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491QE Engine
491QE Engine
Based on the model GW491Q (4Y) carburetor petrol engine, the GW491QE petrol
engine produced by our company is of one petrol engine able to electrically inject fuel
at multiple points, and is developed from electrical control components made by Delphi
company, USA, and Shanghai United Electronic Company. This model shows a
predominant improvement in aspects of power and economical efficiency, and is in
compliance with GB18352.2-2001 “Limits and measurement methods for exhausts
of pollutants from light vehicles (II) ”(equivalent to European Class-II standard), and
conforms to stipulations at phase III for GB18352.3-2005 “Limits and measurement
methods for exhausts of pollutants from light vehicles (at phase III &IV in China)”
(equivalent to European Class-III standard).
To meet the needs from numerous maintenance /technical / management
personnel, we prepare this “GW491QE Petrol Engine Service Manual” based on the
latest technical materials.
All contents, specifications, and data stated in this manual are the latest information
before printing and this service manual will be subject to a supplemental, revision, and
completion from time to time.
This manual may be used for the reference by mechanics, drivers, and technical /
management personnel as the manual is complete in contents, definite in requirements,
and simple in maintenance.
Constrained by the level of the writer, it’s unavoidable to have some defects in
this manual, and your comments and suggestions are highly appreciated.
Model GW491QE petrol engine
Service Manual
Troubleshooting............................................................................................
Unit mm
Name Test items Standard value Use limit
A xial clearance 0.02~0.22 0.30
T hickness of thrust washer 2.450~2.490
Increased by 0.125 2.575~2.615
Increased by 0.250 2.700~2.740
Main journal diameter 58 0-0.015
Clearance of main journal diameter 0.021~0.053 0.10
C rankshaft and
journal diameter of connection rod 48 0-0.015
bearing
journal clearance of connection rod 0.021~0.053 0.10
Circumferential play of main axial
diameter 0.03 0.06
R oundness /diameter of column,
for main axial diameter and 0.01 0.02
connection rod diameter
2. Cooling system
3. L ubrication system
4.Ignition system
Name Test items Standard value Use limit
Model F6RT C
Spark plug
Clearance 1.0~1.2 mm
High-tension
wiring R esistance 16k /m
5.Starting system
Name Test items Standard value Use limit
R ated voltage 12V
Output power 1kw
Zero-load characteristics size of 90A >90A
current specified when it’s 11.5V
Starter R ectifier E xterior diameter 30mm <29mm
Depth of T channel (0.50~0.80)mm <0.20mm
Circumferential radial play 0.05mm >0.05mm
L ength of electric brush 13mm <8.5mm
Work load of spring (17.5~23.7)N <17.56N
6. Charge device
Name Test items Standard value Use limit
Density of electrolyte for battery
B attery 1.25~1.27
When full charge of battery at 20
R esistance of rotor coils 4.0
A C generator Diameter of slip ring (32.3~32.5)mm <32.1mm
E xposed length of electric brush 12.5mm 5.5mm
R egulator A djustment voltage at20 (13.95~14.4)V
A 98N bending-deflection force is
applied to driving belt between AC
Driving belt generator and water pump.
New belt (5~7)mm
Used belt (7~8)mm
Tightening torque
screw pitch
Grade diameter mm hexagonal-headed hexagonal flange bolt
mm
bolt N m N m
6 1 5 6
8 1.25 12.5 14
10 1.25 26 29
4T
12 1.25 47 53
14 1.5 74 84
16 1.5 115
6 1 6.5 7.5
8 1.25 15.5 17.5
10 1.25 32 36
5T
12 1.25 59 65
14 1.5 91 100
16 1.5 140
6 1 8 9
8 1.25 19 21
10 1.25 39 44
6T
12 1.25 71 80
14 1.5 110 125
16 1.5 170
6 1 10.5 12
8 1.25 25 28
10 1.25 52 58
7T
12 1.25 95 105
14 1.5 145 165
16 1.5 230
8 1.25 29 33
8T 10 1.25 61 68
12 1.25 110 120
8 1.25 34 37
9T 10 1.25 70 78
12 1.25 125 140
Engine service /maintenance data-Troubleshooting GI-9
Tightening torque
screw pitch Hexagonal
Grade diameter mm Hexagonal-headed
mm flange bolt
bolt N m
N m
8 1.25 38 42
10T 10 1.25 78 88
12 1.25 140 155
8 1.25 42 47
11T 10 1.25 87 97
12 1.25 155 175
3.engine is slack.
9.E ngine not flame our after the ignition switch is closed.
Spring
sleeve A
guiding rod A
guiding rod B
Tools used to change
the oil seal before the
crankshaft
Tools used to change
the oil seal after the
co-axis.
Spanner for oil filter
Tools used to repair
radiator
Spanner used to adjust
idle-speed screws
Rocker support tools
Oil-seal remover
Universal remover
Engine service /maintenance data- engine service /maintenance data GI-15
Clutch
guiding tools
Tools used to
dismantle
guide bearing
from
crankshaft
Tools used to
dismantle
guide bearing
from
crankshaft
Tools used to
align with
clutch film
spring
Description of system.................................................................................................
Analysis of the function /principal /failure for system parts &components .....................
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
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
cases)
UAES Electronic Control Engine Management System-Notes for Electronic Injection
System Service EF.1-5
1.sealing ring
2. stainless liner
3. PCB plate
4. sensing element
5. shell body
6. stress support
7. welded connection
8. bonded connection
United Electronic engine management system-Analysis of function /principal /
failure for system parts &components EF.1-11
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
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
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.
United Electronic engine management system-Analysis of function /principal /
failure for system parts &components EF.1-13
Performance data
R esistance value k
Temperature
S.N. Tolerance of temperature 1 Tolerance of temperature 0
Min. Max. Min. Max.
clamp connector
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
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
(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:
Value Unit
Measurement
M in. Typical Max Min.
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
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,
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
output signal
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
United Electronic engine management system-Analysis of function /principal /
EF.1-20 failure for system parts &components
pin
(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
United Electronic engine management system-Analysis of function /principal /
EF.1-22 failure for system parts &components
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 .
United Electronic engine management system-Analysis of function /principal /
failure for system parts &components EF.1-23
(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;
(g)Simple measurement method
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
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
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
- 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
- Control the carbon-canister valve
- 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.
United Electronic engine management system-Analysis of function /principal /
EF.1-28 failure for system parts &components
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.
(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.
United Electronic engine management system-Analysis of function /principal /
failure for system parts &components EF.1-29
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
Check
S.N. Operation steps Follow-up steps
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
10 Repair or change the
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
S.N. Operation steps Follow-up steps
result
Clear the displayed failure
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.
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.
Connect the fuel manometer valve. And have the Pin 30 of fuel pump relay Yes 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.
Change the fuel pressure
No
adjustor
United Electronic engine management system-Genaral troubes hooting and steps
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
S.N. Operation steps Follow-up steps
result
Clear the displayed failure
Place ignition switch to the“ON”position. A fault diagnosis instrument may be Yes
1 away.
used to check whether there’s any record of failure information.
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.
4 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
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
11 Check whether fuel contains water or has deteriorated.
No Next step.
United Electronic engine management system-Genaral troubes hooting and steps
to engine EF.1-33
Check
S.N. Operation steps Follow-up steps
result
Yes Next step.
12 Check whether the fuel pressure is below 250kpa.
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.
Change the fuel pressure
Open the fuel manometer valve, and clamp the oil return pipe using oil-return Yes
adjustor
14 barrier to prevent oil from returning, then check whether an oil pressure will be
Repair or change the oil
produced. No
pipe or injector.
Repair or change oil inlet
Yes
15 Check whether the oil inlet pipe has leakage or has been blocked. pipe
No Change the oil pump
Repair or change oil
Yes
return pipe
16 Check whether the oil inlet pipe has leakage or has been bent.
Change the fuel pressure
No
adjustor
Yes Next step.
17 Check whether the pressure of engine cylinder is normal.
No Clear the failure away.
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
S.N. Operation steps Follow-up steps
result
Clear the displayed failure
Place ignition switch to the“ ON”position. A fault diagnosis instrument may be Yes
1 away.
used to check whether there’s any record of failure information.
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.
8 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 13
Check whether the oil injector is able to work in a normal way after it has been Yes 12
9
provided with a 12V voltage by accumulator via special connector. No Next step.
United Electronic engine management system-Genaral troubes hooting and steps
EF.1-34 to engine
Check
S.N. Operation steps Follow-up steps
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
11 Check whether fuel contains water or has deteriorated.
No 18
Yes Next step.
12 Check whether the fuel pressure is below 250kpa.
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.
Change the fuel pressure
Open the fuel manometer valve, and clamp the oil return pipe using oil-return Yes
adjustor
14 barrier to prevent oil from returning, then check whether an oil pressure will be
Repair or change the oil
produced. No
injector or oil pipe.
Repair or change oil inlet
Yes
15 Check whether the oil inlet pipe has any leakage or has been blocked. pipe
No Change the oil pump
Repair or change oil
Yes
return pipe
16 Check whether the oil return pipe has been bent or blocked.
Change the fuel pressure
No
adjustor
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.
No Clear the failure away.
6.The idle-speed during vehicle heating process is unstable.
Check
S.N. Operation steps Follow-up steps
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.
Yes Next step.
2 Check whether the passage of air filter is free.
No Change it.
Yes Next step.
Have the engine running at idle-speed, check whether the pressure of inlet
3 Settle the air leakage
manifold is within 35kpa and 65kpa during the vehicle heating process. No
within air inlet system.
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.
United Electronic engine management system-Genaral troubes hooting and steps
to engine EF.1-35
Check whether the oil injector is able to work in a normal way after it has been Yes 8
6
provided with a 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 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.
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 be
Repair or change the oil
produced. No
injector or oil pipe.
Repair or change the oil
Yes
12 Check whether the oil inlet pipe has any leakage or has been blocked. inlet pipe
No Change the oil pump
Repair or change oil
Yes
return pipe
13 Check whether the oil return pipe has been bent or blocked.
Change the fuel pressure
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.
No Clear the failure away.
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
17 Check whether the spark plug is normal.
No Change the spark plug
United Electronic engine management system-Genaral troubes hooting and steps
EF.1-36 to engine
Check
S.N. Operation steps Follow-up steps
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 Check whether the spark plug is normal.
No Change the spark plug
10.The idle-speed is too high(a self-learning is needed again after a power cut to ECU).
Check
S.N. Operation steps Follow-up steps
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.
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.
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
S.N. Operation steps Follow-up steps
result
1 Yes Clear the displayed failure
Place ignition switch to the“ON”position. A fault diagnosis instrument may be
away.
used to check whether there’s any record of failure information.
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.
United Electronic engine management system-Genaral troubes hooting and steps
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.
Connect the fuel manometer valve. And have the Pin 30 of fuel pump relay Yes Next step.
6 short-circuit connected with the Pin 87, and check whether the fuel pressure is
No 11
within 250kpa and 300kpa while the fuel pump is working.
Check whether the oil injector is working in a normal way after it’s been Yes 10
7
provided with a 12V voltage by accumulator via special connector. No Next step.
Re-check whether the oil injector is working in a normal way after it’s been Yes Next step.
8
washed. No Change the oil injector
Yes Change the fuel
9 Check whether fuel contains water or has deteriorated.
No 15
Yes Next step.
10 Check whether the fuel pressure is below 250kpa.
No 14
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.
Change the fuel 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
Repair or change the oil
pressure rapidly. No
injector or oil pipe.
Repair or change the oil
Yes
13 Check whether the oil inlet pipe has any leakage or has been blocked. inlet pipe
No Change the oil pump
Repair or change the oil
Yes
return pipe
14 Check whether the oil return pipe has been bent or blocked.
Change the fuel pressure
No
adjustor
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 53
15 Repair or change the
(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
S.N. Operation steps Follow-up steps
result
Clear the displayed failure
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.
2 Check whether the passage of air filter is free.
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.
United Electronic engine management system-Genaral troubes hooting and steps
to engine EF.1-39
Check
S.N. Operation steps Follow-up steps
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
5 Repair or change the
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.
Check whether the oil injector is working in a normal way after it’s been Yes 10
8
provided with a 12V voltage by accumulator via special connector. No Next step.
Re-check whether the oil injector is working in a normal way after it’s been Yes Next step.
9
washed. No Change the oil injector
Yes Change the fuel
10 Check whether fuel contains water or has deteriorated.
No 16
Yes Next step.
11 Check whether the fuel pressure is below 250kpa.
No 15
When the valve on fuel meter is closed before a re-connection with ignition Yes Next step.
12 switch to drive the fuel pump working for another three seconds, check
No 14
whether it’s able to produce an oil pressure.
Change the fuel pressure
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
Repair or change the oil
pressure rapidly. No
injector or oil pipe.
Repair or change the oil
Yes
14 Check whether the oil inlet pipe has leakage or has been blocked. inlet pipe
No Change the oil pump
Repair or change the oil
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
S.N. Operation steps Follow-up steps
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
Clear the displayed failure
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.
United Electronic engine management system-Genaral troubes hooting and steps
EF.1-40 to engine
Check
S.N. Operation steps Follow-up steps
result
Connect the fuel manometer valve. And have the Pin 30 of fuel pump relay Yes Next step.
6 short-circuit connected with the Pin 87, and check whether the fuel pressure is
No 11
within 250kpa and 300kpa while the fuel pump is working.
Check whether the oil injector is working in a normal way after it’s been Yes 10
7
provided with a 12V voltage by accumulator via special connector. No Next step.
Re-check whether the oil injector is working in a normal way after it’s been Yes Next step.
8
washed. No Change the oil injector
Yes Change the fuel
9 Check whether fuel contains water or has deteriorated.
No 16
Yes Next step.
10 Check whether the fuel pressure is below 250kpa.
No 15
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 14
whether it’s able to produce an oil pressure.
Change the fuel pressure
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
Repair or change the oil
rapidly. No
injector or oil pipe.
Repair or change the oil
Yes
13 Check whether the oil inlet pipe has any leakage or has been blocked. inlet pipe
No Change the oil pump
Repair or change oil return
Yes pipe
14 Check whether the oil return pipe has been bent or blocked.
Change the fuel pressure
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
S.N. Operation steps Follow-up steps
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.
Check
S.N. Operation steps Follow-up steps
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.
overlapped on Pin 3, 51, 53, 61, 80 is under a normal condition.
Check
S.N. Operation steps Follow-up steps
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
Remove the oil injector, and check whether it has any leakage or has been Yes
7 components.
blocked using a special washing analyzer instrument.
No Next step.
Check the fuel condition, and observe whether the symptom is caused by the Yes Change the fuel
8
filling with petrol. No Next step.
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
10 Check and repair the
specifications. No
ignition timing.
Open the ignition switch to check whether respective power supply to Pin 12, Yes Diagnosis help.
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
S.N. Operation steps Follow-up steps
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.
Yes Wash or change it.
2 Check whether the idle-speed adjustor has got stuck.
No Next step.
Check and observe whether the model and clearance of spark plug on each Yes Next step.
3
cylinder is in compliance with the specification. No Adjust or change it.
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
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.
Check the fuel condition, and observe whether the symptom is caused by the Yes Change the fuel
6 filling with petrol.
No Next step.
Settle the mechanical
Check and observe whether the pressure inside each engine cylinder is Yes
7 failure on engine.
insufficient.
No Next step.
Yes Next step.
Check whether the engine ignition sequence &timing conform to relevant
8 Check and repair the
specifications. No
ignition timing.
Open the ignition switch to check whether respective power supply to Pin 12, Yes Diagnosis help.
9 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.
United Electronic engine management system-Genaral troubes hooting and steps
EF.1-44 to engine
7.Despite of a normal starting, the idle-speed during vehicle heating process is unstable.
Check
S.N. Operation steps Follow-up steps
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.
Check and observe whether the model and clearance of spark plug on each Yes Next step.
2
cylinder is in compliance with the specification. No Adjust or change it.
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
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.
Check the fuel condition, and observe whether the symptom is caused by the Yes Change the fuel
6 filling with petrol.
No Next step.
Settle the mechanical
Check the pressure inside each cylinder, and observe whether there’s any large Yes
7 failure on engine.
difference in pressure across cylinders.
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 relevant
No
overlapped on Pin 3, 51, 53, 61, 80 is under a normal condition. loops.
8.Despite of a normal starting process, the idle-speed is unstable after the vehicle heating process
is ended.
Check
S.N. Operation steps Follow-up steps
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.
Check and observe whether the model and clearance of spark plug on each Yes Next step.
2
cylinder is in compliance with the specification. No Adjust or change it
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.
Check and repair relevant
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
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.
Check the fuel condition, and observe whether the symptom is caused by the Yes Change the fuel
6 filling with petrol.
No Next step.
Settle the mechanical
Check the pressure inside each cylinder, and observe whether there’s any large Yes
7 failure on engine.
difference in pressure across cylinders.
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 relevant
No
overlapped on Pin 3, 51, 53, 61, 80 is under a normal condition. loops.
United Electronic engine management system-Genaral troubes hooting and steps
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
S.N. Operation steps Follow-up steps
result
After a removal of idle-speed adjustor, check whether any carbon deposit is Wash relevant parts and
Yes
1 produced on the throttle valve unit and the idle-speed adjustor, or inside the components.
idle-speed bypass air duct. No Next step.
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.
Open the ignition switch to check whether respective power supply to Pin 12, Yes Diagnosis help.
6 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.
10.The starting is normal yet the idle-speed is too high.
Check
S.N. Operation steps Follow-up steps
result
Yes Adjust it.
1 Check whether the pulling line to gas is too tight or has got stuck.
No Next step.
Check and repair the air
Check whether there’s any air leakage with air inlet system, and its connected Yes
2 inlet system.
vacuum pipes.
No Next step.
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.
Check and repair relevant
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
5 Check and repair the
specifications. No
ignition system.
Open the ignition switch to check whether respective power supply to Pin 12, Yes Diagnosis help.
6 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.
11.The rotating-speed is unable to go up or even flameout when accelerating.
Check
S.N. Operation steps Follow-up steps
result
Check and repair the air
Yes
1 Check whether the air filter has been blocked. inlet system.
No Next step.
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
2 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.
pipe has been pulled away from the fuel pressure adjustor.
Check and observe whether the model and clearance of spark plug on each Yes Next step.
3
cylinder is in compliance with the specification. No Adjust or change it
After a removal of idle-speed adjustor, check whether any carbon deposit is Wash relevant parts and
Yes
4 produced on the throttle valve unit and the idle-speed adjustor, or inside the components.
idle-speed bypass air duct. No Next step.
United Electronic engine management system-Genaral troubes hooting and steps
EF.1-46 to engine
Check
S.N. Operation steps Follow-up steps
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
Remove the oil injector, and check whether it has any leakage or has been Yes
6 components.
blocked using a special washing analyzer instrument.
No Next step.
Check the fuel condition, and observe whether the symptom is caused by the Yes Change the fuel
7 filling with petrol.
No Next step.
Check the fuel condition, and observe whether the symptom is caused by the Yes Change the fuel
9
filling with petrol. No Next step.
Yes Next step.
Check whether the engine ignition sequence &timing conform to relevant
10 Check and repair the
specifications. No
ignition timing.
Yes Next step.
11 Check whether the exhaust pipe is free. Repair or change the
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,
12 Check and repair relevant
13, 44, 45, 63 is under a normal condition; and whether respective metal part No
loops.
overlapped on Pin 3, 51, 53, 61, 80 is under a normal condition.
Criterion to flashing codes and the mounting torque of parts &components within
EF.1-48 M1.5.4 system
Criterion to flashing codes and the mounting torque of parts &components within
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
11 Injector -failure with the driving stage of cylinder 1 22 1 1
12 Injector -failure with the driving stage of cylinder 2 23 1 1
13 Injector -failure with the driving stage of cylinder 3 24 1 1
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.
Criterion to flashing codes and the mounting torque of parts &components within
M1.5.4 system EF.1-49
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
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”
Check
S.N. Operation steps Follow-up steps
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” 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.
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 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
S.N. Operation steps Follow-up steps
result
1 Connect with the diagnosis instrument, and place the ignition switch to the“ON”position. Next step.
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
No Change the sensor.
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.
Repair or change the wiring
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.
EF.1-54 M7.9.7 system service &diagnosis flow process based on fault code
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
No Change the sensor.
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.
Repair or change the wiring
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
low.”
S.N. Operation steps Check Follow-up steps
result
1 Connect with the diagnosis instrument, and place the ignition switch to the“ON”position. Next step.
Observe whether the value at item “cooling-fluid temperature ” in data stream is fit for engine
Yes Continue to proceed until step 6.
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
No Change the sensor.
temperature. .
Pull out the plug of inlet-air temperature sensor from wiring harness, and a multimeter may be Yes Continue to proceed until step 6.
4
used to check whether the voltage between Pin 1 and Pin 2 of sensor is about 5V. No Next step.
Repair or change the wiring
Check whether respective loops between Pin 39 &35 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.
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
S.N. Operation steps Follow-up steps
result
1 Connect with the diagnosis instrument, and place the ignition switch to the“ON”position. Next step.
Observe whether the value at item “cooling-fluid temperature ” in data stream is fit for engine
Yes Continue to proceed until step 6.
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
No Change the sensor.
temperature. .
Pull out the plug of inlet-air temperature sensor from wiring harness, and a multimeter may be Yes Continue to proceed until step 6.
4
used to check whether the voltage between Pin 1 and Pin 2 of sensor is about 5V. No Next step.
Repair or change the wiring
Check whether respective loops between Pin 39 &35 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.
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.
M7.9.7 system service &diagnosis flow process based on fault code EF.1-55
Fault code:P0122“The signal voltage in the loop of throttle position sensor is too low.”
Check
S.N. Operation steps Follow-up steps
result
1 Connect with the diagnosis instrument, and place the ignition switch to the“ON”position. Next step.
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.
Fault code:P0123“The signal voltage in the loop of throttle position sensor is too high”
Check
S.N. Operation steps Follow-up steps
result
1 Connect with the diagnosis instrument, and place the ignition switch to the“ON”position. Next step.
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
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.
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
S.N. Operation steps Follow-up steps
result
1 Connect with the diagnosis instrument, and place the ignition switch to the“ON”position. Next step.
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.
EF.1-56 M7.9.7 system service &diagnosis flow process based on fault code
Fault code:P0132“the signal voltage in the loop of upstream sensor is too high”
(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
S.N. Operation steps Follow-up steps
result
1 Connect with the diagnosis instrument, and place the ignition switch to the“ON”position. Next step.
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 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;;
D、Whether the clearance of air valve is too small;
No Change the sensor.
So on and so forth.
Fault code:P0134“Failure with the signal of 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
S.N. Operation steps Follow-up steps
result
1 Connect with the diagnosis instrument, and place the ignition switch to the“ON”position. Yes Next step.
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 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
S.N. Operation steps Follow-up steps
result
1 Connect with the diagnosis instrument, and place the ignition switch to the“ON”position. Next step.
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
No Continue to proceed until step 4.
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.
M7.9.7 system service &diagnosis flow process based on fault code EF.1-57
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
S.N. Operation steps Follow-up steps
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.
After the connection with fuel manometer (the connection point is on the front Yes Next step.
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.
pipe has been pulled away from the fuel pressure adjustor.
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 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
S.N. Operation steps Follow-up steps
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 900mV(yet
No Diagnosis help.
with less changes) for a long-term period when under some working
conditions.
After the connection with fuel manometer (the connection point is on the front Yes Next step.
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.
pipe has been pulled away from the fuel pressure adjustor.
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.
EF.1-58 M7.9.7 system service &diagnosis flow process based on fault code
Check
S.N. Operation steps Follow-up steps
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.
Repair or change the wiring
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
S.N. Operation steps Follow-up steps
result
Connect with the diagnosis instrument, and place the ignition switch to the
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.
Repair or change the wiring
Yes
Check whether the loop (on power supply end) of carbon-canister control valve harness.
3
is in a broken circuit or is short circuit to ground. Continue to proceed until
No
step 2.
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.
Repair or change the wiring
Check whether the loop between the connection Pin 2 of carbon-canister Yes
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
S.N. Operation steps Follow-up steps
result
Connect with the diagnosis instrument, and place the ignition switch to the
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.
Repair or change the wiring
Yes
Check whether the loop (on power supply end) of carbon-canister control valve harness.
3
is in a broken circuit or is short circuit to ground. Continue to proceed until
No
step 2.
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.
Repair or change the wiring
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:P0480“failure with the control loop of cooling-fan relay”
Check
S.N. Operation steps Follow-up steps
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.
EF.1-62 M7.9.7 system service &diagnosis flow process based on fault code
Check
S.N. Operation steps Follow-up steps
result
Repair or change the wiring
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.
Repair or change the wiring
Check whether the loop between the control end (i.e. Pin 86) of relay and Pin Yes
5 harness.
50 of ECU is a broken loop, or short circuit to power supply or ground.
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
S.N. Operation steps Follow-up steps
result
Connect with a diagnosis instrument, and place the ignition switch to the
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.
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.
Repair or change the wiring
Check whether the loop between the signal line of vehicle speed sensor and Pin Yes
5 harness.
59 of ECU is a broken loop, or short circuit to power supply or ground.
No Diagnosis help.
Fault code; P0506“ The rotating-speed under an idle-speed control is lower than the desired
idle-speed value.”
Check
S.N. Operation steps Follow-up steps
result
Connect with a diagnosis instrument, and place the ignition switch to the
1 Next step.
“ OFF” position.
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
maintenance and service.
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
S.N. Operation steps Follow-up steps
result
Connect with a diagnosis instrument, and place the ignition switch to the
1 Next step.
“ OFF” position.
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
maintenance and service.
Yes Next step.
3 Check whether the idle-speed adjustor is working under a good condition. Perform necessary
No
maintenance and service.
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.
M7.9.7 system service &diagnosis flow process based on fault code EF.1-63
Fault code:P0508“The voltage in the control loop of idle-speed adjustor is too low.”
Check
S.N. Operation steps Follow-up steps
result
Connect with the diagnosis instrument, and place the ignition switch to the
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
S.N. Operation steps Follow-up steps
result
Connect with the diagnosis instrument, and place the ignition switch to the
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:P0511“Failure with the control loop of idle-speed adjustor.”
Check
S.N. Operation steps Follow-up steps
result
Connect with the diagnosis instrument, and place the ignition switch to the
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.
Repair or change the wiring
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
S.N. Operation steps Follow-up steps
result
Connect with a diagnosis instrument, and place the ignition switch to the
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.
Repair or change the wiring
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
S.N. Operation steps Follow-up steps
result
Connect with a diagnosis instrument, and place the ignition switch to the
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.
EF.1-64 M7.9.7 system service &diagnosis flow process based on fault code
Check
S.N. Operation steps Follow-up steps
result
Repair or change the wiring
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.
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
condition. Repair or change the wiring
No
harness.
Fault code:P0563“ The voltage signal of system is too high.”
Check
S.N. Operation steps Follow-up steps
result
Connect with a diagnosis instrument, and place the ignition switch to the
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 charge voltage of generator is always within a scope of Yes Next step.
3
(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
4
condition. Repair or change the wiring
No
harness.
Fault code:P0601 “The verification code for electronic controller has not been programmed yet”
Check
S.N. Operation steps Follow-up steps
result
Connect with the diagnosis instrument, and place the ignition switch to the
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
S.N. Operation steps Follow-up steps
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
S.N. Operation steps Follow-up steps
result
Connect with a diagnosis instrument, and place the ignition switch to the
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.
Repair or change the wiring
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.
M7.9.7 system service &diagnosis flow process based on fault code EF.1-65
Check
S.N. Operation steps Follow-up steps
result
Repair or change the wiring
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
6 Repair or change the
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
S.N. Operation steps Follow-up steps
result
Connect with a diagnosis instrument, and place the ignition switch to the
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 (ie. Pin 30 &85 ) of relay and the negative electrode of power supply is
No Next step.
about 12V.
Repair or change the wiring
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
No Next step.
of power supply is about 3.7V.
Repair or change the wiring
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.
Check whether the electromagnetic clutch for air-conditioner compressor is
6 Repair or change the
working in a normal way. No
electromagnetic clutch.
Fault code:P0647“The voltage in the control loop of air-conditioner compressor relay is too high.”
Check
S.N. Operation steps Follow-up steps
result
Connect with a diagnosis instrument, and place the ignition switch to the
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 (ie. Pin 30 &85 ) of relay and the negative electrode of power supply is
No Next step.
about 12V.
Repair or change the wiring
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
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.
Check whether the electromagnetic clutch for air-conditioner compressor is
6 Repair or change the
working in a normal way. No
electromagnetic clutch.
EF.1-66 M7.9.7 system service &diagnosis flow process based on fault code
Fault code:P1530 “Failure with the loop of temperature sensor for air-conditioner evaporator”
Check
S.N. Operation steps Follow-up steps
result
Connect with a diagnosis instrument, and place the ignition switch to the
1 Next step.
“ OFF” position.
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
No Change 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.
Repair or change the wiring
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
evaporator" on a diagnosis instrument, and the displayed value shall be
No Change the sensor.
decreased accordingly when the temperature of evaporator is reduced.
Fault code:P1651“ Failure with the control loop of engine fault indicator lamp( SVS).”
Check
S.N. Operation steps Follow-up steps
result
Connect with the diagnosis instrument, and place the ignition switch to the
1 Next step.
“ OFF” position.
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.
Repair or change the wiring
Check whether the bulb of engine fault indicator lamp is able to work under a Yes
5 harness.
normal condition.
No Next step.
EF.2-1
Description of system......................................................................................EF.2-2
Troubleshooting.............................................................................................EF.2-27
EF.2-2 Delphi engine management system-Description of system
Description of system
Model GW491QE petrol engine has been installed with Delphi ITMS-6 and MT20U engine management
system for electric-injection: the exhaust from ITMS-6 is in compliance with European Class-II standard, and
the exhaust from MT20U is in compliance with European Class- standard; The engine management system
for electric-injection adopts a multi-point fuel injection controllable by a closed-loop of electronic control module
(ECU), and is subject to a direct ignition (without ignition distributor), and a post-processing technique by a
three-way catalytic converter. Generally speaking, each function of engine, eg. oil injection, ignition, idle speed,
etc. may be effected by a control over respective actuating mechanism, such as fuel injector ignition coil,
etc., as supported by an electronic control module (ECU) which receives appropriate signals from each sensor
(eg. intake pressure &temperature sensor, crankshaft position sensor, throttle position sensor, etc.) and by an
ECU internal control program which calculates the best
The engine management system for electric-injection is mainly composed of three parts: sensor, electronic
control module (ECU), and actuator.
The basic structure of ITMS-6 system is as shown in the figure below:
oxygen sensor
air conditioner fan fuel filter
system voltage signal
E CU engine fault indicator ignition energy
air conditioner request switch light
signal conversion of
system communication waste gas by
air conditioner pressure switch
interface three-way
l
vehicle speed sensor idle-speed & starting air-control valve
Delphi engine management system-Description of system EF.2-3
fuel injector A
5V reference voltage feedback fuel supply
fuel injector B
speed & crankshaft position sensor system
fuel injector C
engine cylinder No. identification signal control
system signal air conditioner load signal ECU air conditioner clutch relay
air conditioner
air conditioner fan relay
st
temperature signal for 1 evaporator system control
Diagnostic & theft- engine rotating-speed signal
nd
temperature signal for 2 evaporator
prevention signal engine fault indicator light communication
diagnosis request signal
Serial communication K W2000 &theft-prevention
theft-detector control signal
theft-detector control system control
standby EGR feedback signal
linear EGR control valve
European-III signal for 2nd oxygen sensor standby
system control
System characteristics:
I ts fuel supply to engine and the idle-speed is subject to a closed-loop control system, which may eliminate the manufacturing
difference between the system and other relevant mechanical parts &components, increase the integrity of whole vehicle, and
reduce the possibility of tolerance produced on vehicle due to abrasion in practical use; The system has divided four engine
cylinders into two groups: group1-4, and group 2-3, usable for a control over fuel supply and ignition respectively, which may have
the structure of system best optimized and simplified, reducing the cost of parts &components in manufacturing and fabrication;
The system has been provided with a three-way catalytic converter, usable for a post-processing on gas having combusted inside
the engine, which will be conversed into nonharmful gas and exhausted to the atmosphere.
Function of ITMS-6 system:
-Measure the position reference of crankshaft and the rotating speed;
-Air velocity &density computation;
-Multi-point fuel injection by group when under a closed-loop control, a simplified system structure, and a decreased processing
cost.
-A direct high-capacity ignition (without ignition distributor), assures an accurate and valid ignition, with less interference , and
without adjustment required.
-Self-learning function is provided for the closed-loop control to effectively eliminate the tolerance resulting from the manufacturing
and abrasion of mechanical parts, and to enhance the integrity &consistency of whole vehicle.
-Step motor is with a closed-loop control over idle-speed;
-Play &plug control applied to the air conditioner system and the cooling system.
-Fuel cut /overflow control: when a ‘flooded engine’ is produced, step on the gas to a Max. extent to stop fuel injection based on
a computer control.
-The fuel-cut control when decelerating saves fuel and decreases the exhaust.
EF.2-4 Delphi engine management system-MT20U system control
modification to closed-loop
constant of injector
self-learning modification
waste-gas circulation
accumulator
high-speed fan for engine
theft-prevention
indicator light
ignition fuse 2
theft
rrequest line accumulator fuse 4
Data line
detector
key having installed
password repeater
EF.2-8 Delphi engine management systm-MT20U system control
Determination on the
principal /utility /failure of key system parts
. System power supply and wire-harness
FUSE 4 B AT T FUSE4 B AT T
ignition FUSE 3
IGN FUSE3 B AT T
switch
FUSE 2 IGN FUSE2 IG N
(a)Function &principal System adopts a 12V DC power supply one current loop coming from accumulator jar and going into
system and E CU via ignition-key switch, is used as main power supply for system working, and transmits the system voltage signal
to E CU, which will modify the actuation from actuating mechanism; T he other current loop goes directly into E CU via fuse, the
uninterrupted power supply makes E CU retain the parameters after a system self-learning, and prepare for the next starting process
at the moment for switching off the device.
(b)F ailur e deter mination I mportant note E ither of following determinations may be concluded based on that the whole
vehicle and other system parts & components are normal in function: Permanent electric wire & loop have been connected to ignition
switch by mistake E rror No. matching between wire-harness and terminal Steel part overlapping on E CU exterior cover might
cause signal deviation T he connection line of engine rotating-speed sensor /crankshaft position sensor / knock sensor is not
shielded wire
2. E ngine contr ol module (E C U)
IT MS-6 engine control module (E CU)
(a) F unction & pr incipal E ngine control module is one microprocessor based on a single-chip device. A nd its function is to
process sensor data coming from different positions of vehicle, to determine the working status of engine, and to exactly
control the engine via an actuator. A uxiliary system control function theft-prevention system; fan cooling system air
conditioner system, etc.
Installation It shall be installed inside the driving cab; and better not have steel part overlapping on exterior cover.
(b) Per for mance par ameter E CU has passed vibration test drop test impact test high /low temperature test, etc., and
may work in a normal way under various circumstances.
Storage temperature (-40 90)
Moisture sensitivity T he design of E CU is able to ensure the normal working of unit when moisture content condenses on internal
components.
(c)W or k humidity T he unit is able to work normally when a power connection is made at ambient temperature 65 ,and
relative humidity 95%.
(e)Engine control-module fail mode:The failure of generator voltage-adjustor will burn and damage the computer.
When the computer is changed, measure first the supply voltage at idle speed and ensure it’s less than 15 volts.
When the engine rotating speed has been increased to a value greater than 2,000 revolutions,the supply
voltage shall be less than 15 volts.
(f)Function &principal The function of signal collecting system is to tell ECU the working status of engine and whole vehicle, and
to meet relevant requirements on dynamic &auxiliary function imposed by the driver. Sofar, signals from following articles has been
covered in system configuration:
- Engine rotating-speed sensor /crankshaft position sensor
- Oxygen sensor
- Throttle position sensor
- Pressure sensor for inlet manifold
- Inlet temperature sensor
- Temperature sensor for engine coolant
- Vehicle speed sensor
- Air conditioner /evaporating temperature sensor
- Electrical load signal
-Theft-prevention locked It has been connected with the theft detector, and may be used again after a decoding process.
-Failure with the signal input system Unable to receive the signal from sensor.
-Failure with the generator adjustor might cause a much higher output voltage, and damage the ECU.
-Failure with the output control system When the driver inside ECU is damaged, the driving &actuating mechanism will not
work any more.
(c)Characteristics of product
16-bit single-chip processor with high performance
10-bit module converter
Rewritable 128Kb memory
8Kb RAM memory
working temperature (-40 85)
normal working voltage (9 16)V
abnormal working voltage (6.3 9)V (16 24)V
over-voltage protection (-12 V 24)V
Delphi engine management systm-Determination on the
principal /utility /failure of key system parts EF.2-11
GND
Delphi engine management systm-Determination on the
EF.2-12 principal /utility /failure of key system parts
6. Engine rotating-speedsensorcrankshaftpositionsensor
(a)Function &principal
B eing one type of magnetoelectric sensor, the engine rotating-speed
sensor /crankshaft position sensor shall be installed nearby the
crankshaft, and shall work with 58x gear ring on crankshaft. W hen
crankshaft is rotating, 58X gear top /groove will pass the sensor
successively yet with different distance to sensor, and the sensor may
feel the A C changes of magnetic reluctance, which results in an A C
changed output signal. Using this signal, E CU is able to determine the
rotati ng posi ti on & speed of crank shaf t. W i ri ng termi nal :
A - signal +, B -signal -, C-shielded layer. I nstallation T hey shall be
installed nearby the crankshaft.
(b)Failure determination
I mpor tant note E ither of following determinations may be concluded based on that the whole vehicle, its wire-harness, and
other system parts & components are normal in function.
-Failures having been diagnosed by system will be read out through a Diagnosis Instrument.
-Shielded wire has not been applied to the signal in wire-harness, or the shielding layer of shielded wire has not been well
connected to ground
-T he magnetic core has absorbed a larger quantity of metal dusts;
-T he distance between sensor and gear ring is beyond limit;
-T he relative position of gear ring to the crankshaft is incorrect or a displacement is produced
(c)C har acter istics of pr oduct
- Working temperature (-40 165)
- Working clearance (0.25 1.75)mm
- Output 400 mV @ 60 r/min
- Coil resistance - Coil inductance
Delphi engine management systm-Determination on the
principal /utility /failure of key system parts EF.2-13
8. Oxygen sensor (O )
2
(a)Function &principal
-The oxygen sensor is regarded as a significant component within the
closed-loop fuel control system, usable to adjust or retain an ideal air /fuel
ratio, so that the three-way catalytic converter could reach an optimum
conversion efficiency. When the air /fuel ratio involved in engine combustion
becomes thin, the accumulative oxygen content in exhaust gas will be
increased, while the output voltage of oxygen sensor will be decreased;
On the contrary, the output voltage value will be increased. In such way,
information concerning the air /fuel ratio may be feedbacked to ECM. The
main sensitive material of oxygen sensor is zirconia. When zirconia is
activated by the heat exhaust gas (300 ), the oxygen ion will pass through
the zirconia component, and reach its outside electrode. The zirconia
component will induce the oxygen content in exhausted gas from engine,
and change its output voltage value. The oxygen sensor is made from
shaped stainless-steel component and Teflon insulation lead wire; And
the reference air is input from lead wire;
-Wiring terminal A-signal low, B-signal high C and D- connect to a
heat power supply
-Installation The oxygen sensor shall be installed between the exhaust
valve and the three-way catalytic converter.
(b)Failure determination
Important note E ither of following determinations may be concluded
based on that the whole vehicle, its wire-harness, and other system parts
& components are normal in function.
-T he voltage value of oxygen sensor may be read out from a Diagnosis
I nstrument; when not on ground, non-heat type
-T he voltage is 450mV ; Heat-type the voltage is less than 450mV
-T he thick-thin abrupt change time is too small; Heavy metal (eg. lead,
manganese, etc.), phosphorus and sulphur poison, or damaged due to high
temperature.
(c) Characteristics of product
-Working temperature (260 850)
-Max. over-heat temperature 930
-Heating resistance(23 ) 13
Delphi engine management systm Determination on the
EF.2-14 principal /utility /failure of key system parts
(b)Failure determination:
Important note E ither of following determinations may be concluded
based on that the whole vehicle, its wire-harness, and other system parts
& component are normal in function. A regular wash is needed as the valve
and its idle-speed hole might be blocked by oil sludge.
(c)C har acter istics of pr oduct
-Diameter of throat opening 38 mm
-Diameter of idle-speed valve hole 10 mm
Delphi engine management systm-Determination on the
EF.2-16 principal /utility /failure of key system parts
(c)Characteristics of product
-Coil resistance 53 10
-Coil inductance: 33mH 20
-Working voltage (7.5 12)V
-L imit voltage (3.5 14)V
(c)Characteristics of product
-R ange A n opening degree within 7% 93%
5V - Working voltage (5 0.1)V
-T hrottle valve close 12% of reference voltage 5%
-T hrottle full opened 83% 93%
ECU -A B impedance 12k
-Working temperature (-40 150)
16. Ignition coil
Ground (a)Function &principal:
The ignition coil assembly includes two groups of coil, each is able to
provide ignition energy to two cylinder spark plugs which have 360 degree
difference in rotating angle on crankshaft. When piston moves to the upper
compression /exhaust stop point, the ignition will be made simultaneously;
Cylinder nearby the upper exhaust stop point has a lower internal air
pressure yet a higher temperature, a small amount of energy could make the
electrode of spark plug through an ignition, that’s so called excessive ignition;
Cylinder nearby the upper compression stop point has gas mixture which
is with higher density and pressure, and a greater amount of energy is
needed for the ignition of cylinder spark plug, and the gas mixture will be
rapidly ignited to do work, the ignition for this cylinder is called valid
ignition
-Wiring terminal(ITMS6 drive the cylinder A-2-3;B+12V drive the cylinder
C-1-4.
wiring terminal(MT20U drive the cylinder A-2-3;B+12V drive the cylinder
C-1-4.
- Installation, It’s installed inside the engine chamber and remember to make
shielding against radio interference.
(b)Failure determination:
Important note Either of following determinations may beconcluded
based on that the whole vehicle, its wire-harness, andother system parts
&components are normal in function.
-Any failure on ingnition coil and loops maybo determined by cheking the
ITMS-6 MT20U
Primary resistance
Secondary resistance
Range of voltage use
(c)Characteristics of product Primary charge time ms mS
Peak value of primary power-cut current
Secondary output voltage
Min. zener energy mJ mJ
Min. ignition lasting time mS mS
Tightening moment
Delphi engine management systm-Determination on the
EF.2-18 principal /utility /failure of key system parts
18 I gnition system
Function &principal
The function of ignition system is to ignite the gas mixture of air and fuel
inside engine at appropriate time in accordance with ignition command
given by the engine control module. Using magnetize &ignite technique,
the ignition system decreases energy loss in the whole system, increases
the output for energy /secondary voltage of ignition coil, and makes the
engine combusting and working more stably.
ignition system
fuel supply
system
(b)Failure determination:
- Any failure on fuel pump and its related loops may be determined by driving the fuel pump relay to act with a Diagnosis Instrument
(when not driving);
-Failure diagnosed by the system may be read out from a Diagnosis Instrument;
-The primary filter screen has been blocked
-Fuel pump damaged;
-The sensing piece on fuel level sensor is broken, or the armed rod is deformed.
(c)Characteristics of product
Items
Fuel level sensor
Resistance value
Maximum Operating current
Fuel pump:
Output flow
Output pressure
Safe decompression
Operating voltage
23. I nj ector
(a)Function &principal:
-The injection nozzle structure is an electromagnetic switch unit. The
coil pulled out from two electrodes will connect with ECM and power
supply respectively via engine wire-harness; And the coil is controlled by
ECM, and after connection with system ground, will produce magnetic
force against spring force, fuel pressure, and vacuum suction force of
manifold. When steel core is lift up by suction force, fuel will spray from
guiding hole into (in a form of fog) air inlet gate after passing through the
valve-hole sealing surface on a same structure as steel core; After a power
cut, the magnetic force will disappear, and the injection nozzle will be
closed. Rubber sealing ring installed on the top of fuel injector will work
with fuel-rail interface to form a secure pressure oiltightness; And
rubbersealing ring installed on the bottom will work with engine inlet
manifold for an airtightness
-Wiring terminal A - +12V, B - ECM -Installation: It is fixed on
the inlet manifold via fuel-rail.
(b)Failure determination:
-Any failure on injector and its related loops may be determined by
driving the injector to act via Diagnosis Instrument (when not driving);
-Failure diagnosed by the system may be read out from aDiagnosis
Instrument
-Blocked by foreign materials;
- A glue film is formed after fuel evaporation;
-Damaged sealing ring cause an air or oil leakage;
-Connectors loosened, and wire-harness damaged;
-Broken coil loop leads to a non oil-injection.
(c)Characteristics of product
-Working temperature -30 125
-Min. working voltage <6 V
-Coil resistance (12.0 0.6)
Digit 0 will flash for ten times, other digits will correspond to their literal flashing times accordingly;
(e)After failure is cleared away, a Fault Diagnosis Instrument shall be used to clear away fault code to avoid any influence on the
determination of next maintenance.
4. Code reading card (fault code reader)
(a) The code reading card may provide a fast way to read fault codes.
(b) The code reading card shall be inserted to a fault diagnosis plug;
(c) The code reading card will have fault code cycling as per the sequence remembered by fault code£»
(d) Whereby any abnormality is found by vehicle owner, or when the fault indicator light is lighting, contact by phone with the
franchised service station to tell the displayed fault code, and the service station will determine the failure degree based on fault code
reported by user, and provide with relevant services. If the failure does not do harm to the driving safety and other parts
&components, user may be suggested to drive the vehicle to service station for repair; If the failure might cause a more severe
consequence, user may be suggested to wait for a field rescue from service station, so as to avoid any safety accident, or any loss
resulting from other parts &components.
5. Fault Diagnosis Instrument
The main function of Diagnosis Instrument is to read system information and system work data stream, to temporarily
control, check and test system parts &components, and read or clear away fault code. Being easy to operate, it is used as key tool
at present to determine any failure on vehicle, and to test and check the system status.
6. Fault code checklist for fault code reader
(a) Fault code checklist for ITMS-6 fault code reader
F ault code check list for fault code reader
F ault F ault
D escription of f ailure D escription of failure
code code
F ailure wi th the loop of inlet manif ol d F ailure w ith the loop of carbon-canister
0105 0443
pressure sensor solenoid valve
F ailure w ith the loop of inlet temperature F ailure w ith the loop of f an in water tank
0110 0481
sensor only f or electrical f an
F ailure w ith the loop of w ater F ailure w ith the loop of idle-speed
0115 0505
temperature sensor control v alv e
F ailure with the loop of throttle position M uch high system v oltage
0120 0560
sensor
0130 F ailure wi th the loop of ox ygen sensor 1362 F ailure wi th the theft detector
A n abnormal read v alue of ox ygen sensor F ailure w ith the loop of air conditioner
0170 1530
clutch
0200 F ailure wi th the loop of injector 1532 A n abnormal read value of temperature
0230 F ailure wi th the loop of fuel pump 1533 sensor on air conditioner evaporator
F ailure w ith the loop of crank shaf t F ailure wi th control computer
0335 1604
position sensor
F ailure w ith the loop of ignition coil1 on
0351 1605
f our cylinders
F ailure w ith the loop of ignition coil1 on
0352 1640
f our cylinders
1 A s code reader is able to read out any history fault code stored yet not being cleared inside the
computer.,
C odes read out by code reader shall be v alid onl y w hen any failure is indicated by f ault indicator
light.
N ote
2 T he display of -------- on code reader indicates the system is work ing normally ; and the
display of E indicates the k ey sw itch has not been opened yet.
3 I t’ s recommended to clear aw ay any f ault code at serv ice station af ter f ailure has been solv ed
each time.
Methods for failure diagnosis /fault code to spare parts EF.2-25
Explanatory note
1. As code reader is able to read out any history fault code stored yet not being cleared inside the
computer, codes read out by code reader shall be valid only when any failure is indicated by fault
indicator light.
2. The display of ———— on code reader indicates the system is working normally; and the
display of E indicates the key switch has not been opened yet.
3. It’s recommended to clear away any fault code at service station after failure has been solved each
time.
EF.2-26 Precautions to the use /service /troubleshooting of electrical injection system
(c)The leadin of spark plug shall not be pulled out when checking whether the ignition system is working, as the injection nozzle is
still working, and some petrol spraying out yet not being used will be combusting rapidly inside three-way catalytic converter and
cause damages;
(d)Do not dismantle system electrical parts &components when ignition switch is connected to avoid damages;
(e)When checking the replacement of ECU, please be noted that the vehicle shall be equipped with computer-based theft detector; If
so, ECU may be replaced after a power cut made to theft detector, otherwise, new ECU will be locked by theft-prevention function,
and can not work on other vehicles;
(f)Anti-interference spark plug plus high-tension wiring shall be used within system, if not, negative effect may be brought to the
ignition-coil drive mode inside ECU, and ECU may even be damaged.
(g)When changing fuel inlet /return pipe, use petrol pipe which can withstand a bursting pressure greater than 2Mpa;
(h)Method like ‘use needle to punch wire-harness’ shall not be used to check the system current signal;
(i)Always remember to disconnect accumulator jar from ECU connector when exterior electrical system tools are applied for welding
purpose
(j)During installation or dismantling of components within the electrical-injection system, severe knocks or strikes against components
are prohibited;
(k)Any check or test shall not proceed when ECU cover is opened to avoid greater damage.
Any loss produced after ECU is opened will not be compensated;
(l)When changing or dismantling the oxygen sensor, it’s unallowable to apply any sealant to the threaded part of oxygen sensor to
avoid burning and damage;
(m)It’s unallowable for fuel pump to run for a long term period when it contains no petrol, neither to run in air even when its contains
petrol;
(n)If any breakage is found in loop, quality insulation tape shall be used for wrapping purpose during maintenance to avoid greater
loss.
(o)Upon the confirmation on damage on electrical-injection components, they shall be changed accordingly in normal case as most of
them are unable to be restored.
T r oubleshooting
1. Solutions to failure
(a)Query diagnostic method
-When query, you shall be earnest, conscientious, amiable, and attentive in listening.
-The query shall be made from an integral view and focus on key points; and you need to further understand the history and the
frequency of symptom.
-Based on the symptom known from vehicle owner when some failure is produced, an analysis, judge, and initial determination may
be concluded.
(b)Observe diagnostic method
-The observation shall be based on the symptom, and consider the whole system and some focus, and proceed as per a certain
sequence
-An exterior inspection is needed to check the water / air/fuel/ electrical loop of vehicle which has failure
- To find the cause of failure, some instruments or instrumentations applicable to vehicle may be used during the inspection.
- A judge shall also be made based on a careful observation on the symptom, fault code, sound, etc. when some failure is produced.
(c) Component displacement method
-New component will be used to take the place of original component which may have possible failures;
-The original component which may have possible failures will be installed on another good vehicle for a further verification;
-The displacement of some component shall be supported by appropriate reasons, and can not be made on blindness.
(d) Case application method
-Based on results concluded from typical cases, direct search the cause, remove the failure, and reduce unnecessary inspections
-This method is only applicable to the same failure produced on the same model of vehicle or the same type of system
-This method is not applicable to common failures, which have a similar symptom yet caused by various causes.
(e) Experience method
-Based on previous results gained from the settlement of various failures, experiences may be accumulated gradually, and the
capability to solve the trouble may be increased as well
-Depending on the similarity and difference of symptoms, a determination may be concluded accordingly by applying previous
experiences in a flexible way
-Existing experiences may be optimized by make a conclusion from the settlement of special or typical failures, and recording the
successes and mistakes in the course of settlement.
(f) Logic thinking method
-A logic thinking method may be adopted to analyze the failure and find out the failure points in accordance with the working
principal of testing data and system
-It’ s required to be familiar with the working principal and function of engine, the electrical-injection system, and system components
-For some failures, a logic thinking & analysis is much compulsory.
EF.2-28 Precautions to the use /service /troubleshooting of electrical injection system
Attached figure III and IV are Electric-Control Schematic diagram for MT20U SystemAttached figure V, V I , VII, and VIII are Typical
Failure Diagnosis Flow Diagram.
(b) Slack accelerating
- Check oil amount and the fuel filter inside oil tank
- Check the air exhaust system for blockage eg. whether three-way catalytic converter has been blocked due to breakage or the
burning of machine-oil; when at a normal idle speed, the pressure value of inlet manifold shall be greater than 60KPa
- Verify whether the pressure within fuel supply loop is 300kPa, and clean the oil nuzzle .
(c) Oil consumption is abnormally high
- After a verification that the mechanical components of engine and the oxygen sensor are under a normal condition, start the engine
and observe the read value of oxygen sensor: the read value shall be always greater than 500mV when at a normal water temperature.
And check whether the injector is leaking oil, and whether the water temperature sensor, and the manifold pressure sensor are
working in a normal way.
(d) Indicating a failure with the air conditioner system is produced on vehicles without air conditioner.
- Check whether the pre-installed air conditioner plug has been contaminated, if so, clean it and provide it with a dustproof
protection, then ECU power supply will be disconnected, and resumed in ten minutes.
- Fault code must be cleared away from MT20 system using a Fault Diagnosis Instrument
(e) Removal of common failures on theft-prevention controller
- The theft-prevention indicator light is not on Check the power supply and the ground wire for theft-prevention controller; As
the failure of control computer results from a current impact which is produced at the time when inductive load on accumulator jar
line is cut off, the electrical-injection system and the theft detector fuse shall be pulled out, and re-inserted after ten seconds.
- Subject to a mating between electrical-injection control and theft detector, the engine fault indicator light, after an ignition, will be
flashing (at 2Hz) for 30 seconds, and then be off; The electrical-injection unable to start (the electrical-injection indicator light will
be flashing at 1H) the theft-prevention indicator light will be on for 2 seconds after a normal ignition, and then be off; Try to
replace the password key; when PCHUB is used to measure the electrical-injection controller, the unselected <no key>may be
seen, which indicates that the password key does not have a valid password repeater That the selected < theft detector no
response> is seen indicates that the communication between the electrical-injection controller and the theft detector has not been
connected.
- When the electrical-injection control has mated with the theft detector, it will be flashing at 2Hz for 30 seconds after an ignition,
then be off, and the electrical-injection is starting (the electrical-injection indicator light is permanently on or off), the theft prevention
indicator light will be on for 2 seconds after a normal ignition, and then be off; Such failure is caused by coils having notbe fastened
onto the ignition lock nut, or ignition nuts having troubles with the raw material; Watch and see if it returns to a normal condition after
coils have been re-fastened onto the ignition lock nut (unscrewing the nuts may be needed before coils arere-fastened) ; A large hole
in supporting bracket for ignition lock might make coils unable to be installed onto the ignition lock nut; if it is still unable back to a
normal condition, the ignition lock nut or coils may be changed.
(f) The key to the theft-prevention controller is lost or damaged:
Normally, the theft detector within electrical-injection system has been provided with two types of key: one in red, others in black.
And only black keys are for routine use.
- Black key lost Provide with one new black key, and a code operation study for black key is needed.
- Red key lost Provide with new red &black keys
Change the original theft-detection computer, as the theft-detector computer provided for original vehicle only accepts original
red key, which is a mark to start the key study flow process. And computer ECU for engine needs to be posted to Delphi company
for a decoding process, as computer ECU for engine only accepts an original mark provided for original vehicle to start the theft-
detector computer flow process.
A study on red key and black key is needed, and shall be performed successively in accordance with the code operation study steps
corresponding to theft-detector key.
(The code operation study steps corresponding to theft-detector key may be claimed from Delphi Company).
Figure 1 and 2 are the Electronic Principle Diagram for ITMS-6 system.
Figure 3 and 4 are the Electronic Principle Diagram for MT20U system.
Figure 5,6,7 and 8 are the Diagnosis Process of Typical Failures.
Delphi engine management system-troubleshooting and common failure EF.2-31
A ttached figure I
electronic ignition timing 3
high-voltage
electronic ignition timing B coil driver
idle-speed &air
idle valve drive A(low)
control valve
injection nozzle
idle valve drive B(high)
idle valve drive B(low)
carbon-canister wash
solenoid valve
ignitionfuse2
fault diagnosis socket
serial data battery fuse4
diagnosis request
A ttached figure II
5V reference voltage
throttle position
throttle position signal
sensor 5 V ground A
5V ground B
manifold
absolute-
pressure sensor manifold absolute-pressure signal
purple &black
front oxygen sensor
red
green &yellow
pink &brown
red &yellow
main relay
green &red
black &blue
red &yellow
red
black &yellow
black &green
black &green
fuel injector1
red &blue
crankshaft position sensor
black& yellow
brown &blue
blue &grey
purple &red
coolant temperature sensor
spark plug
green &yellow
green &red
green &yellow blue &white
green &yellow
knock sensor
green
electromagnetic switch for carbon-canister wash control
red
green
red red &green
power supply/ generator excitation
connected to instrumentation
white &black
grey
throttle-valve position sensor
blue &white
grey &black
electromagnetic clutch
connected to the center-control door &lock
connected to the sensor for vehicle speed odometer
yellow
green
green &white
black &red
black &white
brown &red
grey&white
air conditioner
connected to
grey&white
red red
Delphi engine management system-troubleshooting and common failure
connected to the
machine-oil pressure
switch connected to the
knock sensor connected to the idle-speed connected to the connected to the
EF.2-34
control valve throttle position carbon-canister control
connected to the air inlet connected to the air crankshaft position sensor
sensor valve
temperature /pressure sensor conditioner clutch
Delphi engine management system-troubleshooting and common failure EF.2-35
attached figure V
EF.2-36 Delphi engine management system-troubleshooting and common failure
Attached figure VI
Delphi engine management system-troubleshooting and common failure EF.2-37
Engine body
Page
piston ring
piston
timing chainwheel
chamber cover connection-rod
timing chain and chainwheel connection-rod
bearing bush
timing chainwheel
chamber
sealing gasket
(k)Remove the sealing ring from oil seat on the rear end.
The sealing ring may be removed from oil seat on the rear end by unscrewing
five bolts.
EM.1-4 Preparations before and key points to the disassembly of engine body
front
(b)A twelve-edge socket spanner may be used to unscrew the fixing nuts on
the connection-rod cover.
Preparations before and key points to the disassembly of engine body EM.1-5
(c) A plastic hammer may be used to remove the connection-rod cover by gently
striking against the connection-rod bolt.
Remark Have the lower bearing bush retained inside the connection-rod
cover.
(d)To prevent crankshaft from damage, the connection-rod bolt shall be installed
with short hose sleeve.
(e)Clean the connection-rod bush, and the connection-rod neck-journal.
(f)Check whether each bearing bush has any exfoliation or scratch. If the
connection-rod neck-journal, or the main-bearing bush of crankshaft has some
damages, the crankshaft, and the main-bearing bush shall be changed.
(g)Remove the short hose.
(h)Put one piece of plastic feeler gaugeonto the connection-rod neck-journal.
+ 0 . 036 0
+ 0 . 0211 − 0 . 015
+ 0 . 035 0
+ 0 . 0201 − 0 . 015
Remark
front - Always keep the connection-rod bush and the connection-rod cover as an
integral part.
- Piston and the connection-rod cover shall be put in order as per a correct
sequence.
(b)Theremovedboltmaybeusedtoprizethebearingcoverbackandforthtoremove
the bearing cover which has connected with the lower bearing bush and the
thrust washer only for No. 3 main neck-journal at the same time.
Remark
-Keep the lower bearing bush and the bearing cover as an integral part, and do
not keep them apart.
-Place the lower thrust washer of bearing cover in order as per a correct
sequence.
(c)Dismantle of crankshaft
Remark Keep the upper bearing bush, and the upper thrust washer only
for No.3 main neck-journal with the engine body as an integral part. Do not
keep them apart.
(d)Clean the main neck-journal and the bearing bush.
(e)Check whether the main neck-journal and the main-bearing bush has any
scratch or exfoliation.
If the main neck-journal and the main-bearing bush has some damages, the
crankshaft shall be abraded, repaired, or changed, and the main-bearing bush
shall be changed.
(f)Place the crankshaft onto the engine body.
(g)Place a piece of plastic feeler gauge horizontally onto each main neck
journal.
(h)Install the crankshaft main bearing cover which connects with the lower
bearing bush and the lower thrust washer; And install and tighten bolts on
the main bearing cover do not rotate crankshaft then
(k)Plastic feeler gauge shall be scraped thoroughly away from the main-bearing
bush and the main neck-journal.
Remark If a standard bearing bush is to be used replace with a bearing
bush having the same mark as that made on the engine body at a place close
to cylinder hole and on the contacting surface between the cylinder and the
cylinder cover . And standard bearing bush is available with three size which
may be indicated by relevant marks including: 1, 2, or 3.
Main bearing hole and main neck-journal mm on crankshaft
front D iameter of
D iameter
main M ax .
of main
S .N -journal abrasion
6. Dismantle of main-bearing bush bearing on C learance
on clearance
(a) Remove the crankshaft. crank shaf t
crank shaf t
(b)The upper bearing bush and the upper thrust
0.022
washeroncrankshaft may be removed from the engine 1 58 ++ 00..03 6
0 22 58 0− 0 . 01 5
0.053
body.
(c) Put the main bearing cover, the main-bearing bush + 0 . 03 7 0 0.022
2 58 + 0 . 0 22 58 − 0 . 01 5 0.10
and thethrust washer in order as per a correct 0.052
sequence. 0.021
3 58 ++ 00..03 6
0 21 58 0− 0 . 01 5
0.051
7. Removal of camshaft
(a) Take out the hydraulic tappet.
As shown in the figure, a thin steel wire may be used to take outthe
hydraulic tappet.
(c) The difference of values measured from pushing direction and axial direction
respectively shall be less than the limit of roundness.
Limit of roundness 0.02 mm
+ 0 . 720
A ir inlet cam: 38 mm
+ 0 . 620
+ 0 . 729
A ir ex haust cam:38 mm
+ 0 . 629
(b) Check the mating clearance between the camshaft neck-journal and the
camshaft bearing. The standard value shall be (0.025 0.081)mm, and the limit
value shall be 0.1mm. If the actual clearance value exceeds the limit value, the
bearing or camshaft shall be changed.
EM.1-12 Preparations before and key points to the disassembly of engine body
(b)Manually remove the retaining ring and the oil piston ring on
two sides of oil ring.
Remark The piston ring shall be placed in order as per acorrect
sequence.
Remark
Piston and piston pin are mating members; And the installation of piston,
piston pin, piston ring, connection-rod, and bearing bush shall be subject
to a correct sequence.
(c) Piston may be thoroughly washed using solvent and soft brush.
Note: Do not use steel-wire brush.
(c)The measured value of diameter for piston shall be reduced by that for
the engine body.
Standard piston clearance (0.065 0.085)mm
Oper ation limit: 0.085 mm
If the actual piston clearance is greater than Max. value, all pistons for four
cylinders must be changed, and /or four cylinders must be re-bored.
Standard
value
Max.
value
5. Inspection on connection-rod
(a)A straightener may be used to check the linearity of connection-rod in follo
wing aspects:
- Check the bending deformation.
Max. bending deformation 0.05 mm/100 mm
T he connection-rod component shall be changed if the actual bending
deformation is greater than Max. value.
Preparations before and key points to the disassembly of engine body EM.1-15
(c)Measure the oil clearance between the lining on small end of connection-
rod and the piston pin.
-A caliper gauge shall be used to measure the inner diameter of lining on
small end of the connection-rod.
Standard diameter (24.008 24.009)mm
-A micrometer is used to measure the external diameter of piston pin.
Standar d diameter (24.000 24.009)mm
-T he diameter of piston pin will be reduced by the measured value of
diameter for small end lining on the connection-rod.
Standar d oil clear ance (0.005 0.011)mm
M ax. oil clear ance 0.015 mm
If the actual oil clearance is greater that Max. value, the lining on small end
shall be changed.
SST
(c)New lining will be honed, and check the mating of piston pin with the
lining on small end of the connection-rod.
-New lining will be honed, and check whether the oil clearance is within
a standard scope.
Standard oil clearance (0.005 0.011)mm
-Check the mating of piston pin under a normal room temperature.Piston
pin will be applied with appropriate amount of oil, and be pushed by
thumb into lining on small end of the connection-rod.
7. Inspection on crankshaft
(a)Measure the radial runout of crankshaft
-Place the crankshaft on a V-shaped piece.
-A micrometer may be used to measure the circumferential radial runout
atthe center of the neck-journal.
Max. circumferential radial runout 0.06 mm
If the actual runout is greater than Max. value, the crankshaft shall be
changed.
R emark A long mandrel shall be applied to the micrometer.
Preparations before and key points to the disassembly of engine body EM.1-17
8. Change of oil-seal
(a)Oil-seal shall be removed using screwdriver and hammer.
EM.1-18 Preparations before and key points to the disassembly of engine body
9. Bored cylinder
Remark
Four cylinders will be bored depending on the external diameter of piston with
an increased size.
Respective piston ring shall be replaced to place as per the matching pistons.
(a)Selection of piston with an increased size
Diameter of piston with an increased size 0.50 mm
(b)Calculation of size for cylinder to be bored
-A micrometer may be used to measure the diameter of piston at a position
which form a right angle with the center line of piston pin, and is 24mm away
from the top of piston.
-The size of each cylinder to be re-bored may be calculated as per the formula
given below:
Size to be re-bored =P+C-H
Whereby: P= diameter of piston; C= Clearance of piston 0.03-005mm
H=the surplus of honing less than 0.02mm
(c)The cylinder shall be bored and honed to the calculated size.
Max. honing amount: 0.02 mm
Note: Excessive honing will damage the precisely-made roundness.
-Check whether the piston pin has been pressed and installed to place; Hold the piston by left hand, and pull the connection-rod by
right hand, and rotate the connection-rod, and the rotation of piston pin shall be made in a flexible way.
SST 09221-00020 09221-00030 09221-00040
09221-00071 09221-00081
Remark
The mark “forward” of piston shall be consistent to that of the connection- rod component.
Groups of the connection-rod divided by weight shall consistent to each other.
2. Installation of piston ring
(a)Manually install the oil-ring gasket spring into the ring-groove of combined
oil rings at the apron of piston; And do not overlay at the opening point.
(b)Special piston-ring installation pliers may be used to install the scrapin g
blades of oil ring two blades , the second gas ring, and the first gas ring
first into place sequentially.
Remark Two gas rings vary from each other: The first gas ring has a mark
AT G on end surface, the second one has a mark A 2 on end surface.
And the side of gas ring having marks shall face upward.
second
(c)The adjustment of the opening position of piston ring is as shown in the
symbol mark
figure:
Note:
1.On the top of European- piston, two gr ooves have been installed to
second compression ring pr event air-valve fr om striking, and an anodic oxidation may be performed
upper ring on the top of piston as well.
2.E ur opean- piston and piston r ing may be installed onto E ur opean-
device, but these two par ts must be inter changed simultaneously;
front E ur opean- piston and piston r ing may not be installed onto E ur opean-
device, or air valve will str ike against the piston; E ur opean- piston
r ing may not be installed onto E ur opean- piston, or it will lead to a
lower ring ser ies of tr ouble, eg. bur ning of oil, abnor mal sound pr oduced on engine,
first compression etc.
ring and piston ring
3.Assembly of the connection-rod bush
(a) After the installation of piston ring, the piston &connection-rod
component may be transferred by group to a position where the connection-
rod bush will be installed.
(b)The connection-rod bushes may be selected in accordance with the group
No.(group No. for big-head hole to be:6, 7, 8)marked on the big-
head hole side of the connection-rod.
(c) After nuts on connection-rod have been removed, a special bench vice
may be used to dismantle bush cover from the connection-rod.
oil control
(d) Clean up the inner surface of the hole of connecting rod big end,then
mount the connecting rod bearing to the connecting rod and cover of the
connecting rod bearing respectively,the convex key of the connecting rod
bearing should be inserted into the locating notch of connecting rod.
EM.1-20 Preparations before and key points to the disassembly of engine body
(e)To avoid confusion, one end of bush covers (having been installed with connection-rod bush) , plus relevant nuts, shall be
installed onto the connection-rod unit.
General precautions during the assembly
(a)A ll parts to be installed must be washed thoroughly; Prior to installation, clean oil shall be applied to all sliding or rotating
surfaces.
(b)Pistons within the same group shall be included in the same group divided by mass.
(c)Connection-rod components within the same group shall be included in the same group divided by mass.
(d)T he mark “forward” on the top of piston shall be consistent to that on the connection-rod.
(e)A lways keep clean during the assembly.
oil hole
(b)Two lower thrust washers, whose friction surfaces have been applied with
slight amount of clean oil, may be installed onto the main bearing cover in the
middle, which will be installed onto main neck-journal in the middle while two
thrust washers are being pinched by hand.
(c)Appropriate bolts must be manually screwed into each main bearing cover
by 3 4 threads, and a steel hammer may be used to gently strike the top of
each main bearing cover so that it will be well connected with the main neck
journal, and the engine body.
Preparations before and key points to the disassembly of engine body EM.1-21
(c)Appropriate amount of clean oil shall be applied to the piston ring, and to the
connection-rod bush.
front sign (d)After the piston compressor has been tightened stably (rather than striking
closely against the piston), the wood handle of hammer or similar tools may be
used to gently strike the piston and connection-rod having correct number into
front respective cylinder.
Remark:Die hole on the piston, and the convexity on the connection-rod shall
face the front side of engine.
9. Installation of connection-rod
front (a)Make the numbered bearing cover matching with the numbered connection-
rod, and have them included in the group.
front mark (b) During the installation of bearing cover, its front mark shall face frontward.
EM.1-22 Preparations before and key points to the disassembly of engine body
5. Installation of flywheel
When flywheel has been installed to a place behind the crankshaft, manually
rotate the flywheel to make it facing exactly the assembly mark made on the
rear end surface of crankshaft, then six flywheel bolts will be used to fix the
flywheel onto the rear end of crankshaft: the bolts shall be subject to a pre-
tightening made by a pneumatic wrench, and a re-tightening diagonally to the
specified moment made by a stud bolt tightener.
Tightening moment ( 85 3) N m
-The thrust collar of camshaft shall be fixed onto engine body at the
camshaft hole using two M8 16 bolts with flat washer and
standardspring washer .
Tightening moment ( 18 3) N m
R emark T he thrust collar of camshaft shall make the side having ‘ pit’ mark
face outward.
(b)Manually rotate the camshaft, and its rotation shall be flexible. T henthe
woodruff key of camshaft must be turned to an upward position.
Cylinder head
page
To prevent the cylinder gasket from leaking air or water, the tightening torque of bolts on cylinder head shall
be checked using a torque wrench before new vehicles travel for 500 or1000 kilometers, and will be 90N.m for
ten M12 bolts, or 20N.m for three M8 bolts. And a tightening may not proceed until the engine cools down. To
perform a correct maintenance and adjustment, a general description is provided as below for dismantle /
inspection /maintenance of cylinder head.
valve locker
clamp
valve spring
valve chamber cover valve spring upper seat (air
seat air exhaust inlet)
valve spring
rocker shaft and spring
valve oil seal
rocker shaft valve spring
lower seat
valve
spark plug
push rod
engine
spark plug sleeve
valve guide
cylinder head
water outlet pipe
hydraulic tappet
engine front
engine hook fender
Dismantle of cylinder head EM.2-3
6. Dismantle of rocker-shaft
Subject to the numbering sequence indicated in the figure, bolts and nuts
on rocker-shaft may be removed progressively in three steps.
4. Dismantle of valve
(a)Valve spring seat will be compressed using SST until two valve locker
clamps have been removed.
SST 09202-43013
(b)SST and two valve locker clamps shall be removed.
(c) Take out valve spring seat, valve spring, and spring shim successively.
(d) Remove the oil-seal.
(e) Disassembly the valve.
IN
EX
External diameter of
Standard clearance Max. clearance
standard valve rod
Engine
Air Air Air
model Air inlet Air inlet
exhaust inlet exhaust
valve valve
valve valve valve
(b)The valve guide may be struck out using SST and hammer.
SST 09201-60011
edge thickness
The valve shall be changed whereby the whole length of valve is less than
Min. value.
Cleanup /inspection on each spare part EM.2-9
(e)Check whether the valve rod has been abraded too much on endsurface.
If it does occur, a grinding machine may be used to repair the end surface,
or the valve shall be changed.
Note Do not mak e an over-abr asion to avoid thewhole
length of valve is less than M in. value.
(c)The valve surface and the valve seat shall be checked as per the following:
-If the valve surface shows blue on the 360 circumference, it indicates
that the valve is homocentric, if not, the valve needs to be changed.
-If the valve seat shows blue on the 360 circumference, it indicates that
width the valve guide and the valve seat are homocentric, if not, the valve seat
needs to be abraded and repaired.
-Check whether the contacting width between valve seat and the middle
of valve surface is within (1.2 1.6) mm; If not, a modification to the
valve seat shall be made as per methods stated below:
-If the valve seat is much higher than the valve surface, 30 and 45
carbide tools shall be used to modify the valve seat.
(d)The valve and the valve seat may be manually abraded using
carborundum.
(e)Following a manual abrasion, the valve and the valve seat shall be
cleaned.
(c)A spring tester will be used to check the tensile force for each spring
having specified installation length.
Installation length:40.6 mm
Standard installation tensile force 345 N
M in. installation tensile for ce 282 N
T he spring shall be changed if the installation tensile force is less than
Min. installation tensile force.
(c) Check whether the direction on the rear end of air valve rocker-shaft
is correct. And the valve spring and the rocker-shaft may be assembled as
indicated in the figure. During assembly, special maintenance tools may
be used for an installation of clamps. If the contact surface between valve
and.rocker shaft as been much abraded oil stone provided for valve
refacer may be used for abrading, or they may be changed.
SST 09207-71010
upward
front
convexity
convexity position
-When hydraulic tappet is submerged in light oil, push the plunger piston
for several times to discharge air insidethe hydraulic tappet.
SST 09276-71010
Note:
1. The thickness of cylinder head conforming to Class E ur opean
standar d shall be 0.5mm smaller than that confor ming to C lass
E ur opean standar d; A nd there’ s a mar k E 3 made on the r ight
side of cylinder head confor ming to C lass E ur opean standar d,
and the other one does not have this mar k.
2. A ny mis-installation across the E uropean- cylinder head and
the E ur opean- cylinder head is unallowable. I f E ur opean-
cylinder head was installed onto E ur opean-I I device by mistake, it
might make the valve touch the piston I f E ur opean- cylinder
head was installed onto E ur opean- device by mistak e, the
per for mance of engine might be degr aded, and other failur es might
occur accor dingly.
Assembly of cylinder head EM.2-13
marked with green color 5. Pressed installation of air inlet /exhaust valve
upward (a)A ppropriate amount of clean machine oil shall be taken out from
machine oil pot and be applied to the rod of eight air inlet / exhaust
valves respectively, then, have the cylinder head fixed onto a clamping
fixture applicable to the pressed installation of valves.
(b)I nstall eight valve spring seat gaskets successively into place.A nd
the number of gaskets must be correct.
(c)A special press tool shall be used during the pressed installation of
eight valve oil-seals.
Note F or ce applied to the oil-seal could not be too big,if the pr essed oil seal deviates fr om the
installation position, it shall be taken out and discar ded accor dingly,and may not be r e-
used any longer .
(d)Put the valve spring and the valve spring seat into place successively.
R emark
-T he smaller pitch end (viz colored end )of valve spring must be put to the downside.
-Different from air inlet valve, the spring seat on air exhaust valve has a rotatable mechanism, which can not be mis-installed.
SST 09202-43013
(e)Using a special press tool applicable to valve, each locker clamp of valve may be pressed into the cone hole on the cap of air inlet
/exhaust valve.
EM.2-14 Assembly of cylinder head
(f)To have the locker clamp of valve well connected with the spring seat
and the valve rod, a copper hammer may be used to strike gently against
the tail end of each valve rod.
6. Installation of spark plug component
(a)R espective sealing gasket shall be installed onto the spark plug sheath,
and the level end of sealing ring must be connected with the flanged
surface of socket.
(b)Insert the spark plug into the sleeve of spark plug.
(c)Four sets of spark plug and sleeve component shall be manually installed
into (by 3 4 threads) the installation hole on the right side of cylinder
head, and be tightened with a spark plug wrench.
T ightening tor que (20 3)N m
3. Rocker-shaft assembly
upward (a)Two rocker-shafts inside each cylinder may be fixed together via one
special clamping plate.
(b)The rocker-shaft assembly shall be installed onto two studbolts on
front
convexity the cylinder head in such a way that one endofrocker-shaft having dummy
club (its surface facing upward) will be backward.
SST 09207-71010
convexity position (c)Two M8 nut with flat washer may be manually screwed onto
stud bolt; Screw the short threaded end ofthree bolts (fixing the rocker-
shaft ) into the fixed seat for rocker-shaft, followed by a tightening made
push rod progressively in two steps as from the middle to two sides as shown
in the figure .
push rod Tightening torque ( 18 3)N m
(d)A fter a layer of clean machine oil has been applied to the ball surface
on two ends of the push rod, the lower end will be installed into a ball
socket on the tappet cap, while the upper end will be pressed by a special
press rod into the ball socket of rocker-shaft while the crankshaft is
rotating.
lower part and the upper part of air-inlet manifold are connected, and have six installation holes facing exactly to relevant spacers, and
to six holes on the low part.
-Six M8 30 hexagonal socket head bolts with flat washer and standard spring washer will be used for fixing purpose, and
shall be tightened as per the sequence “from the middle to two ends”: a pre-tightening may be made using a pneumatic wrench before
a re-tightening to specified torque using a fixed-torque wrench.
Tightening torque ( 16 3)N m
(g)Installation of dead plate and the manifold supporting frame
-Using two M8 16 bolts with flat washer and standard spring washer , dead plate may be installed onto front end surface at
the lower /upper part of inlet manifold to link the lower part with the upper part. T ightening torque (16 3)N m
-One M8 16 bolt with flat washer and standard spring washer will be used to have the upper part of manifold supporting
frame on the rear side of cylinder head fixed onto the upper part of inlet manifold. And two bolts on manifold supporting frame may
be tightened using a fixed-torque wrench.
T ightening tor que ( 16 3)N m
Valve mechanism
Page
sealing ring
valve-box cover
rocker shaft
assembly
push rod
tappet
camshaft
thrust disk
vibration absorber
tensioner
cam chainwheel
timing chain cover
cam chainwheel
bolt
timing chain
crankshaft
chainwheel
crankshaft
sealing ring
pulley bolt
Those with mark * refer to spare parts which have been used and can not be re-used.
Valve mechanism Disassembly of timing chain/camshaft EM.3-3
(b)After unscrewing the fixing bolt, SST may be used to have camshaft
chainwheel, crankshaft chainwheel and chain dismantled evenly.
SST 09950-20017
Valve mechanism Inspection &repair for timing chain/camshaft components EM.3-5
(f)Axial clearance between the thrust disk and the camshaft may be
measured using a feeler gage.
Standard axial clearance (0.07 0.22)mm
M ax. axial clear ance 0.30 mm
T he thrust disk needs to be changed when the clearance exceeds Max.
value, and the camshaft needs to be changed as well when necessary.
(c) Machine oil for engine may be filled to the chain tensioner unit, or to
the sliding surface of column.
(d)Have the spring and chain tensioner column installed on the chain
tensioner unit.
(e)Install the side plate to place.
Note I nstallation direction.
(f)Strike the plate into place using hammer and socket spanner.
socket spanner
(b)Strike new oil seal into place using SST and hammer until the surface
of oil seal reaches
The same height as the edge of timing chain cover.
SST 09223-22010
(c)MP multi-purpose grease shall be applied to the jaw of oil seal.
Method II
(a)Dismantle the oil seal using SST.
SST 09308-10010
(b)MP multi-purpose grease shall be applied to the jaw of new oil seal.
(c)Strike new oil seal into place using SST and hammer until the surface
of oil seal reaches
the same height as the edge of timing chain box.
SST 09223-22010
front
EM.3-10 Valve mechanism Installation of timing chain/camshaft
Plastic hammer
(b)A layer of engine machine oil will be applied to the top/screwed parts
of pulley bolt.
(c)The pulley bolt will be installed using SST and tightened as well.
SST 09213-70010 and 09330-00021
Tightening torque 160N m
EM.3-12 Valve mechanism Installation of timing chain/camshaft
Cooling system
Thermostat...................................................................................CO-5
Radiator.......................................................................................CO-6
Cooling system-Composition &characteristics of cooling system, Inspection /change of
CO-2 coolant for engine
sealing ring
fan
The one with mark refer to spare part which has been used and can not be re-used.
CO-4 Cooling system Cooling water pump
Thermostat
Dismantle of thermostat
1.Discharge the coolant.
2.Dismantle the outlet hose of radiator from the inlet of water tank.
3.Dismantle the thermostat, and the inlet of water tankTwo nuts, the
inlet of water tank, sealing ring, and the thermostat shall bedismantled
from the timing chain box.
Inspection on thermostat
Note A constant temperature refers to the starting
temperature of thermostat valve.
1. After the thermostat is submerged in water, add hot
water gradually.
Installation of thermostat
1. Installation of thermostat and the inlet of water tank
clamp valve
(a)New sealing ring shall be applied during the installation of thermostat,
and clamp valve shall be placed on the thermostat as indicated in the
figure.
CO-6 Cooling system radiator
Radiator
Clean &wash of radiator
Dirts and dusts inside the radiation fin may be cleared away using a
steam purger.
Note: Do not damage the radiation fin if a high-
pressure purger is used. When the pressure at the
nozzle of purger is (2.944-3.434) Mpa, keep a Min.
distance as (40-50) cm between the nozzle and the
radiation fin.
Inspection on radiator
1. Check the cap or outlet cover for radiator or water
radiator cap tester tank respectively.
(a)Push one radiator cover tester into place until safety valve is opened.
And check whether the valve may beopened when the pressure is between
73.6kPa and103kPa.
(b)Check and ensure the pressure on cover will not go down sharply
when it’s lower than 58.9 kPa.
(c)The cover shall be changed if any failure has been found in either of
above articles.
Lubrication system
Page
Oil pump.....................................................................................LU-4
LU
ST
CH
Lubrilation system-Composition /function of lubrication system¡¢Inspection on machine-oil
LU-2 pressure
push rod
valve
tappet
camshaft
Oil pump
Part drawing for oil pump
The one with mark * refer to spare part which has been used and can not be re-used
(b)Rotate the shaft of oil pump in a similar way stated above when the
machine-oil outlet has been blocked by finger, and the shaft of oil pump
shall be difficult to rotate.
(c)A gauge may be used to check the clearance between two inner rotors,
or the clearance between the drivin grotor and the driven rotor.
(0.07-0.12)mm
Standard clearance : (0.07-0.12) mm
M ax. clear ance : 0.20 mm
R otor shall be changed when the actual clearance exceeds Max value .
A nd the oil pump assembly maybe changed when necessary.
Tightening torque : 8N .m
Ignition system
IG-2 Ignition system-preventive measures, Circuit diagram /vehicle inspection of ignition system
Preventive measures
Great Wall automotives are driven by petrol engine, which works after the mixture of petrol and air has been
ignited by the high-voltage electric spark produced by one set of ignition system installed inside the engine. And
the ignition system has such function as to transform the low-voltage provided by battery into a high-voltage
current able to ignite the inflammable gas mixture inside engine cylinder; and to distribute the high-voltage
current on time to the spark plug at each engine cylinder as per engine working procedure. And electric sparks
produced between electrodes of spark plug will ignite the inflammable gas mixture to push the piston for actions,
and to drive the connection rod of crankshaft, and to make the engine working.
The preventive measures are given below
1.If the engine can not be started, do not have the ignition key being connected for over ten minutes;
2.During the connection between system and the tachometer, the test line of tachometer shall be connected to
the negative terminal of ignition coil;
3.To prevent any damage on igniter or ignition coil, do not have the terminal of tachometer contacted withground
4.Do not dismantle the battery while engine is running;
5.Always verify whether the igniter has been connected well with the cover.
ignition fuse
ignition coil
spark plug
fuse
battery
Ignition system- Circuit diagram /vehicle inspection of ignition system IG-3
Vehicle inspection
Spark plug test check the form of spark plug
1. Remove the high-tension wiring from spark plug
2. Remove the spark plug
3. Spark plug needs to be installed on each high-tension wiring
4. Spark plug will be grounded
5. Check whether the ignition works when engine starts running.
Note Following test may be performed when the
ignition does not work.
Spark test
you can
Check the resistance of high-voltage Change the high voltage resistance line
damping wiring You can’t
you can
you can
primary grade
secondary grade
you can
Starting system
Testing on starter.................................................................ST-9
ST-2 Starting system-Structure /circuit diagram of starter
The exterior force of petrol engine comes from one starter, which receives power supply from the battery,
and drives the engine to rotate. The starter is of one special DC electrical motor, which has following features
during operation: with a large starting torque, a large staring current, and subject to an intermittent operation.
felt sealing-gasket
armature
excitation winding(excitation frame)
brush bracket
end cover
rear bearing
front bearing
brush spring bearing
solenoid switch
idler wheel
steel ball
release spring
starting pinion
starter shell
clutch assembly
ignition switch
fuse
terminal 30 terminal 50
battery
starter
Disassembly of starter
1. Dismantle thearmature assembly inside the excitation
frame.
(a)Remove nuts from the terminal of solenoid switch, and remove
the lead-wire as well.
(b)Two through-bolts need to be taken out.
(c)Take out the excitation frame together with the armature.
(d)Remove the felt sealing-gasket.
Using screwdriver, spring could be taken out from the brush holder, and
the brush holer could be removed, followed by a removal of four brushes
and brush holders.
Inspection on starter
Armature winding
1. Check whether the rectifier is in an opened loop.
Use an ohmmeter to check whether conduction exists on the
discofrectifier. The armature needs to be changed if the conduction
fails.
conduction
non-conduction
Starting system-Inspection on starter ST-5
Rectifier
1. Check whether the surface of rectifier has been
contaminated or damaged by burning.
If it does occur, sand paper (No.400) or lathe may be used for a repair or
correction purpose.
2. Check the circumferential radial runout of rectifier
Max. circumferential radial runout 0.05 mm
Lathe may be used for a repair or correction purpose if the radial runout
exceeds Max. value.
conduction
non-conduction
ST-6 Starting system-Inspection on starter
Brush
Check the length of brush
Standard length 13.5 mm
Min. length 8.50 mm
The brush frame, and the excitation frame must be changed if the length
is less than Min. Value.
Brush spring
Check the load of brush spring using a Pull up balance.
Standard spring load (17.56-23.64) N
Note Read the load produced at the moment when the spring isleaving
the brush while the brushs pring is being pulled up by a Pull-up balance;
If the read value is not within the specified scope, the brush spring shall
be changed.
Brush holder
Check the insulation of brush holder.
An ohmmeter may be used to check whether nonconduction exists
between positive brush and negative brush.
The brush holder must be repaired or changed if conduction works.
Bearing
1. Check bearing
Manually push each bearing inward, and have it rotating at the same
time.
The bearing may be changed if any resistance has beenmet, or the rotation
is not flexible.
Starting system-Assembly of starter ST-7
Solenoid switch
terminal 50 1. Perform a pull-in winding test in an open circuit
An ohmmeter may be used to check whether conduction exists between
terminal 50 and terminal C.The solenoid switch needs to be changed
if non-conduction exists.
terminal C
Assembly of starter
Note During the assembly of starter, bearings
and gears may be lubricated using high temperature
grease.
1. Installation of armature into the excitation frame
After the armature bearing is applied with greasete ar mature may be
inserted into the excitation frame.
ST-8 Starting system-Assembly of starter
(d)Using two screws, the starter shell and solenoid switch may be
assembled together.
Testing on starter
Note: to avoid any damage on winding due to burning,
terminal C the test must be completed within (3-5s).
1. Perform a pull-in test
(a)Remove the lead-wire of excitation winding from terminal C.
(b)Connect the battery onto solenoid switch as shown in the figure, and
check while small gear is moving outward.
The solenoid switch assembly needs to be changed if small gear does not
terminal 50 move.
terminal 30
CH-1
Charging device
Page
Disassembly of AC generator...................................................................CH-7
Inspection on AC generator......................................................................CH-9
Assembly of AC generator.....................................................................CH-12
CH-2 Structure drawing /electrical schematic diagram of generator
stator coil
excitation coil
I·C adjustor
stator coil
excitation coil
I·C adjustor
CH-4 Structure drawing /electrical schematic diagram of generator
stator coil
excitation coil
I·C adjustor
stator coil
excitation coil
Charge device-Inspection on vehicle CH-5
Inspection on vehicle
1. Check the specific gravity of accumulator
(a)Check the specific gravity for each accumulator unit. Standard
upper liquid specific gravity when charged with full power at 20 (1.25~1.27)g/cm2
(b)Check the electrolyte amount for each accumulator unit.
level
In case of an insufficient electrolyte amount, fill with distilled or pure
water.
Note
-The so called new belt r efer s to belt having wor k ed for less
than five minutes on the r otating engine.
-T he so called used belt r efer s to belt having wor ked for five
minutes or above on the r otating engine.
-F ollowing the installation of belt, check whether the belt is
correct incorrect matching with wheel gr oove appr opr iately.
-If the voltage value is greater than standard value IC adjustor needs to be
changed.
-If the voltage value is less than standard value AC generator needs to be
changed.
Disassembly of AC generator
1. Dismantle the assembly of driving end shell and rotor
from the stator.
(a)Remove three through-screws.
3. Removal of rotor
Use a press tool to press out the rotor.
lead-wire grip
Inspection on AC generator CH-9
5. Removal of IC adjustor
When the terminal of IC adjustor is gripped using nipper pliers,remove it by
welding.
conduction
non-conduction
Stator
1. Check whether the stator is in an open circuit.
Use an ohmmeter to check conduction between leading of the coil.
Note I nter sectant lines must be welded well.
T he stator needs to be changed if non-conduction exists.
conduction
non-conduction
Electrical-brush
1. Check the exposed length of electrical-brush.
Use a ruler to measure the exposed length of electrical brush.
Standard exposed length 12.5 mm
M in. exposed length 5.5 mm
T he electrical-brush needs to be changed if the exposed length is less than
Min. value.
Rectifier
1. Check the positive rectifier
rectifier terminal (a)Using ohmmeter, connect one end of the test head with the rectifier
terminal, and connect the other end with the positive terminal.
(b)Exchange the test joint, and repeat the above step.
ohmmeter (c)Check its conduction or non-conduction covered in above two steps.
(d)The rectifier support shall be changed when its conduction or non-conduction
does not conform to relevant stipulations.
Bearing
1. Check the front bearing
Check whether the bearing is smooth or has been abraded.
Assembly of AC generator
1. Install the rectifier support onto the stator.
Clamp the rectifier terminal using nipper pliers, and weld the wiring terminal.
Note: the heat shall be prevented from transmission to
rectifier.
2. Installation of IC adjustor
Clamp the rectifier terminal using nipper pliers, and weld the wiring terminal.
Note: the heat shall be prevented from transmission to
rectifier.
soft cushion
Assembly of AC generator CH-13
(d)Put two terminal insulators onto the positive stud bolt of the rectifier
frame.
(e)Install the capacitor and the lead-wire grip.
(f)Install four nuts.
(g)Confirm that electrical wire has not been overlapped with the rectifier
shell.
lead-wire grip
4. Installation of rotor
(a)Insert spacer ring into the rotor shaft.
(c)Insert the fan, belt pulley, and spring washer successively into the rotor
shaft.
(d)Install and tighten the nut.
Tightening moment 62.5N m
CH-14 Assembly of AC generator
(b)Bending tools may be used to push the electrical-brush to the end, then
one hard steel wire shall go through the manhole of rectifier end shell, and the
electrical-brush will be put to place.
(c) Following the insertion of the rear bearing for rotorshaft into the rectifier
end shell, the rectifier shell for driving end shell may be assembled.
Clutch
CL-2 Clutch-Dismantle of clutch components, and inspection on clutch components