting about 6V.
No Replace sensor
Note: Camshaft position sensor is an auxiliary sensor which has great influence on system emission.
Vehicle will be difficult to be started when this sensor fails. Even though it is almost normal after vehicle
is started, but there is a restrictive driving measures for engine that maximum speed of engine will not
beyond 4,000rpm.
47
11.12 Fault of Crankshaft Position Sensor
Inspection
Result
2 Remove joint of crankshaft position sensor from Yes Check circuit

harness, use multimeter to check if there is break
No Next step
or short circuit between joint’s pin 1# and ECU’s
pin 34#.
3 Remove joint of crankshaft position sensor from Yes Next step

harness, use multimeter to check if there is break
or short circuit between joint’s pin 3# and ECU’s
ECU
pin 15#.
4 Use multimeter to check if there is break or short Yes Repair or replace

circuit between joint’s pin 2# and ECU’s pin 79#. harness
No Next step
5 Remove joint of crankshaft position sensor from Yes Next step

harness, use multimeter to check if resistance
No Replace sensor
between two signal wires of sensor is around
1,000Ω.
6 Plug connector of sensor and start engine Next step
6 Use oscilloscope to check if signal wire has signal Yes Check other parts
wave output.
No Replace sensor
Note: Crankshaft position sensor is a main sensor of engine’s electric control system. If it fails, engine
will be difficult to be started, engine’s acceleration ability will be greatly restricted after startup and
engine’s maximum speed will not beyond 3,800rpm, meanwhile engine’s emission will be deteriorated.
48
11.12 Ignition Coil Fault
Inspection
Result
2 Remove joint of ignition coil from harness, use Yes Next step
multimeter to check if there is a battery voltage
No Check circuit
around 12V between pin 3# of this joint and ground
wire.
3 Remove joint of ignition coil from harness, use Yes Check circuit and
multimeter to check if there is break or short circuit ECU
between joint’s pin 1# and ECU’s pin 5#.
No Next step
4 Remove joint of ignition coil from harness, use Yes Check circuit and
multimeter to check if there is break or short circuit ECU
between joint’s pin 2# and ECU’s pin 2#.
No Next step
5 Check if resistance of sensor’s primary coil is Yes Next step

around 0.9Ω.
No Replace ignition coil
6 Check if resistance of sensor’s secondary coil is Yes Next step

around 14.5Ω.
7 Use oscilloscope to check if secondary ignition Yes Check other parts

wave-form of ignition system’s high-voltage wire is
normal.
Note: Ignition coil is used to provide power to engine’s ignition system. The coil has very low fault rate
but the fault of coil cannot be completely ignored. When ignition coil fails, shortage on engine’s ignition
power may cause the faults like unstable idle speed of engine and emission deterioration etc.
49
11.13 Fault of Position Sensor of Accelerator Pedal
Fault Code: P2106 P2122 P2123 P2127 P2128 P2138
Inspection
Result
2 Remove joint of accelerator pedal position sensor Yes Next step

from harness, use multimeter to check if there is a
No Check circuit
voltage signal about 5V between this joint’s pin
3#/6# and ground wire.
3 Remove joint of accelerator pedal position sensor Yes Check circuit

from harness, use multimeter to check if there is
No Next step
break or short circuit among this joint’s pin 3#/6#
and ECU’s pin 32#/33#.

No Next step

No Next step
6 Use diagnostic tester to read signal output of Yes Next step

accelerator pedal position sensor and check if
No Replace sensor
signal 1 is increased following increasing of
assembly
accelerator pedal’s opening.
7 Use diagnostic tester to read signal output of Yes Check other parts
accelerator pedal position sensor and check if
No Replace sensor
signal 2 is increasing with increase of accelerator
assembly
pedal’s opening.
Note: This pedal is an integrated circuit device and cannot be repaired. So maintenance station can
carry out maintenance by changing component in service. Do not remove sensor.
50
11.14 Dual-Brake Switch
Fault Code: P0571 P0504
Inspection
Result
2 Remove joint of brake switch from harness, use Yes Next step
multimeter to check if there is break or short circuit
No Check circuit
among this joint’s pin 1#/2# and ECU’s pin
21#/58#.
3 Switch off ignition switch, check if pin 3# of switch’ Yes Next step
joint has a battery voltage about 12V.
No Check circuit
4 Switch on ignition switch, check if pin 4# of switch’ Yes Next step

joint has a battery voltage about 12V.
No Check circuit
5 Disengage brake pedal, disconnect sensor joint Yes Next step

and check if pin 1# and pin 3# are disconnected.
No Replace brake switch
6 Disengage brake pedal, disconnect sensor joint Yes Next step

and check if pin 2# and pin 4# are connected.
7 Step on brake pedal, disconnect sensor joint and Yes Next step
check if pin 1# and pin 3# are connected.
8 Step on brake pedal, disconnect sensor joint and Yes Check others
check if pin 2# and pin 4# are disconnected.
51
11.15 Anti-Theft System Fault
Inspection
Result
1 Insert ignition key into ignition lock Next step
2 Turn ignition switch to “ON” position and observe if Yes Check others
engine fault lamp or EPC lamp is working normally
No Next step
(fast flashing of fault indication lamp or EPC lamp
means abnormal status)
3 Connect diagnostic tester to system and access Yes Eliminate fault and
relevant diagnostic program to check if system has clear fault code
fault code.
No Next step
4 Remove joint of anti-theft module from harness, Yes Next step

use multimeter to check if joint’s pin A1 and A4 has
No Check circuit
working voltage around 12V when ignition switch in
ON.
5 Remove joint of anti-theft module from harness, Yes Check circuit

use multimeter to check if there is apparatus and
No Next step
circuit fault like break and short circuit among
joint’s pin A5/A8 and ECU’s pin 31# and 71#.

use multimeter to check if joint’s pin A2 has
No Next step
improper contact with vehicle’s ground wire.

use multimeter to check if the circuit between
No Replace anti-theft
joint’s pin B1/B2/B3 and inspection coil is existing.
module
52
12. Steps for Fault Diagnosis According to Engine Symptom
12.1 Primary inspection shall be conducted at first before steps for fault diagnosis
according to engine symptom.
(1) Confirm no abnormal condition on ECU and fault indication lamp (or ECP lamp) (Vehicle model
which isn’t equipped with fault indication lamp is exempted.)
(2) Confirm no fault information record by inspecting through fault diagnostic tester.
(3) Check heat idle data of electronic control system through fault diagnostic tester and confirm all of
them are in normal range.
Heat Idle Parameter Table:
Name Parameter
Intake temperature 20-70°C
Battery voltage 12-14V (influenced by engine speed)
Temperature of engine coolant 80-90°C (normal working temperature)
Position of accelerator pedal 0%~99.00%
Air-fuel ratio control integrator 5%-5%
Ignition advance angle 5-10 (change following fluctuation of engine

speed)
Turn angle of throttle valve 0%~99.61%
Fuel injecting time ti 2-7ms (related to engine speed greatly)
Engine speed n Expected idle speed ±50rpm
Duty cycle of carbon canister control valve 0%~99.9%
Self-adaptive control valve of air-fuel ratio 0.95-1.05
Self-adaptive control valve of air-fuel ratio 120-140
Absolute pressure of intake manifold 350-650hPa
Voltage of oxygen sensor 0.1-0.9V fast fluctuation
Intake pressure
(4) Confirm if the fault complained by owner is existing and check exact position of symptom. It shall be
noticed that the information provided by owner is very important, particularly the fault symptom,
occurrence time, position and other symptoms which is never occurred. To obtain these information
can help technologist diagnose symptom quickly and improve speed and quality of maintenance.
Then carry out visual inspection:
Check if grounded positions of harness are clean and tight;
Check if there is fracture and twist on vacuum pipeline and if connection is correct.
53
Check if pipeline is jammed.
Check if intake pipeline is squeezed or damaged.
Check if the sealing face between throttle valve body and intake manifold is fine.
Check if high voltage line of ignition system is fractured, aged and correctly wired.
Check if wire connection is correct and if joint is loose or improperly contacted.
54
12.2 Engine doesn’t rotate or rotation is slow during startup
Inspection Subsequent
Item Operation Steps
Result Steps
1 Use multimeter to check if there is a voltage about Yes Next step

10~12.5V between two terminals of battery.
No Repair or replace
battery
2 Turn ignition switch to “ON”, use multimeter to Yes Next step

check if the terminal on ignition switch connecting to
No Repair pole or
battery’s positive pole has a battery voltage about
replace harness
10~12.5V.
3 Keep ignition switch on start gear, use multimeter to Yes Next step
check if the terminal on ignition switch connecting
No Replace ignition
terminal of start motor’s pull-in winding has a
switch
voltage above 8V.
4 Keep ignition switch on start gear, use multimeter to Yes Next step
check if positive pole of start motor has a voltage
No Repair pole or
above 8V
replace harness
5 Use multimeter to check if start motor is broken or Yes Repair or replace

short circuit. start motor
No Next step
6 Check if engine is jammed due to improper Yes Eliminate fault

lubrication.
No Next step
7 If in winter, check if over-high resistance force of Yes Replace proper

start motor is caused by improper selection on lubricant
engine lubricant and gear box oil.
No Check if other
systems are
normal
Note: Mainly check voltage, starter and ground system if this problem occurs. In modern cars, influence
of lubricant on startup of vehicle is very small and this can be ignored mostly. Also it shall be considered
that if engine itself has excessive resistance force.
55
12.3 Engine can be rotated by traction but cannot start successfully during starting
Inspection
Result
1 Turn ignition switch to “ON” and use fault Yes Eliminate displayed
diagnostic tester to check if there is fault fault
information record.
No Next step
2 Pull out ignition wire, connect spark plug, put Yes 8

electrode of spark plug at the position about
No Next step
8~10mm long to engine body, use start motor
drive engine and check if there is a white-blue
high-voltage spark (disconnect all fuel injector of
engine).
3 Check if resistance value of high voltage line is Yes Next step

normal (no more than 16kΩ).
high-voltage wire
4 Check if ignition coil and high voltage line is Yes Replace

ablated, damaged and has fracture.
No Next step
5 Check if high voltage line is normal Yes Replace
No Next step
6 Check if ignition coil is normal Yes Next step
No Replace
7 Check if connectors of ignition coil and high Yes Next step

voltage line are properly connected
No Connect joint
properly
8 Turn ignition switch to “ON” and check if fuel Yes Next step
pump relay and fuel pump can keep on working
No Check fuel pump
for a period.
circuit
9 Connect fuel pressure gauge valve, short-circuit Yes Next step

pin 30# and 87# of fuel pump relay, operate fuel
No 13
pump and check if fuel pressure is around
400kPa.
10 Pull out fuel distribution pipe with fuel injector, Yes 12

and remove joints of fuel injectors from harness
No Next step
one by one, provide 12V voltage from battery to
fuel injector directly and check if fuel injector can
spray.
11 Check if fuel injector can spray after fuel injector Yes Next step
56
is cleaned. No Replace fuel
injector
12 Check if fuel is deteriorated or water-contained. Yes Replace fuel
No 18
13 Check if fuel pressure is lower than 400kPa Yes Next step
No 17
14 Switch off fuel gauge valve. Switch on ignition Yes Next step
switch again to operate fuel pump for a period
No 16
and check if oil pressure can be built up.
15 Open fuel gauge valve, clamp oil return pipe Yes Check others
strictly with fuel tube clamp to stop oil return and
check if oil pressure can be built up quickly.
fuel pump
16 Check if oil inlet has leakage or jamming. Yes Repair or replace

fuel pump
No Replace fuel pump
17 Check if oil return pipe is jammed or bent Yes Repair or replace

oil return pipe
No Replace fuel
pressure regulator
18 Check if there is break or short circuit among pin Yes Repair or replace
1#/pin 2# of crankshaft position sensor and pin harness
34#/pin 15# of ECU.
No Next step
19 Check if components of intake system have Yes Repair

leakage.
No Next step
20 Check if air flow meter is working normally. Yes Repair or replace
No Next step
21 Check if coolant temperature sensor is normal Yes Next step
No Repair or change
22 Check if unsuccessful startup is caused by Yes Eliminate

mechanical factors such as too big gap between mechanical fault
piston and cylinder, air leakage on cylinder, etc.
No Replace ECU
Note: If all components and parts of electronic injection system are normal when this problem is
checked, engine’s mechanical part shall be considered if it is working normally, the cylinder pressure
and leakage etc. shall also be considered.
57
12.4 Difficult hot-start
Result
1 Turn ignition switch to “ON” and use fault diagnostic Yes Eliminate
tester to check if there is fault information record. displayed faults
No Next step
2 Connect fuel pressure valve, short-circuit pin 30# and Yes Next step
87# of fuel pump relay, operate fuel pump and check if No 9
fuel pressure is around 400kPa.
3 Disconnect connection oil pipe, switch off ignition Yes Next step
switch and observe if fuel system pressure can keep at No Repair leakage of
300kPa 1 hour later. fuel system
4 Connect connection oil pipe, use fuel tube clamp to Yes Replace fuel
stop oil return pipe, meanwhile close fuel pressure pressure regulator
valve. Switch off ignition switch and observe if No Next step
pressure of fuel system can be kept around 400kPa 1
hour later.
5 Check if fuel injector and fuel pipe have fuel leakage. Yes Replace fuel
injector and fuel
pipe
No Next step
6 Remove joint of water temperature sensor, start Yes Check coolant
engine and observe if it can be successfully started. temperature and
circuit
No Next step
7 Install adaptor between ECU and Harness, check if pin Yes Next step
39#/17# of ECU have a voltage around 5V, and No Repair or replace
meanwhile check if resistance value of water harness
temperature is in normal range.
8 Replace ECU, hot-start engine again and observe if it Yes Finished
is successful. No Replace ECU
9 Check if fuel pipe is jammed or bent and if pressure Yes Next step
regulating valve of fuel pump is working normally. No Repair or replace
10 Use multimeter to check if connectors on both sides of Yes Next step
fuel pump have battery voltage. No Repair or replace
fuel pump relay or
harness
11 Try to change fuel pump and observe if system can Yes Next step
return normal condition. No Replace fuel pump
12 Check if fuel pump is jammed. Yes Replace fuel pump
No Replace ECU
Note: Difficulty on hot-start of engine concerns many systems like battery, throttle valve body and water
temperature etc. It is also related to engine’s mechanical part, like throttle valve sealing. Engine’s
resistance force will be strengthened by engine’s thermal expansion when engine is under hot condition.
58
12.5 Start is still difficult to start even though speed is normal

Result
1 Turn ignition switch to “ON” and use fault Yes Eliminate displayed
diagnostic tester to check if there is fault faults
information record.
No Next step
2 Check if air filter is working freely. Yes Next step
No Replace
3 Check if engine’s air input is around 300kg/h Yes Next step

(notice to check if cylinder pressure is normal)
No Eliminate leakage of
after successful startup
intake system
4 Step on throttle valve slightly and observe if Yes Replace electronic

engine can be started easily. throttle valve body
5 Connect fuel pressure valve, short-circuit pin 30# Yes Next step
and 87# of fuel pump relay to operate fuel pump
No 9
and observe if fuel pressure is around 400kPa.
6 Use special joint to provide 12V voltage and Yes 8

uncontinuous grounded wire from battery to fuel
No Next step
injector, observe if fuel injector is normal working
(intermittent work).
7 Check if fuel inject is working normally again after Yes Next step
fuel injector is cleaned.
No Replace fuel injector
8 Replace fuel 8, check if fuel is deteriorated or Yes Replace fuel

water-contained.
No 14
9 Check if fuel pressure is lower than 300kPa. Yes Next step
No 13
10 Close fuel pressure valve, reclose ignition switch Yes Next step
to operate fuel pump working for 3 seconds and
No 12
check if oil pressure can be built up.
11 Open fuel pressure valve, strictly clamp oil return Yes Replace fuel
pipe by fuel tube clamp to stop fuel return and pressure regulator
observe if oil pressure can be built up quickly.
fuel injector or fuel
pipe

fuel inlet
59
13 Check if oil return pipe has jammed or bent. Yes Repair or replace oil
return pipe
No Replace fuel
pressure regulator
14 Remove electronic throttle valve body on harness Yes Next step

when engine coolant is at low temperature and
No Check if electronic
observe if engine speed is rising.
throttle valve body is
broken
15 Turn ignition switch to “ON”. Check if following Yes Next step

pins of ECU are normal: if pin 12#, 14# and 15#
No Check harness and
have battery voltage about 12V; if voltage
connectors
between wire and pin 51#/53#/3#/61#/80# is 0.
16 Check if ignition advance angle is normal. Yes Next step
No Check other
systems
17 Check if cylinder compressing pressure of engine Yes Next step

is normal. If the pressure is relatively low, add a
No Eliminate fault
little lubricant into each cylinder and test if cylinder
pressure is normal.
18 Check if air filter or air flow sensor is jammed. Yes Repair or replace
No Next step
19 Check if coolant temperature sensor is normal. Yes Replace ECU
Note: It shall be noticed if anti-theft system is started. If the anti-theft system has been started, startup
work will be operating normally but engine cannot be started when engine is started. So this system’s
operation shall be noticed if it is normal.
60
12.6 Start is difficult when engine is cool

Result
1 Turn ignition switch to “ON” and use fault diagnostic Yes Eliminate displayed
tester to check if there is fault information record. faults
No Next step
2 Use multimeter to check if coolant temperature Yes Next step

sensor is normal. (A resistance about 2.8kΩ is also
No Replace sensor
connected in series between ECU’s pin 39# and pin
17# instead of coolant temperature sensor to start
engine. If engine can be started, it means coolant
temperature sensor is abnormal.)
3 Turn ignition switch to “ON”. Check if following pins Yes Next step
of ECU are normal: if pin 12#, 14# and 15# have
No Check harness and
battery voltage about 12V; if voltage between wire
connector
and pin 51#/53#/3#/61#/80# is 0.
No Replace
5 Check if engine’s air intake is around 300kg/h at idle Yes Next step
speed (notice to check if cylinder pressure is normal)
No Eliminate intake
leakage fault of
system
6 Step on throttle valve slightly and observe if engine Yes Check electronic
can be started easily. throttle valve
No Next step
7 Remove joint of electronic throttle valve on harness Yes Next step

when engine’s coolant temperature is low and
No Check electronic
observe if engine speed is rising.
throttle valve body
8 Connect fuel pressure valve, ground pin 86# of fuel Yes Next step
pump relay directly, connect to ignition switch to
No 12
operate fuel pump relay and fuel pump, observe if
fuel pressure is around 400kPa.

uncontinuous grounded wire from battery to fuel
No Next step
injector, observe if fuel injector is normally working.
10 Check if fuel inject is working normally again after Yes Next step
11 Replace fuel and check if fuel is deteriorated or Yes Replace fuel
61
water-contained. No 17
No 16
13 Close fuel pressure valve, reclose ignition switch to Yes Next step
operate fuel pump working a little longer and check if
No 15
oil pressure can be built up.
14 Open fuel pressure valve, clamp oil return pipe by Yes Check fuel pressure
fuel tube clamp to stop fuel return and observe if oil regulator and fuel
pressure can be built up quickly. pump
fuel injector or fuel
pipe

fuel oil inlet
16 Check if oil return pipe has been jammed or bent. Yes Repair or replace oil
return pipe
No Replace fuel
pressure regulator or
fuel pump
17 Check if engine’s cylinder pressure is normal. Yes Next step
No Eliminate fault
18 Check of engine’s intake system has leakage. Yes Repair
No Next step
19 Check if air filter or air flow sensor is jammed. Yes Repair or replace
No Replace ECU
Note: Fault points that cold-start concerned are relative more. The relatively important item is water
temperature sensor because main parameters determining width of fuel injection pulse is from water
temperature sensor when engine is started. So, if water temperature sensor fails or has incorrect signal,
system cannot judge temperature and engine will be difficult to be started.
62
12.7 Idle speed is not stable anytime
No Next step
2 Check if engine’s electronic throttle valve system is Yes Repair or replace

working normally. electronic throttle
valve
No Next step
3 Connect to ignition switch, install adaptor between Yes Check harness and
ECU and harness and check if voltage of ECU’s pin connectors
17# & 42# and pin 39# & 17# (signal output ports of
No Next step
intake temperature and coolant temperature
respectively) and its pin 64#/65#/66#/67# (for DC
motor control) is normal.
4 Keep engine running at idle speed, misfire cylinder Yes 8

one by one and observe if engine speed has drop or
No Next step
fluctuation (fuel injector lose fuel supply).
5 Check if working condition of fuel injector in each Yes Next step

cylinder is normal.
No Check fuel injector
and harness
6 Check if resistance value of ignition cable in each Yes Next step

cylinder is normal (cannot beyond 16kΩ).
No Replace
7 Check if ignition system is working normally. Yes Repair
No Next step
8 Check if spark plug is working normally. Yes Next step
No Replace spark plug
and 87# of fuel pump relay to operate fuel pump and
No 13
observe if fuel pressure is around 400kPa.

uncontinuous grounding signal from battery to fuel
No Next step
injector, observe if fuel injector can intermittently
working.
11 Check if fuel injector is working normally again after Yes Next step
12 Change fuel and check if fuel is deteriorated or Yes Replace fuel

water-contained.
No 18
63
No 17
operate fuel pump working a little bit longer and
No 16
check if oil pressure can be built up.
15 Close fuel pressure valve, clamp oil return pipe by Yes Replace fuel
fuel tube clamp to stop fuel return and observe if oil pressure regulator
pressure can be built up quickly.
fuel injector or oil
pipe

fuel return pipe
17 Check if oil return pipe has been jammed or bent. Yes Repair or replace
fuel return pipe
No Replace fuel
pressure regulator
18 Check pressure of intake manifold and if intake Yes Clean by cleaning

temperature sensor’s sensing hole is jammed. agent
No Next step
19 Run engine at idle speed and observe if oxygen Yes Next step
sensor is working normally (fast fluctuating in
No Check oxygen
0.1~0.9V) when coolant temperature reaches the
sensor and harness
temperature that can activate close-loop control.
Check if engine’s intake system has leakage. Yes Eliminate leakage

20
No Next step
21 Check if engine’s cylinder pressure is normal. Yes Next step
No Eliminate leakage
22 Run engine at idle speed and check if ignition Yes Replace ECU
advance angle is in standard range by special
No Check others
diagnostic tester when coolant temperature reaches
normal value.
Note: Unstable idle speed concerns many systems, like air leakage, carbon deposit and throttle body,
etc. But whether engine’s air filter, spark plug and ignition system are normal must be confirmed before
replacement of components and parts.
64
12.8 Unstable idle speed during warming-up
No Next step
No Replace
3 Check if engine’s air input is around 300kg/h (notice Yes Next step
to check if cylinder pressure is normal) after
No Eliminate air leakage
successful startup
of intake system
4 Connect to ignition switch, install adaptor between Yes Next step

ECU and harness and check if voltage of ECU’s pin
No Repair
motor control) are normal.
5 Remove joint of electronic throttle valve body before Yes Next step
warming-up of engine is finished and observe if
No Check electronic
engine speed is changed.
throttle valve body
6 Check if coolant temperature sensor is normal. Yes Next step
No Replace
7 Run engine at idle speed and check if ignition Yes Replace ECU
advance angle is normal by special diagnostic tester
No Check ignition timing
when coolant temperature reaches normal value.
mechanism
Note: Unstable idle speed rarely happens during warming-up. The method to eliminate this problem is
similar to above condition but need to check if water temperature is working normally at first.
65
12.9 Unstable idle speed after warming-up
No Next step

ECU and harness and check if voltage of ECU’s pin
harness
3 Shut down engine and check if air filter is working Yes Next step
freely.
No Replace
4 Check if engine’s air input is around 300kg/h at idle Yes Next step
No Eliminate air leakage
of intake system
No 9
6 Use special joint to provide 12V power supply from Yes 8

battery to fuel injector, disconnect ground wire
No Next step
intermittently and check if fuel injector can work
intermittently.
7 Check if fuel injector can work normally again after Yes Replace
No 14
No 13
operate fuel pump for a period and check if oil
No 12
pressure can be built up.
11 Open fuel pressure valve, strictly clamp fuel return Yes Replace fuel
pipe with fuel tube clamper to stop oil return and pressure regulator
pipe
66
12 Check if oil inlet has leakage or jamming. Yes Repair or replace oil
pipe
13 Check if oil return pipe is jammed or bent. Yes Repair or replace oil
return pipe
No Replace fuel
pressure regulator
14 Run engine at idle speed and check if ignition Yes Next step
No Check other systems
15 Remove coolant temperature sensor and observe if Yes Replace coolant

engine is working normally. temperature sensor
No Next step
16 Check if cylinder compression pressure of engine is Yes Next step

normal.
No Eliminate fault
17 Check if resistance values of each cylinder’s ignition Yes Next step

cables are normal (cannot beyond 16kΩ).
No Replace
18 Check if ignition coil and ignition cable system is Yes Replace

working normally, if ignition coil has fracture.
No Next step
19 Check if spark plug is normal. Yes Replace ECU
Note: Engine will enter normal idle condition after warming-up is finished. Unstable speed under normal
idle condition concerns many factors, such as spark plug, ignition cable, ignition coil, whether system
has air leakage and carbon deposit, and whether cylinder pressure is normal etc.
67
12.10 Unstable idle speed or shut-down on load (air conditioner etc.)
No Next step
2 Connect to air conditioner switch, install adapter Yes Next step

between ECU and harness and check if ECU’s pin
No Repair air
75# (high potential signal input by air conditioner
conditioning circuit
switch through high/low-pressure switch) has signal
input.
3 Check if pressure of air conditioning system, Yes Next step

electromagnetic clutch of compressor and air
conditioning pump are normal.
4 Check if the voltages on ECU’s pin 64#/65#/66#/67# Yes Next step

(for DC motor control) and their corresponding pins
No Check control circuit
on valve body are normal.
5 Remove electronic throttle valve body and check if Yes Check electronic
throttle valve is jammed or not operate freely. throttle valve body
No Next step
6 Start engine, switch on air conditioner, use Yes Replace ECU

diagnostic fault tester to read signals like intake flow
No Check electronic
and engine speed and check if engine is speeding
throttle valve body
up.
Note: Pin 75# is high-level request signal. When air conditioner switch is turned on, a high-level signal
will be sent to ECU from this pin and ECU will check other air conditioning system. If systems are normal,
ECU will control relay of air conditioner to be grounded and air conditioning system. ECU’s pin 60# is
medium-voltage input and cooling fan will be started and running with high speed when this pin receives
high-potential signal.
68
12.11 Unstable periodicity (must conduct self-learning after ECU is power-off)
No Next step
No Replace
speed (notice to check if cylinder pressure is normal) No Repair intake and
after successful startup leakage
4 Run engine at idle speed, misfire cylinder one by one Yes 7
and observe if engine speed has drop and fluctuation No Next step
(forbidden disconnecting ignition cable to conduct
misfire test).
ECU and harness and check if voltages of ECU’s pin No Repair or replace
17# & 42# and pin 39# & 17# (signal output ports of harness
advance angle is normal by special diagnostic tester No Check others
7 Check if intake system has the faults which affects Yes Clean it
engine’s operation such as jamming and air leakage, No Next step
etc.
No Next step
9 Use special joint to provide 12V power supply and Yes Next step
intermittent ground wire from battery to fuel injector. No Repair fuel injector
Check if fuel injector can work intermittently. and relevant harness
10 Check if resistance values of each cylinder’s ignition Yes Next step
cables are normal. No Replace
11 Check if ignition coil is broken or fractured. Yes Replace
No Next step
12 Check if spark plug is normal Yes Replace ECU
Note: Mostly, the system shall be checked if intake system has air leakage or electronic throttle valve
body fails when periodical unstable condition occurs. The method to check electronic throttle valve body
is: throttle valve will have a slight vibration meanwhile ignition key is turned on and the throttle valve shall
act with action of accelerator pedal during self-inspection.
69
12.12 Too high idle speed (self-learning must be carried out after ECU is power-off)
No Next step
2 Check if valve plate of throttle valve is jammed and if Yes Adjust or replace
electronic throttle valve fails.
No Next step
3 Check if carbon canister control valve, fuel pressure Yes Repair or replace
regulator, forced-draught crankcase vacuum tube
No Next step
and the tube of brake system’s vacuum booster are
reliably installed or broken.
4 Run engine at idle speed, step on brake pedal with Yes Next step
neutral gear and observe if idle speed is too high.
No 6
5 Clamp tube of vacuum booster and observe if idle Yes Repair or replace
speed turns to normal condition. vacuum booster
No Next step
6 Replace PVC valve, clamp forced-draught crankcase Yes Replace PVC valve
vacuum tube and observe if idle speed turns to
No Next step
normal condition.
7 Clamp tube of carbon canister control valve and Yes Replace carbon
observe if idle speed turns to normal condition. canister control valve
No Next step
8 Check if electronic throttle valve is inflexible or Yes Repair or replace

jammed.
No Next step
9 Check if intake pipe and other places have leakage. Yes Repair or replace
No Next step
10 Check if fuel injector’s seal ring is fine. Yes Next step
No Replace seal ring
11 Check if intake system has air leakage and if air flow Yes Replace ECU
meter is working normally.
No Replace sensor
Note: Check if system has implemented self-learning. If system doesn’t implement self-learning, it will
keep on fault mode or uncertain status. This will cause too high idle speed of engine. The other problem
is air leakage of system. If the volume of air leakage is too big and beyond ECU’s control range, idle
speed will turn up and down frequently.
70
12.13 Speed cannot rise or misfire during accelerating
No Next step
No Replace
3 Run engine at idle speed and check if the speed is Yes Next step
normal.
No Repair according to
the clauses about
idle speed fault in
next step.
No Repair
No Check other systems
when coolant temperature reaching normal value.
No 10
7 Use special joint to provide 12V power supply and Yes 9

intermittent wire grounding from battery to fuel
No Next step
injector. Check if fuel injector can work intermittently.
8 Check if fuel injector can work normally after Yes Next step
cleaning fuel injector.
No 15
No 14
run fuel pump for a period and check if oil pressure
No 13
can be built up.
pipe
71
inlet
No Change fuel pump
return pipe
No Replace fuel
pressure regulator
15 Turn ignition switch to “ON”. Check if the voltage of Yes Next step
following pins of ECU are normal: if pin 12#/14#/15#
has a battery voltage about 12V and if the voltage
harness
between wires and pin 51#/53#/3#/61#/80# are zero.
16 Check if ignition coil, high voltage line and spark plug Yes Replace ECU
are normal.
relevant components
and parts.
Note: This is a relatively obvious fault and some details shall be checked too e.g. If system cleaner and
air exhaust are jammed etc. Others like spark plug and ignition cable and etc. shall be checked as well.
72
12.14 Slow response during accelerating
No Next step
freely.
No Replace
normal.
the clauses about
idle speed fault
4 Run engine at idle speed and check if intake Yes Next step
pressure is about 35~65kPa.
No Repair
5 Turn ignition switch to “ON” and check if there is Yes Next step
break or short circuit among pin 38#/32#/54#/36# of
ECU connector and pin 1#/2#/4#/6# of electronic
harness
throttle valve body’s throttle valve position sensor.
No Check others
when coolant temperature reaches normal value
No 11
intermittent 12V power supply from battery directly to
No Next step
fuel injector. Check if fuel injector can work
intermittently.
9 Check if fuel injector can work normally after fuel Yes Next step
injector cleaned.
No 16
No 15
No 14
can be built up.
pipe
inlet
return pipe
73
No Replace fuel
pressure regulator
16 Check if exhaust system and 3-way catalytic Yes Replace or clean
converter are jammed.
No Replace ECU
Note: Mostly, when response is slow during acceleration, check intake pressure and width of fuel
injection pulse etc. shall be checked. This problem occurs easily when exhaust pipe is jammed and air
filter is contaminated. Additionally, this problem is caused by fault of spark plug and ignition cable.
74
12.15 Poor performance and weak acceleration during accelerating
1 Check if clutch is slipping, if pressure of tires are low, Yes Repair

if brake is delayed, if dimension of tires is incorrect
No Next step
and if position of four tires is incorrect, etc.
2 Check if electronic throttle valve can be fully opened. Yes Next step
No Replace or repair
throttle
No Next step
4 Run engine at idle speed and check ignition advance Yes Next step
angle by special diagnostic tester when coolant
No Check relevant parts
temperature reaches normal value
and components
5 Turn ignition switch to “ON”, check if there is break or Yes Next step
short circuit among pin 38#/32#/54#/36# of ECU
connector and pin 1#/2#/4#/6# of electronic throttle
harness
body’s throttle position sensor, also check if voltages
of ECU’s pin 17# & 42# and pin 39# & 17# (signal
output ports of intake temperature and coolant
temperature respectively) and its pin
64#/65#/66#/67# (for DC motor control) are normal.
6 Run engine at idle speed and check if intake Yes Next step
pressure is about 35~65kPa.
No Repair
No 11
intermittent ground wire from battery directly to fuel
No Next step
injector, check if fuel injector can work intermittently.
injector is cleaned.
No 16
No 15
No 14
can be built up.
13 Open fuel pressure valve, strictly clamp fuel return Yes Replace pressure
pipe with fuel tube clamper to stop oil return and regulator
pipe
inlet
75
return pipe
No Replace fuel
pressure regulator
16 Check if intake system is leaking or jammed and if air Yes Next step
flow meter is working normally.
No Replace sensor
17 Check if spark plug, ignition cable and ignition coil Yes Next step
are normal.
No Replace or adjust
18 Check if this is caused by air conditioning system. Yes Check air
conditioning system
No Replace ECU
Note: Unfavorable system acceleration concerns many factors, e.g. cylinder pressure and carbon
deposit on throttle valve. This is also related to other systems of engine, e.g. power steering system and
air conditioning system.
76
12.16 Not reach maximum speed during accelerating
No Next step
freely (do not observe by sight purely and conduct No Replace
commissioning after removal of air filter) and if intake
system is jammed.
normal. No Repair according to
the clauses about
idle speed fault
speed (notice to check if cylinder pressure is normal) No Repair
after successful startup.
break or short circuit among pin 38#/32#/54#/36# of No Repair or replace
ECU connector and pin 1#/2#/4#/6# of electronic harness
throttle body’s throttle position sensor.
advance angle is normal by special diagnostic tester No Check others
when coolant temperature reaching normal value
and 87# of fuel pump relay to operate fuel pump and No 11
8 Check if working condition of camshaft/crankshaft Yes Next step
position sensor is normal. No Replace relevant
parts
injector is cleaned. No Replace fuel injector
No 16
No 15
converter are jammed. No Replace ECU
Note: If maximum speed of engine cannot be reached during accelerating, mostly need to check if
exhaust pipe jammed and if air filter is contaminated. Additionally, when crankshaft/camshaft position
sensor of A21’s electric control system fails, ECU system will adopt restrictive driving measures to limit
engine speed within a definite value. So these problems shall be noticed during service.
77
12.17 Loosen accelerator after acceleration and engine gets unstable idle speed
instantly even misfire
No Next step
freely (do not observe by sight purely and conduct
commissioning after removal of air filter) and if intake No Replace
system is jammed.
normal.
the clauses about
idle speed fault
after successful startup No Repair
break or short circuit among pin 38#/32#/54#/36# of
ECU connector and pin 1#/2#/4#/6# of electronic No Repair or replace
throttle valve body’s throttle position sensor. harness
when coolant temperature reaches normal value No Check others
observe if fuel pressure is around 400kPa. No 11
8 Remove intake tube and check if there is carbon Yes Clean carbon deposit
deposit or other contaminations between throttle
valve body’s valve plate and its valve body causing No Next step
engine’s intake system is jammed when valve plate
is closed.
injector is cleaned.
No 16
No 15
converter are jammed.
No Replace ECU
Note: Main actuating components of the intake system of electronically controlled engine with electronic
throttle valve are air flow meter and electronic throttle valve. The air flow meter has very high working
reliability and very low fault rate. Due to particularity road condition in China and impact of operating
environment, the part between valve plate and valve body of electronic throttle valve is easy to be
jammed and this will obstruct air entering engine and causing misfire of engine easily.
78
12.18 Air conditioning system fault
1 Check if system has sufficient refrigerant, if air Yes Next step

conditioning belt is normal, if air conditioning
No Eliminate faults
clutch and pressure switch are normal.
2 Run engine at idle speed, switch on switch of air Yes Eliminate displayed
conditioner and check if air conditioning system faults
fails through self-diagnostic mode of air
No Next step
conditioner.
3 Switch on switch of air conditioner, install adopter Yes Next step

between ECU and harness, check if ECU’s pin
No Check harness
75# (switch of air conditioner) has signal input.
4 If this vehicle model adopts low-level control, Yes Repair or replace

check if air conditioner is working yet when it is harness
shut down.
No Next step
5 Check if ECU’s pin 69# (connect to grounding Yes Repair air conditioning
terminal of air conditioning relay’s sucking coil) relay and harness.
has low-level output.
No Replace ECU
Note: The air conditioner system of A21 is different from that of other vehicle models. This system
adopts automatic air conditioner and use dual-voltage switch to control the connection of air conditioning
system and the fan control after startup.
79
13. Safety Cautions for System Maintenance
13.1 Safety Cautions for Diagnosis and Maintenance of Electronic Gasoline Injection
Control System
(1) Requirement on Removal & Assemble of Electronic Control Unit (ECU):
Controller shall be removed before conducting electric welding and baking paint;
Ignition switch must be turn to “OFF” position during removing of controller, meanwhile disconnect
connection between battery and system to avoid damage on engine’s electronic unit during removal;
Do not disconnect power cable from battery during operation of engine or electric appliance system;
Do not use the equipment with large current like fast charger to start engine directly;
Notice that ambient environmental temperature of controller cannot beyond 80℃;
(2) Requirement on Cleaning: Before operating fuel supply system and fuel injection system,
the following regulations shall be complied carefully:
Removed parts shall be placed at clean place and properly covered and do not use the cloth (cotton
fabric, gauze) whose fiber is easy to be brushed off;
(3) Connection and disconnection for all connectors of harness and diagnostic fault tester shall
be conducted after ignition switch is shut down;
Correctness of connection sequence and mode for detection wiring must be assured when conducting
measurement of power supply voltage or grounding wire earthing to electronic control system;
Disconnecting power supply cable or grounding wire of battery from system and disconnecting wire joint
of electronic control unit (ECU) will make the information about diagnosis and self-learning stored in
electronic control unit (ECU) lost (information retention time of electronic control unit mounted on
different vehicle models after power-off is different too).
(4) Cautions for Maintenance Fuel Supply System (Fuel Supply Pipeline, Fuel Pump and Fuel
Injection System)
When remove and install fuel pump on the fuel tank filled with fuel, it shall be noticed that:
Before operation, the position around open end of fuel tank shall prepare materials which can absorb a
lot of effused fuel in time;
Avoid direct contact between skin and gasoline as much as possible;
Thoroughly clean connected parts and periphery of connectors before loosening this part;
For avoiding loosened part to spray fuel, cloth shall be placed around connected part;
If disassembled parts and components cannot be repaired or taken other treatment timely, they shall be
stored properly;
Spare parts shall be taken out from package after being confirmed to be installed and do not use the
spare part without package or its package is worn heavily;
80
Do not break the O-ring on both ends of fuel injector when installing fuel injector and the O-ring shall be
painted with a little lubricant for convenience of installation.
Do not use compressed air and don’t remove vehicle as much as possible after removal of fuel and fuel
supply system.
(5) Safety Measures
In order to avoid injury to technologist and damage to fuel injection and ignition device, it shall notice
that:
Forbid disconnect ignition harness when engine is operating or under start speed, do not use the method
that disconnect ignition cable to test ignition and judge if engine has the condition that single cylinder is
working abnormally;
If engine is driven by starter but not by itself, for example in the application that inspect engine’s cylinder
pressure and etc., you need to disconnect wire joint from engine’s tachometer and camshaft (phase)
sensor, each sensor shall be connected properly after completion of relevant work and use diagnostic
tester special for Kylin to clear fault code in system;
When engine is running with high speed, do not touch gear train and rotating parts of engine by hands;
When engine reaches normal working temperature, water temperature and pressure of cooling system
will be very high. So service to engine’s cooling system shall be conducted after engine being shut down
if needed and cooling system being fully cooled;
When conducting service to engine’s fuel system, the operation shall be carried out when temperature of
engine casing is fully dropped if concerning maintenance to engine casing;
Do not touch engine cooling fan by hands anytime if system is charged normally because cooling fan is
possible to be started suddenly.
81

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M1 Service Manual

(UAES 473F Engine Electronic Fuel Injection Section)

After-sales Service Department of Chery International Company

1. Removal & Installation of Electronic Fuel Injection System Component .................................... 4

CHAPTER 2 PRINCIPLE OF ELECTRONIC FUEL INJECTION SYSTEM ............................................. 6

І. System Component Overhaul...................................................................................................... 6

1. Intake Pressure & Temperature Sensor ............................................................................... 6

CHAPTER 2 BASIC DIAGNOSIS PRINCIPLE FOR ELECTRONIC INJECTION SYSTEM............... 31

1. Fault Information Record.................................................................................................... 31

1. Removal & Installation of Electronic Fuel Injection System

2. Position & removal of intake pressure sensor

3. Position & removal of camshaft position sensor

4. Remove fixing clamp of intake hose

6. Use screwdriver to press and hold the fixing clip of fuel

7. Use screwdriver to press and hold the fixing clip of knock

8. Water temperature senor is behind thermostat base

9. Pull out the connector of ignition coil’s primary coil by

10. Pull out the connector of engine’s tachometer by hand

І. System Component Overhaul

1. Intake Pressure & Temperature Sensor

1.1 Sensor Function:

1.2 Sensor Principle:

1.3 Technical Characteristics & Parameters

1.4 Fault Symptom and Judgment Method

● General fault cause:

1. Abnormal high pressure or large reverse current occurs during operation;

2. Vacuum component is damaged during service.

● Simple measuring method:

1.4.1 Temperature Sensor Part:

1.4.2 Pressure Sensor Part

2.1 Sensor Function:

2.2 Operation Principle of Sensor

1 Shielding cable 2 Permanent magnets

3 Sensor housing 4 Installation bracket

7 Air gap 8 Tooth coil

2.3 Technical Characteristics and Parameters

2.4 Cautions for Installation

● It is recommended to use seal bolt M6×12 to fix inductive tachometer.

● Tightening torque shall be 8±2Nm.

● General fault cause: man-made fault.

● Simple measuring method:

3.1 Sensor Function:

3.2 Operational Principle of Sensor

3.3 Fault Symptom and Judgment Method

● Normal fault cause: man-made fault.

● Simple measuring method:

4. Water Temperature Sensor

4.1 Sensor Function:

4.2 Operational Principle of Sensor:

Parameter Value Unit

4.4 Cautions for Installation

4.5 Fault Symptom and Judgment Method

● General fault reason: man-made fault.

● Simple measuring method:

5.1 Sensor Function:

5.2 Operational Principle of Sensor:

5.3 Cautions for Installation

5.4 Fault Symptom and Judgment Method

● Caution for service: (refer to the Caution for Installation)

6. Electronic Throttle Body

6.2 Operational Principle:

Electronic throttle valve

6.3 Symptom Diagnosis