United Electronic Engine Management System PDF

EF.
1-1
United Electronic engine management system

Page
Description of system.................................................................................................
Precautions to the maintenance of electric-injection system..........................................
Analysis of the function /principal /failure for system parts &components .....................
General troubleshooting and steps to engine ...............................................................
Criterion to flashing code /mounting torque of components within M1.5.4 system........
Description of the diagnosis function on M7.9.7 system failure....................................
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M7.9.7 system service &diagnosis flow process based on fault code..........................
EF.1-2 UASE Electronic Control Engine Management System -System Introduction
Description of system
Model GW491QE petrol engine adopts BOSCH Motronic1.5.4 and Motronic7.9.7 engine management system
for electric-injection: As for the exhaust, the former is in compliance with European Class-II standard, and the
latter is in compliance with European Class-III standard.
BOSCH Motronic1.5.4 engine management system for electric-injection
As one set of advanced engine management system, M1.5.4 system has one engine electronic control unit
abbreviated to ECU used as the control center, and is able to measure various working parameters of
engine using appropriate sensors installed at different position of engine, to precisely control the oil injection
amount and the ignition lead-angle as per control programs set in engine electronic control unit, and to have
engine working with best performance under various conditions, ie. optimum dynamic output, most cost-
effective oil consumption, and best tail gas exhaust.
M1.5.4 system is subject to a multi-point oil injection control as per some sequence, and its control strategy
covers: starting control, closed-loop control of idle-speed, closed-loop control of air /fuel ratio, carbon-canister
control, transition working condition control, ignition angle control, knock control, air-conditioner control, slide
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oil cut control, over-speed oil cut control, heating &protection control by three-way catalytic converter, and
system self-diagnosis, etc. The system has provided ABS, automatic gear box, air bag, etc, with applicable
communication interfaces, and is with theft-prevention function. The system is composed of three parts: sensor
air inlet pressure /temperature sensor, throttle position sensor, cooling-fluid temperature sensor, knock sensor,
oxygen sensor LSH25, rotating speed sensor, phase sensor , actuator idle-speed adjustor EWD3, oil injector
EV6, electrical fuel pump, fuel pressure adjustor DR, carbon-canister control valve TEV, and ignition coil
ZSK , and ECU electronic controller.
BOSCH Motronic7.9.7 engine management system for electric-injection
The key feature of M7.9.7 engine electronic control management system is the application of a control
strategy based on torque aimed at linking a number of various controlled objects together. And this is the only
fixed method to have various functions integrated on ECU flexibly in accordance with the model of engine and
vehicle.
Basic components within the M7.9.7 engine electronic control system include: electronic controller ,
air inlet pressure /temperature sensor, air mass flowmeter, cooling-fluid temperature sensor, throttle position
sensor, phase sensor, rotating speed sensor, knock sensor, oxygen sensor, idle-speed adjustor, oil injector,
electronic fuel pump, fuel pressure adjustor, oil pump support, fuel distributing pipe, carbon-canister control
valve, and ignition coil.
M7.9.7 engine management system, namely a petrol engine electronic control system, is available with many
control characteristics fit for operator, vehicle, and device, and is the combination of open-looped control and
closed loop control feedback to provide various control signals while engine is running. Key function of
system includes:
1. An application physical model of basic engine management function
(a) System structure based on torque
(b) The cylinder loading capacity to be determined by the air inlet pressure sensor /air-flow sensor
(c) Improve the function as to control the gas mixture under a static or dynamic status;
(d) typed closed-loop control
(e) Fuel injection by cylinder as per some sequence
(f) Ignition timing, inclusive of knock control by cylinder
UASE Electronic Control Engine Management System -System Introduction EF.1-3
(g) Exhaust control function

(h) Heating function of catalytic converter
(i) Carbon-canister control
(j) Idle-speed control
(k) Limped back home
(l) Speed sensing through an incremental system
2. Additional function
(a) Theft-detector function
(b) Connection between torque and exterior system eg. transmission mechanism, or vehicle dynamic control
(c) Control over several types of engine parts and components
(d) Provide a matching interface across EOL-programming tool and maintenance tools.
3. Online diagnosis OBD
(a) Fulfill a series of OBD function
(b) A management system used for diagnosis function
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UAES Electronic Control Engine Management System-Notes for Electronic Injection
EF.1-4 System Service
Precautions to the maintenance of electric-injection system
cases)
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UAES Electronic Control Engine Management System-Notes for Electronic Injection
System Service EF.1-5
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6. Precautions to the replacement with new ECU:
(a)Prior to the change of ECU, remove the negative electrode line from accumulator jar.
(b)Check whether the power supply and the overlapped steel on ECU wiring harness are under a normal condition.
(c)As for the first engine starting process after new ECU has been installed, do not start the engine immediately,
instead, open the ignition switch before wait for ten seconds to restart the engine, Following a successful
starting process, perform a ECU self-learning as per following sequence:
Have the engine running at idle-speed for at least ten minutes;
Flameout for at least ten minutes;
Open the ignition switch rather than an immediate starting process, and wait for at least ten seconds;
United Electronic engine management system-Analysis of function /principal /
EF.1-6 failure for system parts &components
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Analysis of function /principal /failure for system parts &components
1. System circuit diagram and the definition of ECU Pins
(a)United Electronic M1.5.4 system circuit diagram
failure for system parts &components EF.1-7
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(b)Definition of ECU pins within Motronic 1.5.4 system
S.N. Description of function Type S.N. Description of function Type

1 Ignition coil(pin 2) Output 28 Signal of oxygen sensor(pin 4) Input
Pin A on step motor, or
2 Power ground Ground 29 Output
at EWD3.1 case: idle pin
Holding coil of oil pump relay (pin
3 Output 30 Sensor ground Ground
86)
Pin B on step motor or Holding coil of
4 pin 1 on EWD3 Output 31 cooling-fan relay, or Output
when without fan relay：idle pin
Control valve of
5 Output 32 Idle pin
carbon-canister(pin 2)
6 Function reserved 33 Idle pin
Signal of inlet-air pressure
7 Input 34 Injector (pin 2) for cylinder 4 Output
sensor(pin 4)
8 Signal of phase sensor Input 35 Injector (pin 2) for cylinder 3 Output
9 Signal of vehicle speed 36 Function reserved
Power
10 Ground of oxygen sensor(pin 3) Ground 37 Power supply of main relay(pin 87)
supply
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11 Signal of knock sensor(pin 1) Input 38 Idle pin
Power Signal of air-conditioner temperature
12 Internal power supply(5V) 39 Input
supply sensor
Connect to the electromagnetic clutch
relay output for air-conditioner
13 Function reserved 40 compressor(pin 87), or short-circuit Input
connected to Pin 1 of cylinder 4
depending on the type of vehicle
Ground of driving stages for oil
14 injector and carbon-canister control Ground 41 Signal o A/C switch Input
valve
15 Function reserved 42 Idle pin
16 Oil injector (pin 2) for cylinder 2 Output 43 Idle pin
Oil injector (pin 2) for cylinder 1 Signal of air-inlet temperature sensor(pin
17 Output 44 Input
2)
Power
18 8A fuse-accumulator voltage 45 Engine water-temperature signal(pin 1) Input
supply
19 Electronic ground Ground 46 Signal of main relay Output
Second ground of idle pin, and
20 Output 47 Idle pin
dual-spark ignition coil(pin 1)
Pin D on step motor, or at EWD3.1 Ground of Hall sensor(pin 1)，or
21 Output 48 Ground
case; idle pin Ground of rotating speed sensor (pin B)
Electromagnetic clutch relay for
holding coil of air-conditioner Ground of Hall sensor(pin 1)，or
22 Output 49 Input
compressor ground of rotating speed sensor (Pin A)
(pin 86)
Fault indicator lamp, or at a case
23 without fault indicator lamp; idle Output 50 Pre-set
pin
Power ground for other driving Correction of basic ignition timing, or at
24 stages(air-conditioner compressor, Ground 51 a case without ignition distributor: idle Input
motorized fuel pump) pin
Ground enhanced, or at a case without
25 Function reserved 52 Input
ignition distributor: idle pin
Pin C on step motor,
26 Output 53 Signal of throttle position sensor(pin 3) Input
or Pin 2 on EWD3
27 Key switch Input 54 Engine tachometer output Output
Fault diagnosis interface
55 Input/Output
(line K)
c Definition of E CU pins within Motronic 7.9.7 system
Pin C onnection point Type Pin C onnection point Type

Heating point A ir-conditioner
1 Output 42 I nput
of oxygen sensor temperature sensor
2 Ignition coil 2 Output 43
3 Ignition ground Ground 44 Intermittent power supply I nput
4 45 Intermittent power supply I nput
Solenoid valve of
5 Ignition coil 1 Output 46 Output
carbon-canister
Oil injection nozzle 4 (cylinder Oil injection nozzle 3 (cylinder
6 Output 47 Output
No.2) No.4)
Oil injection nozzle 2 (cylinder
7 Output 48
No.3)
8 I N output Output 49
9 50 Fan control 1 Output
10 51 E lectronic ground 2 Ground
11 52
12 Uninterrupted power supply I nput 53 E lectronic ground 1 Ground
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13 I gnition switch I nput 54
14 M ain relay Output 55
E ngine
15 I nput 56
rotating-speed sensor A
T hrottle position sensor A ir-conditioner
16 I nput 57 I nput
compressor switch
17 Sensor ground 1 Ground 58
18 Oxygen sensor I nput 59 Vehicle speed signal I nput
19 K nock sensor A I nput 60
20 K nock sensor B I nput 61 Power ground 1 Ground
21 62
22 63 Intermittent power supply I nput
23 64 Phase D on step motor Output
24 65 Phase A on step motor Output
25 66 Phase B on step motor Output
26 67 Phase C on step motor Output
Oil injection nozzle 1 (cylinder
27 Output 68
No.1)
28 69 Oil pump relay Output
A ir-conditioner
29 Detector lamp Output 70 Output
compressor relay
Output,
30 71 Diagnosis line K
input
31 72
32 A 5V power supply 2 Output 73
33 A 5V power supply1 Output 74
E ngine
34 I nput 75 Air-conditioner switch I nput
rotating-speed sensor B
35 Sensor ground 3 Ground 76
Pole changer
36 Sensor ground 2 Ground 77 I nput
for booster pump
37 Inlet-air pressure sensor I nput 78
38 79 Phase sensor I nput
E ngine cooling-fluid temperature
39 I nput 80 Power ground 2 Ground
sensor
40 A ir-inlet temperature sensor I nput 81
41
2. Air inlet pressure /temperature sensor DS-S-TF

(a) Function: this sensor is used to measure the absolute-pressure /
temperature of inlet manifold, and to provide information concerning engine
load and air-inlet temperature.
(b) Principal: The part measuring the inlet-air pressure is of a piezoelectric
sensor, which is able to provide the controller with “load signal” depending
on the difference of atmospheric pressure and the pressure of inlet manifold;
And the controller will produce a 5V voltage, and a 0-5V voltage will be
feedback to the controller depending on the different inlet-air pressure.
The part measuring the inlet-air temperature is one NTC typed negative
temperature coefficient sensor, whose resistance will be changed by the
change of air-inlet temperature. And the sensor will transmit a voltage
reflecting the change of air-inlet temperature to the controller.
(c) Installation position on the inlet manifold.
(d) Symptom flameout, inferior idle-speed, etc.
(e) Cause of general failures
There’s abnormal high voltage or reversedly large current during operation;
Vacuum elements are damaged during maintenance.
(f) Precautions to maintenance during maintenance, it’s prohibited to
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use highly pressurized air to impact vacuum elements; Whereby the sensor
needs to be changed in case of failure, check whether the output voltage and
current from generator is under a normal condition.
(g) Simple measurement method
Temperature sensor part: after disconnection of joint Have digital
multimeter adjusted to the ohm position, and connect two pens with
characteristic curve of temperature sensor Pin 1 and Pin 2 of sensor respectively; And the rated resistance when at 20
shall be 2.5k 5%, Other corresponding resistances may be measured
from the characteristic curve shown above. A simulation method may be
applied during measurement, details as shown below: send air to the sensor
using an electric blower Keep some distance when blowing , and observe
the change of sensor resistance, and the resistance shall be decreased.
Pressure sensor part: after connection of joint Have digital multimeter
adjusted to the DC voltage position, and connect the black pen to ground,
the red pen to Pin 3 &4 successively. When under an idle-speed status, a 5V
resistance reference voltage will be produced on Pin 3, and an approx. 1.3V voltage
temperature
will be produced on Pin 4; When under a zero load status, slowly open the
throttle valve, and the voltage on Pin 4 will be with slight changes; Quickly
open the throttle valve, the voltage on Pin 4 will reach approx. 4V
instantaneously before being decreased to 1.5V gradually.
1.sealing ring
2. stainless liner
3. PCB plate
4. sensing element
5. shell body
6. stress support
7. welded connection
8. bonded connection
(h)Technical &characteristic parameter

Limit data
Measurement Value
Unit
Min. Typical Max.
Tolerable supply voltage 16 V
Tolerable pressure 500 kPa
Tolerable storage
-40 +130 ℃
temperature
Performance data
Measurement Value
Unit
Min. Typical Max.
Scope of testing pressure 20 115 kPa
Operation temperature -10 125 ℃
Operation supply voltage 4.5 5.0 5.5 V
Current when US=5.0V 6.0 9.0 12.5 mA
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Load current in output loop -0.1 0.1 mA
Load resistance to ground or to accumulator 50 kΩ
Response time 0.2 ms
Weight 27 g
3. Throttle position sensor DKG

(a)Function: this sensor is used to provide ECU with information concerning
the rotation angle of throttle valve. Based on such information, ECU may
obtain relevant information concerning engine load, working condition, (eg.
starting, idle-speed, reverse, partial load, full load), acceleration and
deceleration.
(d)Symptom bad acceleration, etc.

(e)Cause of general failures artifical failure.
(f)Precautions to maintenance take note of the installation position.
(g)Simple measurement method
(after disconnection of joint Have digital multimeter adjusted to the ohm position, connect two pens with Pin 1 and Pin 2 of
sensor respectively; And the resistance value at room temperatrure shall be 2k 20%; Connect two pens with Pin 1 and Pin 3 of
sensor respectively, rotate the throttle valve, and the resistance value will be subject to a linear change with the opening of throttle
valve; When connected with Pin 2 and Pin 3, an opposite situation will be produced.
Remark: When observing the change of resistance value, the main focus is to observe whether the resistance value has a larger leap.
(after connection of joint Open the ignition switch rather than to start the engine, have digital multimeter adjusted to the DC
voltage position, and connect the black pen to ground, the red pen to Pin 2, and a 5V reference voltage shall be produced; Connect the
red pen to Pin 3, and the voltage shall be at about 0.3V when throttle valve is at a full closed position, or about 3V when throttle valve
is at a full open position.
(h) Technical &characteristic parameter

Limit data
M easurement Value U nit
M echanic rotation angle between two extreme positions D egree
Available electrical rotating angle between two extreme positions D egree
A llowable current on sliding contact arm
Storage temperature
A llowable vibration acceleration
Performance data
M easurement V alue
U nit
M in. T y pical M ax .
T otal resistance P in 1-2
P rotection resistance on sliding contac t arm ( w hen
sliding c ontac t arm
is at zero position P in 2-3)
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O peration tem perature
S upply voltage
V oltage ratio on right ex treme position
V oltage ratio on lef t ex trem e position
I ncrement rate of U p/U s
degree
f or the rotation angle of throttle valv e
W eight
4. Knock sensor KS
(a)Function:this sensor is used to provide the electronic controller ECU
with engine knock information for a knock control purpose.
(b)Principal Being one type of vibration acceleration sensor, the knock
sensor is installed on the engine body; Its sensing element is of one
piezoelectric crystal, to which the vibration on engine body may be transmited
via mass block inside the sensor. Under the vibration stress of mass block, a
voltage will be produced on two pole faces of piezoelectric crystal to converse
European Class-II European Class-III the vibration signal into voltage signal
(d)Mounting torque
(e)Symptom Bad acceleration, etc.
(f)Cause of general failur The sensor might be corroded when contacting
with various liquids for long term period, such as machine-oil, cooling-fluid,
braking-fluid, water, etc.
Precautions to maintenance The sensor must have its metal surface closely
contacted with the engine body, and any type of washer is unallowable for
use during installation. During the signal cable pavement for sensor, it’s
noted that do not allow any syntony produced on signal cable to avoid
rupture. Always avoid the connection of high-voltage current between Pin 1
1.shock block
and Pin 2 of sensor, otherwise, piezoelectric elements will be damaged.
2.exterior cover Simple measurement method after disconnection of joint£©Have digital
3.piezoelectric multimeter adjusted with Pin 1 and Pin3 respectively. And the resistance
ceramic body value at roomtemperatureshall be greaterthan1M¦ ¸ Have digital multimeter
4.contact head adjusted to the millivolt position, and use a small hammer to gently knock
5.electrical plug on the area nearby the knock sensor, and a voltage signal output will be
produced.
( i ) Technical &characteristic parameter

Limit data
Measurement Value
Unit
Min. Typical Max.
Working temperature
Performance data
M easur em ent V al ue U ni t
S ensi ti v i ty o f new sens or agai nst a
26 8 m V /g
5 k H z si gnal
1 5% of
L i neari ty w hen w i thin 3 -5 kH z
5 k H z v al ue
L inear ity under a sy nto ny 1 5 -3 9 m V /g
C hange w i thi n w ho l e li f e ti m e per i od -1 7 %
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M ai n sy nto ny f requenc y >20 K Hz
R esi stanc e >1 M
C apac i tanc e 1200 400 PF
I m pedanc e
C apac i tanc e o f
280 60 P F /m
c abl e
L eak age res is tanc e
r esi stanc e betw een tw o output pi ns of 4.8 15% M
s ens or
F l uc tuatio n o f sens iti v i ty af f ec ted by
-0 .0 6 % m V /g k
tem per atur e
5. Cooling-fluid temperature sensor TF-W

(a)Function: this sensor is used to provide engine cooling-fluid
Measuremen temperature information so that a modifcation to oil injection and
ignition may be performed by controller.
R ated voltage
(b)Principal：This sensor is materially a thermal resistor having
R ated resistance when at 20 negativetemperature coefficient（NTC）, its resistance value will
Scope of operation temperature be decreased.
ured M ax. current passing the sensor while the temperature is rising, but does not show a linear correlation.
llowable vibration acceleration Thethermal resistor is installed in one copper heat condution sleeve.
(c)Installation position：on the water oulet mouth of engine.
(d)Mounting torque: 20 N·M（Max）
(e)Symptom: start with difficulty, etc.
(f)Cause of general failures artifical failure.
Structure diagram
(g)Simple measurement method after disconnection of joint Have
digital multimeter adjusted to the ohm position, connect two
Connector penswith Pin 1 &2 of sensor respectively; And the rated resistance when
2.Shell at 2 shall be 2.5k 5%, others may be measured from the
3.NTC resistor characteristiccurve shown above. A simulation method may be applied
during measurement, details as shown below: have the working zone
of sensor submerged into boiled water ensure the submerge is with
sufficient time , then observe the change of sensor resistance, and
the resistance shall be decreased to an extent within 300 -400
Specific value depends on the temperature of boiled water .
(h) Technical &characteristic parameter:
Limit data
Performance data
R esistance value k
Temperature
S.N. Tolerance of temperature 1 Tolerance of temperature 0
Min. Max. Min. Max.
6. Oxygen sensor LSH

(a)Function£ºto measure the oxygen content in exhausted gas from engine, and to determine a sufficient or insufficient combustion
of petrol and air. Based on such information, the electronic controller may perform a closed-loop control to reach an excessive air
coefficient equal to 1, and to assure Max. conversion efficiency of three contaminants (HC, CO and NOx) in exhausted gas by the
three-way catalytic converter.
1.cables 6.heating stick
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2.disk ring 7.contact washer
3.insulated bush 8.sensor seat
9.ceramic probe
4.protective jacket
5.heating element 10.protective tube
clamp connector
(b)Principal The sensing element is one ceramic pipe, whoseinner side

European Class-II links the exhausted gas, and outer side links the atmosphere.
When at a temperature of 350 , the sensing ceramic pipe will have the
characteristic of solid electrolyte, through which the density difference of
oxygen may be conversed into a difference of potential to produce a current
signal output. And a relatively dense gas mixture results in a large difference
of density for oxygen ion inside and outside the ceramic pipe, and a larg e
difference of potential as well that a large number of oxygen ions will move
from the inside to the outside, and the output voltage will be high close
to 900mV ; And a relatively thin gas mixture results in a smaller difference
of density for oxygen ion inside and outside the ceramic pipe, and a smaller
difference of potential as well that a small number of oxygen ions will move
from the inside to the outside, and the output voltage will be low close to
European Class-III 100mV .
(c)Installation position on the front end of exhaust pipe.
(d)Mounting torque (40 60)N m
(e)Symptom inferior idle-speed, bad acceleration, tail gas out of limit,
large oil consumption, etc.
(f)Cause of general failures
Damp moisture content inside sensor, sharp change of temperature, rupture
of probe. Oxygen sensor pisoning . Pb S ,
Br Si
(g)Precautions to maintenance During maintenance, it’s prohibited to
apply any cleaning liquid, oily liquid, or volatile solid onto oxygen sensor.
(h)Simple measurement method
after disconnection of joint Have digital multimeter adjusted to the ohm position, and connect two pens with Pin 1
white and Pin 2 white of sensor respectively; And the resistance value at normal temperature shall be 1 6 .
after connection of joint When the working temperature of oxygen sensor reaches 350 while engine is running at idle-speed,
have digital multimeter adjusted to the DC voltage position, and connect two pens with Pin 3 grey and Pin 4 black of
sensor respectively. And the voltage is subject to a quick fluctuation within 0.1-0.9V.
Value
Measurement Unit
Min. Typical Max.
Storage temperature -40 +100 ℃
End of ceramic pipe 200 850 ℃
Hexagonal headed shell ≤570 ℃
Working temperature Cable grommet and
≤250 ℃
connection cable
Connection plug ≤230 ℃
Allowable Max. Exhausted gas
temperature when heating on the end of ceramic pipe 930 ℃
element is connected（the
Hexagonal headed shell 630 ℃
longest connection time
each time is 10 minutes, Cable grommet and
and Max. accumulation 280 ℃
connection cable
time is 40 hours.）
Allowable temperature
≤100 K/s
variation rate on the end of ceramic pipe
Allowable temperature on ceramic elements when
≤350 ℃
condensed water is produced on the exhausted side.
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random vibration（peak
≤800 m/s2
value）
Allowable simple harmonic vibration
≤0.3 mm
vibration on shell （vibration displacement）
simple harmonic vibration
≤300 m/s2
（vibration acceleration）
Absolute
Uninterrupted DC current at 350℃ μA
value≤10
Interrupted Max. AC current when the exhausted gas is
at a temperature≥350℃, 20 μA
and a frequency f≥1Hz
Lead-free petrol, or petrol
Allowable fuel additive
with allowable lead content up to 0.15g/L
Allowable values and data to be determined by
Consumption &combustion of machine-oil client as per appropriate tests. Guiding value：
≤0.7L/1000km
Performance data
After a
Measurement New
250-hour bench test
Temperature of
350℃ 850℃ 350℃ 850℃
exhausted gas based on performance data
Voltage （mV）of
840±70 710±70 840±80 710±70
sensing element whenλ=0.91(co=1%)
Voltage （mV）of
20±50 50±30 20±50 40±40
sensing element whenλ=1.10
Inner resistance of sensing element（kΩ） ≤1.0 ≤1.0 ≤1.5 ≤0.3
Response time（ms）(600mV-300mV) ＜200 ＜200 ＜400 ＜400
Response time（ms）(300mV-600mV) ＜200 ＜200 ＜400 ＜400
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Electrical data of sensor
Measurement Value Unit
The resistance between At room temperature,
≥30 MΩ
the heating element of and under a power cut to heating element
new sensor and the When exhausted gas is at temperature 350℃ ≥10 MΩ
connector When exhausted gas is at temperature 850℃ ≥100 KΩ
Rated voltage 12 V
Continue working voltage 12-14 V
Uninterrupted working voltage
Working voltage
15 V
sustaining 1% whole life at most
Power of the connector
（exhausted gas temperature≤850℃）
Working voltage
sustaining for 75 seconds at most 24 V
（exhausted gas temperature≤350℃）
Testing voltage 13 V
Heating power under a heat balance at working voltage 13V
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（When the exhausted gas is at 12 W
a temperature of 350℃, and a flow rate of approx. 0.7m/s）
Heating current under a heat balance at working voltage 13V
（When the exhausted gas is at 5 A
a temperature of 350℃, and a flow rate of approx. 0.7m/s）
Fuse in heating circuit 8 A
Service life
The service life of oxygen sensor depends on the lead content in petrol, refer to the list below:
Lead content in petrol Life duration（km）

≤0.6 20000
≤0.4 30000
≤0.15 60000
≤0.005(lead-free petrol) 160000
7. Rotating speed sensor DG

(a)Function: When the induction type of rotating speed sensor is
working with pulse disc, relevant information concerning engine
rotating-speed and the upper stop point of crankshaft will be provided
to the ignition system (without ignition distributor).
(b)Principal:The sensor shall work with pulse disc, which is one
fluted disc having 60 teeth (the respective place for two other teeth is
empty), installed on crankshaft, and rotate simultaneously with
crankshaft.
When the disc passes by in a degree that its tooth tip just touches
the endof sensor, the pulse disk made from ferromagnetic
materialwillcutthemagnetic force line of permanent magnet
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insidesensorto produce an induced voltage on coil used for
arotating-speedsignaloutput.
(c)Installation position: above the cover of chainwheel chamber(M1.
5.4)and on the same plane of rear flywheel of engine .
(d) Mounting torque
(e) Symptom:unable to start, etc.
(f) Cause of general failures:artifical failure.
(g) Precautions to maintenance:Check whether the clearance
betweensensor and the signal tooth on belt pulley is within
mm, it may be adjusted using spacer when necessary.
(h) Simple measurement method
after disconnection of joint Have digital multimeter adjusted to
the ohm position connect two pens with Pin 2 &3 Pin 1 &2
1 shielded wire 2 permanent magne for M7.9.7) systemof sensor respectively The rated resistance when
3 cover of sensor 4 installation support at 20 shall be .
5 soft magnet core 6 coil (after connection of joint)Have digital multimeter adjusted to the A C
7 Air clearance 8 60-2 gear voltage position, connect two pens with Pin 2 &3 Pin 1 &2 for M7.
9.7 system)of sensor respectively, and start the engine, and
itsupposed to have voltage output.
(i) Technical &characteristic parameter

Performance data
Measurement Value
Unit
Min. Typical Max.
R esistance at room temperature20
Inductance m
Output voltage when crankshaft
m
is rotating at a speed of 416 revolutions per minute.
Limit data
Value Unit
Measurement
M in. Typical Max Min.
Coil zone -40 +150
Transition zone B lended blended
Tolerable L ead-wire zone -40 +120
temperature Storage temperature -20 +50
for PUR A mbient temperature when not starting -40 +120
lead-wire L ong-term ambient temperature when

-40 +120
induced starting
type of Short-term ambient 150 hours +150
rotating temperature when
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380 hours +140
speed starting
sensor L ead-wire zone within 150 hours +150
the whole service life 380 hours +140

period 1130 hours +130
Coil zone -40 +150
Transition zone B lended blended

Tolerable
L ead-wire zone -40 +130
temperature
Storage temperature -20 +50
for H& S
A mbient temperature when not starting -40 +130
lead-wire
L ong-term ambient temperature when
induced -40 +130
starting
type of
Short-term ambient temperature when
rotating +150
starting
speed
L ead-wire zone within 500 hours +150
sensor
the whole service life
200 hours +160
period
The 168-hour anti-vibration 20 70Hz Acceleration 40 m/s2
capability on each plane 71 220Hz V ibration amplitude 0.2 mm
Allowable strength
2 kA /m
of external magnetic field in a reversed direction
New form 1 M
Insulation resistance (10s,
Termination
test voltage 100V ) 100 k
of use period
Voltage-withstand 1 3 second, 1200VA C No puncture allowed

8. Phase sensor PG
a)Function:The sensor is applicable to the case that the ignition system (without
ignition distributor) is working with rotating speed sensor, and may provide
ECU with information concerning the phase of crankshaft, which is usable to
identify the upper compression stop point inside cyinder 1 from the the upper
exhaust stop point.
(b)Principal:The sensor is composed of one Hall sensor, and one rotor made
from steel plate: the former shall be fixed, and the latter is of steel blade with
180 columned surface,shall be installed on camshaft.
(c)Installation position:on the end cover of camshaft.
(d)Symptom: exhaust beyond the limit, increment of oil consumption, etc.
(e)Cause of general failures artifical failure.
(f)Precautions to maintenance:Avoid the dismantle of end cover during maintenance to prevent foreign materials from entering,
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otherwise, the magnetic door will be abnormal or damaged;
(g)Simple measurement method:
M1.5.4:(connect with lead-wire)Open the ignition switch rather than to start the engine, have digital multimeter adjusted to the DC
voltage position, connect two pens with the red /black lead-wire of sensor respectively, and ensure a 5V reference voltage is provided.
And a voltage output shall be available between green lead-wire and black lead-wire while the engine is running. It’s recommended to
apply a vehicle oscillograph to the test. M7.9.7:connect with lead-wire)Open the ignition switch rather than to start the engine, have
digital multimeter adjusted to the DC voltage position, connect two pens with Pin 1 &3 of sensor, and ensure a 12V reference voltage
is provided. While the engine is starting, the signal of Pin 2 may be checked using a vehicle oscillograph.
rotating direction
phase signal wheel
output signal

Limit data
Value
Measurement Unit
Min. Typical Max.
Ambient temperature
Ambient temperature 130-5 for 50
Space vibration hours
acceleration Ambient temperature 130-5 for 50
hours
9. Idle-speed adjustor EWD3 M 1.5.4

(a)Function: to provide a bypass air duct for idle-speed, control the bypass
air capacity by changing the cross-section area of channel, and effect a closed-
loop control over the rotating-speed while engine is running at idle-speed.
(b)Principal:One piece of permanent magnet, which may rotate freely on
shaft inside the idle-speed adjustor, is rigidly connected with one piece of
rotating slide block; And the permanent magnet is able to rotate when
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driven by the magnetic field of coil, and the slide block will rotate
simultaneously; The size of bypass air capacity could be adjusted as the
opening degree of bypass air duct depends on the angle position of slide
block, which is controllable by the electrical-pulse occupation rate output
from the electronic controller.
(c)Installation position: on the throttle valve unit.
(d)Symptom: too much high idle-speed, idle-speed flameout, etc.
(e)Simple measurement method:
(after disconnection of joint Have digital multimeter adjusted to
the’ohm’position, connect two pens with Pin 1 &2 of adjustor respectively;
The rated resistance when at 20 shall be 17.5 after connection of
joint Start the engine and have it running at idle-speed; Put your hand
gently on EWD3, you will feel a slight trembling.
10. Idle-speed actuator-step motor M7.9.7

(a)Function: to provide a bypass air duct for idle-speed, control the bypass
air capacity by changing the cross-section area of channel, and effect a closed-
loop control over the rotating-speed while engine is running at idle-speed.
cover cup shaped component

stator assembly touch plate
spring washer bobbin
o ring lead-wire of electromagnet
compressive spring
rotor sleeve
front bearing
connector
dust cap
pin
shaft pin rear bearing

ball bearing
rotor assembly sleeve bearing
o ring
straight line axis
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steel core of rotor
(b)Principal:Being one mini-typed unit, the step motor is composed of one roll of steel stators and rotors (as shown in the fig ure
above): each steel stator has been wrapped with one coil; and the rotor is of one permanent magnet materially, at the center of which
is one nut. All coils on stator are always energized, and the change of current direction on any coil will have the rotor passing one
rotating angle. If the direction of current on each stator coil is changed as per some sequence, a rotating magnetic field will be produced
to drive the rotor made from permanent magnet to rotate in some direction; if the direction of current is changed in a reversed direction,
the rotating direction of rotor will be reversed as well. The nut at the center of rotor is able to have one piece of threaded rod moving
simultaneously, and could only move along the direction of axis as constrained by the design of screw rod, that why the so called name
traignt line axis’ comes into being. On the end of the threaded rod is one choke plug, which is able to extend out or retract so as to
increase or decrease the cross-section area of bypass air inlet channel for idle-speed actuator until itblocked completely. The so-called
step length refers to a fixed rotating angle of rotor once the direction of current on coil is changed, and its value is equal to the number
of stator or coil divided by 360 , and the step length of rotor for the said step motor is 15 . Therefore, the moving distance of screw
rod on eact step is fixed accordingly. The number of moving steps for step motor may be controlled by ECU through a control over
the change times of current on coil so as to adjust the cross-section area of bypass channel plus the flowed air capacity. The air flow
capacity VS. step length shows a linear correlation. And there one spring behind choke plug on the end of screw rod, as shown in the
figure above. The size of utilizable force along the extension direction of choke plug is equal to the force of step motor plus the spring
force; while the size of utilizable force along the retracted direction of choke plug is equal to the spring force reduced bythe force of
step motor.
(c)Installation position:on the throttle valve unit.
(d)Symptom: too much high idle-speed, idle-speed flameout, etc.
(e)Cause of general failures: The accumulation of dusts and oil gas, etc causes partial blockage inside the bypass air duct, and leads
to an abnormality when adjusting the idle-speed of step motor.
(f)Precautions to maintenance:
1. Do not apply any force in axial direction to pull out the shaft or press it into place;
2. Prior to the installation of idle-speed adjustor (installed with step motor) into the throttle valve unit, its shaft shall be at a place
able to be retracted completely;
3. Remember to clean and service the bypass air duct;
4. Following the removal of accumulator jar or ECU, an immediate self-learning shall be performed on step motor.
M7.9.7 system self-learning method:
Open the ignition switch and start the engine five minutes later If any abnormality with engine idle speed is found, settle it by
peatingabove steps.
(g)Simple measurement method (after disconnection of joint)Have digital multimeter adjusted to the ohm position,
andconnect two pens with Pin AD and BC of adjustor respectively; The rated resistance when at shall be
(h) Technical &characteristic parameter£º

Limit data
M easurement V alue
U nit
M in. T ypical M ax .
W ork ing temperature
M ax . contacting times of
T imes
chok e plug on step motor w ith the seat
Characteristic data
M easurement V alue
U nit
R esistance of each coil w hen at 25
R esistance of each coil when
w ithin a scope of w ork ing temperature
I nductance of each coil w hen at 25 , 1000H z
N ormal w ork ing voltage V
P ossible work ing v oltage V
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S tep length of rotor for step motor D egree
P ressure drop on two ends
k pa
w hen the bypass passage is opened
M ax . ax ial force
N
caused by air pressure difference
11. injector E V 6
(a)Function:Based on specfic command given by ECU, the injector
may inject fuel within a specified time limit to provide engine with
evaporated fuel.
(b)Principal:When the coil of injector is energized by ECU, a magnetic
field force will be produced; When the magnetic field force is increased
to a degree that it sufficient to overcome an resultant force of stress
from release spring, gravity force of needle valve, and force friction, the
needle valve will lift up to activate the oil injection process. The Max.
lift of needle valve shall not exceed 0.1mm; When the pulse injection is
ended, needle valve will be re-closed by the stress from release spring;
(c)Installation position:on inlet manifold at one end close to air inlet
1 O-ring door.
2. filter screen (d)Symptom: Inferior idle-speed, bad acceleration, unable to start
3. injector with electrical plug start with difficulty, etc):
4. coil (e)Precautions to maintenance:
5. spring - The injector may have various types; During maintenance, Part No.
6. valve needle with coil anchorcore of injector to be re-installed shall be consistent to the original one as
7. valve seat with an injection-hole injectors looking alike and able to be installed might be inappropriate;
plate -For an easy installation, it recommended to apply clean silicon-free
machine-oil to the surface of oring at the upper position where the fuel
distributing pipe will be installed. Do not apply machine-oil to the inner part or injection hole of injector;
- O ring needs to be changed during the dismantle or re-installation of injector, and be careful not to damage the sealing surface of
injector;
-If the injector has two installation slots, the clamping piece shall be installed to the correct slot; Y ou may refer to the installation
position for original component;
-It strictly prohibited to dismantle, wash or change the filter screen;
-After a dismantle of injector, keep its seat clean, and prevent foreign materials from entering cylinder.
(f)Simple testing method:(recommended to use a special wash instrument applicable to injector for a regular washing purpose
after disconnection of joint)Have the digital multimeter adjusted to the ohm position, and connect two pens with two pins of
injector respectively; And the rated resistance when at 20 shall be : (11-17) after connection of joint)Start the engine and have it
running at idle-speed; Put your hand gently on the injector, you will feel the pulsation of injector .
(g)Technical &characteristic parameter

Limit data
V alue
M easurement U nit
S torage temperature w hen w ith original pack age -40 +70
A llow able temperature of injector inside vehicle
+140
w hen not w ork ing
C ontinuous -40 +110
W ork ing
W ithi n a short-ti me period
temperature of
about 3minutes after heat +130
injector
starting process
A llow able fuel C ontinuous +70
temperature at the
inlet mouth of S hort time ( A bout three minutes) +100
injector
T he dev iation of fuel f low at
-40 +45
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may result in a 5% temperature
F uel moisture content rather than
A llow able leak age of O ring w hen w ithin -35~-40
dripping w ithi n O ring area is allow ed.
M ax allow able vibration acceleration peak v alue 400 m/s 2
S upply voltage 6 16 V
I nsulation resistance 1 M
B earable internal f uel pressure 1100 kP a
B earable bending stress 6 N ·m
B earable ax ial stress 600 N
Characteristic data Value
Quantity Unit
Min. T ypical Max.
Working pressure Pressure difference 300 kPa
Injector resistance at 20 11.4 12.6
12. Electrical fuel pump EKP

(a)Function to transfer the fuel from fuel tank to engine, and to produce
a sufficient fuel pressure, and excessive fuel.
(b) Principal Being one type of vane pumps driven by DC motor, the
fuel pump is installed inside fuel tank, and submerged under fuel, and its
lubrication and heat elimination may be effected using fuel; The accumulator
will provide a power supply to electrical fuel pump via pump relay,
which will connect the loop of electrical fuel pump only when the engine
is running or during a starting process; Whereby the engine stops running
due to accident, the fuel pump will auto. stop working.
(c)Installation position: inside fuel tank.
(d)Symptom Large running noises, bad acceleration,
unableto start(start with difficulty), etc.
1. end cover of oil pump
(e)Cause of general failures The use of inferior fuel might
2. armature
result in:
3. oil passage -An insulation layer formed by accumulative colloid;
4. impeller -A dead hug of bearing bush with armature of oil pump;
-Corrosion of oil-level sensor components.
(f)Precautions to maintenance
-Based on the demand of engine, the electrical fuel pump may have various flow capacities;
During maintenance, Part No. of fuel pump to be re-installed shall be consistent to the original one as fuel pumps looking
alike and able to be installed might be inappropriate;
- To avoid any damage, do not have the fuel pump running under a dry state;
-In cases that fuel pump needs to be changed, always remember to wash the fuel tank andits pipeline, and to change the
fuel filter;
after disconnection of joint Have the digital multimeter adjusted to the ‘ohm’ position, and connect two pens with
two pins of fuel pump respectively; The measured internal resistance shall be an infinite value namely a state other
than short circuit or broken loop , or a value other than zero.
after connection of joint As for the unit installed with oil-return system, connect the oil inlet pipe with fuel
manometer, and observe whether the fuel pump is able to work while engine is running; If not work, check the Pin +
for its supply voltage; If work, check whether the fuel pressure is within 250-300Kpa; When the oil return pipe is being
clamped tightly using oil-return barrier, check whether an oil pressure may be produced rapidly.
(h)Technical &characteristic parameter
M easurement V alue
U nit
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M in. T ypical M ax.
W orking voltage V (D C )
S ystem pressure kPa
Pressure at exhaust point kPa
A mbient temperature
(applicable to storage and transport)
A llowable fuel temperature
A llowable vibration acceleration m/s 2
13. Fuel pressure adjustor DR

Principal: The pressure adjustor is of a membrane typed overflow valve: Once the system fuel pressure is increased
to a degree that the fuel pressure inside oil inlet mouth is greater than a resultant force of the pre-tensioned spring force
and the air pressure force inside spring chamber, the membrane will be supported to open the valve so that the fuel could
overflow via an fuel return mouth at the center of pressure adjustor, and return to the fuel tank, which will result in a
decrement of fuel pressure until the valve is closed.
(b)Installation position: The unit installed with oil-return system
shall be installed onto the fuel distributing pipe assembly.
(c)Symptom The fuel pressure is too low or too high, or hard to
start, etc.
(d)Cause of general failures Along-term use without service
results in
- A blockage on filter screen;
- A major leakage caused by grained foreign materials;
-An artifical mechanical damage, etc.
(e)Precautions to maintenance
During maintenance:
During maintenance:
-It’s prohibited to use highly pressurized gas to impact themembrane
elements;
-It’s prohibited to use strong corrosive liquid for washing purpose;
-It’s prohibited to apply any force causing possible deformation.
(f)Simple measurement method
Connect the fuel inlet pipe with fuel manometer before engine is
started; Have the engine running at idle-speed, and check whether
the fuel pressure is at about 260Kpa; Have the engine running at
speed 2000r/min, pull out the fuel pressure adjustor, and check
whether the fuel pressure is at 300Kpa.
(g)Technical &characteristic parameter

Limit data
M easurement V alue
U nit
L eak age of flow at pressure diff erenc e 80k pa 9 c m 3 /min
A llow able c onstant-w ork ing temperature -40 +80
A llow able M ax . fuel temperature +80
A llow able M ax . pressure
-2% +5%
drift rev ersible w hen at -30?
A llow able M ax . pressure
-5% +2%
drift rev ersible w hen at +80?
P eak value of allow able M ax . acceleration 100 m/s 2
A llow able M ax . pulse value
100 kPa
of pressure at air inlet mouth
Performance data
M easuremen Value Unit
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Min. Typical Max.
R ated pressure difference at flow capacity Q =80 1/h 300 kPa
V ariable value of working pressure when the flow is
17.5 kPa
changed within 15~140 1/h
S cope of flow 10 220 L/h
S lope of characteristic curve 0.14 kPa/L/h
14. Carbon-canister control valve TEV

(a)Principal：The carbon-canister within the fuel evaporation control
system is used to absorb the evaporated gas coming from fuel tank
until it saturated; And the electronic controller is usedto control the
opening of carbon-canister control valve so that a regenerated air flow,
formed by fresh air and saturated &evaporated gas inside
carbon-canisteruel, could be induced to the air inlet pipe of engine;
Depeneding on various working conditions of engine, the electronic
controller may change the occupation rate of pulse signal transmitted
to the electromagnetic coils inside carbon-canister control valve, and
perform a control over the flow capacity of regenerated air flow. Besides,
such flow capacity will also be affected by the difference of pressure on
two ends.
(b)Installation position:On the vacuum pipeline of inlet manifold for carbon-
canister.
(c)Cause of general failures:Rust, corrosion, or bad sealing performance
caused by foreign materials inside the valve;
(d)Symptom:inferior idle-speed, failure of function, etc.
(e)Precautions to maintenance:
-The direction of air flow shall conform to relevant stipulations during
installation;
-Check the condition of carbon-canister whereby its control valve needs to
P denotes the difference between atmospheric
be changed due to its failure caused by the blockage of black grains inside
valve body;
pressure Pu and the inlet-air pressure Ps.
1. fuel gas coming from oil tank
-Prevent liquid (eg. water or oil) from entering the valve during maintenance;
2. carbon-canister
- To avoid the transmission of solid borne sound, it’s recommended to have
3. ambient atmospheric pressure
the carbon-canister control valve handged &installed onto hose.
4. TEV valve
(f)Simple measurement method:
5. Pipeline of regenerated air flow
(after disconnection of joint) Have the digital multimeter adjusted to th
ohm position, and connect two pens with two pins of carbon-canister
6. throttle valve of inlet manifold
control valve respectively; And the rated resistance when at 20 shall be
( )
(g) Technical &characteristic parameter

Limit data
M easurement V alue
U nit
W ork ing voltage
O ne-minute over voltage
M in. starting voltage
A llowable working temperature
A llowable working temperature within short ti me
A llowable storage temperature
B earable pressure difference
between air inlet mouth and ex haust hole
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A llowable open /close times
A llowable vibration acceleration on product
L eak age amount when the pressure difference is 400m
bar
15. Ignition coil ZSK
(a)Function: To transform the low voltage DC current from accumulator
into high voltage current, and to ignite the gas mixture inside cylinder via
spark plug by producing sparks during discharge process.
(b)Principal The primary windings will be charged up when its ground
connection channel is connected; and the charging process will be stopped
once the circuit of primary windings is broken by ECU, but high voltage
current will be induced simultaneously on secondary windings to provide
spark plug with energy for discharge process. Different from ignition coils
installed with ignition distributor, the ignition coil ZSK2 2 has both ends
of its secondary windings connected with one spark plug respectively to
perform two ignitions simultaneously.
(c)Installation position: on engine.
(d)Symptom: unable to start, etc.
(e)Cause of general failures: burning &damage caused by strong current,
damage by exterior force, etc.
(f)Precautions to maintenance: During maintenance, it’s prohibited to test
the function of ignition using a short-circuit fire test method to avoid any
damage on electronic controller.
After disconnection of joint Adjust the digital multimeter to the ohm
position, and connect two pens with two pins of primary windings
respectively. And the resistance when at 20 shall be (0.42-0.58) ; The
resistance for secondary windings shall be (11.2-14.8)k .

Limit data
Performance data
Value
Measurement Unit
Min. Typical Max.
Nominal voltage
R esistance Value Primary windings
20 25 Secondary windings
Inductance value Primary windings
20 25 Secondary windings
L oad 50pF
Formed voltage
L oad 50pF//1M
16. Electronic controller ECU(M1.5.4)
(a)Function
- Control the fuel injection
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- Control the ignition
- Control the idle-speed
- Provide the sensor with power supply 5V/120mA
- Integrated knock control by cylinder, with self-adaptability;
- E closed-loop control, with self-adaptability;
- Control the carbon-canister valve
- Air-conditioner switch
- Engine fault indicator lamp
- Software switch to increase the density of injected oil
- Modification to the fix quantify of fuel
- Output of engine rotating-speed signal TN signal
- Input of vehicle speed signal
- Diagnosis of the failure on driving stage and sensor
- Receive signal from the engine rotating-speed sensor
- Receive the engine load signal, etc.
(b)Power supply Refer to the circuit diagram for UAES M1.5.4 system
-Uninterrupted power supply by accumulator via Pin 18;
-Power supply via Pin 37 when main relay has been connected;
-Power supply via Pin 27 when ignition switch has been connected;
(c) Ground:
Pin 2, 10, 14, 19, 24, 30, 48.
Failure diagnosis interface
Includes Pin 55 and engine data line K. Using line K, the record of failure information inside ECU may be called out, or some
commands may be manually input, such as: elimination of the record of failure information, self-learning of idle-speed actuator,etc.
(d) Increased density of gas mixture at after-sale stage:
Pin 8 and 52 are mainly applicable to some cases whereby the degradation of engine starting performance is caused by the aging of
internal parts &components or the individual difference.
(e) Symptom
Unstable idle-speed, bad acceleration, unable to start, much high idle-speed, tail gas out of limit, start with difficulty, air-conditioner
failed, the oil injector control failed, flameout, etc.
(f) Cause of general failures
-The electrical overload on peripheral device results in a burning and failure of parts and components inside ECU;
-The rust and corrosion on circuit board are caused by water inside ECU.
Precautions to maintenance
-Do not dismantle the ECU casually during maintenance.
-Prior to dismantle of ECU, have the head of accumulator jar being removed for at least five minutes.
-Store the ECU securely after it is dismantled;
-It’s prohibited to install extra loops on the ECU connection line.
(h) Simple measurement method Refer to the circuit diagram for UAES M1.5.4 system
- after connection of joint , read the record of engine failures via engine data line K;
- after disconnection of joint , check whether ECU connection line is intact, and the main focus is to check whether the loop
of power supply /ground for ECU is normal;
- Check whether peripheral sensor is working normally, whether the output signal is reliable, and whether the loop is intact.
17. Electronic controller ECU M 7.9.7

(a)Function
- Oil injection at multi-points as per the sequence
- Control the ignition
- Control the idle-speed
- Provide the sensor with power supply 5V/100mA
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- Knock control
- Etyped closed-loop control, with self-adaptability;
- Air-conditioner switch
- Engine fault indicator lamp
- Modification to the fixed quantity of fuel
- Output of engine rotating-speed signal TN signal
- Input of vehicle speed signal
- Failure self-diagnosis
- Receive signal from the engine rotating-speed sensor
- Receive the engine load signal, etc.
(b)Symptom
Unstable idle-speed, bad acceleration, unable to start, too much high idle-speed, tail gas out of limit, start with
difficulty, air-conditioner failed, the oil injector control failed, flameout, etc.
(c)Cause of general failures
-The electrical overload on peripheral units results in a burning, damage or failure of parts and components inside ECU;
- Water inside ECU causes rust and corrosion on circuit board.
(d) Precautions to maintenance
-Do not dismantle the ECU casually during maintenance.
-Prior to dismantle of ECU, have the head of accumulator jar being removed for at least one minute.
-Store the ECU securely after it is dismantled;
-It’s prohibited to install extra loops on the ECU connection line.
(e)Simple measurement method
- after connection of joint , read the record of engine failures via engine data line K;
- after disconnection of joint , check whether ECU connection line is intact, and the main focus is to check whether the loop
of power supply /ground for ECU is normal;
-Check whether the peripheral sensor is working normally, whether the output signal is reliable, and whether its loops are intact;
-Check whether the actuator is working normally, and whether its loops are intact;
-Finally, perform a test after ECU is changed.
(f)Technical &characteristic parameter

Limit data
V alue
M easurement U nit
M in. T y pic al M ax .
U nder a normal operation
A cc umulator v oltage
W ith li mi ted f unction
L i mit value & ti me to
R etain partial func tions,
W ithstandthe
and able to perform
over-v oltage of
failure diagnosis.
ac cum ulator
W ork ing temperature
S torage temperature
18. Fuel distributing pipe assembly

European (a)Principal The fuel distributing pipe assembly is composed of fuel
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distributing pipe K V S , oil injector E V , and fuel pressure adjustor
D R , and may be used to store and distribute the fuel.
(b)Installation position: on the inlet manifold.
(c)Precautions to installation:
- The place where the fuel inlet pipe is connected with rubber hose shall be
clamped tightly using clips, whose model needs to match with the rubber
hose to assure the tightness of connection between fuel inlet pipe and
rubber hose;
- It shall be free from any crack, damaged trace, groove, burr, or rust on the wall
of fuel inlet pipe;
- Prior to the installation of fuel distributing pipe assembly, clean lubricating oil
shall be applied to lubricate the lower O-ring of oil injector;
(d)Inspection on the sealing performance:
The sealability of fuel distributing pipe may be tested using pressure drop method
: perform a test on the O-ring inside injector on the fuel distributing pipe; and the
tested limit value of leakage shall be≤1.5cm3/min when at a pressure of 4.5bar.
(e) Technical &characteristic parameter：

Limit data
Measurement Value
Unit
Min. Typical Max.
Working temperature when fuel
-40 +120 ℃
Distributing pipe is correctly connected with the O ring.
15-minute Max. working temperature when being soaked +130 ℃
Peak value of Max. allowable vibration acceleration 300 m/s2
- Regarding the system pressure, refer to the characteristic parameter for pressure adjustment valve; Regarding the requirement for
fuel, refer to the characteristic parameter for injector; Regarding the sealability, it’s required to have no fuel leakage under working
pressure.
- The inner diameter of fuel rubber hose shall be ( 7.9 0.3)mm2.
United Electronic engine management system-Genaral troubes hooting and steps
EF.1-30 to engine
General troubleshooting and steps to engine

General troubleshooting and steps to M1.5.4 system
1. When starting, the engine is not rotating or rotating slowly.
Check
S.N. Operation steps Follow-up steps
result
Yes Next step.
A multimeter may be used to check whether the voltage between two binding
1 Repair or change the
posts of accumulator is within 10 and 12.5V. No
accumulator
Place ignition switch to the“ON”position, and a multimeter may be used to Yes Next step.
2 check whether its respective binding post connecting the positive electrode of Repair the binding posts
No
accumulator has a voltage between 10 and 12.5V. or change the lead-wire.
Keep the ignition switch on the“starting”position, and a multimeter may be Yes Next step.
3 used to check whether its respective binding post connecting the positive Repair or change the
No
electrode of starter has a voltage greater than 8V.. ignition switch
Keep the ignition switch on the“starting”position, and a multimeter may be Yes Next step.
4 used to check whether the binding post on the positive electrode of starter has a Repair the binding posts
No
voltage greater than 8V. or change the lead-wire.
Yes Next step.
A multimeter may be used to check whether the starter is in a broken loop or
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has short circuit. No
starting motor
Yes Clear the failure away.
6 Check whether the engine has got stuck due to bad lubrication.
No Next step.
Next step. And change
Yes
If in Winter, check whether the large resistance inside starter is caused by the with appropriate oil.
7
selection of inappropriate engine lubricating oil and gear box oil. Repair or change the
No
timing belt.
2. The hot vehicle is starting with difficulty.
Check
result
Clear the displayed
Place ignition switch to the“ON”position. A fault diagnosis instrument may be Yes
1 failure away.
used to check whether there’s any record of failure information.
No Next step.
Connect the fuel manometer valve. And have the Pin 30 of fuel pump relay Yes Next step.
2 short-circuit connected with the Pin 87, and check whether the fuel pressure is
within 250kpa and 300kpa while the fuel pump is working. No 9
Yes Next step.

Disconnect the oil pipe and close the ignition switch; One hour later, observe
3 Repair the fuel pressure
whether the pressure of fuel system is able to retain within 150kpa and 200kpa. No
system.
Connect the oil pipe, and use an oil-return barrier to prevent oil from returning; Change the fuel
Yes
And close both fuel manometer valve and ignition switch; One hour later, pressure adjustor
4
observe whether the pressure of fuel system is able to retain within 150kpa and
No Next step.
200kpa.
Change the oil pipe
Check the oil pipe &injector for fuel leakage. Yes
5 &injector.
No Next step.
Check and repair the
Pull out the plug of water-temperature sensor, and start the engine to see cooling-fluid
Yes
6 whether it proves to be a success. temperature sensor and
relevant loops.
No Next step.
Connect a connector between ECU and wiring harness, and check whether the
Pin 18 /27 /37 of ECU has voltage, and whether the positive supply line
7 Yes Next step.
connecting the foresaid Pins of ECU plus the ground connection line
connecting the Pin 2 /14 /24 /19 of ECU is under a normal condition.
to engine EF.1-31
Check
result
Change the fuel, and perform a hot starting process again to see whether the Yes Ended.
8
starting is successful. No Change the ECU
Check whether the fuel pipe has been bent or blocked, and whether the Yes Next step.
9
pressure-adjustment valve of oil pump is able to work in a normal way. No Repair or change fuel pipe
Yes Next step.
A multimeter may be used to check whether there’s any accumulator voltage
on two ends of socket connector for fuel pump. No
lead-wire for fuel relay.
A multimeter may be used to check whether the resistance value of fuel Yes Next step.
11
pump is correct. No Change the fuel pump
Yes Change the fuel pump
12 Check whether the fuel pump has got stuck.
No Change the ECU
3．Despite of a normal rotating-speed, the starting is always with difficulty
Check
result
Clear the displayed failure
Place ignition switch to the“ON”position. A fault diagnosis instrument may Yes
1 away.
cardiagn.com
be used to check whether there’s any record of failure information.
No Next step.
Yes Next step.
2 Check whether the passage of air filter is free.
No Change it.
Yes Next step.
Following a successful starting process, check whether the pressure of inlet
3 Settle the air leakage within
manifold when at idle-speed is within 35-65kpa. No
air inlet system.
Check the throttle valve,
Yes
4 Observe whether it’s easy to start by gently stepping on the throttle valve. and idle-speed passage.
No Next step.
5 short-circuit connected with the Pin 87, and check whether the fuel pressure
is within 250kpa and 300kpa while the fuel pump is working. No 9
Check whether the oil injector is working after it has been provided with a Yes 8
6
12V voltage by accumulator via special connector. No Next step.
Check whether the oil injector is able to work normally after it has been Yes Next step.
7
washed. No Change the oil injector
Yes Change the fuel
8 Check whether fuel contains water or has deteriorated.
No 14
Yes Next step.
9 Check whether the fuel pressure is below 250kpa.
No 12
Close the fuel manometer valve, and re-connect the electric spark switch to Yes Next step.
10 have oil pump working for three seconds, then check whether an oil pressure
will be produced. No 12
Change the fuel pressure
Open the fuel manometer valve, and clamp the oil return pipe using oil-return Yes
adjustor
11 barrier to prevent oil from returning, then check whether an oil pressure will
Repair or change the oil
be produced. No
injector or oil pipe.
Repair or change oil inlet
Yes
12 Check whether the oil inlet pipe has leakage or has been blocked. pipe
No Change the oil pump
Repair or change oil return
Yes
pipe
13 Check whether the oil return pipe has been bent or blocked.
No
adjustor
EF.1-32 to engine
Check
S.N Operation steps Follow-up steps
result
Pull out the plug of idle-speed actuator from wiring harness before the engine Yes Next step.
14 cooling temperature reaches 35 ℃ , then observe whether the engine Repair or change the
No
rotating-speed has been decreased. idle-speed adjustor
Place ignition switch on the “ON”position, and check whether respective Yes Next step.
15 voltage on following pins of ECU is normal: Whether the accumulator voltage Check the wiring harness,
No
on Pin 27 is at about 12V, and whether respective voltage on Pin 14 &19 is 0. and socket connector.
Yes Next step.
16 Check whether the compressive pressure inside engine cylinder is normal.
No Clear the failure away.
Check whether the absolute pressure /temperature sensor of inlet manifold has Yes Repair or change it.
17
been blocked. No Next step.
Yes Change ECU
18 Check whether the cooling-fluid temperature sensor is normal.
No Repair or change it
4.The cold vehicle is starting with difficulty.
Check
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result
1 away.
No Next step.
A multimeter may be used to check whether the cooling-fluid temperature Yes Next step.
sensor is normal. (Or a 1.5KΩ resistor may be serially connected between Pin
2 45 and Pin 30 of ECU to take the place of cooling-fluid temperature sensor to
start the engine; That it’s able to be started indicates an abnormality of No Change the sensor
cooling-fluid temperature sensor).
After the connection of ignition switch, connect a commutator between ECU Yes Next step.
and wiring harness, and check whether respective voltage on following pins of
3 Check the wiring harness,
ECU is normal: Whether the accumulator voltage on Pin 27 is at about 12V, No
and socket connector.
and whether respective voltage on Pin 14 &19 is 0V.
Yes Next step.
No Change it.
Yes Next step.
Following a successful starting process, check whether the pressure of inlet
5 Settle the air leakage
manifold when at idle-speed is within 35kpa and 65kpa. No
within air inlet system.
Check the throttle valve
Yes
6 Observe whether it’s easy to start by gently stepping on the throttle valve. and idle-speed actuator.
No Next step.
Pull out the plug of idle-speed actuator from wiring harness before the engine Yes Next step.
7 cooling-fluid temperature reaches 35℃, then observe whether the engine Repair and change the
rotating-speed has been decreased. No
idle-speed actuator.
Following the connection of fuel manometer valve, have the Pin 86 of fuel
Yes Next step.
pump relay directly connected to ground, and connect the ignition switch;
8
Check whether the fuel pressure is within （250~300）kpa while the fuel pump
No 12
and its relay are working.
Check whether the oil injector is able to work in a normal way after it has been Yes 11
9
provided with a 12V voltage by accumulator via special connector. No Next step.
Yes Next step.
10 Re-check whether the oil injector is working after it has been washed.
No Change the oil injector.
Yes Change the fuel
No Next step.
to engine EF.1-33
Check
result
Yes Next step.
No 16
Close the fuel manometer valve, and re-connect the ignition switch to have oil Yes Next step.
13 pump working for three seconds, then check whether an oil pressure will be
No 15
produced.
adjustor
14 barrier to prevent oil from returning, then check whether an oil pressure will be
produced. No
pipe or injector.
Yes
15 Check whether the oil inlet pipe has leakage or has been blocked. pipe
Repair or change oil
Yes
return pipe
16 Check whether the oil inlet pipe has leakage or has been bent.
No
adjustor
Yes Next step.
17 Check whether the pressure of engine cylinder is normal.
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Yes Repair it.
18 Check whether the engine air-inlet system has leakage.
No Next step.
Check whether the absolute pressure /temperature sensor of inlet manifold has Yes Repair or change it
19
been blocked. No Change the ECU
5．The idle-speed at any time is unstable.
Check
result
Place ignition switch to the“ ON”position. A fault diagnosis instrument may be Yes
1 away.
No Next step.
Repair or change the
Yes
2 Check whether the idle-speed actuator has got stuck. idle-speed actuator
No Next step.
After the connection of ignition switch, connect a commutator between ECU Check the wiring harness
and wiring harness, and check whether respective voltage on Pin 14 &45(the Yes
and socket connector.
3 signal output end for air-inlet temperature sensor and cooling-fluid temperature
sensor respectively) of ECU is normal, and whether respective voltage on Pin 4 No Next step.
&26 (used as one signal output end for idle-speed actuator) of ECU is normal.
Have the engine running at idle-speed, and have the cylinder flameout one by Yes 8
4 one to observe whether the engine rotating-speed has been decreased or has
No Next step.
fluctuation.
Yes Next step.
5 Check whether the oil injector for each cylinder is under a normal condition. Check the oil injector and
No
wiring harness.
Yes Next step.
Check whether the resistance value （exact value to be found in the chapter for
6 Check the oil injector and
ignition system）of high-voltage line inside each cylinder is normal. No
wiring harness.
Yes Next step.
7 Check whether the spark plug is normal.
No Change the spark plug
Connect the fuel manometer valve. And have the Pin 30 of fuel pump relay
Yes Next step.
within 250kpa and 300kpa while the fuel pump is working. No 13
9
EF.1-34 to engine
Check
result
Yes Next step.
10 Check whether the oil injector is able to inject oil after it has been washed.
No Change the oil injector
Yes Change the fuel
No 18
Yes Next step.
No 17
Close the fuel manometer valve, and re-connect the ignition switch to have oil Yes Next step.
13 pump working for three seconds, then check whether an oil pressure will be
No 16
produced.
adjustor
produced. No
Yes
15 Check whether the oil inlet pipe has any leakage or has been blocked. pipe
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Yes
return pipe
No
adjustor
Yes Clean it.

Check whether sensing holes on the inlet-manifold pressure sensor and the
17
air-inlet temperature sensor have been blocked.
No Next step.
Have the engine running at idle-speed, and observe whether the oxygen sensor Yes Next step.
18 is able to work in a normal way when the cooling-fluid temperature reaches the Check the oxygen sensor
No
activated temperature under a closed-loop control. and wiring harness.
Yes Settle the leakage.
19 Check whether the engine air-inlet system has leakage.
No Next step.
Yes Next step.
20 Check whether the pressure of engine cylinder is normal.
6．The idle-speed during vehicle heating process is unstable.
Check
result
Clear the displayed
1 failure away.
No Next step.
Yes Next step.
No Change it.
Yes Next step.
Have the engine running at idle-speed, check whether the pressure of inlet
manifold is within 35kpa and 65kpa during the vehicle heating process. No
Following a closure of engine and a connection of ignition switch, connect a Yes Next step.
commutator between ECU and wiring harness, and check whether respective
4
voltage on Pin 44 &45 (the signal output end for air-inlet temperature sensor No Check and repair it.
and cooling-fluid temperature sensor respectively) of ECU is normal.
Yes Next step.
Pull out the plug of idle-speed actuator before the vehicle heating process is
5 Change the idle-speed
ended, and observe whether the engine rotating-speed could be changed. No
actuator.
Check whether the cooling-fluid temperature sensor is working in a normal Yes Next step.
6
way. No Change it.
to engine EF.1-35
7．The idle-speed is unstable after the vehicle heating process is ended.

Check
result
Clear the displayed
Place ignition switch to the“ ON”position. A fault diagnosis instrument may be Yes
1 failure away.
No Next step.
Place ignition switch on the“ON”position, connect a commutator between Yes Next step.
ECU and wiring harness, and check whether respective voltage on the Pin 7
（output of absolute-pressure sensor for inlet manifold）, Pin 44（output of
air-inlet temperature sensor）, Pin 45（output of cooling-fluid temperature No
wiring harness
sensor）, Pin 28（output of oxygen sensor）, and Pin 4 &26 （output to the
idle-speed actuator）of ECU is normal.
Yes Next step.
3 Check whether the passage of air filter is free when engine is closed.
No Change it.
Yes Next step.
Check whether the pressure of inlet manifold is within 35kpa and 65kpa when
at idle-speed. No
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No 9
within 250kpa and 300kpa while the fuel pump is working.
6
Check whether the oil injector is able to work normally after it has been Yes Next step.
7
Yes Change the fuel
No 14
Yes Next step.
No 13
Close the fuel manometer valve, and re-connect the electric spark switch to Yes Next step.
10 have oil pump working for three seconds, then check whether an oil pressure
No 12
will be produced.
adjustor
produced. No
Yes
12 Check whether the oil inlet pipe has any leakage or has been blocked. inlet pipe
Yes
return pipe
No
adjustor
Change the cooling-fluid
Observe whether the engine is working normally after the cooling-fluid Yes
14 temperature sensor
temperature sensor has been pulled out.
No Next step.
Yes Next step.
15 Check whether the compressive pressure inside the engine cylinder is normal.
Check whether the resistance value （about 16kΩ/m, exact data to be found in Yes Next step.
16 the chapter for ignition system）of high-voltage line inside each cylinder is
No Change it.
normal.
Yes Change the ECU
EF.1-36 to engine
8．Unstable idle-speed or even flameout when under load（eg. air-conditioner, etc.）

Check
result
Place ignition switch to the“ON”position. A fault diagnosis instrument may be Clear the displayed failure
Yes
1 used to check whether there’s any record of failure information. away.
No Next step.
After a connection of air-conditioner switch, connect a commutator between Yes Next step.
2 ECU and wiring harness, and measure whether there’s a signal input“*” Check and repair the
between the Pin 40 and Pin 41（air-conditioner switch）of ECU. No
air-conditioner loop.
Check whether the pressure of air-conditioner system, the electromagnetic Yes Next step.
3 clutch of compressor, and the air-conditioner pump are under a normal Repair or change it
condition. No
Place ignition switch on the“ON” position, and check whether respective Yes Next step.
4 voltage on the Pin 4 No Check the control loop.
Check whether the idle-speed actuator has got stuck or is able to run flexibly Repair or change the
Yes
5 after it has been removed. idle-speed actuator
No Next step.
Start the engine, and activate the air-conditioner function, and check for some Yes Change the ECU
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6 time whether the idle-speed actuator is working in a normal way. Change the idle-speed
No
actuator
*The signal of low /high electrical level from Pin 41 may be regarded as an air-conditioner request signal by ECU: ECU is able
to recognize the signal of low electrical level from Pin 41 as an air-conditioner signal requested by vehicle, and the signal from
Pin 41 shall be of high electrical level when A/C switch is OFF. And vice versa.
9．Periodically unstable（Another self-learning is needed after a power cut to ECU
Check
result
1 away.
No Next step.
Yes Next step.
No Change it.
Yes Next step.
Check whether the pressure of inlet manifold is within 35kpa and 65kpa while Check and repair air inlet
3
engine is running at idle-speed. No components or
components leaking air.
Perform a flameout process for each cylinder while engine is running at Yes 7
4 idle-speed, and observe whether the rotating-speed of engine has some
No Next step.
fluctuation or has been decreased.
（output of absolute-pressure sensor for inlet manifold）, Pin 44（output of
5 air-inlet temperature sensor）, Pin 45（output of cooling-fluid temperature Repair or change the
sensor）, Pin 28（output of oxygen sensor）, Pin 19 （electronic ground）, Pin No
wiring harness
27（ignition switch）, and Pin 4 &26 （output to the idle-speed actuator）of
ECU is normal.
Check whether sensing holes on the inlet-manifold pressure sensor and the Yes Clean it.
6
air-inlet temperature sensor have been blocked. No Next step.
Yes Change the fuel
No Next step.
Yes Next step.
Check whether the oil injector is able to work in a normal way after it has been Check and repair the oil
8
provided with a 12V voltage by accumulator via special connector. No injector and its relevant
wiring harness.
to engine EF.1-37
Check
result
Check whether the resistance value of high-voltage line for each cylinder is Yes Next step.
9 under a normal condition (about 16KΩ/m, specific data as given in the chapter
No Change it.
for “ignition system” ).
Yes Change the ECU
10．The idle-speed is too high（a self-learning is needed again after a power cut to ECU）.
Check
result
Clear the displayed
1 failure away.
No Next step.
Check whether the slider fastener connecting the gas pedal is too tight or has Yes Adjust or change it
2
got stuck. No Next step.
Check whether the carbon-canister control valve, the fuel pressure adjustor, the Yes Adjust or change it.
3 forced-ventilation vacuum pipe of crankshaft box, and the vacuum booster
No Next step.
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hose within system are securely installed or have any damage.
When engine is running at idle-speed, put shift to a neutral position, and step Yes Next step.
4 on the braking pedal, and observe whether the rotating-speed at idle speed is
No 6
too much high.
Repair or change the
Observe whether the running at idle-speed is normal when vacuum hose is Yes
5 vacuum booster.
being clamped.
No Next step.
Observe whether the running at idle-speed is normal when the forced Yes Change the PVC valve.
6
ventilation vacuum pipe on crankshaft box is being clamped. No Next step.
Change the
Observe whether the running at idle-speed is normal when the hose of control Yes carbon-canister control
7
valve on carbon-canister is being clamped. valve
No Next step.
Yes Repair or change it.
8 Observe whether the idle-speed actuator is able to act flexibly or has got stuck.
No Next step.
Yes Repair or change it.
9 Check whether there’s any leakage at other places on air inlet pipe.
No Next step.
Yes Next step.
10 Check whether the sealing ring of oil injector is intact.
No Change the sealing ring.
Check whether the absolute pressure sensor and the air-inlet temperature Yes Change the ECU
11
sensor of inlet manifold are intact. No Change the sensor
11．The rotating-speed is unable to go up or even flameout when accelerating
Check
result
1 Yes Clear the displayed failure
Place ignition switch to the“ON”position. A fault diagnosis instrument may be
away.
No Next step.
2 Yes Next step.
Check whether the passage of air filter is free.
No Change it.
3 Yes Next step.
Check whether the engine rotating-speed is normal while it’s running at No Check and repair it as per
idle-speed. the list of idle-speed
failures.
EF.1-38 to engine
Check whether the inlet-air pressure is within 35kpa and 65kpa while engine is Yes Next step.
4
running at idle-speed. No Check and repair it.
Have the engine running at idle-speed, and do not connect the Pin 51 of ECU Yes Next step.
to ground via short connection wire before the cooling-fluid temperature
5 Adjust the ignition
reaches its normal value; Check whether the ignition lead-angle is of a 6.75o No
lead-angle.
rotating angle of crankshaft.
No 11
Check whether the oil injector is working in a normal way after it’s been Yes 10
7
Re-check whether the oil injector is working in a normal way after it’s been Yes Next step.
8
Yes Change the fuel
No 15
Yes Next step.
No 14
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When the valve on fuel meter is closed before a re-connection with ignition Yes Next step.
11 switch to drive the fuel pump working for another three seconds, check
No 13
whether it’s able to produce an oil pressure.
When the valve on fuel meter is opened before oil return pipe is being clamped Yes
adjustor
12 by oil-return barrier to stop oil return, check whether it’s able to produce oil
pressure rapidly. No
Yes
Yes
return pipe
No
adjustor
（signal output end of throttle position sensor）, Pin 30（ground end）, and Pin No
wiring harness
12 （used as one 4.5V~5V power supply to sensor）of ECU is normal.
Yes Change the ECU
Check whether ignition coil, high-voltage line, and spark plug are under a
16 Repair or change relevant
normal condition. No
parts and components.
12．Slow response to acceleration
Check
result
Place ignition switch to the“ON”position. A fault diagnosis instrument may Yes
1 away.
be used to check whether there’s any record of failure information.
No Next step.
Yes Next step.
No Change it.
Yes Next step.
Check whether the engine rotating-speed is normal while it’s running at
3 Provide service as per the
idle-speed. No
list of idle-speed failures.
Check whether the inlet-air pressure is within 35kpa and 65kpa while engine Yes Next step.
4
is running at idle-speed. No Check and repair it.
to engine EF.1-39
Check
result
After the connection of ignition switch, connect a commutator between ECU Yes Next step.
and wiring harness, and check whether respective voltage on Pin 53 (the signal
output end for throttle position sensor), Pin 30 (ground end), and Pin 12 (used No
wiring harness
as one 4.5V-5V power supply to sensor) of ECU is normal.
Have the engine running at idle-speed, and do not connect the Pin 51 of ECU Yes Next step.
to ground via short connection wire before the cooling-fluid temperature
6 Adjust the ignition
reaches its normal value; Check whether the ignition lead-angle is of a 6.75o No
lead-angle.
rotating angle of crankshaft.
Connect the fuel manometer valve (the connection point may vary depending Yes Next step.
on the type of vehicle). And have the Pin 30 of fuel pump relay short-circuit
7
connected with the Pin 87, and check whether the fuel pressure is within No 11
250kpa and 300kpa while the fuel pump is working.
8
9
Yes Change the fuel
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No 16
Yes Next step.
No 15
No 14
When the valve on fuel meter is opened before oil return pipe is being clamped Yes
adjustor
13 by oil-return barrier to stop oil return, check whether it’s able to produce oil
pressure rapidly. No
Yes
14 Check whether the oil inlet pipe has leakage or has been blocked. inlet pipe
15 Check whether the oil return pipe has been bent or blocked. Yes
return pipe
13．The acceleration is slack and with inferior performance.
Check
result
Yes Repair it.
1 Failure like inappropriate positioning of four wheels, etc.
No Next step.
Yes Next step.
2 Check whether the throttle valve is able to be full opened. Repair or change the
No
throttle valve
A fault diagnosis instrument may be used to check whether there’s any record Yes
3 away.
of failure information after ignition switch is placed to the “ON”position.
No Next step.
Place ignition switch on the“ON”position, and check whether respective Yes Next step.
voltage on the Pin 7（output of absolute-pressure sensor for inlet manifold）,
Pin 53（throttle position sensor）, Pin 44（output of air-inlet temperature
4 sensor）, Pin 45（output of cooling-fluid temperature sensor）, Pin 10 &28（used Repair or change the
No
as ground end and signal output end of oxygen sensor respectively）, Pin 30 wiring harness
（signal ground end of oxygen sensor）, and Pin 12 （used as one 4.5V~5V
power supply to sensor）of ECU is normal.
Check whether the inlet-air pressure is within 35kpa and 65kpa while engine is Yes Next step.
5
running at idle-speed. No Check and repair it.
EF.1-40 to engine
Check
result
No 11
7
8
Yes Change the fuel
No 16
Yes Next step.
No 15
No 14
When the valve to fuel meter is opened, clamp the oil return pipe tightly using Yes
adjustor
12 pliers to prevent oil return, and check whether it’s able to produce oil pressure
rapidly. No
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Yes
Repair or change oil return
Yes pipe
No
adjustor
Check whether data read from the absolute-pressure sensor the air-inlet Yes Next step.
15
temperature sensor of inlet manifold are normal. No Change the sensor
Check whether spark plug, high-voltage line, and ignition coil are under a Yes Next step.
16
normal condition. No Change or adjust it.
Check air-conditioner
Yes
17 Check whether the failure is caused by air-conditioner system. system
No Change ECU
14．Failure with the air-conditioner system
Check
result
Check whether system has been provided with sufficient refrigerant, and Yes Repair it.
1 whether the air-conditioner, air-conditioner clutch, and pressure switch are
under a normal condition. No Next step.
Have the engine running at idle-speed, and connect the air-conditioner switch; Yes Next step.
2 And a fault diagnosis instrument may be used to check whether there’s any Repair or change the
failure with the air-conditioner thermal resistor. No
throttle valve
Clear away the displayed
After the connection of air-conditioner switch, measure whether the Pin 40 and Yes
3 failure.
41（air-conditioner switch）of ECU has any signal input.
No Next step.
Yes Next step.

If the vehicle is under a control of low electrical level, check whether the
air-conditioner unit is still working after it is closed. No
wiring harness
Check whether the Pin 22 (connecting the ground end of holding coil of Yes Next step.
5
air-conditioner relay) of ECU has a low electrical level output. No Check and repair it.
*The signal of low /high electrical level from Pin 41 may be regarded as an air-conditioner request signal by ECU: ECU is able to
recognize the signal of low electrical level from Pin 41 as an air-conditioner signal requested by vehicle, and the signal from Pin 41
shall be of high electrical level when A/C switch is OFF. And vice versa.
to engine EF.1-41
General troubleshooting and steps to engine within M7.9.7 system

1．During startup process, the engine is not rotating or rotating slowly.
Check
result
A multimeter may be used to check and measure whether the voltage between Yes Next step.
1
two binding posts of accumulator is within （8-12）V while engine is starting. No Change the accumulator.
Keep the ignition switch at the “starting” position. And a multimeter may be Yes Next step.
2 used to check whether the positive binding post of starter has a voltage above Repair or change the
No
8V.。 wiring harness
Check the action of starter after it is dismantled. The main focus is to check for Yes Repair or change starter
3
broken loops or whether the starter has got stuck due to bad lubrication. No Next step.
If the failure only occurs in Winter, check whether the large resistance inside Change with appropriate
Yes
4 starter is caused by an inappropriate selection of engine lubricating oil and gear grade of lubricating oil
box oil. No Next step.
Check and repair the
failure resulting from the
Check whether the mechanical resistance inside engine is too large, or leads to Yes
5 internal resistance of
a slow or even no rotating of starter.
engine.
No Diagnosis help.
2．During a starting process, engine may be driven to rotate yet the starting is unsuccessful.
Check
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result
After the connection with fuel manometer (the connection point is on the front
Yes Next step.
end of oil inlet pipe included in the fuel distributing pipe assembly), check
1 whether the fuel pressure keeps about 260 kpa while engine is running at
Check and repair the oil
idle-speed; and whether the fuel pressure keeps at about 300kpa after vacuum No
supply system.
pipe has been pulled away from the fuel pressure adjustor.
Yes Next step.
After a connection with diagnosis instrument within the electronic injection
Check and repair the loop
2 system, observe the data entry “engine rotating-speed”; and observe whether
No with rotating-speed
there’s any rotating-speed signal output while engine is starting.
sensor.
Pull out the division line from one of cylinders before it’s connected with spark Yes Next step.
plug, and keep the electrode of spark plug about 5mm away from engine body,
3 Check and repair the
and check whether blue &white high-voltage fire is produced while the engine No
ignition system.
is running.
Settle the mechanical
Check and observe whether the pressure inside each engine cylinder is Yes
4 failure on engine.
insufficient.
No Next step.
After a connection with commutator within the electronic injection system, Yes Diagnosis help.
open the ignition switch to check whether respective power supply to Pin 12,
5. 13, 44, 45, 63 is under a normal condition; and whether respective metal part
No Follow-up steps
overlapped on Pin 3, 51, 53, 61, 80 is under a normal condition.
Operation steps
3. The hot vehicle is starting with difficulty.
Check
result
After the connection with fuel manometer (the connection point is on the front Yes Next step.
1 whether the fuel pressure keeps at about 260 kpa while engine is running at Check and repair the oil
No
idle-speed; and whether the fuel pressure keeps at about 300kpa after vacuum supply system.
ignition system.
is running.
Pull out the plug of cooling-fluid temperature sensor, and start the engine. Check and repair relevant
Observe for some time whether the engine may be started successfully.（Or a Yes loops or change the
3 300 ohm resistor may be serially connected at the joint of cooling-fluid sensor.
temperature sensor to substitute the sensor, then observe whether engine may
No Next step.
be started successfully.）。
Check, repair, or change
Check whether the vacuum pipe of fuel pressure adjustor has been loosened or Yes
4 it.
is leaking air.
No Next step.
EF.1-42 to engine
Check
result
Check the fuel condition, and observe whether the symptom is caused by the Yes Change the fuel
1
filling with petrol. No Next step.
Open the ignition switch to check whether respective power supply to Pin 12, Yes Next step.
2 13, 44, 45, 63 is under a normal condition; and whether respective metal part
No Diagnosis help.
4．The cold vehicle is starting with difficulty.

Check
result
No
plug, and keep the electrode of spark plug about 5mm away from engine body, Check the ignition
2
and check whether blue &white high-voltage fire is produced while the engine No system.
is running.
cardiagn.com
Pull out the plug from the cooling-fluid temperature sensor, and start the Check and repair
engine; Observe whether the starting of engine proves to be a success.（Or a Yes relevant loops or change
3 2500 ohm resistor may be serially connected at the joint of cooling-fluid the sensor.
temperature sensor to substitute the sensor, then observe whether engine may
No Next step.
be started successfully.）
Wash the throttle valve
Yes and the idle-speed air
4 Observe whether it’s easy to start by gently stepping on the throttle valve.
duct.
No Next step.
Change the failed
Remove the oil injector, and check whether it has any leakage or has been Yes
5 components.
blocked using a special washing analyzer instrument.
No Next step.
6 filling with petrol.
No Next step.

insufficient.
No Next step.
Open the ignition switch to check whether respective power supply to Pin 12, Yes Diagnosis help.
8 13, 44, 45, 63 is under a normal condition; and whether respective metal part Check and repair
No
overlapped on Pin 3, 51, 53, 61, 80 is under a normal condition. relevant loops.
5．Despite of a normal rotating-speed, the starting at any time is with difficulty.
Check
result
Check and repair the air
Yes
1 Check the air filter for blockage, and the air inlet passage for air leakage. inlet system.
No Next step.
After the connection with fuel manometer (the connection point is on the front
Yes Next step.
2 whether the fuel pressure keeps at about 260 kpa while engine is running at
Check and repair the oil
idle-speed; and whether the fuel pressure keeps at about 300kpa after vacuum No
supply system.
ignition system.
is running.
Check and observe whether the model and clearance of spark plug on each Yes Next step.
4
cylinder is in compliance with the specification. No Adjust or change it.
to engine EF.1-43
Check
result
Check and repair relevant
Pull out the plug from the cooling-fluid temperature sensor, and start the Yes loops or change the
5
engine; Observe whether the starting of engine proves to be a success. sensor.
No Next step.
Wash the throttle valve
Yes
6 Observe whether it’s easy to start by gently stepping on the throttle valve. and the idle-speed air duct.
No Next step.
Change the failed
7 components.
No Next step.
8
Check and observe whether the pressure inside each engine cylinder is Yes Eliminate engine failures.
9
insufficient. No Next step.
Yes Next step.
Check whether the engine ignition sequence &timing conform to relevant
specifications. No
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ignition timing.
11 13, 44, 45, 63 is under a normal condition; and whether respective metal part Check and repair relevant
No
overlapped on Pin 3, 51, 53, 61, 80 is under a normal condition. loops.
6．Despite of a normal starting process, the idle-speed is unstable at any time.
Check
result
Yes
No Next step.
Yes Wash or change it.
2 Check whether the idle-speed adjustor has got stuck.
No Next step.
3
Check whether any carbon deposit is produced on the throttle valve unit, or Yes Wash it
4
inside the idle-speed bypass air duct. No Next step.
Change the failed
5 components.
No Next step.
No Next step.
insufficient.
No Next step.
Yes Next step.
specifications. No
ignition timing.
No
EF.1-44 to engine
7．Despite of a normal starting, the idle-speed during vehicle heating process is unstable.
Check
result
Yes
No Next step.
2
After a removal of idle-speed adjustor, check whether any carbon deposit is Wash relevant parts and
Yes
3 produced on the throttle valve unit and the idle-speed adjustor, or inside the components.
idle-speed bypass air duct. No Next step.
After a removal of the plug for cooling-fluid temperature sensor, start the Check and repair relevant
Yes
4 engine and observe whether it has a stable idle-speed during vehicle heating loops or change the sensor.
process. No Next step.
Change the failed
5 components.
No Next step.
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No Next step.
Check the pressure inside each cylinder, and observe whether there’s any large Yes
difference in pressure across cylinders.
No Next step.
No
8．Despite of a normal starting process, the idle-speed is unstable after the vehicle heating process
is ended.
Check
result
Yes
No Next step.
2
cylinder is in compliance with the specification. No Adjust or change it
Yes
idle-speed bypass air duct.。 No Next step.
After a removal of the plug for cooling-fluid temperature sensor, start the
Yes loops or change the
4 engine and observe whether it has a stable idle-speed during vehicle heating
sensor.
process.
No Next step.
Change the failed
5 components.
No Next step.
No Next step.
Check the pressure inside each cylinder, and observe whether there’s any large Yes
difference in pressure across cylinders.
No Next step.
No
to engine EF.1-45
9. Despite of a normal starting process, the idle-speed when under partial load （ eg ：
air-conditioner）is unstable or even flameout.
Check
result
Yes
Observe whether the engine output power has been increased when the Continue to proceed until
Yes
air-conditioner is activated, in another word, that's to observe the change of step 4.
2
ignition lead-angle, oil-injection pulse width, and air inlet capacity using a
No Next step.
diagnosis instrument applicable to the electronic injection system.
After a line disconnection of Pin 75 on electronic control unit, check whether Yes Next step.
3 the signal for accumulator jar is high on wire-harness end while the Check and repair the
No
air-conditioner is running. air-conditioner system.
Check whether the pressure within air-conditioner system, the electromagnetic Yes Next step.
4 clutch of compressor, and the air-conditioner compressor are under a normal Check and repair the
No
condition. air-conditioner system.
Following a removal of oil injector, use a special washing analyzer instrument Change the failed
Yes
5 to check whether the oil injector has any leakage, has been blocked, or its flow components.
is out of tolerance. No Next step.
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No
10．The starting is normal yet the idle-speed is too high.
Check
result
Yes Adjust it.
1 Check whether the pulling line to gas is too tight or has got stuck.
No Next step.
Check whether there’s any air leakage with air inlet system, and its connected Yes
2 inlet system.
vacuum pipes.
No Next step.
Yes
After pulling out the plug of cooling-fluid temperature sensor, start the engine Yes loops or change the
4
and observe whether its idle-speed is too high. sensor.
No Next step.
Yes Next step.
Check whether the timing of engine ignition conforms to relevant
specifications. No
ignition system.
No
11．The rotating-speed is unable to go up or even flameout when accelerating.
Check
result
Yes
1 Check whether the air filter has been blocked. inlet system.
No Next step.
No
3
cylinder is in compliance with the specification. No Adjust or change it
Yes
EF.1-46 to engine
Check
result
Yes Next step.
Check whether the inlet-air pressure sensor, throttle position sensor, and its
5 Check and repair relevant
loops are under a normal condition. No
loops or change the sensor.
Change the failed
6 components.
No Next step.
No Next step.
Yes Next step.

specifications. No
ignition timing.
Yes Next step.
9 Check whether the exhaust pipe is free. Repair or change the
No
exhaust pipe.
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No
12．Slow response to acceleration
Check
result
Yes
No Next step.
No
3
Yes
Yes Next step.
Check whether the inlet-air pressure sensor, throttle position sensor, and its
loops are under a normal condition. No
loops or change the sensor.
Change the failed
6 components.
No Next step.
No Next step.
Yes Next step.

specifications. No
ignition timing.
Yes Next step.
No
exhaust pipe.
No
to engine EF.1-47
13. The acceleration is slack and with inferior performance.

Check
result
Check for following failures: slide of clutch, low pressure inside tire, dragging Yes
1 inlet system.
brake, inappropriate size of tires, inappropriate positioning of four wheels, etc.
No Next step.
Yes
No Next step.
No
4
and check whether a normal high-voltage fire is produced while the engine is No Adjust or change it.
running.
5
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Yes
Yes Next step.
Check whether the inlet-air pressure sensor, throttle position sensor, and its Check and repair relevant
7
loops are under a normal condition. No loops or change the
sensor.
Change the failed
8 components.
No Next step.
9
Yes Next step.
specifications. No
ignition timing.
Yes Next step.
No
exhaust pipe.
After a connection with the commutator within the electronic injection system, Yes Diagnosis help.
open the ignition switch to check whether respective power supply to Pin 12,
13, 44, 45, 63 is under a normal condition; and whether respective metal part No
loops.
Criterion to flashing codes and the mounting torque of parts &components within
EF.1-48 M1.5.4 system
M1.5.4 system
1．List of flashing codes within M1.5.4 system
Fault
Type of
S.N. Name of failure information Flashing code indicator
failure
lamp
1 Failure with knock sensor （zero test status） 1 1 1
2 No failure. 11 - -
The temperature of air-conditioner evaporator is
3 13 1 0
unreliable.
4 The signal of throttle position sensor is unreliable. 14 1 1
5 The signal of knock sensor is unreliable. 15 2 1
6 The signal of inlet-air pressure sensor is unreliable. 16 1 1
7 The signal of oxygen sensor is unreliable. 17 1 1
8 The signal of inlet-air temperature sensor is unreliable. 18 1 1
The signal of cooling-fluid temperature sensor is
9 19 1 1
unreliable.
10 Injector -failure with the driving stage of cylinder 4 21 1 1
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Failure with the driving stage of carbon-canister control
14 25 1 1
valve
The air /fuel ratio, and the control &repair coefficient
15 31 2 0
are unreliable.
16 The engine is running out of Max. rotating-speed. 33 2 0
17 Failure with the electronic control unit. 34 2 1
The air /fuel ratio to control the addition modification
18 35 2 0
coefficient（The scope of idle-speed plays a role）
The air /fuel ratio to control the multiplication
19 modification coefficient（The scope of idle-speed plays a 36 2 0
role）
A self-learning of addition modification (for air leakage
20 37 2 0
amount) controlled by the air /fuel ratio
21 The accumulator voltage is unreliable. 38 2 0
22 The signal of vehicle speed is unreliable. 41 2 0
23 Failure with the cooling-fan relay. 42 1 1
24 The signal to determine cylinder is unreliable. 43 2 0
25 Failure with the driving stage of fault indicator lamp. 45 1 0
Failure with the driving stage 1
26 61 1 1
of step motor-EWD coil 1
Failure with the driving stage 2
27 62 1 1
of step motor –EWD coil 2
Type of failure：“1”denotes an open circuit, or a short circuit to ground, or a short circuit to power supply; and“2”
denotes the signal out of limit.
Fault indicator lamp：“1”denotes lighting, and“0” denotes off.
M1.5.4 system EF.1-49
2 Steps to read flashing fault codes:

(a)Connect the engine ignition switch rather than to start the engine.
(b)Connect the diagnosis plug-7# on line K ECU-55# or OBD to ground, and the connection time is longer than 2.5
seconds.
(c)And failures stored in the failure memory will be output by a flashing fault indicator lamp.
(d)Each flashing code is composed of two digits, and each is made up of one number within 0 and 9.
(e)The digit 0 will flash for ten times, and any digit within 1-9 will flash as per its literal meaning; The flashing will be stopped
instantaneously for one second between two digits forming a flashing code, and will be stopped for a long-term period between
(f) An identical fault code will be flashing continuously for three times, and all fault codes will be uninterruptedly flashing until
(g)If no any failure has been stored in the failure memory, the fault indicator lamp will have the “No failure” (ie. “11”) flashed.
(h)To clear any fault code away from the failure memory, simply connect the K line to ground for two continuous times, and each time
shall be longer than 2.5 seconds.
3. List of criterion to the mounting torque of parts &components
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Name of parts Mounting torque Name of parts Mounting torque
S.N. S.N.
&components （N·m） &components （N·m）
Air inlet pressure
1 3.3 6 Rotating speed sensor 8±2
/temperature sensor
Cooling-fluid
2 20(Max) 7 Phase sensor 8±0.5
temperature sensor
3 Knock sensor 20±5 8 Oil injector 6
4 Oxygen sensor 50±10 9 Idle-speed actuator 4±0.4
5 Throttle position sensor 2±0.5
EF.1-50 Description of the diagnosis function on M7.9.7 system failure
Description of the diagnosis function on M7.9.7 system failure

1. Record of failure information
The electronic control unit is uninterruptedly checking the sensor, actuator, relevant loops, fault indicator lamp, accumulator voltage,
or even itself; and also verifying the reliability of output signal from sensor, driving /internal signal from actuator eg.
closed-loop control, cooling-fluid temperature, knock control, rotating-speed control when at idle-speed, accumulator voltage control,
etc. . Once any failure occurs at some step, or if some signal value is unreliable, the electronic control unit will immediately set a
record of failure information in RAM failure memory. Such record is stored in a form of fault code, and displayed as per the priority
of failure display.
Depending on the frequency of display, failures may be divided into “stable failure” and “chance failure” eg. failure caused by a
short broken circuit of wiring harness, or by bad contact between connectors.
2. Three grades of failure
(a)CLASS 5
-Actions to be taken when setting the diagnosis fault code:
Once some failure displays, its corresponding fault code and relevant failure information will enter a fault codememory.
The failure will be verified after being displayed in three continuous driving cycles, but ECU will not light up the fault i n d i c a t o r
lamp.
-Condition as to eliminate the fault indicator lamp/fault code.
Upon a verification of failure, have vehicle running without failure for three continuous driving cyclestosettlethefailure.
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As for verified failure, the fault code will be cleared away after 40 continuous trouble-free preheating cycles from the time of failure
settlement.
As for chance failure, the fault code will be cleared away after 40 continuous trouble-free preheating cycles.
(b)CLASS 31
Once some failure displays, its corresponding fault code and relevant failure information will enter a fault codememory.The failure
will be verified after being displayed in three continuous driving cycles, and ECU will light up the fault indicator lamp.
-Condition as to eliminate the fault indicator lamp/fault code
When the fault indicator lamp is lighting, have vehicle running without failure for one driving cycle to settle the failure, and the fault
indicator lamp will be closed.
As for verified failure, the fault code will be cleared away after 40 continuous trouble-free preheating cycles from the time of
failure settlement.
(c)CLASS 33
Once some failure displays, its corresponding fault code and relevant failure information will enter a fault code memory.
The failure will be verified in two mintues from the display moment, but ECU will not light up the fault indicator lamp.
-Condition as to eliminate the fault indicator lamp/fault code
Upon a verification of failure, have vehicle running without failure for one driving cycle to settle the failure.
As for verified failure, the fault code will be cleared away after 40 continuous trouble-free preheating cycles from the time of failure
settlement.
3. Strategy for the control of fault indicator lamp
When no failure,
-After the ignition switch is ON, the fault indicator lamp will be lighting, then off in four seconds;
-It will be started within four seconds; and the fault indicator lamp will be off after the signal to rotating-speed is found;
-When the ground connection time of line K is longer than 2.5 seconds, the fault indicator lamp will be flashing at a frequency of 2 Hz.
When with failure,
-After the ignition switch is ON, the fault indicator lamp will be always lighting;
-It will be started, and the fault indicator lamp will be off after the signal to rotating-speed is found; If the fault indicator lamp is
defined to a ‘lighting’ mode, it will be always lighting when relevant conditions are satisified;
-When the ground connection time of line K is longer than 2.5 seconds, a flashing code (ie. P-CODE value) will be output. For
instance: P0203 will be flashing in the way below: ten continuous times- intermittance- two continuous times - intermittance- ten
continuous times - intermittance- three continuous times.
Description of the diagnosis function on M7.9.7 system failure EF.1-51
4. Four types of failure

Failure B_mxdfpMax. indicates the signal goes beyond the upper limit of normal scope;
Failure B_mndfpMin. indicates the signal goes beyond the lower limit of normal scope;
Failure B_sidfpsignal indicates some failure without signal.
Failure caused by an inappropriate B_npdf, indicates some inappropriate signal.
5. Connection with diagnosis instrument
The system adopts ISO 9141-2 standard diagnosis plug (as shown in the figure below) to be securely connected with engine wiring
harness, and is supported by line “K” communication protocol. And Pin 4, 7, 16 on diagnosis plug shall be connected respectively
with following parts under the engine management system (EMS): Pin 4 connected to the ground wire on vehicle; Pin 7 connected to
Pin 71 of ECU, namely the engine data line K ; and Pin 16 connected to the positive electrode of accumulator.
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ECU may communicate with peripheral diagnosis instruments via line K , and perform following operations:
(a)Display of engine parameters
-Rotating-speed, cooling-fluid temperature, opening degree of throttle valve, ignition lead-angle, oil-injection pulse width, inlet
airpressure, inlet-air temperature, vehicle speed, system voltage, modification to oil injection, scour rate of carbon-canister, idlespeedair
control, waveform of oxygen sensor;
-Desired rotating-speed, relative load of engine, ambient temperature, ignition closure time, temperature of evaporator, inlet air
capacity, and oil consumption.
-Signal voltage of throttle position sensor, signal voltage of cooling-fluid temperature sensor, signal voltage of inlet-air temperature
sensor, signal voltage of inlet-air pressure sensor, signal voltage for Pin 1 of knock sensor, and signal voltage for Pin 2 of knock sensor.
(b)The displayed status for electronic injection system covers:
Status of theft-prevention system, safety status, editing status, status of cooling system, status of stable working condition, status
of dynamic working condition, exhaust control status, status of oxygen sensor, idle-speed status, status of fault indicator lamp,
status under emergency, status of air-conditioner system, auto. speed changer /torque request status.
(c) Actuator test function
Fault indicator lamp, fuel pump, air-conditioner relay, fan, ignition, and oil injection single-cylinder oil cut .
(d)Display of milemeter
Mileages &time traveled.
(e)Display of version information
No. of vehicle frame VIN , No. of ECU hardware, No. of ECU software.
(f)Display of failures
Inlet-air pressure sensor, inlet-air temperature sensor, engine cooling-fluid temperature sensor, throttle position sensor, oxygen
sensor, the heating loop of oxygen sensor, modification to air /fuel ratio, oil injector inside each cylinder, fuel pump, knock sensor,
rotating speed sensor, phase sensor, carbon-canister control valve, cooling-fan relay, vehicle speed signal, rotating- speed when at
idle-speed, idle-speed adjustor, system voltage, ECU, air-conditioner compressor relay, temperature sensor of evaporator, fault
indicator lamp.
6. Read failure information via flashing code
Open the ignition switch, and have the engine data line K i e. Standard diagnosis plug No. 7 being connected to ground for at
least 2.5 seconds; The availability of fault code stored in ECU failure memory will be indicated by a flashing code (i e. P- CODE
value) output from an engine fault indicator lamp. For instance, P0203 will be flashing in the way below: ten continuous times-
intermittance- two continuous times - intermittance- ten continuous times - intermittance- three continuoustimes.
EF.1-52 M7.9.7 system service &diagnosis flow process based on fault code
M7.9.7 system service &diagnosis flow process based on fault code

1.List of fault codes within M7.9.7 system
S.N. Fault code Description Grade of failure
1 P0107 The signal voltage in the loop of inlet-air pressure sensor is too low. Class31
2 P0108 The signal voltage in the loop of inlet-air pressure sensor is too high. Class31
3 P0112 The temperature indicated by inlet-air temperature sensor is too low. Class31
4 P0113 The temperature indicated by inlet-air temperature sensor is too low. Class31
5 P0117 The temperature indicated by engine cooling-fluid temperature sensor is too low. Class31
6 P0118 The temperature indicated by engine cooling-fluid temperature sensor is too low. Class31
7 P0122 The signal voltage in the loop of throttle position sensor is too low. Class31
8 P0123 The signal voltage in the loop of throttle position sensor is too low. Class31
9 P0130 The failure is caused by an inappropriate signal of upstream oxygen sensor. Class31
10 P0132 The signal voltage in the loop of upstream oxygen sensor is too high. Class31
11 P0134 Failure with the signal of upstream oxygen sensor. Class31
12 P0135 Failure with the heating loop of upstream oxygen sensor. Class31
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13 P0171 The self-adaptive value for a closed-loop control of air /fuel ratio is beyond the upper limit. Class5
14 P0172 The self-adaptive value for a closed-loop control of air /fuel ratio is beyond the upper limit. Class5
15 P0201 Failure with the loop of oil injector inside cylinder 1 Class31
19 P0230 Failure with the control loop of oil pump Class31
20 P0324 Failure with the processing chip of knock signal, and its loops. Class5
21 P0325 Failure with the loop of knock sensor. Class31
22 P0335 Failure with the signal of crankshaft position sensor. Class33
23 P0336 The failure is caused by an inappropriate signal of crankshaft position sensor. Class33
24 P0340 Failure with the signal of phase sensor. Class31
25 P0443 Failure with the control loop of driving stage for carbon-canister control valve. Class31
26 P0444 The voltage in the control loop of driving stage for carbon-canister control valve is too low. Class31
27 P0445 The voltage in the control loop of driving stage for carbon-canister control valve is too high. Class31
28 P0550 The failure is caused by an inappropriate signal of vehicle speed. Class31
29 P0506 The rotating-speed under an idle-speed control is lower than the desired idle-speed value. Class31
30 P0507 The rotating-speed under an idle-speed control is higher than the desired idle-speed value. Class31
31 P0508 The voltage in the control loop of idle-speed adjustor is too low. Class31
32 P0509 The voltage in the control loop of idle-speed adjustor is too high. Class31
33 P0511 Failure with the control loop of idle-speed adjustor. Class31
34 P0560 Inappropriate signal of system voltage. Class31
35 P0562 The signal of system voltage is too low. Class31
36 P0563 The signal of system voltage is too high. Class31
37 P0601 The verification code of electronic controller has not been programmed yet. Class31
38 P0602 The diagnosis data ID code of electronic controller has not been programmed yet. Class31
39 P0645 Failure with the control loop of air-conditioner compressor relay. Class31
40 P0646 The voltage in the control loop of air-conditioner compressor relay is too low. Class31
41 P0647 The voltage in the control loop of air-conditioner compressor relay is too high. Class31
42 P1651 Failure with the control loop of engine fault indicator lamp（SVS）. Class5
M7.9.7 system service &diagnosis flow process based on fault code EF.1-53
2.M7.9.7 system service &diagnosis flow process based on fault code

Fault code：P0107“the signal voltage in the loop of inlet-air pressure sensor is too low”
Check
result
1 Connect with the diagnosis instrument, and place the ignition switch to the“ON”position. Next step.
Observe whether the item “inlet air pressure” in data stream is about 101kpa (specific data Yes Continue to proceed until step 5.
2
depends on the existing pressure). No Next step.
Pull out the plug of inlet-air pressure sensor from wiring harness, and a multimeter may be Yes Continue to proceed until step 5.
3
used to check whether the voltage between Pin 3 and Pin 1 of plug is about 5V. No Next step.
Repair or change the wiring
Check whether respective loops between Pin 17/33/37 of ECU and the connection Pin 1/3/4 of Yes
4 harness.
sensor are short circuit to ground.
No Next step.
Start the engine and have it running at idle-speed; Step on the gas slowly until it’s full opened
and observe the change of value at item“inlet-air pressure”on diagnosis instrument, the Yes Diagnosis help.
5
displayed value shall be with slight changes; Step on the gas quickly until it’s close to a full
No Change the sensor.
open degree, the displayed value shall reach a value greater than 90kpa instantaneously.
Fault code：P0108 “the signal voltage in the loop of inlet-air pressure sensor is too high”
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Check
result
Observe whether the item “inlet-air pressure” within data stream is about 101kpa (exact data is Yes Continue to proceed until step 5.
2
subject to the existing pressure). No Next step.
Pull out the plug of inlet-air pressure sensor from wiring harness, and a multimeter may be Yes Continue to proceed until step 5.
3
used to check whether the voltage between Pin 3 and Pin 1 of plug is about 5V. No Next step.
Check whether respective loops between Pin 17/33/37 of ECU and the connection Pin 1/3/4 of Yes
4 harness.
sensor are short circuit to power supply.
No Next step.
Start the engine and have it running at idle-speed; Step on the gas slowly until it’s full opened
and observe the change of value at item“inlet-air pressure”on diagnosis instrument, the Yes Diagnosis help.
5
displayed value shall be with slight changes; Step on the gas quickly until it’s close to a full
open degree, the displayed value shall reach a value greater than 90kpa instantaneously. No Change the sensor.
Fault code：P0112“The temperature indicated by the inlet-air temperature sensor is too low”
Check
result
Observe whether the value of item“inlet-air temperature”in data stream is fit for the Yes Continue to proceed until step 5.
2 temperature inside the air-inlet pipe (specific value depends on the existing pressure). Note: If
the displayed value is always -40℃, it indicates a possible failure caused by a broken loop. No Next step.
Pull out the plug of inlet-air temperature sensor from wiring harness, and a multimeter may be Yes Next step.
3 used to check whether the resistance between Pin 1 and Pin 2 of sensor is fit for the
temperature.
Pull out the plug of inlet-air temperature sensor from wiring harness, and a multimeter may be Yes Continue to proceed until step 5.
4
used to check whether the voltage between Pin 1 and Pin 2 of sensor is about 5V. No Next step.
Check whether respective loops between Pin 17 &40 of ECU and the connection Pin 1 &2 of Yes
5 harness.
sensor are broken loops, or short circuit to power supply.
No Next step.
“inlet-air
Start the engine and have it running at idle-speed. Observe the change of value at item Yes Diagnosis help.
6 temperature”displayed on diagnosis instrument, and whether the value is increased accordingly
when the engine inlet-air temperature is being increased. No Change the sensor.
Fault code：P0113“The temperature indicated by inlet-air temperature sensor is too high”

Check
result
Observe whether the value of item “inlet-air temperature”in data stream is fit for the
Yes Continue to proceed until step 5.
2 temperature inside the air-inlet pipe (specific value depends on the existing pressure). Note: If
the displayed value is always -40℃, it indicates a possible failure caused by a broken loop. No Next step.
Pull out the plug of inlet-air temperature sensor from wiring harness, and a multimeter may be Yes Next step.
3 used to check whether the resistance between Pin 1 and Pin 2 of sensor is fit for the
temperature.
4
Check whether respective loops between Pin 17 &40 of ECU and Pin 1 &2 of sensor are Yes
5 harness.
broken loops or short circuit to ground.
No Next step.
“inlet-air
Start the engine and have it running at idle-speed. Observe the change of value at item Yes Diagnosis help.
6 temperature”displayed on diagnosis instrument, and whether the value is increased accordingly
when the engine inlet-air temperature is being increased. No Change the sensor.
Fault code：P0117“The temperature indicated by engine cooling-fluid temperature sensor is too
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low.”
S.N. Operation steps Check Follow-up steps
result
Observe whether the value at item “cooling-fluid temperature ” in data stream is fit for engine
2 temperature (specific data depends on the existing pressure). Note: If the displayed value is
always -40℃, it indicates a possible failure caused by the broken loop. No Next step.
Pull out the plug of cooling-fluid temperature sensor from wiring harness, and a multimeter Yes Next step.
3 may be used to check whether the resistance between Pin 1 and Pin 2 of sensor is fit for the
temperature. .
4
5 harness.
No Next step.
Start the engine and have it running at idle-speed. Observe whether the value of item Yes Diagnosis help.
6 “cooling-fluid temperature” displayed on diagnosis instrument is increased accordingly
when the temperature of engine cooling-fluid is being increased. No Change the sensor.
Fault code：P0118“The temperature indicated by the engine cooling-fluid temperature sensor
is too high”
Check
result
Observe whether the value at item “cooling-fluid temperature ” in data stream is fit for engine
2 temperature (specific data depends on the existing pressure). Note: If the displayed value is
always -40℃, it indicates a possible failure caused by the broken loop. No Next step.
Pull out the plug of cooling-fluid temperature sensor from wiring harness, and a multimeter Yes Next step.
3 may be used to check whether the resistance between Pin 1 and Pin 2 of sensor is fit for the
temperature. .
4
5 harness.
No Next step.
Start the engine and have it running at idle-speed. Observe whether the value of item Yes Diagnosis help.
6 “cooling-fluid temperature” displayed on diagnosis instrument is increased accordingly
when the temperature of engine cooling-fluid is being increased. No Change the sensor.
Fault code：P0122“The signal voltage in the loop of throttle position sensor is too low.”
Check
result
Observe whether the value of item “absolute opening degree of throttle valve”in data stream Yes Next step.
2
is within 4%-10%. No Continue to proceed until step 5.
Step on the gas slowly until it’s full opened, and observe whether the value of item“absolute Yes Next step.
3 opening degree of throttle valve”in data stream is increased to a degree of 85%-95% when the
No Continue to proceed until step 5.
opening degree of throttle valve is being increased.
Repeat step 3 to observe the item “absolute opening degree of throttle valve”in data stream, Yes Change the sensor.
4
and whether any abrupt change exists during the change of value. No Next step.
Pull out the plug of throttle valve sensor from wiring harness, and check whether respective Repair or change the wiring
Yes
5 loops between Pin 32/17/16 of ECU and the connection Pin 1/2/3 of sensor are broken loops, harness.
or short circuit to ground. No Next step.
A multimeter may be used to check whether the voltage between Pin 1 and Pin 2 of the plug is Yes Diagnosis help.
6
about 5V. No Continue to proceed until step 5.
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Fault code：P0123“The signal voltage in the loop of throttle position sensor is too high”
Check
result
Observe whether the value of item“absolute opening degree of throttle valve”in data stream is Yes Next step.
2
within 4%-10%. No Continue to proceed until step 5.
Step on the gas slowly until it’s full opened, and observe whether the value of item “absolute Yes Next step.
3 opening degree of throttle valve”in data stream is increased to a degree of 85%-95% when the
opening degree of throttle valve is being increased.
Repeat step 3 to observe the item “absolute opening degree of throttle valve”in data stream, Yes Change the sensor.
4
and whether any abrupt change exists during the change of value. No Next step.
Pull out the plug of throttle valve sensor from wiring harness, and check whether respective Repair or change the wiring
Yes
5 loops between Pin 32/17/16 of ECU and the connection Pin 1/2/3 of sensor are broken loops, harness.
or short circuit to ground. No Next step.
A multimeter may be used to check whether the voltage between Pin 1 and Pin 2 of the plug is Yes Diagnosis help.
6
about 5V. No Continue to proceed until step 5.
Fault code：P0130“Failure caused by inappropriate signal for upstream sensor”
（Note: The diagnosis flow process below is applicable to cases excluding that P0135 is not produced simultaneously; if P0135 is
produced simultaneously, you need to settle the failure with P0135 first before performing a check and repair as per the flow process
below.）
Check
result
Start the engine and have it running at idle-speed until the cooling-fluid temperature reaches its
Yes Diagnosis help.
2 normal value. Observe the change of value at the item“oxygen sensor voltage”on diagnosis
instrument, and whether the displayed value makes a rapid change within 100mV~900mV. No Next step.
Check whether respective loops between Pin 36 &18 of ECU and the connection Pin A Repair or change the wiring
Yes
3 (corresponding to the grey connection line of oxygen sensor) and B(corresponding to the black harness.
connection line of oxygen sensor) of sensor are broken loops. No Change the sensor.
Fault code：P0132“the signal voltage in the loop of upstream sensor is too high”
produced simultaneously, you need to settle the failure with P0135 first before performing a check and repair as per the flow process
below.）
Check
result
Yes Diagnosis help.
Yes
3 (corresponding to the grey connection line of oxygen sensor) and B (corresponding to the harness.
black connection line of oxygen sensor) of sensor are broken loops. No Change the sensor.
A、Whether the exhaust system is leaking air or has been blocked;
Check and repair it based on
B、Whether the oil injector has any leakage; Yes
diagnosis.
4 C、Whether the fuel pressure is too big;；
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D、Whether the clearance of air valve is too small；
So on and so forth.
Fault code：P0134“Failure with the signal of upstream sensor”
produced simultaneously, you need to settle the failure with P0135 first before performing a check and repair as per the flow
process below.）
Check
result
1 Connect with the diagnosis instrument, and place the ignition switch to the“ON”position. Yes Next step.
Yes Diagnosis help.
Yes
3 (corresponding to the grey connection line of oxygen sensor) and B (corresponding to the harness.
black connection line of oxygen sensor) of sensor are broken loops. No Change the sensor.
Fault code：P0135“Failure with heating loop of upstream oxygen sensor.”
Check
result
Pull out the plug of oxygen sensor from wiring harness, and a multimeter may be used to check
Yes Next step.
whether the voltage between Pin C（corresponding to the white connection line of oxygen
2
sensor） and Pin D （corresponding to the white connection line of oxygen sensor）of the plug
is about 12V.
A multimeter may be used to check whether the resistance between Pin C (white) and Pin Yes Next step.
3
D(white) of oxygen sensor is within （1-6）Ω when at 20℃. No Change the sensor.
Yes Change the fuse
4 Check whether the 8A fuse in the heating loop of oxygen sensor has been blown and broken.
No Next step.
Check whether respective loops between Pin 1 of ECU / Pin 87 of main relay and the Repair or change the wiring
Yes
connection Pin C (corresponding to the while connection line of oxygen sensor) and Pin D harness.
5
(corresponding to the while connection line of oxygen sensor) of sensor are broken loops, or
No Diagnosis help.
short circuit to ground or power supply.
Fault code：P0171“The self-adaptive value for a closed-loop control of air /fuel ratio is beyond the upper limit. ”
（Note: The diagnosis flow process below is applicable to cases excluding that fault codes are produced simultaneously on
inlet-air pressure sensor, carbon-canister control valve, oxygen sensor, etc. If fault codes are produced simultaneously, settle
other failures first before performing a check and repair as per the flow process below.）
Check
result
Connect with the diagnosis instrument, and place the ignition switch to the
1 Next step.
“ON”position.
Start the engine and have it running at idle-speed until the cooling-fluid
Yes Next step.
temperature reaches its normal value. When under a full working condition,
observe the change of value at the item“oxygen sensor voltage”on diagnosis
2
instrument, and whether the displayed value remains at about 100mV(yet
No Diagnosis help.
with less changes) for a long-term period when under some working
conditions.
end of fuel inlet pipe included in the fuel distributing pipe assembly), check
3 whether the fuel pressure keeps at about 260 kpa while engine is running at Check and repair the fuel
No
idle-speed; and whether the fuel pressure keeps at about 300kpa after vacuum system.
Check whether respective loops between Pin 36 &18 of ECU and the Repair or change the wiring
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Yes
connection pin A (corresponding to the grey connection line of oxygen sensor) harness.
4
&B (corresponding to the black connection line of oxygen sensor) of sensor
No Next step.
are short circuit to ground.
A、 Check whether severe air leakage exists in the air inlet system;
B、 Whether fuel injector has been blocked; Check and repair it based
Yes
C、 Whether the clearance of spark plug is too big; on diagnosis.
5
D、 Whether the resistance of fire division line is too big;
E、 Whether the clearance of air valve is too big;
No Diagnosis help.
So on and so forth.
Fault code: P0172 “The self-adaptive value for a closed-loop control of air /fuel ratio is beyond
the lower limit”
（Note: The diagnosis flow process below is applicable to cases excluding that fault codes are produced simultaneously on
inlet-air pressure sensor, carbon-canister control valve, oxygen sensor, etc. If fault codes are produced simultaneously, settle other
failures first before performing a check and repair as per the flow process below.）
Check
result
1 Next step.
“ON”position.
Start the engine and have it running at idle-speed until the cooling-fluid
Yes Next step.
temperature reaches its normal value. When under a full working condition,
observe the change of value at the item“oxygen sensor voltage”on diagnosis
2
instrument, and whether the displayed value remains at about 900mV(yet
No Diagnosis help.
with less changes) for a long-term period when under some working
conditions.
end of fuel inlet pipe included in the fuel distributing pipe assembly), check
3 whether the fuel pressure keeps at about 260 kpa while engine is running at Check and repair the fuel
No
idle-speed; and whether the fuel pressure keeps at about 300kpa after vacuum system.
Check whether respective loops between Pin 36 &18 of ECU and the Repair or change the wiring
Yes
connection pin A (corresponding to the grey connection line of oxygen sensor) harness.
4
&B (corresponding to the black connection line of oxygen sensor) of sensor
No Next step.
are short circuit to power supply.
A、 Whether the injector is leaking; Check and repair it based
Yes
B、 Whether the exhaust pipe has been blocked; on diagnosis.
C、 Whether the clearance of air valve is too small;
No Diagnosis help.
So on and so forth.
Fault code：P0201“Failure with the loop of fuel injector inside cylinder 1”

Check
result
1 Next step.
“ON”position.
Pull out the plug of fuel injector for cylinder 1 from wiring harness, and a Continue to proceed until
Yes
2 multimeter may be used to verify whether the voltage between the connection step 4.
Pin 1 and the negative electrode of power supply is about 12V. No Next step.
Check whether the loop between the connection Pin 1 of fuel injector for Yes
3 harness.
cylinder 1 and main relay is a broken loop, or short circuit to ground.
No Next step.
A multimeter may be used to check whether the resistance between Pin 1 and Yes Next step.
4
Pin 2 of fuel injector for cylinder 1 is within （11-17）Ω when at 20℃. No Change the fuel injector
A multimeter may be used to check whether the voltage between Pin 2 of fuel Yes Diagnosis help.
5 injector for cylinder 1 and the negative electrode of power supply is about
3.7V. No Next step.
Check
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result
1 Next step.
“ON”position.
Yes
3 harness.
No Next step.
4
3.7V. No Next step.
Check whether the loop between Pin 2 of fuel injector for cylinder 2 and the Yes
6 harness.
Pin 6 of ECU is a broken loop, or short circuit to ground or power supply.
No Diagnosis help.
Check
result
1 Next step.
“ON”position.
Yes
3 harness.
No Next step.
4
3.7V. No Next step.
6 harness.
No Diagnosis help.

Check
result
1 Next step.
“ON”position.
Yes
3 harness.
No Next step.
4
3.7V. No Next step.
6 harness.
No Diagnosis help.
Fault code：P0230“Failure with the control loop of fuel pump”
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Check
result
1 Next step.
“ON”position.
Pull out the fuel pump relay, place the ignition switch to the “ON” position, Continue to proceed until
Yes
and check whether respective voltage between the negative electrode of power step 4.
2
supply and the power supply end (ie. Pin 30 &86) of fuel pump relay is about
No Next step.
12V.
Check whether the loop on the power supply end of relay is a broken loop or Yes
3 harness.
short circuit to ground.
No Next step.
Change the fuel pump
A multimeter may be used to check whether the resistance between Pin 1 and Yes
4 relay.
Pin 2 of fuel injector for cylinder 1 is within （11-17）Ω when at 20℃.
No Next step.
A multimeter may be used to check whether the voltage between the control Yes Diagnosis help.
5 end (ie.Pin 85) of fuel pump relay and the negative electrode of power supply
is about 3.7V. No Next step.
Fault code；P0324“Failure with the processing chip of knock signal, and its loops.”
Check
result
1 Next step.
“ON”position.
Yes Next step.
2 Eliminate any fault code, and re-check whether the failure is a stable failure.
No System is normal.
3 Change the ECU.
Fault code：P0325“Failure with the loop of knock sensor.”
Check
result
1 Next step.
“ON”position.
Pull out the plug of knock sensor from wiring harness, and a multimeter may Yes Next step.
2 be used to verify whether resistance between Pin 1 and Pin 2 of knock sensor is
greater than 1MΩ. No Change the sensor.
Check whether respective loops between the connection pin 1 &2 of knock Repair or change the wiring
Yes
3 sensor and Pin 19 &20 of ECU are broken loops, or short circuit to ground or harness.
power supply. No Next step.
Change the knock sensor as per installation specification. Have a loop test and Yes Diagnosis help.
4 make the rotating-speed of engine greater than 2200 revolutions per minute. Continue to proceed until
No
And re-check whether the fault code P0325 will be shown. step 3.
Fault code：P0335“Failure with the signal of crankshaft position sensor.”

Check
result
1 Next step.
“ON”position.
Pull out the plug of rotating speed sensor from wiring harness, and a Yes Next step.
2 multimeter may be used to verify whether the resistance between Pin 1 and Pin
2 of rotating speed sensor is within （770-950）Ω when at 20℃. No Change the sensor.
Check whether respective loops between the connection Pin 1 &2 of rotating Repair or change the wiring
Yes
3 speed sensor and Pin 15 &34 of ECU are broken loops, or short circuit to harness.
ground or power supply. No Next step.
Yes Change the sensor.
Check whether the installation position of sensor satisfies relevant
4 Check and repair it based
requirements, and whether the signal panel of flywheel is intact. No
on diagnosis.
Fault code：P0336“The failure is caused by an inappropriate signal of crankshaft position sensor.”
Check
result
1 Next step.
“ON”position.
Pull out the plug of rotating speed sensor from wiring harness, and a Yes Next step.
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2 multimeter may be used to verify whether the resistance between Pin 1 and Pin
2 of rotating speed sensor is within （770-950）Ω when at 20℃. No Change the sensor.
Check whether respective loops between the connection Pin 1 &2 of rotating Repair or change the wiring
Yes
3 speed sensor and Pin 15 &34 of ECU are broken loops, or short circuit to harness.
ground or power supply. No Next step.
Check whether the installation position of sensor satisfies relevant
4 Check and repair it based
requirements, and whether the signal panel of flywheel is intact. No
on diagnosis.
Fault code：P0340“Failure with the signal of phase sensor.”
Check
result
1 Next step.
“ON”position.
Pull out the plug of phase sensor from wiring harness, and a multimeter may be Continue to proceed until
Yes
2 used to verify whether the voltage between Pin 1 and Pin 3 of phase sensor is step 4.
about 12V. No Next step.
Check whether the loop between the connection pin 1 of phase sensor and Pin Repair or change the wiring
Yes
3 87 of main relay is a broken loop, or short circuit to ground. And check harness.
whether the pin 3 of phase sensor has been well grounded. No Next step.
Continue to proceed until
Check whether the voltage between the connection Pin 2 of phase sensor and Yes
4 step 6.
the negative electrode of power supply is about 9.9V.
No Next step.
Check whether the loop between the connection pin 2 of phase sensor and Pin Yes
5 harness.
79 of ECU is a broken loop, or short circuit to power supply or ground.
No Next step.
6 Check whether the signal panel of camshaft is intact.
No Change the signal panel
Fault code：P0443“Failure with the control loop of driving stage for carbon-canister control valve.”
Check
result
1 Next step.
“ON”position.
Pull out the plug of carbon-canister control valve from wiring harness, and a Continue to proceed until
Yes
2 multimeter may be used to verify the voltage between Pin 1 of the plug and the step 4.
negative electrode of power supply is about 12V. No Next step.
Yes
Check whether the loop (on power supply end) of carbon-canister control valve harness.
3
is a broken circuit or short circuit to ground. Continue to proceed until
No
step 2.
Check
result
A multimeter may be used to verify whether the resistance between Pin 1 and Yes Next step.
4
Pin 2 of carbon-canister control valve is within （22-30）Ω when at 20℃. No Change the control valve.
A multimeter may be used to verify whether the voltage between the Yes Diagnosis help.
5 connection Pin 1 of carbon-canister control valve and the negative electrode of
power supply is about 3.7V. No Next step.
Check whether the loop between the connection Pin 2 of carbon-canister Yes
6 harness.
control valve and Pin 46 of ECU is a broken loop.
No Diagnosis help.
Fault code：P0444“The voltage in the control loop of driving stage for carbon-canister control
valve is too low.”
Check
result
1 Next step.
“ON”position.
Yes
Yes
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3
is in a broken circuit or is short circuit to ground. Continue to proceed until
No
step 2.
4
6 harness.
control valve and the Pin 46 of ECU is short circuit to ground.
No Diagnosis help.
Fault code：P0445“The voltage in the control loop of driving stage for carbon-canister control
valve is too high.”
Check
result
1 Next step.
“ON”position.
Yes
Yes
3
is in a broken circuit or is short circuit to ground. Continue to proceed until
No
step 2.
4
6 harness.
control valve and Pin 46 of ECU is a broken loop.
No Diagnosis help.
Fault code：P0480“failure with the control loop of cooling-fan relay”
Check
result
Connect with a diagnosis instrument, and place the ignition switch to the
1 Next step.
“OFF”position.
Pull out the relay from the cooling-fan, place the ignition switch to the“ON” Continue to proceed until
Yes
2 position, and verify the voltage between the power supply end (ie. Pin 30 &85) step 4.
of relay and the negative electrode of power supply is about 12V. No Next step.
Check
result
Yes
Check whether the loop on the power supply end of cooling-fan relay is a harness.
3
broken loop or short circuit to ground. Continue to proceed until
No
step 2.
A multimeter may be used to check whether the voltage between the control Yes Change the relay.
4 end (i.e. Pin 86) of cooling-fan relay and the negative electrode of power
No Next step.
supply is about 3.7V.
Check whether the loop between the control end (i.e. Pin 86) of relay and Pin Yes
5 harness.
No Next step.
Yes Diagnosis help.
6 Check whether the cooling-fan is working under a normal condition.
No Change the fan.
Fault code： P0500“ The failure is caused by an inappropriate signal of vehicle speed.”
Check
result
1 Next step.
“ OFF” position.
Check and repair ABS
For vehicles having been equipped with ABS system, check ABS system for Yes
2 system.
any fault code.
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No Next step.
Yes Next step.
3 Check whether the needle of tachometer is working under a normal condition. Check and repair the
No
instrumentation loop.
Yes Next step.
4 Check whether the vehicle speed sensor is working under a normal condition. Change the vehicle speed
No
sensor.
Check whether the loop between the signal line of vehicle speed sensor and Pin Yes
5 harness.
No Diagnosis help.
Fault code； P0506“ The rotating-speed under an idle-speed control is lower than the desired
idle-speed value.”
Check
result
1 Next step.
Yes Next step.
Check whether adjusting screws of throttle valve, pulling line of gas pedal, and
2 Perform necessary
throttle valve are working under a good condition. No
maintenance and service.
Yes Next step.
3 Check whether the idle-speed adjustor is working under a good condition. Perform necessary
No
A、 Check whether the pressure of fuel supply system is too low; Perform necessary
B、 Check whether the fuel injector has been blocked； Yes
4 maintenance.
C、 Check whether the inlet /exhaust gas within the system is free；
So on and so forth. No Diagnosis help.
Fault code： P0507“ The rotating-speed under an idle-speed control is higher than the desired
idle-speed value.”
Check
result
1 Next step.
Yes Next step.
Check whether adjusting screws of throttle valve, the pulling line of gas pedal,
2 Perform necessary
and throttle valve are working under a good condition. No
Yes Next step.
3 Check whether the idle-speed adjustor is working under a good condition. Perform necessary
No
D、 Check the fuel supply system for air leakage; Perform necessary
E、 Check the fuel injector for fuel leakage; Yes
4 maintenance.
F. Check whether the inlet /exhaust gas within the system is too high, so on
and so forth. No Diagnosis help.
Fault code：P0508“The voltage in the control loop of idle-speed adjustor is too low.”
Check
result
1 Next step.
“ON”position.
Pull out the plug from idle-speed adjustor, and a multimeter may be used to Yes Next step.
2 verify whether the resistance values between Pin A and D, and between Pin B
and C are about （53±5.3）Ω when at 20℃. No Change the step motor.
Check whether respective loops between the connection Pin A /B /C /D of Repair or change the wiring
Yes
3 idle-speed adjustor and the Pin 65 /66 /67/ 64 of ECU are short circuit to harness.
ground. No Diagnosis help.
Fault code：P0509“The voltage in the control loop of idle-speed adjustor is too high.”
Check
result
1 Next step.
“ON”position.
Check whether respective loops between the connection Pin A /B /C /D of Repair or change the wiring
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Yes
3 idle-speed adjustor and the Pin 65 /66 /67/ 64 of ECU are short circuit to harness.
ground. No Diagnosis help.
Fault code：P0511“Failure with the control loop of idle-speed adjustor.”
Check
result
1 Next step.
“ON”position.
Check whether respective loops between the connection Pin A /B /C /D of Yes
3 harness.
idle-speed adjustor and the Pin 65 /66 /67/ 64 of ECU are a broken loop
No Diagnosis help.
Fault code：P0560“ Inappropriate signal of system voltage.”
Check
result
1 Next step.
“OFF”position.
A multimeter may be used to verify whether the voltage of accumulator jar is Yes Next step.
2
about 12V.
No Change the accumulator jar.
Check whether the respective loop between Pin 87 of main relay and Pin 44 Yes
3 harness.
/45 /63 of ECU is a broken loop or short circuit to ground.
No Next step.
Check whether the charge voltage of generator is always within a scope of Yes Next step.
4
（9-16）V while engine is starting at various rotating-speed. No Change the generator
Yes Diagnosis help.
Check whether the ground point of engine wiring harness is under a good
5 Repair or change the wiring
condition. No
harness.
Fault code：P0562“The signal of system voltage is too low.”
Check
result
1 Next step.
“OFF”position.
2
about 12V.
Check
result
Check whether the resistance in the respective loop between Pin 87 of main Yes
3 harness.
relay and Pin 44 /45 /63 of ECU is too large.
No Next step.
4
Yes Diagnosis help.
5
condition. Repair or change the wiring
No
harness.
Fault code：P0563“ The voltage signal of system is too high.”
Check
result
1 Next step.
“OFF”position.
2
about 12V.
3
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Yes Diagnosis help.
4
condition. Repair or change the wiring
No
harness.
Fault code：P0601 “The verification code for electronic controller has not been programmed yet”
Check
result
1 Next step.
“ON”position.
Clear away any fault code, and re-verify whether the failure is of a stable Yes Next step.
2
failure. No System is normal.
3 Change ECU. END
Fault code：P0602“ The diagnosis data ID code of electronic controller has not been programmed
yet.”
Check
result
Connect with the diagnosis instrument, and place the ignition switch to the Next step.
1
“ON”position.
Clear away any fault code, and re-verify whether the failure is of a stable Yes Next step.
2
failure. No System is normal.
3 Change ECU. END
Fault code：P0645“Failure with the control loop of air-conditioner compressor relay.”
Check
result
1 Next step.
“OFF”position.
Pull out the relay from the air-conditioner compressor, place the ignition Continue to proceed until
Yes
switch to the“ON”position, and verify the voltage between the power supply step 4.
2
end (i.e. Pin 30 &85) of relay and the negative electrode of power supply is
No Next step.
about 12V.
Yes
Check whether the loop on the power supply end of relay is a broken loop or harness.
3
short circuit to ground. Continue to proceed until
No
step 2.
A multimeter may be used to verify the voltage between the control end (i.e. Yes Change the relay.
4 Pin 86 of relay) of air-conditioner compressor relay and the negative electrode
of power supply is about 3.7V. No Next step.
Check
result
Check whether the loop between the control end (i.e. Pin 86 ) of Yes
5 harness.
air-conditioner compressor relay and Pin 70 of ECU is a broken loop.
No Next step.
Yes Diagnosis help.
Check whether the electromagnetic clutch for air-conditioner compressor is
working in a normal way. No
electromagnetic clutch.
Fault code：P0646“The voltage in the control loop of air-conditioner compressor relay is too low.”
Check
result
1 Next step.
“OFF”position.
Yes
2
end (ie. Pin 30 &85 ) of relay and the negative electrode of power supply is
No Next step.
about 12V.
Yes
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3
No
step 2.
No Next step.
of power supply is about 3.7V.
Check whether the loop between the control end (ie. Pin 86) of air-conditioner Yes
5 harness.
compressor relay and Pin 70 of ECU is a broken loop.
No Next step.
Yes Diagnosis help.
Fault code：P0647“The voltage in the control loop of air-conditioner compressor relay is too high.”
Check
result
1 Next step.
“OFF”position.
Yes
2
end (ie. Pin 30 &85 ) of relay and the negative electrode of power supply is
No Next step.
about 12V.
Yes
3
No
step 2.
No Next step.
of power supply is about 3.7V.
Check whether the loop between the control end (i.e. Pin 86 of relay) of Repair or change the wiring
Yes
5 air-conditioner compressor relay and Pin 70 of ECU is short circuit to power harness.
supply. No Next step.
Yes Diagnosis help.
Fault code：P1530 “Failure with the loop of temperature sensor for air-conditioner evaporator”
Check
result
1 Next step.
Observe whether the item“ temperature of evaporator”in data stream is suitable Yes Continue to proceed until
2 6
to the existing temperature of evaporator. No Next step.
Pull out the plug to the temperature sensor of air-conditioner evaporator, use a Yes Next step.
3 multimeter to verify the resistance value between Pin 1 and Pin 2 of the sensor
is corresponding to its temperature value.
Pull out the plug to the temperature sensor of air-conditioner evaporator from Continue to proceed until
Yes
4 the wiring harness, use a multimeter to verify the voltage value between Pin 1 step 6.
and Pin 2 is about 5V. No Next step.
Check whether the loop between pin 35 &42 of ECU and Pin 1 &2 of sensor is Yes
5 harness.
a broken loop, or short circuit to power supply or ground.
No Next step.
When the engine is running at idle-speed and the air-conditioner is opened,
Yes Diagnosis help.
observe the change of value corresponding to the item "temperature of
6
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evaporator" on a diagnosis instrument, and the displayed value shall be
decreased accordingly when the temperature of evaporator is reduced.
Fault code：P1651“ Failure with the control loop of engine fault indicator lamp（ SVS）.”
Check
result
1 Next step.
The item “actuator action test” displayed on diagnosis instrument may be used Continue to proceed until
Yes
2 to test the action of engine fault indicator lamp to observe it’s within a step 6.
flameout status or a lighting status. No Next step.
Check whether the loop (on power supply end) of engine fault indicator lamp Yes Next step.
3
is a broken circuit or short circuit to ground. No Change the sensor
Check whether the loop between the connector pin (on control end) of engine Continue to proceed until
Yes
4 fault indicator lamp and Pin 29 of ECU is a broken loop, or short circuit to step 6.
power supply or ground. No Next step.
Check whether the bulb of engine fault indicator lamp is able to work under a Yes
5 harness.
normal condition.
No Next step.

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United Electronic engine management system

Precautions to the maintenance of electric-injection system..........................................

General troubleshooting and steps to engine ...............................................................

Criterion to flashing code /mounting torque of components within M1.5.4 system........

Description of the diagnosis function on M7.9.7 system failure....................................

(g) Exhaust control function

Precautions to the maintenance of electric-injection system

(b)Definition of ECU pins within Motronic 1.5.4 system

S.N. Description of function Type S.N. Description of function Type

c Definition of E CU pins within Motronic 7.9.7 system

Pin C onnection point Type Pin C onnection point Type

2. Air inlet pressure /temperature sensor DS-S-TF

(h)Technical &characteristic parameter

3. Throttle position sensor DKG

(d)Symptom bad acceleration, etc.

(h) Technical &characteristic parameter

( i ) Technical &characteristic parameter

5. Cooling-fluid temperature sensor TF-W

6. Oxygen sensor LSH

1.cables 6.heating stick

(b)Principal The sensing element is one ceramic pipe, whoseinner side

Lead content in petrol Life duration（km）

7. Rotating speed sensor DG

(i) Technical &characteristic parameter

Coil zone -40 +150

Transition zone B lended blended

Tolerable L ead-wire zone -40 +120

temperature Storage temperature -20 +50

for PUR A mbient temperature when not starting -40 +120

lead-wire L ong-term ambient temperature when

the whole service life 380 hours +140

Coil zone -40 +150

Transition zone B lended blended

The 168-hour anti-vibration 20 70Hz Acceleration 40 m/s2

capability on each plane 71 220Hz V ibration amplitude 0.2 mm

Voltage-withstand 1 3 second, 1200VA C No puncture allowed

phase signal wheel

(h) Technical &characteristic parameter

9. Idle-speed adjustor EWD3 M 1.5.4

10. Idle-speed actuator-step motor M7.9.7

cover cup shaped component

shaft pin rear bearing

(h) Technical &characteristic parameter£º

(g)Technical &characteristic parameter

12. Electrical fuel pump EKP

13. Fuel pressure adjustor DR

(g)Technical &characteristic parameter

14. Carbon-canister control valve TEV

(g) Technical &characteristic parameter

(h) Technical &characteristic parameter

17. Electronic controller ECU M 7.9.7

(f)Technical &characteristic parameter

18. Fuel distributing pipe assembly

(e) Technical &characteristic parameter：

General troubleshooting and steps to engine

Yes Next step.

Yes Clean it.

7．The idle-speed is unstable after the vehicle heating process is ended.

8．Unstable idle-speed or even flameout when under load（eg. air-conditioner, etc.）

Yes Next step.

General troubleshooting and steps to engine within M7.9.7 system

4．The cold vehicle is starting with difficulty.