ZD30国五发动机电控故障诊断手册 EDC17C63 V6+SCR（第一版）-译文

Diagnostic Guidebook
EDC17C63+SCR
High pressure common rail fuel injection system of ZD30

engine
EDC17C63_V6
© Dongfeng Light Engine Co., Ltd. 2017 -1-
Diagnostic Guidebook EDC17C63+SCR
Copyright statement and disclaimer

Without the written permission of our company, all organizations and individuals are prohibited to use,
duplicate, modify, translate, or propagate any part of this document by any means or reason.
This manual can’t substitute the related Warranty Agreement for the defect and malfunction authentication of
replaced parts or the judgment of corresponding liabilities.
All data and diagrams contained in this manual are for reference only and can’t be used for the design,
installation, or description of products. This manual takes all necessary efforts to guarantee the accuracy of the
information provided, but will not be liable for any consequence arising from the use of the text information.
Dongfeng Light Engine Co., Ltd. reserves the right to change the text contents at any time.
Prepared by:
Copyright © Dongfeng Light Engine Co., Ltd.
No. 58, Xinjiang Road, Shiyan, Hubei, China
Postal code: 442003
First Edition in October, 2017

1 Contents
1 Contents ....................................................................................................................................................... 3
2 Precautions .................................................................................................................................................. 9
2.1 Document overview ..................................................................................................................... 9
2.2 Safety precautions ....................................................................................................................... 9
2.2.1 General safety precautions..................................................................................................... 9
2.2.2 Checking and repair of high pressure fuel system ................................................................. 9
2.2.3 Elevating of vehicle ............................................................................................................. 10
2.2.4 Parking of vehicle ................................................................................................................ 10
2.2.5 Service trench ...................................................................................................................... 10
2.2.6 Treatment of exhaust gas ..................................................................................................... 11
2.2.7 Rotating parts....................................................................................................................... 11
2.2.8 High temperature parts ........................................................................................................ 11
2.2.9 Inflammables and explosives (Such as diesel, gasoline, and detergent).............................. 11
2.2.10 Cleanliness requirement for checking and repair of high pressure common rail fuel
injection system ................................................................................................................... 12
2.3 Use of inspection equipment ..................................................................................................... 13
2.3.1 Basic preconditions for diagnosis ........................................................................................ 13
3 How to Use This Manual........................................................................................................................... 15
3.1 Malfunction checking and repair guidance................................................................................ 15
3.2 Precautions for malfunction diagnosis....................................................................................... 17
3.2.1 Preliminary judgment .......................................................................................................... 17
3.2.2 Read trouble codes............................................................................................................... 17
3.2.3 Diagnose by steps. ............................................................................................................... 17
4 System and Part Overview ........................................................................................................................ 18
4.1 Common rail fuel injection system ............................................................................................ 18
4.1.1 High pressure fuel pump (CP1H) ........................................................................................ 18
4.1.2 Common rail fuel injector (CRI2.1) .................................................................................... 20
4.1.3 High pressure fuel rail ......................................................................................................... 21

4.1.4 Rail pressure sensor (RPS) .................................................................................................. 21
4.1.5 Fuel filter ............................................................................................................................. 21
4.1.6 Fuel tank .............................................................................................................................. 22
4.1.7 Manual fuel pump................................................................................................................ 23
4.1.8 Electronic control unit (ECU) .............................................................................................. 23
4.1.9 Turbocharged pressure and temperature sensor................................................................... 24
4.1.10 Crankshaft signal sensor ...................................................................................................... 24
4.1.11 Camshaft sensor................................................................................................................... 24
4.1.12 Coolant temperature sensor ................................................................................................. 25
4.1.13 DOC differential pressure sensor......................................................................................... 25
4.1.14 Glow plug (GLP) ................................................................................................................. 25
4.1.15 Throttle ................................................................................................................................ 26
4.2 FAI-SCRL1.0 non-air assisted dosing system ........................................................................... 26
4.2.1 Supply module ..................................................................................................................... 28
4.2.2 Dosing nozzle ...................................................................................................................... 30
4.2.3 Dosing control unit (DCU) .................................................................................................. 32
4.2.4 AdBlue tank assembly ......................................................................................................... 33
4.2.5 AdBlue delivery pipe ........................................................................................................... 33
4.2.6 Water cutoff solenoid valve ................................................................................................. 34
4.2.7 NOx sensor .......................................................................................................................... 35
4.2.8 Exhaust gas temperature sensor ........................................................................................... 36
5 Checking and Repair Tools ....................................................................................................................... 38
5.1 Low pressure test suite .............................................................................................................. 38
5.2 Fuel injector fuel return volume test suite ................................................................................. 38
5.3 Transparent hose........................................................................................................................ 39
5.4 Protective cap ............................................................................................................................ 39
5.5 Measuring glass ......................................................................................................................... 39
5.6 Oscilloscope and parts ............................................................................................................... 40
5.7 Cylinder pressure test suite with adapter ................................................................................... 40
5.8 Manual pump ............................................................................................................................. 40

5.9 Multimeter ................................................................................................................................. 41
5.10 Jumper case ............................................................................................................................... 41
5.11 Connector adapter (Type Y cable)............................................................................................. 42
5.12 Basic repair tools of after-treatment system .............................................................................. 42
6 Example of Actual Signal Value ............................................................................................................... 43
7 Malfunction Checking and Repair Guidance ............................................................................................ 46
7.1 Malfunction symptoms .............................................................................................................. 46
7.1.1 Staxrt failure of engine ........................................................................................................ 47
7.1.2 Flameout of Engine during Running ................................................................................... 49
7.1.3 Difficult start of engine........................................................................................................ 51
7.1.4 No response of accelerator pedal during running of engine ................................................ 51
7.1.5 Engine noise. ....................................................................................................................... 53
7.1.6 Idling jitter of engine ........................................................................................................... 54
7.1.7 Low engine power ............................................................................................................... 55
7.1.8 Constant turn-on of system indicator lamp/malfunction indicator lamp ............................. 57
7.1.9 Increased engine idling speed .............................................................................................. 58
7.1.10 Smoke of engine .................................................................................................................. 59
7.1.11 Engine overheating .............................................................................................................. 60
7.1.12 Constant turn-on of preheating indicator lamp .................................................................... 61
7.1.13 Over-high fuel consumption ................................................................................................ 62
7.1.14 Diluted engine oil ................................................................................................................ 63
7.1.15 Over-high AdBlue consumption .......................................................................................... 64
7.1.16 Presence of AdBlue smell or white crystal powder ............................................................. 65
7.2 Table of Trouble Codes ............................................................................................................. 66
7.2.1 Table of trouble codes for EDC17C63 V6 version of ZD30 China-V engine ..................... 66
7.2.2 Table of trouble codes for after-treatment FAI-SCR dosing system ................................... 74
7.3 Trouble codes of parts ............................................................................................................... 80
7.3.1 Electric checking ................................................................................................................. 80
7.3.2 Trouble code - Main relay ................................................................................................... 93
7.3.3 Trouble code - Battery ......................................................................................................... 96

7.3.4 Trouble code - Clutch switch............................................................................................... 98
7.3.5 Trouble code - Brake switch .............................................................................................. 104
7.3.6 Trouble code - Fuel metering unit ..................................................................................... 110
7.3.7 Trouble code - Preheater relay ........................................................................................... 115
7.3.8 Trouble code - Throttle ...................................................................................................... 120
7.3.9 Trouble code - Fuel injectors ............................................................................................. 125
7.3.10 Trouble code - Accelerator pedal sensor ........................................................................... 131
7.3.11 Trouble code - Crankshaft sensor ...................................................................................... 137
7.3.12 Trouble code - Rail pressure sensor................................................................................... 142
7.3.13 Trouble code - Camshaft sensor ........................................................................................ 147
7.3.14 Trouble code - Crankshaft and camshaft senor reasonableness......................................... 153
7.3.15 Trouble code - DOC differential pressure sensor .............................................................. 157
7.3.16 Trouble code - Coolant temperature sensor ....................................................................... 162
7.3.17 Trouble code - Turbocharged pressure and temperature sensor ........................................ 167
7.3.18 Trouble code - Cruise control switch................................................................................. 173
7.3.19 Trouble code - CAN bus communication module ............................................................. 177
7.3.20 Trouble code - Electronic control unit (ECU) ................................................................... 181
7.3.21 Trouble code - ECU internal temperature sensor .............................................................. 187
7.3.22 Trouble code - Barometric pressure sensor ....................................................................... 190
7.3.23 Trouble code - Sensor power supply module .................................................................... 192
7.3.24 Trouble code - Sensor power supply module 2 ................................................................. 195
7.3.25 Trouble code - Sensor power supply module 3 ................................................................. 197
7.3.26 AdBlue level and temperature sensor malfunction ............................................................ 200
7.3.27 AdBlue supply pump malfunction ..................................................................................... 200
7.3.28 AdBlue nozzle malfunction ............................................................................................... 201
7.3.29 Malfunction of NOx sensor ............................................................................................... 202
7.3.30 Malfunction of exhaust gas temperature sensor ................................................................ 203
7.3.31 Emission over-limit malfunction ....................................................................................... 204
7.4 Checking of fuel system .......................................................................................................... 205
7.4.1 Low pressure system ......................................................................................................... 205

7.5 Checking of intake system ....................................................................................................... 214
7.5.1 Intake pipeline ................................................................................................................... 214
7.5.2 Turbocharger ..................................................................................................................... 215
7.6 After-treatment system ............................................................................................................ 217
7.6.1 Maintenances of AdBlue tank ........................................................................................... 217
7.6.2 Maintenances of nozzle ..................................................................................................... 218
7.6.3 Maintenances of exhaust gas temperature sensor and NOx sensor ................................... 218
7.6.4 Daily maintenance ............................................................................................................. 218
7.6.5 Checking of sensor ............................................................................................................ 218
7.7 Test of other parts .................................................................................................................... 220
7.7.1 Engine mechanical part ..................................................................................................... 220
7.7.2 Starter motor ...................................................................................................................... 222
7.7.3 Accelerator pedal ............................................................................................................... 225
7.7.4 Cooling system .................................................................................................................. 226
7.7.5 Preheating System ............................................................................................................. 228
8 Disassembling and Installation Instructions of High Pressure Parts ....................................................... 230
8.1 Safety precautions ................................................................................................................... 230
8.2 Disassembling and installation of fuel injectors ...................................................................... 230
8.2.1 Precautions ........................................................................................................................ 230
8.2.2 Electric precautions ........................................................................................................... 230
8.2.3 Hydraulic precautions ........................................................................................................ 230
8.2.4 Installation of fuel injectors ............................................................................................... 231
8.2.5 Disassembling of fuel injectors ......................................................................................... 232
8.3 Disassembling and installation of fuel rail .............................................................................. 232
8.3.1 Precautions ........................................................................................................................ 232
8.3.2 Installation of fuel rail ....................................................................................................... 233
8.3.3 Disassembling of fuel rail .................................................................................................. 233
8.4 Disassembling and installation of CP1H fuel pump ................................................................ 233
8.4.1 Precautions ........................................................................................................................ 233
8.4.2 Installation of CP1H fuel pump ......................................................................................... 233

8.4.3 Disassembling of CP1H fuel pump ................................................................................... 234
9 Daily Checking (Driver’s notice) ............................................................................................................ 235
10 Acronym............................................................................................................................................ 236
11 Data Stream ....................................................................................................................................... 238
12 Version Update Record ..................................................................................................................... 240

2 Precautions
2.1 Document overview

This document includes the malfunction diagnostic instructions for the fuel injection system parts of ZD30
China-V engine. In some cases, the description of the parts other than fuel injection system are also included.
For all descriptions of fuel injection system parts contained in this manual, the test methods and valve scopes
are already verified. The descriptions for the parts other than fuel injection system (Such as relays and
turbocharger) are for reference only.
The diagrams in this manual are only used for the descriptions of the parts and their basic checking and repair
methods. Please be noted that the parts used are probably different for specific model of engine.
During checking and repair, ensure to avoid damaging the ECU pins and part connectors. Ensure to use
appropriate adapters and tools for the checking and repairs of electric, oil, and air circuits.
2.2 Safety precautions

During the checking and repairs of vehicle and parts, please ensure to fully understand and strictly abide by all
safety rules and warnings. Otherwise, it will probably result in personal harms, property losses, and
environmental pollutions.
2.2.1 General safety precautions
In consideration of the safety, only the professionals qualifying the trailing are allowed for the repairs and
maintenances of vehicles and parts at a service shop with corresponding equipment and qualification.
During operations, ensure to abide by the relevant labor protection and environmental protection laws and
regulations, accident prevention rules, technical specifications and standards, and manufacturer’s instructions
currently in force.
2.2.2 Checking and repair of high pressure fuel system
During the operation of high pressure fuel system and its related parts, ensure to abide by the disassembling
and installation specifications provided by the manufacturer. All national laws, regulations, specifications, and
standards must be strictly followed, though they are probably not included in this manual. Only the well-
training professionals with corresponding qualification are allowed for the checking and repairs of high
pressure fuel system. The huge pressure of overflown high pressure fuel can probably cause serious harms to
your skin and eyes.
The leaking high pressure fuel will probably be ignited upon exposure to high temperature engine parts or
exhaust system to result in the danger of fire accident.
Details:
● Ensure to wear necessary personal protection appliances, such as goggles and protective clothing, during
all operations.
● Please ensure to take corresponding protection measures during any specific operation.
● All personal protection appliances, special protection appliances, and safety measures must meet the
corresponding requirements and objectives and, which is more important, must be used strictly as per the
regulations.
● Ensure to take effective and sufficient fire prevention measures throughout the whole process of

checking and repair. Ensure to abide by this rule for other neighboring working areas.
● All personnel within or near the dangerous areas must also take personal protection measures.
● It’s absolutely prohibited to disassemble or assemble the fuel injection system while the engine is
running.
● Ensure that the residual fuel pressure is completely relieved before checking or
disassembling/assembling any high pressure fuel part.
● Check and repair the high pressure fuel system only under the cold state of the engine. Check and repair
the high pressure fuel system only under the cold state of the engine.
● The fuel delivery pipeline and its parts shall be free of any damage. Any malfunctioned or damaged part
must be replaced with new one and can’t be further used.
● All checking and adjustment works shall be fulfilled with the ignition key withdrawn if possible. If
impossible, it’s prohibited to touch any electrified part.
● Any person with heart pacemaker is prohibited to access the dangerous area of high voltage system or
high voltage control part, such as solenoid valve.
● Only use the original electric connectors supplied by the manufacturer.
● While disassembling or assembling the harnesses, all wire connectors must be of the same characteristics
with the original connectors, such as the same wire length, wire diameter, and shield.
2.2.3 Elevating of vehicle
During checking and repair, only elevate and support the vehicle by appropriate qualified elevating devices.
These elevating devices (Such as elevators and jacks) and support devices (Such as cushion blocks) and their
safety devices must be suitable for the corresponding vehicle load and their safe and reliable status must be
guaranteed. Meanwhile, these devices must be provided with corresponding safety and approval markings.
Ensure to abide by the operation instructions and accident prevention regulations of the elevating devices
while elevating the vehicle. All elevating operations must be fulfilled by the designated well-trained personnel.
All load-carrying parts (Such as the support arms of elevator) can be only supported at the specific support
points of the vehicle. The locations of such support points can be found in the owner’s manual and repair data
of the vehicle manufacturer. Before elevating the vehicle, ensure to check and ensure that the elevating
devices are free of malfunctions and defects. Ensure to secure the safety devices of elevating equipment after
the vehicle is elevated in place.
2.2.4 Parking of vehicle
If the elevating is not required, ensure to park the vehicle on an even and suitable site. Apply the parking
brake to prevent gliding of vehicle. In addition, if the vehicle is equipped with automatic transmission, ensure
to shift to gear P. If the above-mentioned measures can’t be taken, ensure to place the wheel wedges to at least
two wheels. In addition, ensure to take appropriate measure to prevent the accidental start of the engine.
2.2.5 Service trench
The service trench, unground elevating device, and other similar device must meet the corresponding
standards and requirements and must pass the acceptance before use. While using these equipment, ensure to
abide by the operation instructions and accident prevention regulations of the elevating devices.
Details:
● The selection and use of service trench and other devices must be applicable for the size of vehicle and
© Dongfeng Light Engine Co., Ltd. 2017 - 10 -

the objective of service and ensure safety.
● The service trench and other devices must be provided with corresponding safety and approval markings.
● All related service trenches and other devices must be operated by designated trained personnel.
● Access the service trench only by specified anti-slip ladder and exit.
● When the service trench is not in use, the corresponding measure must be taken to prevent the falloff of
other personnel into the trench.
● To use the elevating device within the service trench, please to section “Elevating of vehicle” for the
precautions.
● Due to higher density than air, some gases probably accumulate on the bottom of the service trench to
probably cause intoxication and fire accident. Therefore, ensure to pay attention to related descriptions
and take necessary measures.
2.2.6 Treatment of exhaust gas
The exhaust gas from engine or other equipment contains toxic substances that probably seriously harm the
personal health or even result in death. The exhaust gas from engine or other equipment contains toxic
substances that probably seriously harm the personal health or even result in death. In addition, the exhaust
gas discharge device must be turned on before the generation of exhaust gas.
2.2.7 Rotating parts
Ensure to guard yourself against being entangled or injured by rotating parts during the checking, repair, and
assembling of the vehicle, especially the engine. For instance, the electric radiator fan can run automatically in
some cases, even after the engine is stopped. Therefore, ensure to take appropriate effective measures to
prevent engine and other parts from harming yourself or other personnel during repairs.
2.2.8 High temperature parts
Ensure to guard yourself against the scalding by high temperature parts during the repairs of vehicle,
especially during the checking, repair, and assembling of engine exhaust system and brake system brake
wheels.
2.2.9 Inflammables and explosives (Such as diesel, gasoline, and detergent)
During repairs, some inflammables and explosives will probably flow out from the vehicle and its parts to
result in the risks of fire and explosion.
Therefore, to avoid the occurrence of serious accidents such as fire and explosion, please observe and abide
by following precautions:
● Before disassembling any pipeline or part full of inflammable, ensure to relieve the internal pressure by
appropriate reliable measure.
● All outflowing inflammables and explosives must be stored by appropriate containers. Then handle as
per the relevant specifications and requirements.
● All immersed rags and adhesives must be removed immediately from the working site, stored
temporarily in appropriate containers, and then handled as per corresponding specifications and
requirements.
● Before the start of any repair operation, ensure to take appropriate measures to eliminate the generation
of sparks. For instance, disconnect the battery negative wire or use insulated tools.

Do not perform any operation that will generate high temperature, such as welding, cutting, and grinding, in a
working site with inflammables or explosives.
● If there is any possible generation of fire source near the workshop, ensure to take reliable and
appropriate measures for isolation. Ensure to take effective and appropriate ventilation measures to
eliminate fires and explosions. In addition, ensure to take the measures against electrostatic and chemical
corrosion in some cases.
● Ensure to take sufficient and effective fire prevention measures throughout the whole process throughout
the checking and repair.
● All inflammables and explosives must be stored in appropriate containers. Ensure to abide by related
laws and regulations during storage.
2.2.10 Cleanliness requirement for checking and repair of high pressure common rail fuel
injection system
The fuel injection system on a modern diesel engine is composed of high-precision parts capable of carrying
extreme loads.
The fuel injection system on a modern diesel engine is composed of high-precision parts capable of carrying
extreme loads. Even the dirt in diameter of 0.2mm can probably cause failure of some parts and damage the
engine.
Ensure to abide by the following regulations before the repair of fuel system:
● The entire fuel system must be sealed.
● Visually observe the fuel system for presence of fuel leakage and damage.
● Before operating the fuel system, the engine and the engine compartment must be dry and clean.
Otherwise, ensure to clean the engine or engine compartment.
● Cover the electric parts and connectors before cleaning the engine and engine compartment by high
pressure water gun.
● It’s prohibited to spray directly towards electric parts by high pressure water gun.
● Before drying the fuel system by compressed air, ensure the airtightness of the fuel system.
● Ensure to cover the engine by clean covering film during checking and repair, in order to prevent the
foreign materials on some locations from falling onto the engine.
● Keep the inside of workshop clean and dust-free whenever possible before repairs. Take cautions to
prevent raised dusts during following operations.
 Grinding and welding
 Repair of brakes
 Start of engine
 Use of ventilation and heating equipment
 Use of dynamometer
● Ensure to wear clean working cloth for operations of fuel system.

● Wipe and clean the fuel system only by special non-woven fabrics.
● Ensure to clean the tools and equipment to be used before starting operations.
● Do not use any damaged tool (Such as cracking of chrome plating).
● The disassemble parts shall be repaired only in a special working site.
Ensure to abide by the following regulations during the repair of fuel system:
● It’s prohibited to use any used cleaning oil or testing oil.
● Do not blow directly by a blower gun. Use an appropriate suction device (Such as an industrial vacuum
cleaner) to remove the foreign materials such as paint chippings and insulation materials.
● During the disassembling and assembling of parts, it’s absolutely prohibited to use common rag, paper
board, or wood, as such materials probably have fallen particles and fibers.
● At completion of disassembling, immediately seal the openings of parts by clean and appropriate sealing
caps.
● Prepare sufficient sealing caps in diversified types and place them by category before disassembling.
● Any sealing cap used must be placed back to original package after use, in order to guard against dusts
and rusting.
● All disassembled parts must be preserved in a clean and enclosed container.
● New parts shall be unpacked only immediate before the use. Ensure to pack the replaced old parts with
the packaging materials of new parts.
2.3 Use of inspection equipment

While using inspection equipment, ensure to follow the operation instructions and safety regulations of the
equipment manufacturer.
The general principle is as below:
● The use of inspection equipment must be consistent with the specific inspection objective.
● Ensure that all inspection equipment and their safety devices are safe and reliable.
● All equipment must be provided with relevant safety and certification markings.
● All inspection equipment must be operated by the designated well-trained personnel.
2.3.1 Basic preconditions for diagnosis
● The battery is well charged.
● All connectors are connected securely, without any incorrect connection. This is especially important for
an accident vehicle or refitted vehicle.
● The engine, vehicle body, and electronic control unit (ECU) are under good grounding status.
● All other systems influencing the engine control are normal. For instance:
 A/C system

 Transmission
 Immobilizer
● The engine mechanical part is normal. For instance:
 Valve timing and valve clearance
 Compression ratio and cylinder airtightness
 No leakage in exhaust system
 Intake system airtightness
 Ventilation of Crankcase
● The level and quality of diesel, engine, and coolant are normal and meet the manufacturer’s specification.
● The parts used for historic repairs and maintenances of vehicle are good in quality and correct in
specification.
● No measure for change of power is taken for the engine (especially the change of chip data and the
adjustment of valve timing).

3 How to Use This Manual
3.1 Malfunction checking and repair guidance

The most part of this manual is the guided troubleshooting (GTS). The guided troubleshooting can instruct the
repair technicians to check step by step and finally find out the cause of malfunction. As this manual adopts
the guided troubleshooting based on the malfunction symptoms, the malfunction symptoms are the leading
information and the trouble codes are helpful for the quick and accurate diagnosis. The guided troubleshooting
can provide different checking methods for the repair technicians based on different trouble codes or when
there is no trouble code.
The guided troubleshooting in Chapter 7 is divided into 7 parts:
● Malfunction symptom: Including the detailed malfunction symptoms and corresponding checking and
repair methods.
● Classification of trouble code: All trouble codes are divided into two categories for quick and accurate
diagnosis.
● Trouble codes of parts: Including all trouble codes related to specific part.
● Fuel system: Including the detailed method and procedure for the test of fuel system.
● Air system: Including the detailed checking and repair method of air system.
● After-treatment system: Including the detailed checking and repair method of after-treatment system.
● Test of other parts: Including the detailed methods and procedures for checking of other parts.
The "Figure 1 Operation Description of Guided Troubleshooting” below can help you better understand and
use the section “7.1 Malfunction symptom” below.

Start of troubleshooting: Inquire the driver for

malfunction symptoms.
Start failure of engine
Read trouble codes: Read out the trouble
codes by a diagnostic unit.
Checking of battery Checking of battery
Does the starter work? N (see sec tion 7.3.3) (see section 7.7.2)
Classification of trouble codes:
The trouble codes are classified into two
N categories, namely part
Read tr ouble c odes related malfunctions and after-treatment related malfunctions.

Has the fault been Has the fault been
N
solved? solved?
Y Y Other possible malfunction

Is there any component cause:
fault code?
N
- Starter relay is damaged.
- Fuse is blown out.
Check ing end
- Immobilizer system
malfunction
Refer to ins pection method of

concrete parts (see the
Read data stream
section 7.3).
Checking end
Readout of data stream:

Judge for normal engine signal based on the
Rail pressure buildup
N
actual signal values
Is engine s peed too low? N
of Chapter
Is synchronous 6.
signal
N A
failure ？ lost?
Checking end
Y Y Y
Check the low-voltage

Check the battery. (see Check the crankshaft sensor
system(see s ection 7.4.1.1 to
Part checking and repair method: Refer to section 7.4.1.2)
section 7.3.3) (see sec tion 7.3.11)
section 7.3 for detailed part checking and

repair method.
Has the fault been
solv ed?
Diagnostic test:
Has the fault been
solved?
Has the fault been
solved?
N
PerformN
checking and repair Nas per the
Check injector r eturn oil (see
methods provided by section
Check the starter (see section
7.4~7.7 Test of
Check the camshaft sens or
Parts.
section 7.4.1.4) 7.7.2) (see s ection 7.3.13)

solved? solv ed?
Check ing end

N N
Low-voltage system Check the relative position

performance test (see section between the crank shaft and
7.4.1.3 ) camshaft. (see section 7.3.14)
Has the fault been

solved?
Checking end
Other possible malfunction Judgment:

cause:
- Oil pipe is clo gged or leaks.
- High-pressure fuel pump Judge whether the malfunction cause is found and
overflowing valve i s stuck/opened
Y
constantly.
- Fuel metering unit malfunction
- Abnormal ECU power supply
the malfunction is solved.
If yes, the malfunction is solved and the procedure is
- Wrong data is written or damaged.
complete.
Checking end
If not, continue the diagnosis as per the procedure.
Checking procedure or possible malfunction cause:

Simply describe the checking method and possible
malfunction cause.
Figure 1: Operation Description of Guided Troubleshooting

3.2 Precautions for malfunction diagnosis
3.2.1 Preliminary judgment
Firstly inquire the driver of the malfunction symptom1 and the condition where this malfunction symptom
occurs. Then, verify the malfunction symptom and read out trouble code. It’s prohibited to replace any part
before performing corresponding checking procedure.
3.2.2 Read trouble codes.
The trouble code can be read out by a diagnostic unit.
The trouble codes used in this manual are either the trouble codes conforming to the laws and regulations or
the self-defined trouble codes. A distinctive difference between an electronic control system and a mechanical
system is that the electronic control system can store the vehicle malfunction into the ECU in form of trouble
code.
If more than one trouble code is read out simultaneously and it’s not sure whether these trouble codes are
related to the malfunction symptom, operate as per the following procedure:
Read trouble codes Record trouble code Clear trouble code Read trouble codes Record
trouble code.
3.2.3 Diagnose by steps.
Check one by one and carefully analyze every malfunction characteristic. Do not disassemble/assemble or
replace any part before the malfunction cause is determined.
Notice:
Most trouble codes can only indicate that one subsystem or part is malfunctioned and can’t determine the
specific cause of the malfunction.
For instance, P0087 - Actual rail pressure below minimum rail pressure (MeUn scheme).
Such trouble code is really important for the troubleshooting.
If no trouble code is read and the communication failure is displayed on the diagnostic unit, please check the
following items:
 Check diagnostic unit for normal functioning (Including the software update).
 Check for normal communication between diagnostic unit and ECU.
 Check ECU for normal functioning (Including the power supply and damage of ECU).
Notice:
It’s prohibited to plug or unplug the ECU under live status during the checking and repair.
As the checking and repair based on the trouble code is not all contents for guided troubleshooting, if the
malfunction symptom is still not solved after the checking of part related trouble code, please check further as
per the checking procedure of “No malfunction”.
1 Ensure to carefully analyze and think about the malfunction symptom described by the driver.

4 System and Part Overview
4.1 Common rail fuel injection system

The common rail fuel injection system is a fuel direct injection system applied in internal combustion engines.
In a common rail fuel injection system, the system pressure buildup function is separated from the fuel
injection function so that the pressure buildup is free of the influence of engine speed and fuel injection
volume. The electronic diesel control system (EDC) controls every component of the common rail system.
Rail pressure sensor

CP1H high pressure
fuel pump
Common rail
Filter
Sensor Actuator
Fuel injectors
Electronic
Fuel tank control High pressure
unit Low pressure
EDC17C6
Figure 2: Fuel supply system of 2nd generation common rail system
4.1.1 High pressure fuel pump (CP1H)
CP1H high pressure fuel pump is functioned to supply and control the fuel volume and is a radial plunger
pump, in which three plungers are arranged radially.
Figure 3: CP1H high pressure fuel pump

On CP1H high pressure fuel pump, there is one gear pump directly driven by the fuel pump shaft. Under the
suction action of the gear pump, the fuel in the fuel tank is supplied from fuel tank into the fuel filter and then
into the gear pump via fuel inlet port of pump body and into the fuel metering unit of the high pressure fuel
pump. Based on the actual fuel demand, the metering unit controls the fuel volume supplied into the high
pressure circuit.
High pressure fuel outlet

Fuel metering unit Oil return port
Oil inlet port

Breather
Overflowing valve
Figure 4: External interfaces of CP1H high pressure fuel pump
Some technical parameters:
 Three radial plungers, integrated with gear pump (ZP26) and fuel metering unit (MeUn).
 Diesel-lubricated
 Pump rated speed (High idling speed): 3000rpm
 Max. allowable pressure: 1600bar
 Fuel metering unit (MeUn) coil resistance: 2.6~3.15Ω (20°C)
4.1.1.1 Fuel metering unit (MeUn)
The fuel metering unit (MeUn) is a proportional solenoid valve controlled by electronic control unit (ECU)
and can control the fuel volume supplied into the high pressure fuel pump to thus control the fuel pressure in
the common rail.
Figure 5: Fuel metering unit (MeUn)
4.1.1.2 Gear pump
The gear pump is functioned to supply sufficient fuel for the high pressure fuel pump. The gear pump is
directly installed with the high pressure fuel pump. The gear pump is composed of two engaged gears so that
the fuel is conveyed from the suction end to compression end by the space between gears. The linear contact
area between gears isolates the suction end from the compression end to prevent backflow of fuel.

Figure 6 and Figure 7: Gear pump
To bleed the air from fuel system during the first start or when there is no fuel in the fuel tank, a manual fuel
pump can be directly installed on the vane pump or low pressure fuel pipeline.
4.1.2 Common rail fuel injector (CRI2.1)
The common rail fuel injectors are functioned to inject a very few amount of high pressure fuel into the
combustion chamber accurately. The fuel injectors are installed on cylinder head by conical lock means and
the combustion chambers are sealed by copper washers.
Figure 8: Common rail fuel injector
The fuel injection volume of the common rail fuel injectors are controlled by electronically triggered fuel
injectors. The fuel injection start timing is controlled by the timing system of electronic diesel control (EDC)
system.
 Coil resistance: 215~295mΩ (20°C-70°C)
 Booster voltage: 48V
 Booster current: 17.5~18.5A (Setting: 18A)
 Holding current: 11.5A~12.A (Setting: 12A)
 Max. electrifying duration: 4000µs
 Maximum working rail pressure: 1600bar

4.1.3 High pressure fuel rail
The high pressure fuel rail is functioned to build up the pressure and supply high pressure fuel to the fuel
injectors. Therefore, the high pressure fuel rail must be capable of eliminating the pressure fluctuation arising
from the fuel supply of high pressure fuel pump and the injection of fuel. Only this can guarantee the constant
pressure of fuel in the fuel rail when the fuel injectors are opened. On one hand, the fuel rail capacity must be
large enough to meet the pressure maintaining requirement of the fuel rail. On the other hand, the fuel rail
capacity must be small enough so that the fuel pressure can rapidly rise to a high enough level during the start
of engine.
Figure 9: High pressure fuel rail
4.1.4 Rail pressure sensor (RPS)
The rail pressure sensor is functioned to measure the actual pressure in the high pressure fuel rail of the high
pressure common rail system. The rail pressure sensor converts the pressure signal to a voltage signal and
sends the signal to electronic control unit (ECU) to realize the closed-loop control of the fuel pressure.
Figure 10: Rail pressure sensor
 Maximum working rail pressure: 1800bar
 Signal voltage output: 0.5V~4.5V
4.1.5 Fuel filter
The direct injection system for modern diesel engines is really sensitive to the tiny impurities contained in the
fuel. The particle corrosion and the water erosion are the main causes for the damages of components. The
design life of fuel injections system is determined based on the highest purity of fuel.

Figure 11: Fuel filter
Function of fuel filter:
● Filtration of particulates
One basic function of the filter is the reduction of particulate impurities. This can protect the fuel injection
system components easily vulnerable to wear. In other work, the fuel injection system specifies the necessary
filtration accuracy. Besides the prevention of wear, the filter also requires a sufficient particulate storage
capacity, otherwise the filter will probably be blocked prior to the replacement. The blockage will reduce the
fuel delivery volume and at the same time deteriorate the engine performance.
● Fuel-water separation
The second main function of the diesel filter is to separate the water from the diesel, in order to guard engine
against corrosion and damage.
4.1.5.1 Water-in-fuel sensor
The water-in-fuel sensor is functioned to check and indicate that the filter has contained a large amount of
water, of which the signal is supplied to the electronic control unit (ECU) or water-in-fuel indicator lamp.
 Rated voltage: 13.5V
 Working voltage: 8~16V
 Working environment temperature: -40~120℃
 Rated current: <200mA
4.1.6 Fuel tank
Just as its name implies, the fuel tank is functioned to store fuel. The fuel tank must be corrosion-proof and
leakage-proof under certain pressure and must be installed with an effective ventilation port or safety valve to
prevent over-pressure. During the driving of the vehicle on a bend or in event of inclination or impact of the
vehicle, the fuel shall not leak out from the filler port or pressure compensation device. The fuel must be far
away from the engine, in order to prevent the ignition of fuel in event of an accident.

Figure 12: Fuel tank
4.1.7 Manual fuel pump
During replacement of fuel filter or depletion of fuel in the fuel tank, the manual fuel pump can be used to
empty the fuel from fuel system or add fuel into the fuel tank.
4.1.8 Electronic control unit (ECU)
The electronic control unit of diesel engine can accurately adjust the fuel injection parameters under
diversified working conditions. This is the sole cause that the modern diesel engine can be applied in
diversified applications.
Figure 13: Electronic control unit (EDC17C63)
The electronic control unit (ECU) can be divided into 3 modules:
● The sensors are functioned to convert the physical signals to electric signals so that the electronic control
unit can understand the currenting working conditions (Such as engine speed) and settings (Such as
switch position) of the engine.
● The electronic control unit processes the signals acquired from the sensors based on the specific open-
loop or closed-loop control algorithm and outputs electric control signals to actuators. In addition, the
ECU is also the communication interface between other vehicle systems and onboard diagnostic system.
● The actuators are functioned to convert electric signals to mechanical actions (Such as the turn-on of
solenoid valve in fuel injection system).
The electronic control unit (ECU) monitors all sensors and actuators for normal functioning. In addition, it can
check the loose connection, short-circuit, and open-circuit of connectors and the reasonableness with signals.
In event of any malfunction, the electronic control unit (ECU) will store the corresponding trouble code of the
malfunction and activate the safe mode.
The EDC17C63 series electronic control unit (ECU) contains one 94-pin harness connector.

Working environment temperature: -40~105℃
Working voltage: 12V
Number of connector pins: 94-pin
4.1.8.1 Barometric pressure sensor
The barometric pressure sensor is integrated in the electronic control unit (ECU). Its signal is used for some
closed-loop control systems (Such as turbocharged pressure control) to correct setting based on altitude, in
order to enable the system to adjust the working based on different altitudes. The barometric pressure sensor
measures the absolute pressure.
4.1.9 Turbocharged pressure and temperature sensor
Figure 14: Turbocharged pressure sensor
The turbocharged pressure and temperature sensor is functioned to measure the absolute pressure and intake
temperature within the intake manifold. The engine intake volume depends on the intake pressure and engine
speed.
4.1.10 Crankshaft signal sensor
Figure 15: Crankshaft sensor (Engine speed sensor)
The crankshaft sensor is functioned to calculate the engine speed and crankshaft position. This sensor can also
be used for other speed detection systems (Such as gear position and engine speed sensor).
4.1.11 Camshaft sensor
The camshaft sensor is functioned to check the position of camshaft. It works with crankshaft sensor for
judgment of cylinders and determination of fuel injection timing.

Figure 16: Camshaft sensor (Phase sensor)
4.1.12 Coolant temperature sensor
The coolant temperature sensor is installed on the coolant recirculation circuit and is functioned to indicate the
engine temperature by measuring the temperature of the coolant. The coolant temperature signal can be used
for the cold start and fan control functions.
Figure 17: Coolant temperature sensor
4.1.13 DOC differential pressure sensor
The DOC differential pressure sensor is functioned to measure the differential pressure between upstream and
downstream of DOC, convert the differential pressure to a voltage signal, and send this signal to ECU. Based
on the differential pressure signal, the ECU checks whether the DOC is blocked or removed.
Figure 18: DOC differential pressure sensor
4.1.14 Glow plug (GLP)
For a direct injection engine, the glow plug can be used to directly heat up the air within the cylinder block to
optimize the start performance. The glow plug only takes several seconds to reach the required temperature.
The preheating after the start can not only optimize the emission, but also reduce the noise.

Figure 19: Glow plug
 Rated voltage: DC 11±0.1V.
 Under rated voltage, the time shall be ≤6s to reach 770 ℃ surface temperature and the working
temperature shall be ≥ 920℃ after 30s.
4.1.15 Throttle
The function of the throttle in a diesel engine clearly differs from that in a gasoline engine. The throttle in a
diesel engine is functioned to indirectly change the proportion of exhaust gas recirculation by adjusting the
fresh air volume. This valve generally works only at low load and low speed.
Figure 20: Throttle
4.2 FAI-SCRL1.0 non-air assisted dosing system

FAI-SCRL1.0 dosing system is a non-air assisted SCR dosing system and its core components include
AdBlue supply pump, DCU, dosing nozzle, AdBlue delivery pipe, and AdBlue return pipe. The integration
diagram of the core components is shown in Figure 21. Its application on the engine is shown in Figure 22.

AdBlue return pipe
AdBlue dosing
nozzle
AdBlue delivery pipe
Adblue supply pump
Figure 21 Composition of core components for FAI-SCR L1.0 non-air assisted dosing system
Actuator
Engine cooling Sensor

system
Water cutoff
solenoid valve
Supply pump
Exhaust gas Exhaust gas

temperature sensor temperature sensor
Nitrogen oxygen
Dosing nozzle
sensor
Engine exhaust
Engine exhaust
Figure 22 Application structural diagram of FAI-SCR L1.0 non-air assisted dosing system

4.2.1 Supply module
4.2.1.1 Composition of supply module
The supply module is mainly composed of supply pump, DCU, level sensor, AdBlue filter, pump-back
solenoid valve, plastic cover, and its accessories, as shown in Figure 23 below:
1-DCU.
2- Pump-back solenoid valve
3-Supply pump
4-Adblue filter
5-Liquid level/temperature sensor
6-Heating pipe
7- Plastic cap
Figure 23 Composition of supply module
The functions and specifications of various components are as below:
a. The 12V specification supply pump controls the motion of plunger by the electromagnetic force of the
internal coil to output AdBlue. Two stainless steel pipes (3.5mm and 6mm) are installed thereon. The
3.5mm pipe is the AdBlue delivery pipe and the 6mm pipe is the supply pump drive pipe.
b. The AdBlue filter is in orifice diameter of approximately 60μm and is functioned to filter out the
impurities from the AdBlue and supply clean AdBlue to the supply pump.
c. The AdBlue level/temperature sensor is functioned to measure the AdBlue level and temperature so that
the DCU can judge the environmental conditions, execute the OBD, and feed back via instrument the
level to the user.
d. The floater limiter of the level sensor is mainly functioned to indicate the maximum level of the floater
and reserve a certain expansion space for the AdBlue tank. The height is 30mm.
e. There are four types of stainless steel pipelines. Besides the delivery pipe and drive pipe, there are one
spiral heating pipe (water pipe) and one electronic pipe. The electronic pipe is internally installed with
the PCB board of level and temperature sensors to measure the AdBlue level and temperature.
f. The toothed rings are used to connect the stainless steel pipelines and plastic covers and fix them onto the
AdBlue tank. They are composed of 8 teeth. To fix them, rotate them clockwise to clamp securely to the
clamping slots on the AdBlue tank.
g. DCU is the after-treatment control unit.
4.2.1.2 Precautions for installation of supply module
While installing the supply module, place φ82mm O-ring in to the O-ring groove, place the top toothed ring
into the clamping slot of AdBlue tank toothed opening, and rotate clockwise to fix the supply module. The
final fixing position may be determined as per customer’s required harness or coolant pipeline arrangement

position. The external plastic cover and its parts of the AdBlue are shown in Figure 24.
AdBlue outlet port
Coolant inlet pipe Connected to silicon

breather
Pump-back solenoid
DCU connector
valve connector
Coolant outlet pipe

Supply pump drive
connector
Pasted with DCU label
Liquid level and temperature

sensor connector
AdBlue return port
Figure 24 Plastic cover and its parts
a. The AdBlue filler port and the AdBlue return port are provided on the top of the FAI-SCR L1.0 supply
module. The one in outside diameter of 7.9mm is the outlet port and the one in outside diameter of
6.3mm is the return port.
b. The coolant inlet and return pipes are interconnected with the water pipes within the module and are
connected in series to the engine recirculated cooling system to heat up and unfreeze the AdBlue at low
environmental temperature. The coolant flow direction is indicated by arrow. Take cautions not to
connect reversely while connecting them to the water inlet and outlet pipelines of the engine. Generally,
the connecting pipes for coolant inlet and outlet are in inside diameter of φ14 and are tightened by
special clamps.
c. To balance between the internal pressure of AdBlue tank and the outside barometric pressure, the FAI
sets up the ventilation port on the plastic cover. If the AdBlue tank is provided with ventilation device,
this ventilation port can be plugged. One silicon hose in inside diameter of 6mm is connected to this
ventilation port.
d. The pump-back solenoid valve is functioned to pump back the residual fluid contained in the AdBlue
pipes to the AdBlue tank after the stop of engine, in order to avoid the urea crystallization within the
pipelines and prevent the freezing of AdBlue within pipelines under low temperature in winter from
damaging the parts.
e. For level and temperature sensor and supply pump drive connectors, it’s necessary to protect and fix the
pump drive and level and temperature sensor wires during installation. The exposed pump drive wire
shall be in length of 100±10mm and shall be protected by glass fiber protective sleeve. The exposed level
and temperature sensor wire shall be in length of 120±10mm and shall be protected by PVC protective
sleeve.
4.2.1.3 Protection of supply module
For vehicle-mounted installation, generally no special protection is required for the supply module. The parts
on the supply module plastic cover, especially the DCU, shall be protected. Due to their direct connection
with the harness, it’s recommended to install them at a position with less rainwater splash and mud (It’s better
to install them in a relatively enclosed space), in order to prevent damaging the electric connectors and

pipeline connectors. The AdBlue inlet and return ports and the ventilation ports are installed with protective
caps at the time of delivery, in order to prevent the ingress of dusts and impurities into the supply pump via
the ports. The protective caps shall be removed before the installation of system pipelines and shall be
immediately installed after the disassembling of system pipelines.
Notice: When the key is rotated to “OFF”, the supply pump starts pump-back. The pump-back sound issued
by the supply pump shall be approximately 60dB and the duration depends on the length of the AdBlue
pipelines on the vehicle. This sound is a normal symptom.
4.2.2 Dosing nozzle
4.2.2.1 Composition of dosing nozzle
As shown in Figure 25, the dosing nozzle is functioned to inject a fixed volume of atomized AdBlue into the
exhaust pipe under the control of the DCU. To guarantee the sufficient mixing between AdBlue mist and
exhaust gas within the exhaust pipe, the installation distance between the nozzle and the catalyst carrier shall
be >400mm, as shown in Figure 26.
1- Mounting bracket
2- AdBlue outlet port
3- Nozzle drive connector
4- AdBlue inlet port
Figure 25 Dosing nozzle
Figure 26 Distance between dosing nozzle and carrier
4.2.2.2 Installation of dosing nozzle
The installation of dosing nozzle on the exhaust pipe is shown in Figure 27. The dosing nozzle includes
dosing nozzle body, nozzle mounting base, exhaust pipe, and blade mixer. For vehicle-mounted installation,
the nozzle shall be placed to a position with least possible damage by the road surface. To prevent the air
leakage of nozzle, ensure to tighten the compression bolts to specified torque (30±5N·m). The mixer must be
consistent with the exhaust gas direction and the distance from the nozzle base to the mixer shall be adjusted
as per the actual pipe diameter and nozzle installation position to ensure that the atomized AdBlue is injected
onto the mixer as long and straight as possible.

1-AdBlue inlet port

2-Nozzle drive connector
3-Thermal baffle
4-Air outlet pipe
5-Blade mixer
6-Injector nozzle base
7-Holding down bolt
8- AdBlue outlet port
Exhaust
Figure 27 Nozzle installation position diagram
Due to high exhaust gas temperature, pay attention to the following items:
a. The maximum working environmental temperature for the foremost part of dosing nozzle shall be -40°C-
550°C, the environmental temperature range for rear plastic pump body part shall be -40°C-200°C, the
temperature range for AdBlue at inlet port shall be -10℃~ 60℃, and the differential temperature
between inlet port and outlet port shall be < 10℃.
b. When the vehicle is stationary, the exhaust gas temperature at the mounting position of dosing nozzle
shall be no higher than 450℃. When the traveling speed of the vehicle is >20km/h, the exhaust gas
temperature at the mounting position of dosing nozzle shall be no higher than 550℃.
c. The dosing nozzle requires the cooling of the recirculating AdBlue supplied by supply pump. It’s
prohibited to run the engine under high-load when the after-treatment system is not working, otherwise it
will result in burning and damage of nozzle. In addition, ensure that the AdBlue tank contains sufficient
AdBlue for recirculation.
d. The medium used by the dosing nozzle must be NOx reductant conforming to the requirements of
GB29518-2013. The deionized water may be used for partial test.
e. The rotation angle of nozzle on the exhaust pipe also influences its function. Figure 28 shows the
instructions for axial installation of the dosing nozzle. The green zone indicates the permissible
installation angles and the red zone indicates the disallowed installation angles. It’s mainly intended to
prevent the air bubbles in the AdBlue, which are difficult to be bled, from influencing the dosing result
and meanwhile prevent the road impurities from damaging the downward installed nozzle.
Allowable mounting
position.
Unallowable mounting position.
Figure 28 Nozzle installation position diagram

4.2.3 Dosing control unit (DCU)
The dosing control unit (DCU) is shown in Figure 29. The DCU mainly incorporates two functions. One is the
accurate control of AdBlue injection volume, injection pressure, heating system, and pump-back solenoid
valve, the signal acquisition of various sensors, and the drive of actuators. The other is the OBD diagnosis.
AdBlue control procedure: Communicate with engine ECU via CAN bus to acquire the engine running status
data, acquire the temperature signal of catalytic converter, and accurately control the injected volume of
AdBlue as per rated MAP to reduce the NOx contained in the engine exhaust gas to N2 and H2O. DCU sends
the OBD information to ECU via CAN bus message. Please refer to 7.2 for the list of OBD codes.
Figure 29 DCU
Generally, the DCU is already installed on the supply module at the time of delivery. It can also be used
independently. For independent installation, the vibration acceleration at the installation position shall be <6G.
If this requirement can’t be mt, use the shock pads. Other requirements for DCU installation are as below:
a. Working environmental temperature: -40°C-85°C;
b. Protection grade: IP67;
c. Salt fog grade: 8;
d. The working voltage shall be 9~17V and the static current shall be <150mA after turn-on of ignition
switch. Connect one 5A fuse in series to the positive wiring terminals of DCU drive supply pump and
dosing nozzle respectively. After the turn-off of ignition switch, the turn-on duration of standby power
supply shall be <30min, the static current shall be <100mA, and the current shall drop to 0 after turn-off
of standby power supply.
e. The DCU installed on the supply module shall be kept far away from heat sources (Such as exhaust pipe
and catalyst), in order to guard the DCU against the heat radiation generated by the heat sources.
f. Keep as far as possible from high frequency and high energy sound sources, such as alternator, fuel
pump, water pump, and air pump.
g. The DCU is fixed by two types of fastening bolts in different lengths. The place A is fastened by two
bolts M5 and their nuts are installed in the clamping slots of the plastic cover. The place B is fixed by
two bolts M5 and the nuts are placed into the clamping slots shown by place B, as shown in Figure 30.

Figure 30 Mounting holes of DCU
h. If the DCU is damaged, replace it integrally and send it to after-service department for repair and
treatment. It’s prohibited to open the DCU housing without permission. FAI will not accept the claim for
any malfunction arising from the breakup of DCU without permission.
4.2.4 AdBlue tank assembly
The AdBlue tank assembly is used for storage of AdBlue and is mainly composed of AdBlue tank body,
AdBlue filler cap, drainage plug, and ventilation pipe. The AdBlue tank is shown in Figure 31.
1-Vent pipe
2-Liquid-discharging bolt
3-Adblue tank body
4-Adblue filler cap
Figure 31 AdBlue tank assembly
To guarantee the normal working of AdBlue dosing system, pay special attention to the following item during
the installation and use of AdBlue tank:
The AdBlue installed on the vehicle shall be whenever possible guarded against the risk of deteriorated
AdBlue due to the influence of heat source irradiations, including engine, transmission, SCR catalytic
converter, and exhaust pipe. To ease the filling of AdBlue, the AdBlue tank and the fuel tank can be installed
on one same side. During the installation of AdBlue, pay attention to the protection for the bottom of AdBlue
tank.
To prevent adding diesel or other fluid into the AdBlue tank, while adding fuel and AdBlue, ensure to
differentiate the markings to eliminate incorrect adding of fluid.
Before using the AdBlue tank, check the inside of AdBlue tank for presence of impurities, such as machined
plastic chippings. If present, flush thoroughly to prevent blocking the dosing system during use.
Before adding AdBlue, thoroughly remove the mud and dirt from the surrounding area of AdBlue filler cap
and the surface of the cover, in order to prevent the ingress of impurities (Such as mud and dirt) into the
AdBlue tank from blocking the dosing system.
4.2.5 AdBlue delivery pipe
For FAI-SCR L1.0 system, the AdBlue delivery pipes are mainly divided to outlet pipe and return pipe and
are of electric heating pipes in specification of 12V or 24V. The 12V AdBlue pipe corresponds to 12V
AdBlue pump and 24V AdBlue pipe corresponds to 24V AdBlue pump. The AdBlue outlet pipe is a PA66
AdBlue nylon pipe in inside diameter of φ3mm, with the pipe connector at φ7.89 (Refer to SAE-J2044). The
AdBlue return pipe is a PA66 AdBlue nylon pipe in inside diameter of φ3mm, with the pipe connector at φ6.3
(Refer to SAE-J2044). There is one electric heating connector in length of approximately 20cm on one end of
the pipe connector to energize the electric heating wire. Figure 32 shows the AdBlue outlet pipe and Figure 33
shows the AdBlue return pipe.

Figure 32 AdBlue outlet pipe Figure 33 AdBlue return pipe
The AdBlue pipes shall be made of a material resistant to AdBlue corrosion and shall not be made of buna
rubber-N, neoprene, silicon, polyethylene, or similar material. The lining of the pipes shall be made of PTFE,
in order to reduce the risk of adhered AdBlue crystals on the pipe walls. The pipelines must have sufficient
strength to prevent the collapse by the vacuum pressure of the pump-back and shall be in inside diameter of
3mm. To prevent the crystallization of any non-removed AdBlue after the stop of engine, the pipeline
arrangement shall be free of inclination and shall minimize the U-pipelines and bends to prevent the long-time
placement of residual AdBlue from causing urea crystallization and blockage due to vaporization. The best
path is the downward arrangement from supply pump to nozzle.
The AdBlue delivery pipes are the important parts in the after-treatment system. Pay attention to the following
items for their arrangement and use:
a. For vehicle-mounted installation, every connector of AdBlue delivery pipes shall be free of leakage, in
order to prevent crystallization.
b. The arrangement of AdBlue delivery pipes shall be kept far away from heat sources, especially the
exhaust pipe.
c. For vehicle arrangement, arrange the AdBlue delivery pipelines as short as possible.
d. The first fixing point of the AdBlue delivery pipes shall be no more than 200mm reach to the connector;
e. While plugging or unplugging AdBlue pipelines each time, properly control the direction and operating
force. The improper operations will probably break the AdBlue inlet and return ports of the module.
4.2.6 Water cutoff solenoid valve
The water cutoff solenoid valve is mainly functioned to unfreeze the frozen AdBlue in the AdBlue tank and
the working environmental temperature is -40℃~ 80℃. Working principle: Upon judgment of frozen AdBlue
via temperature sensor in supply module and the ambient temperature sensor, the DCU controls the system to
enter the unfreezing mode to firstly unfreeze the supply pump. If the engine coolant temperature
reaches >70°C, DCU controls the heating recirculating fluid to open the solenoid valve. The hot recirculating
fluid flows into the coolant pipeline of supply module to unfreeze the AdBlue around the supply pump. The
engine coolant supply port used for heating depends on the specific structural layout of engine model.
Generally, the inlet port is near the engine oil cooler cover and the return port is near the engine water pump
inlet (Pipeline between vehicle water tank and water pump). The engine coolant flows out from the engine to
the coolant port of supply module to unfreeze the AdBlue within the AdBlue tank as per the requirements and
then returns to the engine via return port of supply module to form one circuit. The solenoid valve is arranged
and fixed at appropriate position on the engine and vehicle and the fixing brackets can be designed as per the
arrangement need of the vehicle. Figure 34 shows the water cutoff solenoid valve.

Figure 34 Water cutoff solenoid valve
4.2.7 NOx sensor
NOx sensor is functioned to measure the NOx concentration after the reaction of the catalytic converter and
its signal is used for OBD diagnosis. The sensor is installed on the canister body on downstream of catalyst or
the mounting base installed on the exhaust pipe and is tightened to 50±10N·m. The control unit is installed on
the bracket.
Working environmental temperature of NOx sensor module: -40°C~115°C; Storage temperature: -40°C~95°C;
Workable temperature and NOx concentration range: Exhaust gas temperature at 100~ 800℃ and NOx
concentration at 0~1,500ppm. The NOx sensor is shown in Figure 35.
Figure 35 NOx sensor
NOx sensor shall be installed to be perpendicular to the catalytic converter or exhaust pipe and the working
environmental temperature shall be -80°~80°. Do not install the NOx to lowest position, otherwise the sensor
will be damaged by the splashed condensates from the water vapors contained in the exhaust gas or by the
immersion of the accumulated fluid. Install as per Figure 36. To prevent breaking the sensor wire due to
vibration during the traveling of vehicle, a certain length of safety wire shall be reserved between the last
fixing point of NOx sensor wire and the sensor.

Figure 36 Installation position of NOx sensor
4.2.8 Exhaust gas temperature sensor
As shown in Figure 37, the exhaust gas temperature sensor is installed on the upstream of EGP on the after-
treatment system. The exhaust gas temperature sensor used for FAI adopts PT200 platinum thermistor and its
resistance is 200Ω at 0°C temperature. Its resistance will increase as per positive temperature coefficient along
with the increasing of the temperature. Please refer to the contents of 7.3 for the relationship between exhaust
gas temperature sensor resistance and temperature.
Figure 37 Exhaust gas temperature sensor

For the installation of exhaust gas temperature sensor, pay attention to the following items:
a. The installation position shall be perpendicular to the exhaust gas flow direction and the top of the sensor
shall be free of contact with any object. A sufficient space shall be reserved for the sensor before
installation.
b. Before the sensor is completely removed from the mounting hole, ensure to remove the sensor linearly
along the central axis.
c. Ensure the 45±5N·m tightening torque.
d. The sensor wire shall not be bent for >90° and the curvature radius of the wire connected to the tail of the
sensor shall be no less than 25mm. The working environmental temperature of the electric system shall
be within -40℃~ 200℃

5 Checking and Repair Tools

The tools introduced in this chapter are for reference only and the use of such tools is not mandatorily
required. To use the tools manufactured by other manufacturer, ensure that the tools incorporates all functions
described in this chapter.
5.1 Low pressure test suite

The low pressure fuel system pressure can be measured by multifunctional low pressure test suite.
Measurement objective:
 Check low pressure fuel pipelines for damage and blockage.
 Check fuel filter for damage and blockage.
Figure 38 Low pressure test suite
5.2 Fuel injector fuel return volume test suite

This test suite is used to test the fuel return volume of fuel injectors in the common rail system to thus judge
the normal working of fuel injectors. This device is mainly composed of one two-stage measuring cylinder (in
two different diameters) and also includes return pipeline and fixing protection straps.
Figure 39 Fuel injector fuel return volume test suite

5.3 Transparent hose

Connect the transparent hose to the low pressure fuel pipeline to check for presence of air content in the fuel
pipeline (by visual observation).
Figure 40 Transparent hose
5.4 Protective cap

The protective cap is used to plug the disassemble connector, in order to prevent damaging the parts due to
ingress of impurities.
Applicable object:
 Fuel rail
 High pressure fuel pump
 Fuel injectors
Figure 41 Protective cap
5.5 Measuring glass

The measuring glass can be used to store the leaking fuel and measure the fuel volume.
Equipment specification: Measurement range:
o 1000ml measurement range is used to measure the fuel return volume of high pressure fuel pump.
o 25ml measurement range is used to measure the fuel return volume of fuel injectors (Under the condition
of unavailable fuel injector fuel return volume test suite).

Figure 42: Measuring glass
5.6 Oscilloscope and parts

The oscilloscope can real-time track the voltage and current and display on the display. It’s mainly used to
measure the signals of camshaft/crankshaft sensor, water-in-fuel sensor, glow plug current, fuel injector
current, and key authentication.
Parts: BNC wire and current clamp
Figure 43, Figure 44 and Figure 45: Oscilloscope, current clamp, and BNC wire.
5.7 Cylinder pressure test suite with adapter

This tool is used to measure and record the pressure of engine cylinders. To measure the pressure of various
engine cylinders, ensure to use the compatible adapters, in order to ensure the successful connection between
engine cylinders and tester and measure and record the cylinder pressure.
Figure 46: Cylinder pressure tester
5.8 Manual pump

The manual pump is functioned to supply the pressures (including positive and negative pressures) required
for the checking, in order to check the normal functioning of pneumatic parts such as turbocharger air
bleeding valve and throttle.

Figure 47: Manual pump
5.9 Multimeter
The multimeter can measure the voltage, current, and resistance of the electric circuits.
Figure 48: Multimeter
5.10 Jumper case

The jumper case is an electric device that can enable the repair personnel to easily measure various electric
signals of vehicle, without destroying the ECU or its connector pin or puncturing the insulation layer of cables.
In addition, it can realize the connection or disconnection of harness by plugging or unplugging the
corresponding short-circuit plug on the jumper case. During the use, the jumper case is connected between
ECU and its vehicle harness connector.
Figure 49: System test adapter (Jumper case)

5.11 Connector adapter (Type Y cable)

The repair personnel can use connector adapter (Type Y cable) to easily measure various electric signals of
vehicle, without damaging the pins of electric connector or puncturing the insulation layer of cables. During
use, connect the connector adapter between the part and part harness connector.
Figure 50: Connector adapter (Type Y cable)
5.12 Basic repair tools of after-treatment system

During the after-treatment malfunction diagnosis and repair, the instruments and tools to be probably used are
listed in Table 1.
Table 1 After-treatment malfunction diagnostic and repair tools for FAI-SCR system
Part name Instrument/tool specification

AdBlue dosing nozzle 8mm Allen wrench
Refer to the diagnostic unit of vehicle
Diagnostic unit and connecting wire
manufacturer.
Multimeter Universal type
NOx sensor 22# open wrench
Exhaust gas temperature sensor 17# open wrench

6 Example of Actual Signal Value
This chapter lists the actual signals (data stream) that can be measured by EDC17C63 software. This table is for reference only. Depending on the specific vehicle
configuration, this table probably differs.
Low idling Moderate Maximum Low idling
Moderate speed Maximum speed
speed speed speed speed
(2,000r/min at (~4,400r/min at
(800r/min at (2,000r/min at (~4,400r/min (800r/min at
70°C water 70°C water
30°C water 30°C water at 30°C water 70°C water
temperature) temperature)
temperature) temperature) temperature) temperature)
Acronym Name of data stream Unit Value Value Value Value Value Value
BattU_u Battery voltage V 14.2 14.1 14.1 14.2 14.2 14.2
Epm_nEng Engine speed rpm 800 2000 4400 800 2000 4400
Synchronization
Epm_stSync - 30 30 30 30 30 30
signal
Accelerator pedal
APP_uRaw1 mV 742.6 1368.4 3924.6 747.6 1324.4 3916.04
sensor 1 voltage
Accelerator pedal
APP_uRaw2 mV 366.4 674.4 1958.8 366.4 654.8 1954.8
sensor 2 voltage
Accelerator pedal
APP_rUnFlt % 0 8.84 100 0 7.09 100
opening extent
Actual injection
InjCtl_qCurr mg/stroke 7.35 7.77 13.54 5.37 6.69 12.08
volume
Main injector
InjCrv_tiMI1ET us 755.49 493.11 414.03 657.87 503.98 406.80
energization time
RailP_uRawMax mV 1042.52 1601.31 3666.37 1007.51 1504.68 3590.96
voltage
RailP_pLin Actual rail pressure bar 277 556 159 260 504 157
Fuel metering unit
MeUn_rPs % 20.49 21.19 23.40 20.57 21.39 24.16
output duty ratio


Fuel metering unit
MeUn_uRaw mV 958.10 1003.86 1231.4 966.85 1045.28 1208.26
voltage
Fuel metering unit
MeUn_iActFlt mA 698.31 736.63 864.35 703.72 732.79 856.75
current
Coolant sensor
CEngDsT_uRaw mV 1940.2 1529.6 1446.6 796.6 821 786.8
voltage
CEngDsT_t Coolant temperature °C 30 30 30 70 70 70
Intake temperature and
Air_uRawtCACDs mV 3112.04 2771 2216.02 2257.8 2243.2 1912.19
voltage
Air_tCACDs Intake temperature °C 26.36 33.86 41.22 46.36 46.66 50.74
Airflow sensor output

AFS_tiRaw us 369.57 523.34 835.65 347.22 508.87 827.85
signal period
Actual inhaled fresh air

AFS_mAirPerCyl mg/stroke 271.82 352.26 838.54 229.35 342.17 807.38
volume
EnvP_p Atmospheric pressure hPa 1006 1006 1006 1006 1006 1006
Environmental
EnvT_t °C 26.16 26.96 26.96 27.66 27.66 27.66
temperature
AFS_dm Engine intake volume Kg/h 26.22 85.84 444.86 22.02 82.11 429.45
Air_pCACDs Turbocharger pressure hPa 25 25 25 25 25 25
EnvP_pSens Environmental pressure hpa 1006 1006 1006 1006 1006 1006


Fuel temperature
FuelT_uRaw mV 2218.8 2228.6 2223.8 2155.64 2165 2151.59
sensor voltage
ThrVlv_r Throttle valve position % 92.65 0 0 93.00 0 0
ThrVlv_rPs Throttle duty ratio % 19.72 10.95 10.61 17.83 10.24 12.42
Turbocharger actuator
TrbCh_r % 84.90 90.28 43.94 84.99 89.88 40.43
position
Turbocharger actuator
TrbCh_rPs % 85 90.28 43.94 85 89.88 40.97
duty ratio
FuelT_t Fuel temperature °C 30.16 29.96 30.06 31.46 31.36 31.56

7 Malfunction Checking and Repair Guidance
Before the malfunction checking and repairs, ensure the normal checking results of following items:
● Normal battery voltage
● Normal electric circuits, fuses, connectors, and harnesses
● Normal ECU power supply
● Sufficient fuel in fuel tank
● Qualified fuel and oil quality
● No leakage in fuel pipeline
● Normal engine mechanical parts, such as timing, flywheel, suspension, and pistons
7.1 Malfunction symptoms

Start failure of engine Page 42
Flameout of Engine during Running Page 44
Difficult start of engine Page 46
No response of accelerator pedal during running of engine Page 47
Engine noise. Page 48
Idling jitter of engine Page 49
Low engine power Page 50
Constant turn-on of system indicator lamp/malfunction indicator lamp Page 52
Increased engine idling speed Page 53
Smoke of engine Page 54
Engine overheating Page 55
Constant turn-on of preheating indicator lamp Page 56
Over-high fuel consumption Page 57
Diluted engine oil Page 58
Over-high AdBlue consumption Page 59
Presence of AdBlue smell or white crystal powder Page 60

7.1.1 Staxrt failure of engine
Start failure of engine after multiple attempts
Start failure of engine
Check ing of battery Checking of battery

Does the starter work? N (see sec tion 7.3.3) (see s ec tion 7.7.2)
Read tr ouble codes

N
solv ed? solved?
Y
Y Y Other possible malfunction
Is there any component cause:
fault code?
N
- Starter relay is damaged.
- Fuse is blown out.
Checking end
- Immobilizer system
malfunction
Refer to inspection method of

concrete parts (see the
Read data stream
section 7.3).
Check ing end
Rail pressure buildup Is synchronous signal

N Is engine speed too low? N N A
failure？ lost?
Check ing end
Y Y Y

Check the battery. (see Check the cranks haft sensor
sy stem(see s ection 7.4.1.1 to
section 7.3.3) (see sec tion 7.3.11)
section 7.4.1.2)
Has the fault been Has the fault been Has the fault been
solv ed? solv ed? solv ed?
N N N
Check injector r eturn oil (see Check the starter (see s ection Check the c amshaft sens or
section 7.4.1.4) 7.7.2) (see s ec tion 7.3.13)

solved? solved?
Checking end
N N
Low-voltage sy stem Check the r elative position

performance test (see s ec tion between the crankshaft and
7.4.1.3 ) cams haft. (see s ection 7.3.14)
Has the fault been

solv ed?
Check ing end
Other possible malfunction

cause:
- Oil pipe is clogged or leaks.
- High-pressure fuel pump
overflowi ng valve i s stuck/opened
constantly. Y
- Fuel metering unit malfunction
- Abnormal ECU power supply
- Wrong data is written or damaged.
Checking end

Inspection of intake system (see section

7.5)
Have the fault been identified?
Check injector return oil (see section

7.4.1.4)
Check the preheater system. (see section

7.7.5)
Other possible malfunction cause:

- Intake/ Air outlet pipe blockage
- Injector is blocked/stuck completely.
-Low pressure fuel pipelines blockage.
-Engine cylinder is cold as its glow does
not work.
Y
Checking end

7.1.2 Flameout of Engine during Running
Flameout during running of engine, including immediate flameout after start and flameout during acceleration
Flameout of Engine during

Running
Is the engine shut down The engine is shut

N
after startup? down at acceleration.
Is there a fault
Read trouble codes N
code?
Is there any
Is there any Is there any component
N
Y N component fault
component fault code: fault code:
code:
Refer to inspection method of Check the low-voltage system

Refer to inspection method of concrete parts (see the section (from section 7.4.1.1 to section
concrete parts (see the section Read the "rail pressure" data at 7.3). 7.4.1.2)
7.3). startup.
Is the rail pressure Has the fault been

higher than 200bar?
Checking end Y Checking end solved?
N
Check injector return oil
Check the low-voltage Check injector return (see section 7.4.1.4)
system (from section oil (see section 7.4.1.4)
7.4.1.1 to section 7.4.1.2)
N
Has the fault been

Has the fault been Has the fault been solved?
solved? solved?
N
N Low-voltage system
performance test (see
Low-voltage system Inspection of intake/ section 7.4.1.3 )
performance test (see exhaust system (see
section 7.4.1.3) section 7.5)
Has the fault been

Has the fault been
solved?
Has the fault been solved?
solved? N N
N Check the low-voltage system Y

(from section 7.4.1.1 to section Other possible malfunction
Other possible malfunction cause: 7.4.1.2) cause:
- Damage of fuel metering
- Damage of fuel metering unit
unit - Oil- return pipe is Y
- High pressure fuel pump Y
Has the fault been blocked
malfunction solved?
Y
N
Checking end
Checking end A Checking end

Low-voltage system performance test

(see section 7.4.1.3 )
Inspection of aftertreatment system

(see section 7.6)

- Intake exhaust pipe blockage
-Oil- return pipe is blocked.
Checking end

7.1.3 Difficult start of engine
Longer start time of engine than ordinary times or start only after multiple operations of starter motor
Difficult start of engine
Check the preheater

Is the engine cold? system. (see section
Y Checking end
7.7.5)
Is there a fault
N
code?
Is there any
Is there fuel system
component fault N N
fault code?
code?
Check the synchronizing
Y Y signal. (see section
7.3.14)
Refer to inspection
method of concrete parts Read data stream
(see the section 7.3).
Have the fault been
identified?
N
Checking end Is the rail pressure higher Result normal or test
than 200bar? failure Check injector return oil
(see section 7.4.1.4)
Y
Check the low-voltage system
Check injector return oil (see (from section 7.4.1.1 to section
section 7.4.1.4) Have the fault been
7.4.1.2) identified?
N
Have the fault been
Have the fault been Check the low-voltage system
identified?
identified? (from section 7.4.1.1 to
section 7.4.1.2)
N
Check injector return oil (see
N
section 7.4.1.4) Have the fault been
* Only if the test fails, can it be identified?
required.
N Y
cause: Low-voltage system
Y performance test (see
- Injector process hole is
leaked. Have the fault been section 7.4.1.3 )
identified?
Have the fault been

N
identified?
Checking end Low-voltage system
performance test (see N
section 7.4.1.3 ) Inspection of intake/exhaust

system (see section 7.8.6)
Have the fault been

identified? Have the fault been
identified?
N
Other possible malfunction N
cause: Other possible malfunction

- Damage of fuel metering
cause:
unit - Damage of fuel metering
unit
overflowing valve is stuck/
- High pressure fuel pump
opened constantly. malfunction
- High-pressure fuel pump - Fuel injectors blockage
fails.
Checking end Checking end
7.1.4 No response of accelerator pedal during running of engine
No response of engine at depressing of accelerator pedal during running of engine

No response of accelerator pedal during

running of engine
Is there any component fault code? N
Check if the brake signal is

Y activated.
Refer to inspection method of concrete parts(

see the section 7.3).
Check the accelerator pedal. (see
section 7.7.3)
Checking end

7.1.5 Engine noise.
Different noise of engine from normal status.
Engine noise.
Is there abnormal sound Mechanical noise/

There is roaring/exhausting
only in idling or N N abnormal noise during
noise during acc eleration.
acceleration? load acceleration.
Y Y Y
Is there any component Is there any component fault Is there any component fault
fault code? code? code?
Y Y Y
N
Refer to ins pection method of Refer to ins pection method of Refer to inspection method of N
concrete parts (see the s ec tion concrete parts (see the s ec tion N concrete parts (see the section
7.3). 7.3). 7.3).
Checking end Check ing end Check ing end
Check the low-pressure oil Check the mec hanical part of

Check intake/exhaust
sy stem (from section 7.4.1.1 engine. (see section 7.7.1)
sy stems(see s ec tion 7.5.1)
to s ection 7.4.1.2)
Have the fault been

Hav e the fault been
identified?
identified? Check ing end
N N
Low-voltage system
Check the turboc harger. (see
performance test (see section
section 7.5.2)
7.4.1.3)
Hav e the fault been

identified? Hav e the fault been
identified?
N
Read the r ail pressure data.
- Air outlet pipe leakage

Is the rail pressure data
N abnormal? Y

section 7.4.1.4)
Check ing end
Other possible malfunction cause: Have the fault been

identified?
- Check the filter( mixed with water
or not)
- Pr eheating system abnormal (only
for engine at c old status) N
- Fuel injectors blockage or
stagnation
- The rail pr essur e contr ol valve is
blocked or stuck. Other possible malfunction cause:
-Injector process hole is leaked.
Check ing end

7.1.6 Idling jitter of engine
Clearly jitter or fluctuating speed of engine under stopped status of vehicle and no-load and hot status of
engine
Smoke of engine
Is there any component

N
fault code?
Refer to inspection method of Inspection of low-voltage system

concrete parts( see the (from section 7.4.1.1 to section
section 7.3). 7.4.1.2)
Have the fault been

identified?
Checking end N
Low-voltage system performance
test (see section 7.4.1.3)
Have the fault been

identified?
Read the rail pressure data.

N
abnormal?
Y Y
Check injector return oil (see Inspection of intake/exhaust
section 7.4.1.4) system (see section 7.5.1)
Have the fault been Have the fault been

identified? identified?
N N

- Check the fuel filter (mixed with water or
-Injector process hole is leaked.
not)
- Check if there is air in the fuel.
- Check if the valve clearance is normal.
- Injector is blocked/stuck.
Checking end
Checking end

7.1.7 Low engine power
Insufficient power and deteriorated acceleration performance of engine, including restrained torque or failure
to reach original maximum speed.
Low engine power
Is there a fault code? N A
Fault codes related to

Is there any component
N Fuel system fault c ode? N "exhaust gas
fault code?
aftertreatment sys tem"
Y Y Y
Refer to ins pection method of Refer to ins pection method of

concrete parts (see the s ection Read the r ail pressure data. concrete parts (see the s ection
7.3). 7.3).
Is the rail pressure data Res ult normal or test

N Checking end
abnormal? failure
Checking end
Y
Check the low-voltage system

(from section 7.4.1.1 to
section 7.4.1.4)
section 7.4.1.2)

N N
Check injector r eturn oil *

Other possible malfunction cause: (see section 7.4.1.4)
* Only if the test fails, can it be
- Injector process hole is leaked.
required.
Y
Have the fault been

identified?
Checking end
Low-voltage sy stem
performance test (see s ection
7.4.1.3 )

abnormal?

overflowing valve is stuck/opened
constantly. Y
- High pressure fuel pump
malfunction
Checking end

Inspection of low-voltage system (see

section 7.4.1)
Inspection of aftertreatment system (see

section 7.6)
Check the turbocharger. (see section

7.5.2)
Inspection of intake/exhaust system (see

section 7.5.1)
- Air outlet pipe blockage

- Altitude too high.
- Because of overheating protection,
check the cooling system. Y
Checking end

7.1.8 Constant turn-on of system indicator lamp/malfunction indicator lamp
Constant turn-on of system lamp or malfunction indicator lamp on instrument panel
Constant turn-on of
system indicator lamp/
malfunction indicator
lamp
Read trouble codes N A
Is there any
Aftertreatment
component fault N Fuel system fault code? N
system fault code
code?
Y Y Y
Refer to inspection Refer to inspection method of

Read the rail pressure
method of concrete parts concrete parts (see the
data.
(see the section 7.3). section 7.3).
Is the rail pressure Result normal or

N Checking end
data abnormal? test failure
Checking end
Y

Check injector return
system (from section
oil (see section 7.4.1.4)
7.4.1.1 to section 7.4.1.2)

N N
Other possible malfunction Check injector return oil *

cause: (see section 7.4.1.4)
- Injector process hole is leaked. * Only if the test fails, can it
Y be required.
Have the fault been

identified?
Checking end
Low-voltage system
section 7.4.1.3 )
Is the rail pressure

data abnormal?

cause:

- High pressure fuel pump Y
malfunction
Checking end

7.1.9 Increased engine idling speed
Clearly higher engine idling speed than ordinary value under hot status.
Increased engine idling speed
Is there any component fault

Y
code?
Check the accelerator pedal. (see

Refer to inspection method of section 7.7.3)
concrete parts (see the section
7.3).
Have the fault been

identified?
Checking end N
Check the A/C and its

request switch.
Have the fault been

identified?

- Damage of coolant temperature
sensor
Y
Checking end

7.1.10 Smoke of engine
Smoking (Including black, white, and blue smokes) of engine under hot status after start
Smoke of engine
The engine emits

Is there black smoke? N white or blue
smoke.
Is there any Is there any component fault

N
N code?
component fault code?
Y
Y
Refer to inspection method Inspection of low-voltage system Refer to inspection method

(from section 7.4.1.1 to section of concrete parts (see the Check intake/exhaust
of concrete parts( see the systems(see section 7.5.1)
section 7.3). 7.4.1.2) section 7.3).

Checking end N Checking end N
Low-voltage system
Check the turbocharger.
(see section 7.5.2)
section 7.4.1.3)

N
N
Read the rail pressure

data. Other possible malfunction cause:
- Preheating system abnormal (only for
engine at cold status)
- Coolant is mixed with engine oil.
Is the rail pressure - Engine oil is mixed with coolant.
N - Water in fuel Y
data abnormal?
- DOC sulfur poisoning
- Engine ECU data is unreasonable.
Y
Check injector return oil Inspe ctio n of int ake/exha ust

(see section 7.4.1.4) system (see section 7.5.1)
Checking end
Have the fault been

Have the fault been
identified?
identified?
N N
Other possible malfunction Other possible malfunction cause:

cause:
-Injector process hole is - Damage of coolant temperature
Y
leaked. sensor
- Supercharger pressure sensor is
damaged.
- Engine valve clearance is too wide. Y
- Intake preheater fails (only for engine
Checking end
at cold status)
- Engine ECU data is unreasonable.
Checking end

7.1.11 Engine overheating
Water temperature gauge pointer within red zone or turn-on of water temperature warning lamp
Engine overheating

N
code?

Check the cooling system. (see
section 7.7.4)
7.3).
Have the fault been

identified?
Checking end
Check the coolant temperature

sensor. (see section 7.3.16)
Checking end

7.1.12 Constant turn-on of preheating indicator lamp
Constant turn-on of preheating indicator lamp on instrument panel under hot status.
Constant turn-on of preheating

indicator lamp

code?
Refer to inspection method of N

7.3).
Checking end

7.1.13 Over-high fuel consumption
Clearly higher fuel consumption than that under same conditions (Same vehicle model, emission, load, road
condition, and driving habit)
Over-high fuel consumption

N
code?

Inspection of low-voltage system
(see section 7.4.1)
7.3).
Have the fault been

Checking end identified?
Check the intake system. (see

section 7.5.1)
Have the fault been

identified?

- Damage of coolant temperature
sensor
Y
Checking end

7.1.14 Diluted engine oil
Raised engine oil level due to dilution of engine oil.
Diluted engine oil

N
code?

Inspection of low-voltage system
(see section 7.4.1)
7.3).
Have the fault been

identified?
Checking end

-High pressure fuel pump leakage
-Damage of engine oil cooler
Y
Checking end

7.1.15 Over-high AdBlue consumption
Clearly higher AdBlue consumption than other vehicle of same conditions (Including vehicle model, emission,
load, road condition, and driving habit) or clearly higher AdBlue consumption of one same vehicle under
same conditions.
Over-high AdBlue
consumption
Read trouble codes
Check the SCR liquid-supply Check the metering

Is there a fault code? N module (see section 42.1) nozzle. (see section 4.2.2)
Y Checking end
Is there a fault code Fault codes related

Does the trouble code
N related to "SCR hydraulic N to "SCR conversion
indicate specific part?
system" efficiency"
Y Y
Refer to inspection method Check the Adblue box

Inspection of NOx sensor
of concrete parts (see the assembly. (see section
(see section 4.2.7)
section 7.3). 4.2.4)
Inspection of exhaust
Check AdBlue delivery
temperature sensor (see
pipe (Section 4.2.5).
section 4.2.8)
Checking end
Have the fault been Is the result normal?

identified?
N N
Check the metering Perform the maintenance

Y nozzle. (see section 4.2.2) on the sensor. (see section
7.6.3)
Perform the maintenance

Checking end on metering nozzle (see
section 7.6.2)
Is the result normal? N
Y
- Adblue injection unit is
contaminated or blocked and
Other possible malfunction cause: thus needs to be replaced.
- At downstream of SCR catalyst, NOx
sensor fails.
- SCR catalyst malfunction
- Engine original exhaust
Checking end
Checking end

7.1.16 Presence of AdBlue smell or white crystal powder
Presence of urea smell or white crystal powders due to leakage of AdBlue.
Presence of AdBlue smell or

white crystal powder
Read trouble codes
Is there a fault code that is

clearly directed to a certain N
part?

Check the aftertreatment system
(see section 7.6)
7.3).
Checking end Checking end

7.2 Table of Trouble Codes

Most vehicle malfunctions can be expressed by trouble codes. Many trouble codes directly point to the
malfunction of specific part. However, some only point to the malfunctions of specific subsystem. The
malfunctions pointing to one same subsystem are categorized as one group (Such as fuel system group and air
system group) and some specific procedures are required for further checking to find out the specific causes.
Note:
The trouble codes listed in this manual may not completely apply to all vehicle models, depending on the
system configuration and specific ratings of the vehicle.
All trouble codes are in hexadecimal format.
7.2.1 Table of trouble codes for EDC17C63 V6 version of ZD30 China-V engine
Trouble Trouble
Trouble
Trouble indicator indicator
No. Chinese description of fault Codes
level lamp lamp
(ISO)
(MIL) (SVS)
1 Over-high internal battery voltage signal P0563 1 OFF OFF
2 Under-low internal battery voltage signal P0562 1 OFF OFF
3 Unreliable braking signal P0504 3 OFF ON_3DC
4 CAN A passive malfunction U0074 1 OFF OFF
5 CAN A communication interruption U0078 1 OFF OFF
Water temperature sensor voltage above upper
6 P0118 8 ON OFF
limit
Water temperature sensor voltage below lower
7 P0117 8 ON OFF
limit
8 Unreliable clutch signal P1700 3 OFF ON_3DC
9 DCU control-torque signal sent out U1125 1 OFF OFF
10 Vehicle performance restraint 0 triggered P110A 1 OFF OFF
11 Vehicle performance restraint 1 triggered P110B 1 OFF OFF
12 Vehicle performance restraint 2 triggered P110C 1 OFF OFF
13 Vehicle performance restraint 3 triggered P110D 1 OFF OFF
14 Vehicle performance restraint function triggered P110E 0 OFF OFF
15 Unreasonable signal of cruise control buttons P0579 1 OFF OFF
ECU internal chip Cy327 communication
16 P0607 2 OFF ON
malfunction
17 DCU message error U0113 8 ON OFF
18 Timeout of DCU message U0114 8 ON OFF
Stoppage of relevant parts due to over-high
19 P150A 1 OFF OFF
battery voltage
Shutdown of related parts due to under-low
20 P150B 1 OFF OFF
battery voltage

Trouble Trouble
Trouble
level lamp lamp
(ISO)
(MIL) (SVS)
Electric control unit (ECU) memory EEPROM
21 P1650 1 OFF OFF
erase fault
22 P1651 1 OFF OFF
read fault
23 P1652 1 OFF OFF
write fault
24 Fuel injection cutoff request indicator P1610 2 OFF ON
25 Engine overspeed indicator P0219 1 OFF OFF
26 Camshaft signal interference or loss malfunction P0339 8 ON OFF
27 Camshaft signal not detected P0340 8 ON OFF
Excessive deviation between camshaft signal and
28 P0341 8 ON OFF
crankshaft signal
29 Crankshaft signal interference or loss malfunction P0336 8 ON OFF
30 Crankshaft signal not detected P0335 8 ON OFF
Open-circuit of exhaust brake control relay drive
31 P141C 2 OFF ON
circuit
Overheating of electronic control unit (ECU)
32 P141D 2 OFF ON
internal exhaust brake control relay drive circuit
Short-circuit to power supply of exhaust brake
33 P141E 2 OFF ON
control relay drive circuit
Short-circuit to ground of exhaust brake control
34 P141F 2 OFF ON
relay drive circuit
35 Unreliable GNS signal malfunction P1721 2 OFF ON
Open-circuit of preheating plug control drive
36 P0670 8 ON OFF
circuit
37 P160C 8 ON OFF
internal preheating plug control drive chip
Short-circuit to power supply of preheating plug
38 P0384 8 ON OFF
drive circuit
Short-circuit to ground of preheating plug drive
39 P0383 8 ON OFF
circuit
40 IC1 CAN frame signal length error U1009 1 OFF OFF
IC1 CAN signal receiving timeout (namely signal
41 U100A 1 OFF OFF
loss)
Open-circuit of ignition sequence 1st cylinder fuel
42 P0201 8 ON OFF
injector drive circuit
Open-circuit of ignition sequence 2nd cylinder
43 P0203 8 ON OFF
fuel injector drive circuit

Trouble Trouble
Trouble
level lamp lamp
(ISO)
(MIL) (SVS)
Open-circuit of ignition sequence 3rd cylinder
44 P0204 8 ON OFF
Open-circuit of ignition sequence 4th cylinder
45 P0202 8 ON OFF
Fuel injection control module 1 (Harness) short-
46 P2146 8 ON OFF
circuit malfunction
Short-circuit of ignition sequence 1st cylinder fuel
47 P121A 8 ON OFF
injector harness
Short-circuit of ignition sequence 2nd cylinder
48 P121B 8 ON OFF
fuel injector harness
Short-circuit of ignition sequence 3rd cylinder
49 P121C 8 ON OFF
Short-circuit of ignition sequence 4th cylinder
50 P121D 8 ON OFF
Low-end short-circuit to high-end of ignition
51 P1200 8 ON OFF
sequence 1st cylinder harness
52 P1201 8 ON OFF
sequence 2nd cylinder harness
53 P1202 8 ON OFF
sequence 3rd cylinder harness
54 P1203 8 ON OFF
sequence 4th cylinder harness
No fuel injector fuel injection volume correction
55 P0263 8 ON OFF
(IQA) code for ignition sequence 1st cylinder
56 P0269 8 ON OFF
(IQA) code for ignition sequence 2nd cylinder
57 P0272 8 ON OFF
(IQA) code for ignition sequence 3rd cylinder
58 P0266 8 ON OFF
(IQA) code for ignition sequence 4th cylinder
ECU software malfunction indication during
59 P062F 1 OFF OFF
write/read
Loose connector of high pressure fuel pump fuel
60 P0255 8 ON OFF
metering unit (MeUn)
Open-circuit of high pressure fuel pump fuel
61 P0251 8 ON OFF
metering unit (MeUn) drive circuit
62 P0252 8 ON OFF
internal fuel metering unit (MeUn) drive chip
Short-circuit to power supply of fuel metering unit
63 P0254 8 ON OFF
(MeUn) drive circuit

Trouble Trouble
Trouble
level lamp lamp
(ISO)
(MIL) (SVS)
Short-circuit to ground of fuel metering unit
64 P0253 8 ON OFF
(MeUn) drive circuit
Over-high drive current of high pressure fuel
65 P025D 8 ON OFF
pump fuel metering unit (MeUn)
Under-low drive current of high pressure fuel
66 P025C 8 ON OFF
pump fuel metering unit (MeUn)
Report error of electronic control unit (ECU)
67 internal software and hardware low-level P1660 2 OFF ON
monitoring (MoC)
monitoring (MoC)
monitoring (MoC)
monitoring (MoC)
monitoring (MoC)
monitoring (MoC)
monitoring (MoC)
monitoring (MoC)
monitoring (MoC)
monitoring (MoC)
monitoring (MoC)
monitoring (MoC)

Trouble Trouble
Trouble
level lamp lamp
(ISO)
(MIL) (SVS)
79 internal software and hardware low-level P1615 2 OFF ON-
monitoring (MoC)
monitoring (MoC)
81 internal software and hardware low-level P166A 2 OFF ON
monitoring (MoC)
82 internal software and hardware low-level P060A 2 OFF ON
monitoring (MoC)
83 internal software and hardware low-level P060D 2 OFF ON
monitoring (MoF)
84 internal software and hardware low-level P061C 2 OFF ON
monitoring (MoF)
85 internal software and hardware low-level P166B 2 OFF ON
monitoring (MoF)
monitoring (MoF)
87 internal software and hardware low-level P166D 0 OFF OFF
monitoring (MoF)
88 internal software and hardware low-level P166F 2 OFF ON
monitoring (MoF)
monitoring (MoF)
monitoring (MoF)
91 internal software and hardware low-level P1670 0 OFF OFF
monitoring (MoF)
monitoring (MoF)
monitoring (MoF)

Trouble Trouble
Trouble
level lamp lamp
(ISO)
(MIL) (SVS)
monitoring (Mon)
95 internal software and hardware low-level P061D 2 OFF ON
monitoring (Mon)
monitoring (Mon)
monitoring (Mon)
monitoring (Mon)
99 Earlier breaking malfunction of main relay P0686 1 OFF OFF
100 Stagnation malfunction of main relay P0687 1 OFF OFF
Turbocharger pressure sensor voltage signal
101 P0238 8 ON OFF
above upper limit
Turbocharger pressure sensor voltage signal
102 P0237 8 ON OFF
below lower limit
Barometric pressure sensor voltage signal above
103 P2229 8 ON OFF
upper limit
Barometric pressure sensor voltage signal below
104 P2228 8 ON OFF
lower limit
No call malfunction indicator of torque fuel
105 P1008 0 OFF OFF
volume changeover MAP
DOC differential pressure voltage signal above
106 P2461 8 ON OFF
upper limit
DOC differential pressure voltage signal below
107 P2460 8 ON OFF
lower limit
Pressure limiting valve (PRV) reached maximum
108 P1001 2 OFF ON
permissible opening cycles
109 Pressure limiting valve (PRV) opened P1005 8 ON OFF
Pressure limiting valve (PRV) reached maximum
110 P1002 2 OFF ON
permissible opening time
Rail pressure positive deviation above limit (real
111 P1011 8 ON OFF
rail pressure below limit)
Rail pressure negative deviation exceeding the
112 limit at maximum set flow rate of fuel metering P1012 8 ON OFF
unit (actual rail pressure below the setting)

Trouble Trouble
Trouble
level lamp lamp
(ISO)
(MIL) (SVS)
Rail pressure negative deviation exceeding the
113 limit at minimum set flow rate of fuel metering P1013 8 ON OFF
unit (actual rail pressure above the setting)
Actual rail pressure below minimum rail pressure
114 P0087 8 ON OFF
(MeUn)
Actual rail pressure above maximum rail pressure
115 P0088 8 ON OFF
(MeUn)
Rail pressure above maximum limit under reverse
116 P0089 8 ON OFF
drag status
Rail pressure sensor signal drifting malfunction
117 P0191 7 ON_3DC OFF
(Over-high voltage)
118 P0194 7 ON_3DC OFF
(under-low voltage)
Rail pressure sensor voltage signal above upper
119 P0193 8 ON OFF
limit
Rail pressure sensor voltage signal below lower
120 P0192 8 ON OFF
limit
121 Simple immobilizer malfunction (loop function) P1643 2 OFF ON
Accelerator pedal sensor 1 voltage signal above
122 P0123 2 OFF ON
upper limit
Accelerator pedal sensor 2 voltage signal above
123 P0223 2 OFF ON
upper limit
Accelerator pedal sensor 1 voltage signal below
124 P0122 2 OFF ON
lower limit
Accelerator pedal sensor 2 voltage signal below
125 P0222 2 OFF ON
lower limit
126 Malfunction of sensor power supply module 1 P0643 8 ON OFF
129 Invalid variant data identifier P165A 1 OFF OFF
130 Variant data changeover malfunction P165B 1 OFF OFF
131 EEPROM code read malfunction P165C 1 OFF OFF
132 Virtual starter instruction P1629 1 OFF OFF
133 ECU software reset_0 P161D 2 OFF ON
134 ECU software reset_1 P161E 4 OFF OFF
135 ECU software reset_2 P161F 0 OFF OFF
Accelerator pedal 1 and accelerator pedal 2 signal
136 P2135 2 OFF ON
reasonableness malfunction

Trouble Trouble
Trouble
level lamp lamp
(ISO)
(MIL) (SVS)
Turbocharged and intercooled intake temperature
137 P0098 8 ON OFF
sensor voltage signal above upper limit
Turbocharged and intercooled intake temperature
138 P0097 8 ON OFF
sensor voltage signal below lower limit
Electronic control unit (ECU) internal temperature
139 P0669 2 OFF ON
sensor voltage signal above upper limit
Electronic control unit (ECU) internal temperature
140 P0668 2 OFF ON
sensor voltage signal below lower limit
Reliability malfunction of ECU temperature
141 P16E5 1 OFF OFF
sensor
Frozen valve body due to permanent deviation of
142 P2072 8 ON OFF
throttle valve (TVA) controller
143 Throttle valve (TVA) H-bridge drive open-circuit P2100 8 ON OFF
Throttle valve (TVA) H-bridge drive current
144 P2101 8 ON OFF
overload
145 P1040 8 ON OFF
internal throttle valve (TVA) H-bridge drive chip
Throttle valve (TVA) H-bridge drive circuit high-
146 P2103 8 ON OFF
end short-circuit to power supply
Throttle valve (TVA) H-bridge drive circuit low-
147 P1046 8 ON OFF
end short-circuit to power supply
Throttle valve (TVA) H-bridge drive circuit high-
148 P2102 8 ON OFF
end short-circuit to ground
Throttle valve (TVA) H-bridge drive circuit low-
149 P1044 8 ON OFF
end short-circuit to ground
Short-circuit and overload of throttle valve (TVA)
150 P1041 8 ON OFF
H-bridge drive circuit
Overheating of throttle valve (TVA) H-bridge
151 P1042 8 ON OFF
drive circuit
Low voltage of throttle valve (TVA) H-bridge
152 P1045 8 ON OFF
drive circuit
153 Unreliable throttle valve (TVA) self-learning P061F 8 ON OFF
Open-circuit of throttle valve (TVA) drive
154 P0487 8 ON OFF
interface circuit
Overheating of throttle valve (TVA) drive
155 P0488 8 ON OFF
interface circuit
Permanent positive deviation of throttle valve
156 P2173 9 OFF OFF
(TVA) controller
Permanent negative deviation of throttle valve
157 P2175 9 OFF OFF
(TVA) controller

Trouble Trouble
Trouble
level lamp lamp
(ISO)
(MIL) (SVS)
Throttle valve (TVA) physical opening position
158 P1049 8 ON OFF
above upper limit
Throttle valve (TVA) physical opening position
159 P1047 8 ON OFF
below lower limit
Short-circuit to power supply of throttle valve
160 P104A 8 ON OFF
(TVA) drive circuit
Short-circuit to ground of throttle valve (TVA)
161 P1048 8 ON OFF
drive circuit
Throttle valve (TVA) self-learning short-time
162 P0068 8 ON OFF
deviation malfunction
Throttle valve (TVA) position feedback sensor
163 P2622 8 ON OFF
value above upper limit
164 P2621 8 ON OFF
value below lower limit
Unreliable value of throttle valve (TVA) position
165 P104D 9 OFF OFF
feedback sensor
Throttle (TVA) position feedback sensor signal
166 P104E 9 OFF OFF
malfunction
167 Stagnation malfunction of main relay ECU P0687 3 OFF ON_3DC
Error of catalyst upstream temperature signal
168 P0435 1 OFF OFF
received from CAN bus
Description: MIL: OBD exhaust malfunction lamp;SVS: system malfunction lamp; ON_3DC: 3 driving
cycles are needed for illuminating
7.2.2 Table of trouble codes for after-treatment FAI-SCR dosing system
The FAI-SCR system dosing system incorporates the OBD malfunction diagnosis function and the
descriptions of the trouble codes are listed in Table 3. Use corresponding diagnostic unit to obtain the trouble
code (PCODE) and perform the troubleshooting accordingly.

Table 3 Descriptions of OBD trouble codes

OBD Is the
Trouble Possible fault Troubleshooting SCR
PCODE lights torque
description causes methods lamp
up limited?
Exhaust gas 1. Sensor is not Check the exhaust gas
temperature connected temperature sensor; The
It
sensor It lights torque is
P0546 2. Sensor harness Check if the associated lights
(upstream) up not
becomes abnormal circuit is normal or not up
above upper limited
limit 3. Sensor fails damaged
Exhaust gas Check the exhaust gas
temperature 1. Sensor harness temperature sensor; The
It
sensor becomes abnormal It lights torque is
P0545 Check if the associated lights
(upstream) up not
2. Sensor fails circuit is normal or not up
below lower limited
limit damaged
Exhaust gas 1. Sensor is not Check the exhaust gas
temperature connected temperature sensor; The
It
sensor It lights torque is
P2032 2. Sensor harness Check if the associated lights
(downstream) up not
becomes abnormal circuit is normal or not up
above upper limited
limit 3. Sensor fails damaged
Exhaust gas Check the exhaust gas
temperature 1. Sensor harness temperature sensor; The
It
sensor becomes abnormal It lights torque is
P2031 Check if the associated lights
(downstream) up not
2. Sensor fails circuit is normal or not up
below lower limited
limit damaged
1. Sensor harness
Check if the harness is
becomes abnormal
connected correctly and
2. Sensor fails plugged again if needed;
3. Engine Check the sensor and
SCR combustion is replace it if needed; It The
temperature is abnormal and It lights
P2428 Check the engine body lights torque is
exhaust gas is up
above 550℃ associated parts up limited
overheated
(injector, supercharger,
4. SCR ECU data, etc.);
temperature model
Update the calibration
calibration or DCU
data
data is wrong
Check the sensor
Liquid level sensor connector; The
AdBlue level It
is not connected or It lights torque is
above upper P203D Check the liquid level lights
its connector is up not
limit sensor and replace it if up
damaged limited
needed
Check the sensor
connector; The
AdBlue level Short circuited to It
It lights torque is
below lower P203C power supply, sensor Check the liquid level lights
up not
limit damaged, etc sensor and replace it if up
limited
needed

OBD Is the
PCODE lights torque
up limited?
1. Adblue
temperature sensor
itself becomes
abnormal
2. Adblue
temperature sensor Check the circuit and
AdBlue resistance; The
harness is connected It It
temperature torque is
P205D abnormally Stop heating to check lights doesn’t
above upper not
3. Adblue tank the heating valve and up light up
limit limited-
heating duration is replace it if needed.
longer than the set
time, and heating
valve is opened
abnormally or
damaged
1. Adblue
temperature sensor
AdBlue itself becomes The
abnormal Check the circuit and It It
temperature torque is
P205C the Adblue temperature lights doesn’t
below lower 2. Adblue not
sensor up light up
limit temperature sensor limited
harness is connected
abnormally
1. Sensor harness
Check NOx sensor The
NOx sensor or its circuit It
circuit; It lights torque is
heater short P2207 becomes abnormal lights
Replace the NOx sensor up not
circuit 2. The sensor is up
if needed. limited
damaged
1. Sensor harness
heater open P2205 becomes abnormal lights
circuit 2. The sensor is up
if needed. limited
damaged
1. Sensor harness
or its circuit It
NOx sensor, circuit; It lights torque is
P2203 becomes abnormal lights
short circuit Replace the NOx sensor up not
2. The sensor is up
if needed. limited
damaged
1. Sensor harness
wiring circuit P2202 becomes abnormal lights
is open 2. The sensor is up
if needed. limited
damaged
1. Sensor harness
Unacceptable or its circuit It
value from P2201 becomes abnormal lights
NOx sensor 2. The sensor is up
if needed. limited
damaged

OBD Is the
PCODE lights torque
up limited?
1. Sensor harness
NOx sensor circuit becomes It
communication U0108 abnormal lights
failure 2. The sensor is up
if needed. limited
damaged
Non-air
The
assisted supply Check if the connector It
Harness or its circuit It lights torque is
pump short P1490 is plugged in place and lights
becomes abnormal up not
circuit to re-plug it if needed up
limited
power supply
Non-air
assisted supply The
Check if the connector It
pump short Harness or its circuit It lights torque is
P1492 is plugged in place and lights
circuit to becomes abnormal up not
re-plug it if needed up
ground or open limited
circuit
Check if the Adblue
Internal 1. Adblue pipeline pipeline leaks
machine of is clogged or seeps Check if the Adblue The
non-air It
2. The supply pipeline is clogged It lights torque is
assisted P1494 lights
module fails internally; up not
metering up
3. AdBlue nozzle Check the supply pump limited
nozzle goes
wrong malfunction and Adblue nozzle, and
replace them if needed
Check if the DCU
harness and data It The
DCU drive failure, It lights
DCU fault P1495 configuration are lights torque is
without T3, etc. up
correct, and replace the up limited
DCU if needed.
ACU failure to read
internal data, ACU
The
failure to be It
It lights torque is
EEPROM fault P1496 initialized, metering Replace the DCU lights
up not
unit uncalibrated, or up
limited
driving voltage
abnormal
Non-air
assisted 1. Harness The
Check the harness It
metering connection abnormal It lights torque is
P2047 connection and replace lights
nozzle short up not
2. Nozzle damaged the Adblue nozzle up
circuit to limited
power supply
Non-air
assisted 1. Harness
connection abnormal Check the harness The
metering connection It
It lights torque is
nozzle drive P2049 2. Nozzle lights
Replace the Adblue up not
short circuit to unconnected up
nozzle limited
ground or open 3. Nozzle damaged
circuit

OBD Is the
PCODE lights torque
up limited?
1. Insufficient Check if the Adblue
Adblue level in its tank is at The
AdBlue tank proper level and It
2. Float stuck It lights torque is
low liquid P203B replenish it if needed; lights
3. Liquid level up not
level up
sensor fails Check the Adblue level limited
internally sensor
1. Adblue runs out Check if the Adblue

level in its tank is at
2. Float stuck proper level and It The
AdBlue tank It lights
P203F 3. Liquid level replenish it if needed lights torque is
nearly empty up
sensor fails up limited
Check the Adblue level
internally sensor
1. Adblue is
disqualified
2. The supply
module fails The added Adblue
should meet GB29518-
3. Because of 2013;
Adblue nozzle
failure, Adblue Check the supply
cannot be sprayed module and replace it if
out or sprayed out needed
poorly Check the Adblue
4. ECU and DCU nozzle and replace it if
are wired needed;
abnormally, and Check if the harness
SCR system cannot connection is normal;
work normally The
It
NOx Emission Check ECU or DCU It lights torque is
P0421 5. ECU or DCU lights
over 3.5g/kWh data or hardware and up not
data version is up
replace it if needed; limited
wrong
Check the exhaust gas
6. ECU or DCU is temperature sensor;
damaged
Check the catalyst and
7. Malfunction of replace it if needed;
exhaust gas
temperature sensor Check the NOx sensor
and replace it if needed;
8. Catalyst is
damaged (clogged or Change the engine body
aged) associated parts
9. NOx sensor fails etc.)
10. Original
emission of engine
is deteriorated

OBD Is the
PCODE lights torque
up limited?
1. Adblue is used
up or disqualified
2. The supply
module fails The added Adblue
should meet GB29518-
3. Because of 2013;
Adblue nozzle
failure, Adblue Check the supply
cannot be sprayed module and replace it if
out or sprayed out needed
poorly Check the Adblue
4. ECU and DCU nozzle and replace it if
are wired needed;
abnormally, and Check if the harness
SCR system cannot connection is normal;
work normally It The
NOx Emission Check ECU or DCU It lights
P0422 5. ECU or DCU lights torque is
over 7g/kWh data or hardware and up
data version is up limited
replace it if needed;
wrong
Check the exhaust gas
6. ECU or DCU is temperature sensor;
damaged
Check the catalyst and
7. Malfunction of replace it if needed;
exhaust gas
temperature sensor Check the NOx sensor
and replace it if needed;
8. Catalyst is
damaged (clogged or Change the engine body
aged) associated parts
9. NOx sensor fails etc.)
10. Original
emission of engine
is deteriorated
Charge the power The
Drive voltage It It
Power supply supply, or replace with a torque is
below the P3386 lights doesn’t
voltage is too low new power supply if not
lower limit up light up
needed limited
Power supply is The
Drive voltage It It
Power supply configured wrongly and torque is
above the P3387 lights doesn’t
voltage is too high thus needs to be not
upper limit up light up
replaced limited
Check if the solenoid
Short or open 1. Solenoid valve
valve harness or its The
circuit between harness or It It
circuit and connector is torque is
coolant P2602 connection is wrong; lights doesn’t
wrong; not
magnetic valve 2. Solenoid valve up light up
Check/replace the limited
and ground is damaged
solenoid valve

OBD Is the
PCODE lights torque
up limited?
Short circuit
between The
It It
coolant torque is
P2603 Same as P2602 Same as P2602 lights doesn’t
magnetic valve not
up light up
and power limited
supply
AdBlue pipe 1. Heater is not Check if the harness The
electric heater connected circuit is correct; It
It lights torque is
short circuit to P1407 lights
2. Heater harness Check the heater pin on- up not
ground or open up
is disconnected off signal limited
circuit
AdBlue pipe Check if the harness The
electric heater circuit is correct; It
Heater is short It lights torque is
drive short P1408 lights
circuited Check the heater pin on- up not
circuit to up
off signal limited
power supply
Mechanical 1. Adblue filter is Clean or replace the The
clogged filter; It
failure of non- It lights torque is
P1497 lights
air assisted 2. Supply pump is Check the supply pump up not
up
supply pump damaged and replace it if needed limited
Non-air Check if the solenoid

assisted valve harness or its The
circuit and connector is It
extractor Pump-back is short It lights torque is
P2061 wrong; lights
solenoid valve circuited up not
up
short circuit to Check/replace the limited
power supply solenoid valve
Non-air 1. Pump-back
Check if the solenoid
assisted solenoid valve is not
valve harness or its The
extractor connected It
circuit and connector is It lights torque is
solenoid valve P2059 2. Pump-back wrong; lights
up not
short circuit to solenoid valve up
Check/replace the limited
ground or open harness is
circuit solenoid valve
disconnected
7.3 Trouble codes of parts
7.3.1 Electric checking
The methods described below apply to the checking of electric malfunctions. Pay attention to the following
items during the troubleshooting:
7.3.1.1 Checking of battery and ground
Visually observe the battery wiring poles for oxidization and good contact and the ground for poor contact,
corrosion, rusting, and electromagnetic interference.

Figure 51 Battery
7.3.1.2 Checking of voltage and harness open-circuit and short-circuit
1 Checking of voltage
Rotate the ignition switch to ON to power on the part to be checked.
Connect the negative probe of a multimeter (Voltage measurement range) to the vehicle compartment ground
and connect the positive probe to the positive pole of the part.
2 Checking of harness
Before the checking of harness, ensure to disconnect the harness connector from the ECU and the part.
Connect the wires of multimeter to the pins of the part.
Open-circuit checking: Unplug the ECU connector and part connector (For instance, temperature sensor or
brake switch) and measure the resistance between corresponding pins of two connectors.
Short-circuit checking: The harness short-circuit to ground can be checked and determined by the measured
resistance to ground.
7.3.1.3 Checking of plugs, connectors, or harnesses
1 While loosening or unplugging the plugs, pull the plugs instead of the harnesses.
2 While plugging a plug, check the plug for deformation, damage, and looseness.
3 While plugging a plug, forcibly push down the plug, till the plug is clamped properly (A click sound).
4 Ensure that the wires and plugs can be re-connected completely.
5 Do not distort or pull the harnesses whenever possible.
6 Do not clamp the harness during the installation of parts.
7 Do not damage the protective caps of the harnesses.
8 Failure case

Figure 52: Failure case
7.3.1.4 Checking of ECU connectors and pins
1 Turn-off of key switch
Notice: Turn off the key switch and wait for the ECU to completely power off before the disassembling (It’s
recommended to wait for at least 2min).
2. Loosen the lock catches as shown in the diagram, unplug the ECU plug, and effectively protect the plug.
Figure 53: Plugging and unplugging of ECU
3 Check the ECU harness connector for rusting and check the ECU pins for bending and rusting.

Figure 54: ECU connector
4 Plug the ECU plug as shown in diagram below and fix the ECU lock catch (As shown by red circle in the
diagram).
Figure 55: Fix the ECU lock catches
5 Fix the ECU harness and ensure that the distance between first fixing point of harness to the ECU
connector is 10~15cm.
7.3.1.5 Check fuses or fusible parts.
1 Open main fuse case.
2 Unplug the fuse of related electric circuit.
3 Visually check fuse for burnout.
4 Check the fuse for intactness by a multimeter (Measurement of resistance). If the measured resistance is
0Ω, it indicates that the fuse is normal.
Figure 56: Fuse

7.3.1.6 Checking of relays
1 Open main fuse case.
2 Visually observe the relays for proper installation.
3 Measure the coil resistance by a multimeter.
Figure 57: Relay
7.3.1.7 Checking of ECU power supply
Preparations
1. The battery power is sufficient.
2. All vehicle fuses are normal.
3. All connectors are normal, without looseness or rusted pin.
Checking tools
1. Multimeter, type Y cables, and diagnostic unit.
2. Jumper case
Circuit/connection diagram
Figure 58: ECU power circuit diagram

Figure 59: ECU harness connector pin diagram
Figure 60: ECU position diagram (Reference)
1 Checking of power supply.
1.1 Rotate the ignition switch to OFF (If the ignition switch is previously at ON, rotate it to the OFF and wait
for at least 2min before subsequent operations, in order to prevent plugging/unplugging under live
condition)
1.2 Connect the jumper case.
1.3 Rotate the ignition switch to ON.
1.4 Measure the voltage between ECU pins 4 and 6 and vehicle compartment ground.
Normal value: 10~14V
Possible cause:
Result abnormal
Abnormal ECU power supply (Check further by section 7.3.1.2).
Result normal
The test is complete

7.3.1.8 Troubleshooting of ECU power supply malfunction
Preparations
Checking tools
1. Multimeter, type Y cables, and diagnostic unit.
2. Jumper case
Circuit/connection diagram
Diagram of parts:
Figure 63 Main relay pin diagram (Left: Relay; Right: Relay socket)

Figure 64: Main relay position (Reference)
Definitions of main relay pins (Reference)
Relay coil power Power supply (To

Relay coil control
Pin definition supply (To battery ECU power input battery positive
signal pin
positive pole) pole)
Main relay pin
86 85 87 30
number
ECU harness
connector pin BAT+ 50 4,6 BAT+
number
condition)
1.2 Unplug the main relay.
1.3 Measure the voltages of main relay socket pins 86 and 87 to vehicle compartment ground respectively.
Normal value: 10~14V/Main relay socket pins 86 and 87 to vehicle compartment
Result abnormal Possible cause:
Damage of harness (Check further by step 3 “harness checking”.)
Damage of connector (Visually observe connector for intactness.)
Result normal

2 Grounding checking
condition)
2.2 Unplug the ECU harness connector.
2.3 Measure the resistances between ECU pins 1 and 2 and vehicle compartment ground respectively.
Normal value: ~0Ω
3.1 Open-circuit checking
3.1.1 Rotate the ignition switch to OFF (If the ignition switch is previously at ON, rotate it to the OFF and
wait for at least 2min before subsequent operations, in order to prevent plugging/unplugging under live
condition)
3.1.2 Unplug the ECU harness connector.
3.1.3 Unplug the main relay.
3.1.4 Disconnect the positive connector of the battery.
3.1.5 Measure the resistance between ignition switch pin T15 and ECU harness connector pin 71.
3.1.6 Measure the resistance between main relay socket pin 85 and battery positive connector.
3.1.7 Measure the resistance between main relay socket pin 30 and battery positive connector.
3.1.8 Measure the resistances between main relay socket pin 30 and ECU harness connector pins 4 and 6
respectively.
3.1.9 Measure the resistance between ECU harness connector pins 1 and 2 and the vehicle compartment
ground.
Normal value: ~0Ω/Ignition switch T15 to ECU pin 71
Normal value: ~0Ω/Main relay pin 85 to ECU pin 50
Normal value: ~0Ω/Main relay pin 86 to battery positive connector
Normal value: ~0Ω/Main relay pin 87 to battery positive connector
Normal value: ~0Ω/Main relay pin 30 to ECU pins 4 and 6
Normal value: ~0Ω/ECU pins 1 and 2 to vehicle compartment ground

Open-circuit of harness
Damage of ECU power fuse
Result normal
3.2 Checking of short-circuit
condition)
3.2.4 Disconnect the positive connector of the battery.
3.2.5 Measure the resistance between ignition switch pin T15 and vehicle compartment ground.
3.2.6 Measure the resistance between main relay socket pin 85 and vehicle compartment ground.
Normal value: ≥1MΩ/Ignition switch T15 to vehicle compartment ground
Normal value: ≥1MΩ/Main relay pin 85 to vehicle compartment ground
Possible cause:
Harness short-circuit to ground
Result normal
3.3 Checking of harness internal short-circuit

condition)
3.3.4 Measure the resistances from main relay socket pin to all other socket pins.
Normal value: ≥1MΩ/Main relay pin 87 to all other pins
Normal value: ≥1MΩ/Main relay pin 86 to all other pins (Except pin 30)
Normal value: ≥1MΩ/Main relay pin 85 to all other pins
Normal value: ≥1MΩ/Main relay pin 30 to all other pins (Except pin 86)
Possible cause:
Harness short-circuit to ground and connector damage (Visually observe

connector for intactness.)
Result normal
4 Checking of parts
4.1 Checking of ignition switch voltage signal
condition)
4.1.3 Connect the positive connector of the battery.
4.1.4 Measure the voltage from ECU harness connector pin 71 to vehicle compartment ground.
Normal value: 10~14V/Rotate the ignition switch to ON.
Normal value: ~0V/Rotate the ignition switch to OFF.
Possible cause:
Damage of ignition switch
Result normal
4.2 Checking of main relay resistance
condition)

4.2.3 Measure the resistance between main relay pins 85 and 86.
Normal value: 70~80Ω
Possible cause:
Damage of main relay
Result normal
4.4 ECU: Main relay control signal
condition)
4.4.2 Plug the ECU harness connector.
4.4.3 Connect battery positive connector to battery positive wiring pole.
4.4.4 Plug the main relay.
4.4.5 Rotate the ignition switch to ON.
4.4.6 Measure the voltage between ECU pin 50 and vehicle compartment ground.
Normal value: 0~1.5V
Possible cause:
Poor contact between ECU harness connector and ECU pin
Damage of ECU
Result normal
4.5 Checking of main relay action
condition)
4.5.4 Measure the voltage between ECU pins 4 and 6 and vehicle compartment ground.

Damage of ECU fuse
Result normal

7.3.2 Trouble code - Main relay
Trouble
Trouble type Trouble description Trouble name
code
Earlier breaking malfunction of main

P0686 00 DFC_MRlyErlyOpng
relay
P0687 00 Stagnation malfunction of main relay DFC_MRlyStk
Possible malfunctions
1. Constant turn-on of system indicator lamp/malfunction indicator lamp
2. Start failure of engine
3. Flameout during running of engine
Preparations
Checking tools
1. Multimeter, connector adapter (Type Y cable), and diagnostic unit
2. Jumper case Circuit/wiring diagram
Figure 64: Main relay circuit diagram

Figure 66: Main relay pin diagram (Left: Relay; Right: Relay socket)
Diagram of parts
Figure 67: Main relay position diagram (Reference)
Definitions of main relay pins (Reference)
Relay coil power Power supply (To

Relay coil control
Pin definition supply (To battery ECU power input battery positive
signal pin
positive pole) pole)
Main relay pin
86 85 87 30
number
ECU harness
connector pin BAT+ 50 4,6 BAT+
number

1 Checking of parts:
1.1 Checking of main relay resistance
condition)
1.1.3 Measure the resistance between main relay pins 85 and 86.
Normal value: 70~80Ω
Result normal
1.2 ECU: Main relay control signal
condition)
1.2.4 Measure the voltage between ECU pin 50 and vehicle compartment ground by jumper case.
Normal value: 0~1.5V
Possible cause:
Result abnormal
Poor contact between ECU vehicle harness connector and ECU pin
Damage of ECU
Result normal

7.3.3 Trouble code - Battery

Trouble
code
Over-high internal battery voltage signal
P0563 85 DFC_BattUSRCMax
of electronic control unit (ECU)
Under-low internal battery voltage signal
P0562 84 DFC_BattUSRCMin
of electronic control unit (ECU)
Stoppage of relevant parts due to over-
P0563 17 DFC_DevLibBattUHi
high battery voltage
Shutdown of related parts due to under-
P0562 16 DFC_DevLibBattULo
low battery voltage
Possible malfunctions:
2. Engine noise.
3. Unstable engine idling speed
4. Engine jitter
5. Smoke of engine
6. Low engine power
7. Difficult start of engine
Preparations
Checking tools

Diagram of parts
Figure 69: Battery
1 Checking of battery voltage
1.2 Measure the voltage between positive and negative poles of battery.
Low battery power.
Alternator malfunction
Damage of charging relay or fuse
Result normal

7.3.4 Trouble code - Clutch switch

Trouble Trouble
Trouble description Trouble name
code type
P1700 01 Unreliable clutch signal DFC_ClthNpl
Preparations
Checking tools
2. Jumper case
Data stream. If the diagnostic unit is available, read the actual sensor signals as below:
Signal name Depress clutch pedal. Release clutch pedal Note
Normal value without

Clutch switch Depress Release
system malfunction
Electric circuit/wiring diagram
Figure 70: Clutch switch schematic diagram

Figure 71: Clutch switch harness connector (Reference)
Diagram of parts
Figure 73: Clutch switch position (Reference)

Clutch pin definition (Reference)
Pin definition Clutch power supply Clutch signal

Clutch harness connector pin
2 3
number
ECU harness connector pin
Main relay pin 87 23
number
condition)
1.2 Unplug the clutch switch harness connector.
1.4 Measure the voltage between clutch switch harness connector pin 2 and vehicle compartment ground.
Result normal
condition)
2.1.3 Unplug the clutch switch harness connector.
2.1.5 Measure the resistance between clutch switch harness connector pin and corresponding ECU pin.
Normal value: ~0Ω/Pin 2 to main relay socket pin 87
Normal value: ~0Ω/Pin 3 to ECU pin23

Harness open-circuit and connector damage (Visually observe connector for

intactness.)
Result normal
2.2 Checking of short-circuit to ground
condition)
2.2. 3 Unplug the clutch switch harness connector.
2.2.5 Measure the resistance between clutch switch harness connector pin and vehicle compartment ground.
Normal value: ≥1MΩ/Pin 2 to vehicle compartment ground
Possible cause:
Result abnormal
Result normal
condition)
2.3.5 Measure the resistance between clutch switch harness connector pins 2 and 3.
Normal value: ≥1MΩ

Internal short-circuit of harness and damage of connector (Visually observe

Result normal
3 Checking of parts
3.1 Checking of resistance
condition)
3.1.3 Measure the resistance between clutch switch sensor pins 2 and 3.
Normal value: ≥1MΩ/With clutch released
Normal value: ~0Ω/With clutch depressed
Damage of clutch switch
Result normal

3.2 Checking of clutch switch signal
condition)
3.2.3 Plug the clutch switch harness connector.
3.2.6 Read data stream by diagnostic unit: Clutch switch.
Data stream: Normal value: Depress/Depress clutch pedal.
Normal value: Release/Release clutch pedal.
Notice: If it’s impossible to read corresponding signals by the diagnostic unit, please use a jumper case to
directly measure the voltages at corresponding pins of clutch switch.
Clutch switch signal
Jumper case ECU pin 23 to vehicle compartment ground
Normal value: ~0V (With clutch released)
Normal value: 10~14V (With clutch depressed)
Damage of clutch switch
Result normal

7.3.5 Trouble code - Brake switch
Trouble
code
Brake signal not plausible, main brake signal and

P0504 62 DFC_BrkPlausChk
auxiliary brake signal varying at different time
Preparations
Checking tools
2. Jumper case
Data stream. If the diagnostic unit is available, read the actual sensor signals as below:
Release brake
Signal name Depress brake switch Note
switch
Normal value without
Brake switch Depress Release
system malfunction
Electric circuit/wiring diagram
Figure 74: Brake switch circuit diagram

Figure 75 and Figure 76: Brake switch harness connector and corresponding ECU harness connector
Diagram of parts
Figure 77: Brake switch position (Reference)
Brake pin definition (Reference)
Main brake Auxiliary brake Auxiliary brake

Pin definition Main brake signal
power supply power supply signal
Harness connector pin
2 3 1 4
number
ECU harness Main relay pin
80 Main relay pin 87 24
connector pin number 87
condition)
1.2 Unplug the brake switch harness connector.

1.4 Measure the voltage between brake switch harness connector pin 1 to vehicle compartment ground.
1.5 Measure the voltage between brake switch harness connector pin 2 to vehicle compartment ground.
Result normal
condition)
2.1.3 Unplug the brake switch harness connector.
2.1.5 Measure the resistance between brake switch harness connector pin and corresponding ECU pin.
Normal value: ~0Ω/Pin 3 to ECU pin 80
Result normal

condition)
2.2.5 Measure the resistance between brake switch harness connector pin and vehicle compartment ground.

Result normal
condition)
2.3.5 Measure the resistance between brake switch harness connector pin and all other connector pins.
Internal short-circuit of harness
Result normal

condition)
3.1.3 Measure the resistance between brake switch sensor pins 3 and 2.
3.1.4 Measure the resistance between brake switch sensor pins 4 and 1.
Normal value: ≥1MΩ/Release (Pins 3 and 2)
Normal value: ~0Ω/Depress (Pins 3 and 2)
Normal value: ~ 0Ω/Release (Pins 4 and 1)
Normal value: ≥1MΩ/ Depress (Pins 4 and 1)
Damage of brake switch
Result normal
3.2 Checking of brake switch signal
condition)
3.2.3 Plug the brake switch harness connector.
3.2.6 Read data stream by a diagnostic unit: Brake switch
Brake switch data stream
Normal value: Depress/Depress the brake pedal.
Normal value: Release/Release brake pedal.
Notice: If it’s impossible to read corresponding signals by the diagnostic unit, please use a jumper case to
directly measure the voltages at corresponding pins of brake switch.

Main brake switch signal
Normal value: ~0V (With brake released)
Normal value: 10~14V (With brake depressed)
Auxiliary brake switch signal
Normal value: 10~14V (With brake released)
Normal value: ~0V (With brake depressed)
Damage of brake switch
Result normal

7.3.6 Trouble code - Fuel metering unit

Trouble Trouble
code type
Fuel metering unit (MeUn) drive circuit short-
P0254 12 DFC_MeUnSCB
circuit to power supply
Fuel metering unit (MeUn) drive circuit short-
P0253 11 DFC_MeUnSCG
circuit to ground
Rail pressure positive deviation exceeding the limit
P1012 F5 at maximum set flow rate of fuel metering unit DFC_RailMeUn1
(MeNu) (actual rail pressure below the setting)
Rail pressure negative deviation exceeding the limit
P1013 F4 at minimum set flow rate of fuel metering unit DFC_RailMeUn2
(MeNu) (actual rail pressure above the setting)
2. Flameout of Engine during Running
Preparations
Checking tools
2. Jumper case
Circuit/wiring diagram

Figure 78: Fuel metering unit circuit diagram
Figure 79 and Figure 80: Fuel metering unit harness connector and corresponding ECU harness connector
Figure 81: Main relay pin diagram (Left: Relay; Right: Relay socket)
Diagram of parts
Figure 82: Fuel metering unit position

Definition of fuel metering unit pins
Fuel metering unit drive Fuel metering unit power

Pin definition
terminal terminal
Fuel metering unit harness
1 2
connector pin
ECU harness connector pin number 89 Main relay 87
condition)
1.2 Unplug fuel metering unit harness connector.
1.4 Measure the voltage between fuel metering unit harness connector pin 2 to vehicle compartment ground.
Result normal
condition)
2.1.3 Unplug fuel metering unit harness connector.
2.1.5 Measure the resistance between fuel metering unit harness connector pin 1 and corresponding pin of
ECU harness connector 89.
2.1.6 Measure the resistance between fuel metering unit harness connector pin 2 and main relay socket pin 87.
Normal value: ~0Ω/Pin 2 to main relay pin 87

Harness open-circuit
Connector damage (Visually observe connector for intactness.)
Result normal
condition)
2.2.5 Measure the resistance between fuel metering unit harness connector pin and vehicle compartment
ground.
Possible cause:
Result abnormal
Result normal
condition)
2.3.5 Measure the resistance between fuel metering unit harness connector pins 1 and 2.

Result normal
3.1 Checking of fuel metering unit resistance
condition)
3.1.3 Measure the resistance of fuel metering unit parts.
Normal value: 2.6~3.1Ω (At 20℃)/Pin 1 to pin 2
Damage of fuel metering unit
Result normal
3.2 ECU: Fuel metering unit control signal
condition)
3.2.6 Measure the voltage between fuel metering unit harness connector pin 1 to vehicle compartment ground.
Normal value: 3.0~4.0V
Damage of ECU
Result normal

7.3.7 Trouble code - Preheater relay

Trouble
code
Glow plug low-voltage system in open
P0670 F4 DFC_GlwPlgLVSOL
circuit
Electric control unit (ECU) glow plug low-
P160C 4B DFC_GlwPlgLVSOvrTemp
voltage system drive chip overheated
Glow plug low-voltage system shorted to
P0384 12 DFC_GlwPlgLVSSCB
power supply
Glow plug low-voltage system shorted to
P0383 11 DFC_GlwPlgLVSSCG
ground
Notice:
This trouble code only applies to preheater relay malfunction, but is not related to glow plug.
3. Smoke of engine
Preparations
Checking tools

Figure 83: Preheater relay circuit diagram
Diagram of parts (Reference position)
Figure 85: Preheater relay position (Reference)
condition)

1.2 Unplug the preheater relay.
1.4 Measure the voltage between preheater relay socket pin 87 to vehicle compartment ground.
1.5 Measure the voltage between preheater relay socket pin 30 to vehicle compartment ground.
Normal value: 10~14V/Preheater relay socket pin 87 to ground
Normal value: 10~14V/Preheater relay socket pin 30 to ground
Possible cause:
Result abnormal
Result normal
condition)
2.1.3 Unplug the preheater relay.
2.1.5 Measure the resistance between preheater relay socket pin ST and ECU harness connector pin 49.
2.1.6 Measure the resistance between preheater relay socket pin DI and ECU harness connector pin 41.
2.1.7 Measure the resistance between preheater relay socket pin 87 and main relay socket pin 30.
2.1.8 Measure between preheater relay socket pin 30 and power positive pole.
Normal value: ~0Ω/Preheater relay socket pin ST to ECU pin 49
Normal value: ~0Ω/Preheater relay socket pin DI to ECU pin 41
Normal value: ~0Ω/Preheater relay socket pin 87 to main relay 30
Normal value: ~0Ω/Preheater relay socket pin 30 to battery positive pole

Result normal
condition)
2.2.5 Measure the resistance between preheater relay socket pin and vehicle compartment ground.
Normal value: ≥1MΩ/Resistance between socket pin ST to vehicle compartment ground
Normal value: ≥1MΩ/Resistance between socket pin DI to vehicle compartment ground
Normal value: ≥1MΩ/Resistance between socket pin 30 to vehicle compartment ground
Normal value: ≥1MΩ/Resistance between socket pin 87 to vehicle compartment ground
Result normal
condition)
2.3.5 Measure the resistances from preheater relay socket pin to all other pins.

Result normal
3 Checking of parts
3.1 ECU: Preheater relay control signal
condition)
3.1.6 Measure the voltage between preheater relay socket pin ST to vehicle compartment ground.
Damage of ECU
Result normal

7.3.8 Trouble code - Throttle
Trouble
Trouble
code (P Trouble description Trouble name
type
code)
Permanent positive deviation of throttle valve

P2173 85 DFC_ThrVlvGovDvtMax
(TVA) controller
Permanent negative deviation of throttle valve

P2175 84 DFC_ThrVlvGovDvtMin
(TVA) controller
Throttle valve (TVA) H-bridge drive open-

P2100 13 DFC_ThrVlvHBrgOpnLd
circuit
Throttle valve (TVA) H-bridge drive current

P2101 1D DFC_ThrVlvHBrgOvrCurr
overload

P1040 4B internal throttle valve (TVA) H-bridge drive DFC_ThrVlvHBrgOvrTemp
chip
Throttle valve (TVA) H-bridge drive circuit

P2103 F0 DFC_ThrVlvHBrgShCirBatt1
high-end short-circuit to power supply

P1046 12 DFC_ThrVlvHBrgShCirBatt2
low-end short-circuit to power supply

P2102 F1 DFC_ThrVlvHBrgShCirGnd1
high-end short-circuit to ground

P1044 11 DFC_ThrVlvHBrgShCirGnd2
low-end short-circuit to ground
Short-circuit and overload of throttle valve

P1041 F2 DFC_ThrVlvHBrgShCirOvrLd
(TVA) H-bridge drive circuit
Overheating of throttle valve (TVA) H-bridge

P1042 92 DFC_ThrVlvHBrgTempOvrCurr
drive circuit
Low voltage of throttle valve (TVA) H-bridge

P1045 A2 DFC_ThrVlvHBrgUndrVltg
drive circuit

P2622 12 DFC_ThrVlvSRCMax
value above upper limit (Analog signal)

P2621 11 DFC_ThrVlvSRCMin
value below lower limit (Analog signal)
2. Low engine power
3. Increased engine idling speed

4. Over-high fuel consumption
5. Diluted engine oil
Preparations
Checking tools
Figure 86: Throttle circuit diagram
Figure 87 and Figure 88: Throttle harness connector and corresponding ECU harness connector

Diagram of parts
Figure 89: Throttle position
condition)
1.2 Unplug the throttle harness connector.
1.4 Measure the voltages between throttle harness connector pins 3 and 4 and vehicle compartment ground.
Normal value: ~5V/Pin 3 to vehicle compartment ground
Possible cause:
Result abnormal
Result normal
condition)
2.1.2 Unplug the throttle harness connector.

2.1.4 Measure the resistance between throttle harness connector pin and corresponding ECU pin.
Throttle position sensor
Throttle drive motor
Result normal
condition)
2.2.4 Measure the resistance between throttle harness connector pin and vehicle compartment ground.
Throttle position sensor
Throttle drive motor

Result normal
condition)
2.3.4 Measure the resistance between throttle harness connector pin and all other pins of harness connector.
Normal value: ≥1MΩ/Pin 1 to all other pins
Result normal
3 Checking of parts
condition)
3.1.3 Directly measure the resistance between throttle connector pins 4 and 1.
Normal value 2.0: ~4.0Ω/Pin 4 to pin 1
Damage of throttle
Result normal

7.3.9 Trouble code - Fuel injectors
Trouble Trouble
Trouble description Trouble description
code type
Open-circuit of ignition sequence 1st cylinder fuel

P0201 13 DFC_InjVlv_DI_NoLd_0
Open-circuit of ignition sequence 2nd cylinder fuel

Open-circuit of ignition sequence 3rd cylinder fuel

Open-circuit of ignition sequence 4th cylinder fuel

Fuel injection control module 1 (Harness) short-

P2146 F0 DFC_InjVlv_DI_ScBnk
circuit malfunction
Short-circuit of ignition sequence 1st cylinder fuel

P121A 12 injector harness ((high terminal or low terminal DFC_InjVlv_DI_ScCyl_0
shorted to power supply or ground)
Short-circuit of ignition sequence 2nd cylinder fuel

P121B 12 injector harness (high terminal or low terminal DFC_InjVlv_DI_ScCyl_1
Short-circuit of ignition sequence 3rd cylinder fuel

P121C 12 injector harness (high terminal or low terminal DFC_InjVlv_DI_ScCyl_2
Short-circuit of ignition sequence 4th cylinder fuel

P121D 12 injector harness (high terminal or low terminal DFC_InjVlv_DI_ScCyl_3

P1200 11 DFC_InjVlv_DI_ScHsLs_0
sequence 1st cylinder harness

sequence 2nd cylinder harness

sequence 3rd cylinder harness

sequence 4th cylinder harness
2. Low engine power
4. Engine jitter

6. Engine cylinder misfire
Preparations
Checking tools
Low end at 1st cylinder fuel injector
1st cylinder fuel injector

ECU Electronic control unit
High end at 1st and 4th cylinders
Low end at 4th cylinder fuel injector

4th cylinder fuel injector
Low end at 3rd cylinder fuel injector
High end at 2nd and 3rd cylinders 3rd cylinder fuel injector
Low end at 2nd cylinder fuel injector

2nd cylinder fuel injector
Figure 90: Fuel injector circuit diagram
Figure 91 and Figure 92: Fuel injector harness connector and corresponding ECU harness connector

Figure 93: Fuel injector position
Definitions of fuel injector pins
Fuel injector 1/1st Fuel injector 2/2nd Fuel injector 3/3rd Fuel injector
cylinder cylinder cylinder 4/4th cylinder
High- Low- High- Low- High- Low- High- Low-

Pin definition
level level level level level level level level
Fuel injector
harness
2 1 2 1 2 1 2 1
connector pin
number
ECU harness
connector pin 3 73 5 51 5 29 3 7
number
Notice:
The engine cylinder near the fan is the 1st cylinder and the cylinder near the transmission is the 4th cylinder.
condition)
1.1.3 Unplug the harness connectors of all fuel injectors.
1.1.4 Measure the resistance between fuel injector harness connector pin and corresponding pin of ECU
harness connector.

Fuel injector 1:
Normal value: ~0Ω/Pin 2 to pin 3
Fuel injector 2:
Fuel injector 3:
Fuel injector 4:

intactness.)
Result normal
condition)
1.2.4 Measure the resistance between fuel injector harness connector pins 1 and 2 and the vehicle
compartment ground.
All fuel injectors:

Result normal
1.3 Checking of short-circuit to battery
condition)
1.3.4 Measure the voltages between fuel injector harness connector pins 1 and 2 and vehicle compartment
ground.
All fuel injectors:
Harness short-circuit to battery
Result normal
1.4 Checking of high-level/low-level short-circuit
condition)
1.4.4 Measure the resistance between fuel injector harness connector pins 1 and 2
All fuel injectors:
Normal value: ≥1MΩ/Pin 1 to pin 2
Harness high-level short-circuit to low-level
Result normal

2 Checking of parts: Fuel injector
condition)
2.1.3 Measurement of fuel injector resistance
All fuel injectors:
Normal value: 0.1~0.3Ω/Pin 1 to pin 2
Damage of fuel injector
Result normal

7.3.10 Trouble code - Accelerator pedal sensor
Trouble
code
Accelerator pedal sensor 1 voltage signal

P0123 12 DFC_SRCHighAPP1
above upper limit

P0223 12 DFC_SRCHighAPP2
above upper limit

P0122 11 DFC_SRCLowAPP1
below lower limit

P0222 11 DFC_SRCLowAPP2
below lower limit
Accelerator pedal 1 and accelerator pedal 2

P2135 64 DFC_SyncAPP
signal reasonableness malfunction
3. Poor response of accelerator pedal during running of engine
Preparations
Checking tools
2. Jumper case
Data stream and normal value. If the diagnostic unit is available, read the actual sensor signals as below:
Fully depress the

Signal name Fully release the pedal. Note
pedal.
Accelerator pedal
0% 100%
opening extent
Accelerator pedal
0.76V 3.75V
sensor 1
Accelerator pedal
0.38V 1.85V
sensor 2

Electric circuit diagram
Accelerator pedal sensor 1 power

supply
ECU Electronic
Accelerator pedal sensor 1 Accelerator pedal sensor 1 signal
control unit
Accelerator pedal sensor 1 signal ground
Accelerator pedal sensor 2 power supply
Accelerator pedal sensor 2 Accelerator pedal sensor 2 signal
Accelerator pedal sensor 2 signal ground
Figure 94: Accelerator pedal circuit diagram
Figure 95 and Figure 96: Accelerator pedal harness connector and corresponding ECU harness connector
Diagram of parts
Figure 97: Accelerator pedal position (Reference position)

Definitions of accelerator pedal sensor pins
Accelerator Accelerator Accelerator Accelerator

Accelerator Accelerator
Pin pedal 2 pedal 1 pedal 1 pedal 2
pedal 2 pedal 1
definition signal signal power power
signal signal
ground ground supply supply
Accelerator
pedal
2 4 5 1 3 6
connector
pin number
ECU harness
connector 82 83 18 60 61 40
pin number
condition)
1.2 Unplug the harness connector of accelerator pedal sensor.
1.4 Measure the voltage between accelerator pedal harness connector pin 5 and vehicle compartment ground.
Accelerator pedal sensor 1 /
Result normal

condition)
2.1.3 Unplug the harness connector of accelerator pedal sensor.
2.1.4 Measure the resistance between accelerator pedal sensor harness connector pin and corresponding ECU
harness connector pin.

intactness.)
Result normal
condition)
2.2.4 Measure the resistance between sensor harness connector pin and vehicle compartment ground.

Result normal
condition)
2.3.4 Measure the resistance between accelerator pedal sensor harness connector pin and all other connector
pins.
Result normal
3 Checking of parts
3.1 Checking of signal voltage
condition)

3.1.3 Plug the harness connector of accelerator pedal sensor.
3.1.5 Read the signal voltages and calculated opening extents of accelerator pedal sensors 1 and 2 by a
diagnostic unit.
Notice:
If the corresponding signal can’t be read by the diagnostic unit, please use an additional accelerator pedal
connector adapter (Type Y cable) or a jumper case to directly measure the voltages at corresponding pins of
accelerator pedal switch.
Accelerator pedal sensor 1
Jumper case
ECU pin 61 to vehicle compartment ground
Connector adapter (Type Y cable)
Sensor pin 3 to vehicle compartment ground
Normal value: 0.65~0.80V (With accelerator pedal fully released)
Normal value: 3.80~4.20V (With accelerator pedal fully depressed)
Accelerator pedal sensor 2
Jumper case
Sensor pin 1 to vehicle compartment ground
Normal value: 0.32~0.39V (With accelerator pedal fully released)
Normal value: 1.90~2.10V (With accelerator pedal fully depressed)
Damage of accelerator pedal sensor
Result normal

7.3.11 Trouble code - Crankshaft sensor

Trouble
code
P0336 31 Crankshaft signal not detected DFC_EpmCrSNoSig
Crankshaft signal interference or loss
P0335 29 DFC_EpmCrSErrSig
malfunction
Preparations
Checking tools
Crankshaft positive signal
Crankshaft sensor Crankshaft negative signal

Harness shield GND
Figure 98: Circuit diagram of crankshaft sensor
Figure 99 and Figure 100: Crankshaft sensor harness connector and corresponding ECU harness connector

Diagram of parts
Figure 101: Crankshaft sensor position
Crankshaft sensor pin definitions
Pin definition Crankshaft positive signal Crankshaft negative signal

Crankshaft sensor harness connector pin
1 2
number
ECU harness connector pin number 52 74
condition)
1.1.3 Unplug the crankshaft sensor harness connector.
1.1.4 Measure the resistance between crankshaft sensor harness connector pin and corresponding pin of ECU
harness connector.
Result normal

condition)
1.2.4 Measure the resistance between crankshaft sensor harness connector pin and vehicle compartment
ground.
Possible cause:
Result abnormal
Result normal
condition)
1.3.4 Measure the resistance between crankshaft sensor harness connector pins 1 and 2.
Result normal

2 Checking of parts
condition)
2.1.3 Measure the resistance between crankshaft sensor pins 1 and 2.
Normal value: 330~490Ω (At 25°C)
Crankshaft sensor malfunction
Result normal
2.2 Checking of crankshaft sensor signal
condition)
2.2.2 Plug the crankshaft sensor harness connector.
2.2.5 Start/drag the engine.
2.2.6 Use an oscilloscope to measure the waveform of crankshaft sensor signal via connector adapter (Type Y
cable) or jumper case.
Notice:
Connect the positive probe of oscilloscope to crankshaft sensor pin 1 or ECU pin 52 and negative probe to
crankshaft sensor pin 2 or ECU pin 74.
Crankshaft sensor waveform
Jumper case
ECU pin 52 (Positive probe of oscilloscope) to ECU pin 74 (Negative probe of oscilloscope)
Sensor pin 1 (Positive probe of oscilloscope) to sensor pin 2 (Negative probe of oscilloscope)

Figure 102: Crankshaft sensor waveform
Installation error of crankshaft and error of wheel disc
Clearance between crankshaft sensor and wheel disc
Crankshaft sensor malfunction
Result normal

7.3.12 Trouble code - Rail pressure sensor
Trouble Trouble
code type

P0191 85 DFC_RailPOfsTstMax
(Over-high voltage)

P0194 84 DFC_RailPOfsTstMin
(under-low voltage)
Rail pressure sensor voltage signal above upper

P0193 12 DFC_RailPSRCMax
limit
Rail pressure sensor voltage signal below lower

P0192 11 DFC_RailPSRCMin
limit
4. Low engine power
Preparations
3. All connectors are normal, without looseness or rusted pin
Checking tools

ECU Electronic control
Rail pressure sensor power

supply
Rail pressure sensor Rail pressure signal
unit
Rail pressure sensor signal

ground
Figure 103: Rail pressure sensor circuit diagram

Figure 104 and Figure 105: Rail pressure sensor harness connector and corresponding ECU harness connector
Diagram of parts
Figure 106: Rail pressure sensor position
Definitions of rail pressure sensor pins
Rail pressure signal Rail pressure sensor

Pin definition Rail pressure signal
ground power supply
Rail pressure sensor harness
1 2 3
connector pin number
76 54 32
number
condition)
1.2 Unplug the rail pressure sensor harness connector.
1.4 Measure the voltage between rail pressure sensor harness connector pin 3 and vehicle compartment
ground.

Normal value: ~5V
Result normal
condition)
2.1.3 Unplug the rail pressure sensor harness connector.
2.1.4 Measure the resistance between rail pressure sensor harness connector pin and corresponding pin of
ECU harness connector.
Possible cause:
Result normal

condition)
2.2.4 Measure the resistance between rail pressure sensor harness connector pin and vehicle compartment
ground.
Possible cause:
Result normal
condition)
2.3.4 Measure the resistance between rail pressure sensor harness connector pin and all other connector pins.
Possible cause:
Result normal

3 Checking of parts
3.1 Checking of rail pressure sensor signal
condition)
3.1.2 Plug the rail pressure sensor harness connector.
3.1.5 Read data stream: rail pressure sensor by a diagnostic unit.
Data stream: Rail pressure
Normal value: ~277bar (At 800r/min low idling speed)
Normal value: ~556bar (At 2,000r/min high idling speed)
Notice:
If the corresponding signal can’t be read by diagnostic unit, use an additional connector adapter (Type Y cable)
or a jumper case to directly measure the signal voltage at corresponding pins of rail pressure sensor.
Rail pressure sensor signal voltage
Jumper case
Sensor connector pin 2 to vehicle compartment ground
Normal value: ~ 1.04V (At 800r/min low idling speed)
Normal value: ~ 1.60V (At 2,000r/min high idling speed)
Damage of rail pressure sensor
Result normal

7.3.13 Trouble code - Camshaft sensor

Trouble Trouble
code type
Camshaft signal interference or loss
P0339 29 DFC_EpmCaSI1ErrSig
malfunction
P0340 31 Camshaft signal not detected DFC_EpmCaSI1NoSig
Preparations
Checking tools

ECU Electronic control
Camshaft sensor power supply
Camshaft sensor Camshaft signal

unit
Camshaft signal ground
Figure 107: Circuit diagram of camshaft sensor

Figure 108 and Figure 109: Camshaft sensor harness connector and corresponding ECU harness connector
Diagram of parts
Figure 110: Camshaft sensor position
Definitions of camshaft sensor pins
Camshaft signal Camshaft sensor power

Pin definition Camshaft signal
ground supply
Camshaft sensor harness

2 1 3

44 46 45
number
condition)

1.2 Unplug the camshaft sensor harness connector.
1.4 Measure the voltage between camshaft sensor harness connector pin 3 and vehicle compartment ground.
Normal value: ~5V
Result normal
condition)
2.1.3 Unplug the camshaft sensor harness connector.
2.1.4 Measure the resistance between camshaft sensor harness connector pin and corresponding pin of ECU
harness connector.
Normal value: ~ 0Ω/Pins 2 and pin 44
Result normal

condition)
2.2.4 Measure the resistance between camshaft sensor harness connector pin and vehicle compartment ground.
Possible cause:
Result abnormal
Result normal
condition)
2.3.4 Measure the resistance between camshaft sensor harness connector pin and all other connector pins.
Result normal

3 Checking of parts
3.1 Checking of camshaft sensor signal
condition)
3.1.3 Plug the camshaft sensor harness connector.
3.1.6 Use an oscilloscope to measure the waveform of camshaft sensor signal via connector adapter (Type Y
cable) or jumper case.
Notice:
Connect the positive probe of oscilloscope to camshaft sensor pin 1 or ECU pin 46 and connect the negative
probe to vehicle compartment ground.
Camshaft sensor waveform
Jumper case ECU pin 46 (Positive probe of oscilloscope) to vehicle compartment ground ECU pin 44
(Negative probe of oscilloscope)
Figure 111: Camshaft sensor waveform

Installation error of camshaft sensor
Wheel disc error
Clearance between camshaft sensor and wheel disc
Camshaft sensor malfunction
Result normal

7.3.14 Trouble code - Crankshaft and camshaft senor reasonableness
Trouble
code
Excessive deviation between camshaft

P0341 01 DFC_EpmCaSI1OfsErr
signal and crankshaft signal
Preparations
Checking tools
Crankshaft positive
ECU Electronic
signal
control unit
Crankshaft sensor Crankshaft negative signal

Harness shield GND
Figure 112: Circuit diagram of crankshaft sensor
Camshaft sensor power

ECU Electronic
supply
control unit
Camshaft signal
Camshaft sensor
Camshaft signal ground
Figure 113: Circuit diagram of camshaft sensor

Figure 115 and Figure 116: Crankshaft sensor and camshaft sensor harness connector
Diagram of parts
Figure 117 and Figure 118: Crankshaft sensor and camshaft sensor position
Crankshaft sensor pin definitions
Crankshaft negative
Pin definition Crankshaft positive signal
signal
Crankshaft sensor harness connector pin
1 2
number


ground supply
2 1 3
44 46 45
number
1 Checking of parts
1.1 Checking of crankshaft and camshaft sensor signals
condition)
1.1.3 Use an oscilloscope to measure the waveform of crankshaft and camshaft sensor signals via connector
adapter (Type Y cable) or jumper case.
Notice:
Connect the positive probe of oscilloscope channel 1 to crankshaft sensor pin 1 or ECU pin 52 and connect
the negative probe to vehicle compartment ground.
Crankshaft sensor waveform
Jumper case
ECU pin 52 (Positive probe of oscilloscope) to vehicle compartment ground (Negative probe of oscilloscope)
Sensor pin 1 (Positive probe of oscilloscope) to vehicle compartment ground (Negative probe of oscilloscope)
Notice:
Connect the positive probe of oscilloscope channel 2 to camshaft sensor pin 1 or ECU pin 46 and connect the
negative probe to vehicle compartment ground.
Camshaft sensor waveform
Jumper case
ECU pin 46 (Positive probe of oscilloscope) to vehicle compartment ground (Negative probe of oscilloscope)
Sensor pin 1 (Positive probe of oscilloscope) to vehicle compartment ground (Negative probe of oscilloscope)

Crankshaft sensor and camshaft sensor signals
Figure 119: Crankshaft sensor and camshaft sensor waveforms
Installation error of crankshaft sensor and camshaft sensor
Crankshaft and camshaft wheel disc error
Result normal

7.3.15 Trouble code - DOC differential pressure sensor
Trouble code (P
code)
DOC differential pressure sensor

P2461 12 DFC_PPFltDiffSRCMax
voltage signal above upper limit
DOC differential pressure sensor

P2460 11 DFC_PPFltDiffSRCMin
voltage signal below lower limit
Possible symptoms
2. Low engine power
Pre-checking
1. Sufficient battery power.
Checking tools
1. Multimeter and diagnostic unit
Figure 120: DOC differential pressure sensor circuit diagram

Figure 121 and Figure 122: DOC differential pressure sensor harness connector and corresponding ECU
harness connector
Diagram of parts
Figure 123: Installation position of DOC differential pressure sensor
Pin definition
Differential pressure
Pin definition Power supply Signal ground
signal
DOC differential pressure

sensor harness connector pin 1 2 3
number

13 59 36
number
condition)
1.2 Unplug the DOC differential pressure sensor harness connector.

1.4 Measure the voltage between DOC differential pressure sensor harness connector pin 1 and vehicle
compartment ground.
Result normal
condition)
2.1.3 Unplug the DOC differential pressure sensor harness connector.
2.1.4 Measure the resistance between DOC differential pressure sensor harness connector pin and ECU
harness connector pin.
Result normal
condition)
2.2.4 Measure the resistance between DOC differential pressure sensor harness connector pin and vehicle
compartment ground.

Result normal
condition)
2.3.4 Measure the resistance between DOC differential pressure sensor harness connector pin and all other
connector pins.
Result normal
3 Checking of parts
3.1 DOC differential pressure signal voltage
condition)
3.1.3 Plug the DOC differential pressure sensor harness connector.
3.1.5 Read the data stream by a diagnostic unit.

Data stream: DOC differential pressure
Normal value: ~0hPa (At 800rpm idling speed)
Normal value: ~53hPa (At 4,400rpm maximum speed)
Notice:
If the corresponding signal can’t be read by a diagnostic unit, please use a jumper case to directly measure the
DOC differential pressure signal voltage.
DOC differential pressure signal voltage
Normal value: ~0.54V (At 800rpm idling speed)
Normal value: ~0.76V (At 4,400rpm maximum speed)
Damage of DOC differential pressure sensor
Result normal
3.2 Checking of pressure pipe and connector
3.2.1 Check two pressure pipes connected to the DOC and differential pressure sensor for leakage and
blockage.
3.2.2 Check the pressure pipe connectors connected to the DOC and differential pressure sensor for intactness
and secure connection.
3.2.3 Check the installation position of pressure pipes. One pipe is connected to the upstream of DOC and
one pipe is connected to the downstream of DOC. It’s prohibited to install reversely two pressure pipes
on the differential pressure sensor end.
Possible cause:
Result abnormal
Leakage or blockage of pressure pipes and loose connectors of pressure pipes
Reversed installation of two pressure pipes
Result normal

7.3.16 Trouble code - Coolant temperature sensor

Trouble Trouble
code type
Coolant temperature sensor voltage below lower
P0117 12 DFC_CEngDsTSRCMin
limit
Coolant temperature sensor voltage above upper
P0118 11 DFC_CEngDsTSRCMax
limit
2. Low engine power
Preparations
Checking tools
Figure 124: Circuit diagram of coolant temperature sensor
Figure 125 and Figure 126: Coolant temperature sensor harness connector and corresponding ECU harness
connector

Diagram of parts
Figure 127: Coolant temperature sensor position
Definitions of coolant temperature sensor pins
Coolant temperature
Pin definition Coolant temperature signal
signal ground
Coolant temperature sensor harness 1 2

condition)
1.2 Unplug the coolant temperature sensor harness connector.
1.4 Measure the voltage between coolant temperature sensor harness connector pin 1 and vehicle
compartment ground.
Normal value: ~5V
Result normal

condition)
2.1.3 Unplug the coolant temperature sensor harness connector.
2.1.4 Measure the resistance between coolant temperature sensor harness connector pin and corresponding
ECU harness connector pin.
Result normal
condition)
2.2.4 Measure the resistance between coolant temperature sensor harness connector pin and vehicle
compartment ground.
Result normal

condition)
2.3.4 Measure the resistance between coolant temperature sensor harness connector pins 1 and 2.
Result normal
3 Checking of parts
condition)
3.1.3 Measure the resistance between coolant temperature sensor pins.
Normal value: 2.3~2.6KΩ/ Between pins 1 and 2 (At 20°C)
Damage of coolant temperature sensor
Result normal
condition)
3.2.2 Plug the coolant temperature sensor harness connector.

Data stream: Coolant temperature and coolant temperature signal voltage
Normal value: 2.6~2.8V (At 20°C)
Notice: If the corresponding signal can’t be read by the diagnostic unit, please use a jumper case to directly
measure the voltages at corresponding pins of coolant temperature sensor.
Coolant temperature sensor signal voltage
Damage of coolant temperature sensor
Result normal

7.3.17 Trouble code - Turbocharged pressure and temperature sensor
Trouble code Trouble

(P code) type
Turbocharger pressure sensor voltage

P0237 11
signal below lower limit
Turbocharger pressure sensor voltage

P0238 12 DFC_PIntkVUsSRCMax
signal above upper limit
Turbocharged and intercooled intake

P0097 11 DFC_TCACDsSRCMin
temperature sensor voltage signal
Turbocharged and intercooled intake

P0098 12 DFC_TCACDsSRCMax
temperature sensor voltage signal
Possible symptoms
2. Low engine power
3 Increased engine idling speed
5 Diluted engine oil
Pre-checking
Checking tools
Figure 128: Turbocharged pressure and temperature sensor circuit diagram

Connect to turbocharged pressure and temperature sensor
Figure 129 and Figure 130: Turbocharged pressure sensor harness connector and corresponding ECU harness
connector
Diagram of parts
Figure 131: Turbocharged pressure sensor position
Pin definition
Turbocharged
Power Turbocharged
Pin definition Signal ground temperature
supply pressure signal
signal
Turbocharged pressure
sensor harness connector 4 2 3 1
pin number
78 35 87 56
number
condition)
1.2 Unplug the turbocharged pressure sensor harness connector.
1.4 Measure the voltage between turbocharged pressure sensor harness connector pin 1 and vehicle

compartment ground.
1.5 Measure the voltage between intake temperature sensor harness connector pin 3 and vehicle
compartment ground.
Result normal
condition)
2.1.3 Unplug the turbocharged pressure sensor harness connector.
2.1.4 Measure the resistance between turbocharged pressure sensor harness connector pin and ECU harness
connector pin.
Result normal
condition)

2.2.3 Unplug the turbocharged pressure and temperature sensor harness connector.
2.2.4 Measure the resistance between turbocharged pressure sensor harness connector pin and vehicle
compartment ground.
Result normal
condition)
2.3.3 Unplug the turbocharged pressure and temperature sensor harness connector.
2.3.4 Measure the resistance between turbocharged pressure and temperature sensor harness connector pin
and other connector pins.
2.3.5 Measure the resistance between turbocharged pressure and temperature sensor pins 3 and 4.
Normal value: 26.0~28.0KΩ (At 0°C)
Result normal

3 Checking of parts
3.1 Turbocharged pressure signal voltage
condition)
3.1.3 Plug the turbocharged pressure sensor harness connector.
Data stream
Turbocharged pressure and turbocharged pressure signal voltage
Normal value: ~1.62V (At 0 altitude and under idling condition)
Intake temperature and intake temperature signal voltage
Normal value: 3.3~3.5 (At 20°C)
Notice:
If the corresponding signal can’t be read by a diagnostic unit, please use a jumper case to directly measure the
turbocharged pressure and temperature signal voltage.
Turbocharged pressure signal voltage
Normal value: ~1.62V (At 0 altitude and under idling condition)
Intake temperature signal voltage

Damage of turbocharged pressure and temperature sensor
Result normal

7.3.18 Trouble code - Cruise control switch
Trouble
Trouble
code (P Trouble description Trouble name
type
code)
Unreasonable signal of cruise control

P0579 62 DFC_CrCNPL
switch
Possible symptoms
Pre-checking
Checking tools
Figure 132: Cruise control switch circuit diagram
Figure 133: ECU harness connector

Diagram of parts
Figure 134: Cruise control switch position (Reference)
Definitions of cruise control switch pins (Reference)
Cruise control switch Cruise control switch signal

Pin definition
control signal ground
Harness connector pin number 1 2
condition)
1.2 Unplug the cruise control switch harness connector.
1.4 Measure the voltage between harness connector pin 1 and vehicle compartment ground.
Normal value: 4.9~5.1V/Pin 1 to vehicle compartment ground
Result normal

condition)
2.1.3 Unplug the cruise control switch harness connector.
2.1.5 Measure the resistance between harness connector pin and ECU harness connector pin.
Result normal
condition)
2.2.4 Measure the resistance between harness connector pin and vehicle compartment ground.
Result normal

condition)
2.3.4 Measure the resistance between harness connector pins 1 and 2.
Normal value: ≥1MΩ/Pin 1 to pin 2
Result normal

7.3.19 Trouble code - CAN bus communication module
Trouble code
(P code)
U0078 F0 Bus communication interruption DFC_INMBusOff
Possible symptoms
Pre-checking
Checking tools
CAN low
CAN communication
module CAN high
Figure 135: CAN communication module circuit diagram

Diagram of parts
Figure 137: Diagnostic interface harness connector pin
Pin definition
Pin definition CAN_H CAN_L

Diagnostic harness connector pin
6 14
number
Notice:
CAN bus communication module is used for diagnosis and update of the ECU data.
condition)
1.1.2 Unplug the ECU vehicle harness connector.
1.1.3 Measure the resistance between diagnostic connector pin and ECU vehicle harness connector pin.
Normal value: ~ 0Ω/Pins 14 to ECU pin 65
Result normal

condition)
1.2.3 Measure the resistance between diagnostic connector pin and vehicle compartment ground.
Result normal
2 Checking of parts
condition)
2.1.3 Measure the resistance between diagnostic connector pins 6 and 14.
Normal value: ~60Ω
Poor contact between ECU harness connector and ECU
Damage of ECU
Result normal
condition)
2.2.4 Measure the voltage between ECU pins 65 and 66 and vehicle compartment ground.

Normal value: ~ 2.5V/Pin 65 to vehicle compartment ground
Normal value: ~ 2.5V/Pin 66 to vehicle compartment ground
Possible cause:
Result abnormal
Please disconnect the connecting nodes from CAN bus communication module.
Result normal

7.3.20 Trouble code - Electronic control unit (ECU)

Trouble Trouble
code type
Vehicle performance restraint 0
P110A F0 DFC_CoVehPrfmLim0
triggered
P110B F1 DFC_CoVehPrfmLim1
triggered
P110C F2 DFC_CoVehPrfmLim2
triggered
P110D F3 DFC_CoVehPrfmLim3
triggered
Vehicle performance restraint function
P110E F4 DFC_CoVehPrfmLimAct
triggered
ECU internal chip Cy327
P0607 F0 DFC_Cy327SpiCom
communication malfunction
Electric control unit (ECU) memory
P1651 F1 DFC_EEPRdErr
EEPROM read fault
Electric control unit (ECU) memory
P1652 44 DFC_EEPWrErr
EEPROM write fault
P1610 0 Fuel injection cutoff request indicator DFC_EngICO
P0219 0 Engine overspeed indicator DFC_EngPrtOvrSpd
ECU software malfunction indication
P062F F2 DFC_LLim_EEPErr
during write/read
Report error of electronic control unit
P1660 F0 (ECU) internal software and hardware DFC_MoCADCNTP
low-level monitoring (MoC)
P1662 0 (ECU) internal software and hardware DFC_MoCADCTst
P1663 A1 (ECU) internal software and hardware DFC_MoCADCVltgRatio
P1664 F0 (ECU) internal software and hardware DFC_MoCComErrCnt
P1665 F1 (ECU) internal software and hardware DFC_MoCComSPI
P1666 F2 (ECU) internal software and hardware DFC_MoCROMErrXPg
P1667 F3 (ECU) internal software and hardware DFC_MoCSOPErrMMRespByte

Trouble Trouble
code type
P1672 F4 (ECU) internal software and hardware DFC_MoCSOPErrNoChk
P1668 F5 (ECU) internal software and hardware DFC_MoCSOPErrRespTime
P1614 F6 (ECU) internal software and hardware DFC_MoCSOPErrSPI
P1617 13 (ECU) internal software and hardware DFC_MoCSOPLoLi
P1618 F7 (ECU) internal software and hardware DFC_MoCSOPMM
P1615 F8 (ECU) internal software and hardware DFC_MoCSOPOSTimeOut
P1673 F9 (ECU) internal software and hardware DFC_MoCSOPPsvTstErr
P166A FA (ECU) internal software and hardware DFC_MoCSOPTimeOut
P060A FB (ECU) internal software and hardware DFC_MoCSOPUpLi
P060D 0 (ECU) internal software and hardware DFC_MoFAPP
low-level monitoring (MoF)
P061C 0 (ECU) internal software and hardware DFC_MoFESpd
P166B 0 (ECU) internal software and hardware DFC_MoFInjDatET
P166C 0 (ECU) internal software and hardware DFC_MoFInjDatPhi
P166D 0 (ECU) internal software and hardware DFC_MoFInjQnt
P166F 0 (ECU) internal software and hardware DFC_MoFMode1

Trouble Trouble
code type
P1674 0 (ECU) internal software and hardware DFC_MoFMode2
P1613 0 (ECU) internal software and hardware DFC_MoFMode3
P1670 F0 (ECU) internal software and hardware DFC_MoFModeEom
P1671 F1 (ECU) internal software and hardware DFC_MoFModeTotQntBnd
P061B 0 (ECU) internal software and hardware DFC_MoFOvR
P167C 0 (ECU) internal software and hardware DFC_MonLimCurr
low-level monitoring (Mon)
P061D 0 (ECU) internal software and hardware DFC_MonLimLead
P062B 0 (ECU) internal software and hardware DFC_MonLimSet
P1637 0 (ECU) internal software and hardware DFC_MonUMaxSupply1
P1638 0 (ECU) internal software and hardware DFC_MonUMinSupply1
No call malfunction indicator of torque
P1008 64 DFC_PhyModNonMonMapNpl
fuel volume changeover MAP
P165A F3 Invalid variant data identifier DFC_SSwtSVarMngDatasetIdErr
P165B F4 Variant data changeover malfunction DFC_SSwtSVarMngDatasetSwtErr
P165C F5 EEPROM code read malfunction DFC_SSwtSVarMngEEPErr
P161D 0 ECU software reset_0 DFC_SWReset_0
P161E 0 ECU software reset_1 DFC_SWReset_1
P161F 0 ECU software reset_2 DFC_SWReset_2

3. Low engine power
Preparations
Checking tools

Diagram of parts
Figure 140: Electronic control unit (ECU) (Reference position)
1 Checking of ECU power supply
condition)
1.2 Connect a jumper case between ECU harness connector and ECU.
1.4 Measure the voltage between ECU pins 4 and 6 and vehicle compartment ground.
Normal value: 10~14V/Pin 4 to vehicle compartment ground
Abnormal ECU power supply (Further check as per troubleshooting of power

supply malfunction in section 7.3.1.2.)
ECU data error
Damage of ECU
Result normal

2 Checking of ECU grounding
condition)
2.3 Measure the resistance between ECU harness connector pins 1 and 2 and the vehicle compartment
ground.
Normal value: ~0Ω/Pin 1 to vehicle compartment ground

7.3.21 Trouble code - ECU internal temperature sensor

Trouble code Trouble
(P code) type
Electronic control unit (ECU) internal
P0669 12 temperature sensor voltage signal above upper DFC_TECUSigRngMax
limit
Electronic control unit (ECU) internal
P0668 11 temperature sensor voltage signal below lower DFC_TECUSigRngMin
limit
Possible symptoms
Pre-checking
Checking tools

Figure 142: ECU harness connector
Diagram of parts
Figure 143: ECU temperature sensor (within ECU)
1 Checking of ECU power supply
condition)
1.2 Connect a jumper case between ECU harness connector and ECU.
1.4 Measure the voltage between ECU harness connector pin and vehicle compartment ground.
Burnout of fuse and malfunction of harness
Result normal
2 Checking of ECU grounding
condition)
2.3 Measure the resistance between ECU harness connector pin and vehicle compartment ground.

Possible cause:
Result normal

7.3.22 Trouble code - Barometric pressure sensor

Trouble Trouble
code type
Barometric pressure sensor voltage signal
P2228 11 DFC_PEnvSigRngMin
below lower limit
Barometric pressure sensor voltage signal
P2229 12 DFC_PEnvSigRngMax
above upper limit
Preparations
Checking tools
2. Jumper case
Notice:
Environmental pressure sensor is within the ECU.
Data stream and normal value. If the diagnostic unit is available, read the actual sensor signals as below:
Signal name Normal value Note

Atmospheric pressure sensor
3.97V (At 0 altitude) No system malfunction
voltage
Electric circuit diagram

Diagram of parts
Figure 145: Atmospheric pressure sensor (within ECU)
1 Checking of parts
1.2 Read the data stream by a diagnostic unit.
Data stream
Atmospheric pressure ~1.01bar (At 0 altitude)
Atmospheric pressure sensor voltage ~3.97V (At 0 altitude)
Possible cause:
Damage of ECU
Result normal

7.3.23 Trouble code - Sensor power supply module

Trouble Trouble
code type
P0643 12 Malfunction of sensor power supply module 1 DFC_SSpMon1
2. Engine noise.
4. Engine jitter
5. Smoke of engine
6. Low engine power
Preparations
Checking tools
2. Jumper case
Definitions of rail pressure sensor pins

Rail pressure signal Rail pressure sensor

Pin definition Rail pressure signal
ground power supply
Rail pressure sensor harness
1 2 3
76 54 32
number

ground supply
2 1 3
44 46 45
number
Definitions of turbocharged pressure sensor pins
Signal Power Turbocharged Turbocharged

Pin definition
ground supply temperature signal pressure signal
Turbocharged pressure sensor
4 2 3 1
harness connector pin number
78 35 87 56
number
condition)
1.3 Unplug the rail pressure sensor harness connector.
1.4 Unplug the camshaft sensor harness connector.
1.5 Unplug the turbocharged pressure sensor harness connector.
1.8 Measure the voltage between rail pressure sensor harness connector pin 3 and vehicle compartment
ground.
1.9 Measure the voltage between camshaft sensor harness connector pin 3 and vehicle compartment ground.
1.10 Measure the voltage between turbocharged pressure sensor harness connector pin 1 and vehicle
compartment ground.
Normal value: ~5V/Rail pressure sensor pin 3 to vehicle compartment ground
Normal value: ~5V/Camshaft sensor pin 3 to vehicle compartment ground
Normal value: ~5V/Turbocharged pressure sensor 1 to vehicle compartment

Possible cause:
Damage of rail pressure sensor harness (Check further with reference to trouble
code - rail pressure sensor in section 7.3.12.)
Damage of camshaft sensor harness (Check further with reference to trouble code
- camshaft sensor in section 7.3.13.)
Damage of turbocharged pressure sensor harness (Check further with reference to

trouble code - turbocharged pressure sensor in section 7.3.17.)
Damage of ECU
Result normal

7.3.24 Trouble code - Sensor power supply module 2

Trouble Trouble
code type
Malfunction of sensor power supply module
P0653 12 DFC_SSpMon2
2
Preparations
Checking tools
2. Jumper case
Diagram of parts
Figure 146 and Figure 147: Accelerator pedal harness connector and corresponding ECU harness connector

Definitions of accelerator pedal pins
Accelerator Accelerator Accelerator Accelerator

Pin pedal 2 pedal 1 pedal 1 pedal 2
pedal 2 pedal 1
definition signal signal power power
signal signal
Accelerator
pedal
2 4 5 1 3 6
connector
pin number
ECU harness
connector 82 83 18 60 61 40
pin number
condition)
Possible cause:
Damage of accelerator pedal sensor harness (Check further with reference to

trouble code - accelerator pedal sensor in section 7.3.10.)
Damage of ECU
Result normal

7.3.25 Trouble code - Sensor power supply module 3
Trouble Trouble
code type
P0699 12 Malfunction of sensor power supply module 3 DFC_SSpMon3
4. Low engine power
5. Smoke of engine
6. Engine noise.
8. Engine jitter
Preparations
Checking tools
2. Jumper case
Definitions of DOC differential pressure sensor pins
signal
DOC differential pressure
sensor harness connector pin 1 2 3
number

signal
15 55 10
number
Definitions of accelerator pedal pins
Accelerat Accelerator Accelerator Accelerator

or pedal pedal 1 pedal 1 pedal 2
Pin definition pedal 2 pedal 1
2 signal signal power power
signal signal
Accelerator
pedal connector 2 4 5 1 3 6
pin number
ECU harness
connector pin 82 83 18 60 61 40
number
Definitions of throttle pins
H-bridge H-bridge Position

Position
Position drive drive sensor
Pin definition sensor Vacant
sensor circuit circuit low- signal
signal
high-level level ground
Throttle
harness
6 3 4 5 1 2
connector pin
number
ECU harness
connector pin 38 15 62 63 53
number
condition)
1.2 Unplug the accelerator DOC differential pressure sensor harness connector.
1.5 Unplug the throttle pedal sensor harness connector.
1.7 Measure the voltage between DOC differential pressure sensor harness connector pin 1 and vehicle
compartment ground.
1.8 Measure the voltage between accelerator pedal sensor harness connector pin 6 and vehicle compartment
ground.
1.10 Measure the voltage between throttle sensor harness connector pin 3 and vehicle compartment ground.

Normal value: ~5V
Damage of DOC differential pressure sensor harness (Check further with

reference to trouble code - DOC differential pressure sensor in section 7.3.15.)
Damage of accelerator pedal sensor harness (Check further with reference to

trouble code - accelerator pedal sensor in section 7.3.10.)
Damage of throttle position sensor harness (Check further with reference to

trouble code - throttle in section 7.3.8.)
Damage of ECU
Result normal

7.3.26 AdBlue level and temperature sensor malfunction
Malfunction symptoms:
Constant turn-on of malfunction indicator lamp and OBD lamp
The AdBlue level indication on the instrument is incorrect
The checking by diagnostic unit detects one or more trouble codes.
Over-high input voltage of AdBlue level sensor P203D

Under-low input voltage of AdBlue level sensor P203C
Over-high input voltage of AdBlue temperature sensor P205D
Under-low input voltage of AdBlue temperature sensor P205C
Possible cause:
Non-connected harness, damaged connector, or retracted plug pin of level and temperature sensor
Open-circuit or loose connection of harness
Short-circuit to power supply
Abnormal connection of vehicle instrument harness.
Damage of sensor.
Solution and procedure:
Check the locations with highest malfunction rate: Sensor connector and harness.
Unplug the sensor connector, check for retracted pins that lead to harness open-circuit, and re-fix the pins.
Measure the resistance between two ends of level sensor connector by a multimeter (The resistance shall be
5.6kΩ when the T01 floater is at topmost position and shall be 446kΩ when the T01 floater is at bottommost
position) and verify the level sensor for damage.
Measure the resistance between two ends of temperature sensor connector by a multimeter and verify the
AdBlue temperature sensor for damage. The relationship between normal temperature and resistance is shown
in attached table.
7.3.27 AdBlue supply pump malfunction
No or less AdBlue injection
Check for presence of one or more trouble codes by a diagnostic unit.
Mechanical malfunction of supply pump P14B8

AdBlue pump drive solenoid valve open-circuit P1492

Possible cause:
The AdBlue supply pump is a core component of SCR system and its malfunctions are mainly divided into
mechanical malfunctions and electric malfunctions.
The electric malfunctions include harness connection, retracted pin, and internal coil malfunction.
The mechanical malfunctions include wear and blockage of pump and blockage of filter.
The malfunction of AdBlue supply pump will influence the engine emission and probably result in retrained
torque of engine.
Non-connected harness, damaged connector, or retracted plug pins of supply pump drive solenoid valve.
Open-circuit, loose connection, or short-circuit of harness.
Blockage of AdBlue filter.
Leakage of AdBlue tank, leading to long-time working of pump without AdBlue.
Damage of AdBlue supply pump.
Check the locations with highest malfunction rate: Connector and harness.
Check for appropriate AdBlue volume within AdBlue tank and ensure that AdBlue tank can’t be empty of
AdBlue.
Check the AdBlue filter for adherence of numerous impurities and blockage of filter. Upon detection of
blockage, clean the air filter by compressed air.
Replace AdBlue supply pump.
Notice: The AdBlue supply pump is a high-precision part and has stringent requirements on the assembling of
body and module. Please ensure to replace by a professional service shop and do not disassemble it without
permission.
7.3.28 AdBlue nozzle malfunction
No AdBlue injection or insufficient or excessive AdBlue injection
A lot of urea crystals within exhaust pipe
AdBlue nozzle short-circuit P2047

AdBlue nozzle open-circuit P2049

Possible cause:
The AdBlue nozzle is a core component of SCR system and its malfunctions are mainly divided into
mechanical malfunctions and electric malfunctions. The electric malfunctions include harness connection,
retracted pin, and internal coil malfunction. The mechanical malfunctions include wear and blockage of
nozzle and overheating burnout of connector. The malfunction of AdBlue nozzle will influence the engine
emission and probably result in retrained torque of engine.
Non-connected harness, damaged connector, or retracted plug pins of AdBlue nozzle.
Open-circuit, loose connection, or short-circuit of harness.
Burnout of AdBlue pipeline connector, leakage of AdBlue pipelines, or abnormal AdBlue supply.
Blockage, wear, or internal damage of AdBlue nozzle or abnormal atomization of injected AdBlue.
Check the locations with highest malfunction rate: Connectors, harness, and AdBlue pipelines.
In winter, please check for presence of frozen AdBlue within AdBlue pipelines and verify the AdBlue tank
heater and AdBlue pipeline heater for normal working.
Check for presence of impurities within the AdBlue of the AdBlue pipelines or check the AdBlue filter for
damage. Any damage or impurities will easily result in internal wear and damage of nozzle. Immediately
replace with new AdBlue filter and clean the AdBlue pipelines.
Replace AdBlue nozzle.
Notice: The AdBlue nozzle is a high-precision part. Do not disassemble the nozzle body without permission.
7.3.29 Malfunction of NOx sensor
Restrained torque of engine
NOx sensor heater short-circuit P2207

NOx sensor heater open-circuit P2205
NOx sensor connection short-circuit P2203
NOx sensor connection open-circuit P2202
Unreasonable NOx value of NOx sensor P2201
Communication failure of NOx sensor U0108
Possible cause:
The malfunctioned NOx sensor will influence the engine emission monitoring accuracy and will probably lead
to restrained torque of the engine.

NOx sensor wiring malfunction.
Non-heated NOx sensor.
Malfunction of CAN cable connected to NOx sensor.
Damage of NOx sensor.
Check the voltages at 4 pins of NOx sensor and judge for circuit malfunctions such as incorrect connection,
open-circuit, and short-circuit.
Under power-on condition of the system, check the NOx sensor for heating.
Check the CAN cable connected to the NOx for short-circuit and open-circuit.
Replace NOx sensor.
7.3.30 Malfunction of exhaust gas temperature sensor
Turn-on of OBD lamp
The checking by diagnostic unit detects one or more trouble codes as below and the reading of the exhaust gas
temperature indicated by the diagnostic unit is clearly incorrect, without variation.
Over-high input voltage of upstream temperature sensor P0546

Under-low input voltage of upstream temperature sensor P0545
Over-high input voltage of downstream temperature
P2032
sensor
Under-low input voltage of downstream temperature
P2031
sensor
Possible cause:
Open-circuit of exhaust gas temperature sensor connector or circuit.
Open-circuit or short-circuit due to wear, burnout, or other cause of sensor harness or plug.
Aging and failure of sensor.
Check sensor connector for looseness.
Check sensor harness for continuity.
Check whether the resistance between two sensor pins is within normal range (Refer to 6.2). If beyond range,
the sensor is failed. Replace the sensor.

7.3.31 Emission over-limit malfunction
Turn-on of OBD lamp
Restrained torque of engine
NOx value over-limit (>3.5) P0421

NOx value over-limit (>7) P0422
Possible cause:
No AdBlue or disqualified AdBlue.
Supply module malfunction.
No AdBlue injection or poor atomization due to AdBlue nozzle malfunction.
Abnormal working of SCR system due to abnormal connection between ECU and DCU and harness.
Incorrect data version of ECU or DCU.
Damage of ECU or DCU.
Malfunction of exhaust gas temperature sensor;
Damage of catalyst (Blockage or aging).
Failure of NOx sensor.
Deteriorated engine original emission.
Use a diagnostic unit to check for presence of trouble codes other than P0422 and P0421. If present, firstly
solve the malfunctions related to these trouble codes.
Add AdBlue that conforms to the requirements of GB29518-2013.
Check the supply module, AdBlue nozzle, various sensors, and harnesses and pipelines for normal working as
per the troubleshooting method described above.
Check the ECU or DCU for correct data version and check hardware for damage.
Check catalyst for aging, blockage, crystallization, and damage. If any, replace the catalyst.
Check the engine body parts related to combustion emission (Such as fuel injectors and turbocharger) for
deteriorated performance and malfunction, verify the engine original emission for deterioration, and replace
related parts.

7.4 Checking of fuel system
7.4.1 Low pressure system
A tiny malfunction in low pressure system can also cause adverse influence on the whole engine system.
Therefore, even if the low pressure fuel is not the malfunction cause (Such as high pressure system or part),
the accurate checking of the low pressure fuel line system is also really necessary.

CP1H high pressure
fuel pump
Common rail
Detection
3
Detection 2
Detection 4
Filter
Actuator
Sensor Fuel
injectors
Detection 1
Electronic
control unit
High pressure
EDC17C63
Fuel tank Low pressure
Figure 148: System layout and checking position
Checking 1: Fuel suction pressure: fuel tank Filter Page 201
Checking 2: Fuel suction pressure: filter gear pump Page 203
Checking 3: Return fuel volume of high pressure fuel pump (Low pressure system performance test)
Page 205
Checking 4: Return fuel volume of individual fuel injector Page 207
Test preparations:
The fuel tank contains sufficient diesel, the fuel quality is qualified, and the filter and fuel pipeline are normal.
Testing tools:
The preparation of following tools is required for the checking of low pressure fuel line system:
1.) Pressure gauge with vacuum pressure measurement range (-1bar~5bar, in graduation of 0.1bar)
2.) Pressure test adapter (Type Y)
3.) Temporary hose and metal connecting pipe used to direct return fuel of high pressure fuel pump to the
fuel tank
4.) Fuel injector fuel return volume test suite

5.) Measuring glass (Measurement range: 25ml)
6.) Measuring glass (Measurement range: 1000ml)
7.) Stopwatch
7.4.1.1 Checking 1: Suction pressure: Fuel tank Filter
Testing tools – Recommended tools
1.) Pressure gauge with vacuum pressure measurement range
Installation procedure
1.) Disassemble the filter inlet pipe.
2.) Connect the pressure test adapter (Type Y) to the fuel tank outlet pipe and the filter inlet port just
disconnected.
3.) Connect a pressure gauge
4.) Tighten the system (Ensure there is no leakage!)
Figure - Connection of Parts/Tools
Pressure test adapter To pressure

(Type Y) gauge
To filter inlet
From fuel tank
Figure 149: Installation diagram
Test procedure
1.) Start/drag the engine (The start time will probably become longer), run the engine for several minutes,
and ensure the stable running of the engine.
2.) Observe the fuel suction pressure under diversified working conditions.
* Test data - Typical pressure:

Relative pressure
Working condition Note
Lower limit Upper limit
Dragging of engine Drag the engine at 100~120rpm,
unplug the crankshaft and camshaft
sensor harness connectors or unplug
-8kPa -3kPa
the harness connectors of all fuel
injectors. The engine will be dragged,
but will not inject fuel.
Low idling speed -12kPa -8kPa 800 r/min
Moderate speed -12kPa -8kPa 2000 r/min
Maximum speed -12kPa -8kPa 4400 r/min
*Note:
The typical values in above table are only taken as the reference values of this manual and can’t be used as the
direct basis for the judgment of normal parts.
Notice:
Under dragging condition of engine, the running time of the starter motor shall not exceed 20s each time. The
over-long single working time of starter motor will probably damage the starter motor.
Result abnormal Conclusion/possible cause
Insufficient fuel suction pressure or above upper limit:
1.) Under-low level and insufficient fuel of fuel tank. Open the fuel tank cap and observe the fuel level.
2.) Check the fastening status of fuel pipes and connectors. The insufficient tightening will result in loss of
fuel suction pressure, suction of air into fuel pipe, and reduction of sucked fuel volume (This can be
determined by observing for presence of air bubbles in the return fuel of high pressure fuel pump in the
checking of 7.4.1.3.).
3.) Blockage of filter: (Contamination by particulates) It will reduce the fuel suction pressure (Judge the
blockage of filter by comparing the differential pressure between two ends of filter in 7.4.1.2. If the
differential pressure is >40kPa, it’s recommended to replace the filter).
4.) In rare cases: Gear pump malfunction.
Over-high fuel suction pressure or below lower limit:
1.) Blockage of fuel pipe between fuel tank outlet and filter inlet and blockage or bending of fuel tank or
other fuel pipe.
2.) Unreasonable size of fuel pipe between fuel tank outlet and filter inlet (At least 8mm in inside diameter).
3.) Blocked/contaminated fuel tank ventilation (Open the fuel tank cap and check for fuel suction sound.).
Result normal
Next step (Refer to process diagram in section 7.1.)

7.4.1.2 Checking 2: Fuel suction pressure: Filter Gear pump
Testing tools– Recommended tools
1.) Pressure gauge with vacuum pressure measurement range
1.) Disassemble the filter.
2.) Disassemble the filter outlet fuel pipe.
3.) Connect the pressure test adapter (Type Y) to the filter outlet and the filter outlet fuel pipe just
disconnected.
4.) Connect a pressure gauge
5.) Tighten the system (Ensure there is no leakage!)
Figure - Connection of Parts/Tools
To pressure
Pressure test adapter gauge
(Type Y)
Filter outlet
To high-pressure
fuel pump
Figure 150: Installation diagram
Test procedure
1.) Start/drag the engine (The start time will probably become longer), run the engine for several minutes,
and ensure the stable running of the engine.
2.) Observe the fuel suction pressure under diversified working conditions and check for leakage.

Relative pressure
Working condition Nominal value
Drag the engine at 100~120rpm,
unplug the crankshaft and camshaft
sensor harness connectors or unplug
Dragging of engine -10kPa -5kPa
the harness connectors of all fuel
injectors. The engine will be
dragged, but will not inject fuel.
Low idling speed -18kPa -13kPa 800r/min
Moderate speed -18kPa -13kPa 2000 r/min
Maximum speed -18kPa -13kPa 4400 r/min
*Note:
The typical values in above table are only taken as the reference values of this platform version manual and
can’t be used as the direct basis for the judgment of normal parts.
Notice:
Under dragging condition of engine, the running time of the starter motor shall not exceed 20s each time. The
over-long single working time of starter motor will probably damage the starter motor.
Result abnormal Conclusion/possible cause
Insufficient fuel suction pressure or above upper limit:
1.) The fuel tank contains insufficient fuel. Open the fuel tank and observe the fuel level.
2.) Check the fastening status of fuel pipes and connectors. The insufficient tightening will result in loss of
fuel suction pressure, suction of air into fuel pipe, and reduction of sucked fuel volume (This can be
determined by observing for presence of air bubbles in the return fuel of high pressure fuel pump in the
checking of 7.4.1.3.).
3.) In rare cases: Gear pump malfunction.
Over-high fuel suction pressure or below lower limit:
1.) Blockage of filter (Judge the blockage of filter by comparing the differential pressure between two ends
of filter in 7.4.1.1. If the differential pressure is >40kPa, it’s recommended to replace the filter).
2.) The size of fuel pipe between filter outlet and gear pump inlet is incorrect (At least 8mm in inside
diameter). Check the connector for crushing deformation and damage.
3.) Blockage of fuel pipe between fuel tank outlet and filter inlet
4.) Unreasonable size of fuel pipe between fuel tank outlet and filter inlet (At least 8mm in inside diameter)
5.) Contamination of fuel tank
6.) Blocked/contaminated fuel tank ventilation (Open the fuel tank cap and check for fuel suction sound.)

Result normal
7.4.1.3 Checking 3: Return fuel volume of high pressure fuel pump (Low pressure system performance
test)
It’s recommended to test the performance of low pressure system by this test. This test can ensure the
checking of low pressure fuel line system under normal working condition.
Testing tools– Recommended measurement tools
1.) Temporary hose + connector
2.) Measuring glass (1,000ml) and measuring glass (50ml)
3.) Stopwatch
1.) Disassemble the fuel return port pipeline of high pressure pump.
2.) Disassemble the fuel return pipe of fuel injector and plug the pipe port near the pump end.
3.) Connect the temporary hose to the fuel return port of high pressure pump.
4.) Collect the diesel outflowed from the temporary hose by measuring glass 1.
Connection of Parts/Tools:
Fuel return of high-

pressure fuel pump
A hose is temporarily connected to

the metering cup 1.
Figure 151: Measurement of return fuel of high pressure fuel pump
Test procedure
1.) Start/drag the engine, till the diesel flows out from temporary hose.
2.) Use an empty measuring glass.

3.) Collect the diesel outflowed within specified time by the measuring glass.
4.) Record the diesel volume in measuring glass 1.
Working condition of Flow (ml)

Nominal value
engine 10s flow 30s flow 60s flow
Drag the engine at
100~120rpm, unplug
the crankshaft and
camshaft sensor harness
Dragging of engine 95~115ml 195~235ml 400~440ml connectors or unplug
the harness connectors
of all fuel injectors. The
engine will be dragged,
but will not inject fuel.
Low idling speed 280~300ml 560~590ml 1130~1170ml 800r/min
*Note:
Notice: If the engine can’t be started, only measure the return fuel volume of high pressure fuel pump under
dragging condition of the engine. Under dragging condition of engine, the running time of the starter motor
shall not exceed 20s each time. The over-long single working time of starter motor will probably damage the
starter motor. Therefore, measure the return fuel volume of fuel injector for 6 times and run the starter motor
for 10s each time.
Result abnormal Conclusion/possible cause:
Clearly under-low return fuel volume:
1.) Ensure that the fuel tank contains sufficient fuel and open the fuel tank and observe the fuel level.
2.) Check fastening status of fuel pipe and connectors between fuel tank and gear pump. The insufficient
tightening will result in loss of fuel suction pressure, suction of air into fuel pipe, and reduction of sucked
fuel volume (If the return fuel contains air bubbles, it’s really probably caused by low pressure fuel line.
Please check the low pressure fuel lines (Section 7.4.1.1 and 7.4.1.2)).
3.) Crushed damage or inappropriate diameter of hose and connectors between fuel tank and gear pump.
4.) Blockage or damage of filter (Check further as per section 7.4.1.1 and 7.4.1.2 to determine. If the
differential pressure is >40kPa, it’s recommended to replace the filter.).
5.) Possible contamination of fuel tank ventilation device (Open the fuel tank cap and check for fuel suction
sound.).
6.) In rare cases: Gear pump malfunction；
Result normal

7.4.1.4 Checking 4: Return fuel of individual fuel injector
Testing tools– Recommended measurement tools
1.) Fuel injector fuel return volume test suite
2.) Stopwatch
3.) Measuring glass (At least 25ml)
1.) Disconnect the fuel return pipe of individual fuel injector.
2.) Connect a measuring glass to the fuel return port of fuel injector.
3.) Prepare the stopwatch and measuring glasses.
Connection of Parts/Tools:
Injector fuel return
Figure 152: Fuel injector return pipe
Test procedure
1.) Run the engine, till the coolant temperature reaches 65°C.
2.) Start/drag the engine, till the diesel flows out from the hose.
3.) Observe the return fuel volume flowed into the fuel injector within approximately 60s.
4.) Record the return fuel volume of every fuel injector.
* Test data - Typical value:

Volume (ml/min)
Working condition of engine Nominal value
Dragging of engine Drag the engine at
100~120rpm, unplug the
crankshaft and camshaft
sensor harness connectors
2ml 5ml or unplug the harness
connectors of all fuel
injectors. The engine will
be dragged, but will not
inject fuel.
Low idling speed 6ml 10ml 800r/min
Moderate speed 15ml 19ml 2000 r/min
Maximum speed 33ml 37ml 4400 r/min
*Note:
Notice: If the engine can’t be started, only measure the return fuel volume of individual fuel injector under
dragging condition of the engine. Under dragging condition of engine, the running time of the starter motor
shall not exceed 20s each time. The over-long single working time of starter motor will probably damage the
starter motor. Therefore, measure the return fuel volume of fuel injector for 6 times and run the starter motor
for 10s each time.
Result abnormal Conclusion/possible cause:
Excessive return volume:
1.) If the return fuel volume of one/more fuel injectors is higher by >3 times than the fuel injector with low
return fuel volume, replace the fuel injectors with higher return fuel volume.
Result normal

7.5 Checking of intake system
7.5.1 Intake pipeline
Preparations: The battery voltage is normal, the electric circuits are normal, and the fuses, connectors,
harnesses, and main relay function normally.
1. Visual checking of air filter
1.1 Check the cleanliness of air filter.
Result abnormal Possible malfunction causes:
1.) Air filter blockage
Result normal
2. Visually observe the intake pipe.
2.1 Check the intake pipeline for secure connection, good airtightness, and high cleanliness (Check for
presence of oil dirt) and for presence of soft pipeline.
1.) Loose intake pipeline.
2.) The intake pipe is soft so that it will be probably collapsed under high load.
3.) If there are oil stain (engine oil loss) on the intake pipeline, check for oil
leaking position.
Result normal
3. Visual checking of turbocharger air pipeline
3.1 Check the turbocharger pipeline for secure connection, good airtightness, and high cleanliness (Check for
presence of oil stain.).
3.2 Check turbocharger pipelines for cracking.
1.) Loose or damaged turbocharger pipeline.
2.) If there are oil stain (engine oil loss) on the turbocharger pipeline, check for
oil leaking position.
Result normal

7.5.2 Turbocharger
Preparations: The battery voltage is normal, the electric circuits are normal, and the fuses, connectors,
harnesses, and main relay function normally.
Testing tools: Manual pump
1. Check the turbocharger pressure control system (Mechanical parts).
1.1 Check the airtightness of turbocharger pipeline.
1.2 Check the air bleeding valve control handle for stable running (Refer to introduction of manual pump).
Possible malfunction causes:

Result abnormal
1.) Leakage or damage of turbocharger control valve or turbocharger pipeline -
Please replace.
2.) Incorrect adjustment of control handle
3.) If the compressor and/or turbine is damaged, replace turbocharger.
Result normal
2. Check the mechanical parts of turbocharger.
2.1 Check air bleeding valve for stable working (Check air bleeding valve control handle for obstruction.).
2.2 Disassemble the intake pipe and turbocharger pipe and check the compressor and turbine for damage and
excessive clearance.
Result abnormal Possible malfunction causes
1.) Blockage of air bleeding valve. Please attempt to move the air bleeding
valve.
2.) If the compressor and/or turbine is damaged, replace turbocharger.
Result normal

Introduction of manual pump:
The use of manual pump is required for the checking of turbocharger and turbocharger system. Use the
manual pump switch to select vacuum pressure or positive pressure. Measurement range: -1bar~1.5bar.
Connect one end of connecting hose to the manual pump and connect other end to the turbocharger control
valve. Use adapters if necessary. Use the manual pump to generate pressure and check whether the control
handle moves between air bleeding valve and turbocharger control valve.
Air pipeline behind the Air pipeline behind the

turbocharger supercharged intercooler
Figure 153: Intake pipeline
Figure 154: Turbocharger

7.6 After-treatment system

The SCR system is basically maintenance-free. The user only needs to fill sufficient AdBlue to ensure its
normal working and keep the system surfaces clean, the electric connectors dry, and the AdBlue pipelines
sealed without leakage.
Notice: In winter, add the AdBlue till the full level is reached and do not add excessive AdBlue. This is
because that, when the air temperature is below -11℃, the volume of the frozen AdBlue will expand by
approximately 17%. The excessively added AdBlue will probably expand and crack the AdBlue tank if
frozen. In addition, as the SCR system will automatically pump back the residual AdBlue from the AdBlue
pipelines after the stop of engine, please cut off the power supply of vehicle in 180s after the turn-off of the
key switch.
7.6.1 Maintenances of AdBlue tank
a. Adding of AdBlue: To prevent the overflow of excessive AdBlue, generally the capacity at maximum
AdBlue level is smaller than 100% of the tank total capacity. When the AdBlue is consumed to 20% of
the tank capacity, it’s necessary to add the AdBlue.
b. Upon detection of white crystal substance at ventilation valve or filler port during non-periodical
checking, flush by clean water or wipe by a wet cloth.
c. Check the accessories and pipeline connectors for good status non-periodically.
d. Clean the AdBlue tank once every 6 months. Open the drainage plug on the bottom of the AdBlue
tank and drain the precipitated impurities from the inside of the tank.
e. The AdBlue filter will be blocked by the accumulated impurities of the AdBlue after long-time use. In
such case, the DCU will diagnose and report the supply pump malfunction. It’s necessary to take out the
supply module and clean the filter by compressed air.
d. If the AdBlue filter is damaged, the immediate replacement is required.
Disassembling of AdBlue filter:
To replace the AdBlue filter, firstly disassemble the supply module. The AdBlue filter is located on the
bottom of supply module and is fixed onto the module by clamps. The disassembling procedure is shown in
Figure 163.
Assembling of AdBlue filter:
Install the O-ring and O-ring seat between AdBlue filter and air bleeding port connector into the air bleeding
port connector, align the filter with the ports of supply pump and air bleeding pipe, press it tightly by a large
force, and finally fix it by clamps, as shown in Figure 164.
1) Pry open the clamp 2) Pull out the clamp 3) Disassemble the filter 4) The disassembling of
in downward direction filter is complete
Figure 155 Disassembling procedure of AdBlue filter

1) Install the O-ring and O-ring 2) Install the filter. 3) Install the clamp. 4) Complete of
seat. installation
Figure 156 Installation procedure of AdBlue filter
7.6.2 Maintenances of nozzle
It’s prohibited to repeatedly disassemble the dosing nozzle. If the nozzle is mechanically damaged, FAI
recommends replacing with new nozzle. During replacement, take cautions to guard the nozzle against the
encapsulation of other substance, in order to prevent influencing the heat dissipation of the nozzle.
7.6.3 Maintenances of exhaust gas temperature sensor and NOx sensor
The carbon deposit will accumulate on both sensors after working for a period within exhaust pipe. Generally,
the carbon deposit will not influence the performance of temperature sensor or NOx sensor. In event of poor
working of sensor due to serious carbon deposit, clean the sensors by a soft brush. It’s prohibited to clean the
sensors by any mechanical means or liquid cleaning. It’s disallowed to disassemble and reinstall the
temperature sensor and NOx sensor repeatedly, in order to prevent damage.
7.6.4 Daily maintenance
a. Frequently check the SCR system fasteners and connectors for looseness and timely handle any loose
one.
b. Check the harnesses for damage. If any, repair or replace.
7.6.5 Checking of sensor
7.6.5.1 Exhaust gas temperature sensor
Check the exhaust gas temperature sensor with reference to the resistance-temperature comparison table listed
in Table 7-2.
Table 7-2 Resistance-temperature comparison table of exhaust gas temperature sensor
Temperature (°C) Resistance (Ω)

-40 170.2
-20 185.6
0 201.0
50 239.0
100 276.4
150 313.2
200 349.5
250 385.1

Temperature (°C) Resistance (Ω)

300 420.2
350 454.7
400 488.6
450 521.9
500 554.6
550 586.7
600 618.3
650 649.3
700 679.7
750 709.5
800 738.7
850 767.3
900 795.4
950 822.8
1000 849.7
1050 876.0
1100 901.7
7.6.5.2 AdBlue level sensor
Check the AdBlue level sensor for T01 vehicle model with reference to the resistance-temperature comparison
table listed in Table 7-3.
Table 7-3 Resistance comparison table of AdBlue level sensor
Effective capacity (%) Resistance (Ω) H (mm)

＞100% 5600 ＞227
100% 10130 227
90% 15490 208
80% 21690 189
70% 29190 170
60% 38500 151
50% 50300 132
40% 69900 113
30% 99300 94
20% 146300 75
10% 246300 56
0% 446300 42

7.7 Test of other parts
7.7.1 Engine mechanical part
Preparations: Sufficient engine oil and transmission oil.
Normal coolant level.
1. Mechanical part
1.1 Checking of engine timing
1.) Non-alignment between timing marking on crankshaft and/or camshaft and

marking on timing housing cover and cylinder head.
Result normal
1.2 Checking of valve timing and valve clearance
1.) Incorrect valve timing. Adjust the valve clearance.
Result normal
1.3 Checking of engine airtightness and cylinder pressure
1.) Wear of pistons and cylinders.
2.) Damage of piston rings (Excessive clearance, blockage, and breakage).
3.) Damage of cylinder head gasket and deformation or cracking of cylinder

head.
Result: Ingress of compressed air into cooling system. Ingress of engine oil into cooling system or ingress of
coolant into oil. Breakage of valve springs (Insecure closing of valves). Loose fuel injectors.
Result normal

2. Abnormal engine sound
2.1 Piston

Result abnormal
1.) Excessive piston clearance
2.) Bending of connecting rods and wear of piston pin.
Result normal
2.2 Valve noise

Result abnormal
1.) Incorrect valve clearance
2.) Breakage of valve spring
3.) Wear of camshaft bearings
4.) Wear of rocker arms/or rockshaft
Result normal
2.3 Other noise
1.) Seizure of pistons
2.) Wear of crankshaft bearings
3.) Wear of timing chain
4.) Wear of timing chain tensioning mechanism and/or timing chain control
mechanism
Result normal

7.7.2 Starter motor
Preparations
The battery power is sufficient, the battery connectors are securely tightened, and the wires and grounding of
the starter motor are normal.
The electric circuits are normal and the fuses, electric connectors, harnesses, and main relay function normally.
Testing tools
Multimeter and current clamp (Up to 600A)
Data stream
Battery voltage
Symptom
1. When the starter motor is not rotating
2. When the starter motor is rotating
1. The starter motor is not rotating
1.1 Non-energization of solenoid coil switch or quick and continuous switchover of solenoid coil switch
1.1.1 Check the battery wires, battery wiring poles, and battery connectors. The battery wiring poles and the
harness connectors shall be intact and securely connected and shall be under good contact.
1.1.2 Check the grounding connection of starter motor, engine, and battery. The grounding wires of starter
motor, engine, and battery shall be normal and shall be in good contact with the frame.
1.1.3 Check the connection and power supply of starter motor relay control pins.
1.1.4 Check solenoid coil switch.
1.1.5 Check the ignition switch and/or starter motor switch.
1.1.6 Check the starter motor current (Refer to 2.3.).
1.) Oxidized battery connectors. Clean the battery connectors.
2.) Poor grounding between starter motor and battery and the vehicle. Clean the
(oxidized) connector on the solenoid coil switch.
3.) Starter motor/solenoid coil switch
4.) Ignition switch (T15) and/or starter motor switch (T50)

5.) Damage of solenoid coil switch
6.) Damage of starter motor relay
Result normal
1.2 Under energization status of solenoid coil switch
1.2.1 Check the wiring of solenoid coil switch and starter motor.
1.2.2 Check solenoid coil switch.
1.2.3 Check the starter motor relay.
1.2.4 Wear of carbon brush, armature, or rotor winding
Result abnormal Possible malfunction causes
1.) Clean the (oxidized) connector on the solenoid coil switch.
2.) Switching of solenoid coil switch
3.) Starter motor
4.) Damage of starter motor relay
Result normal
2. The starter motor is rotating
2.1 Rotation of engine at really low speed
2.1.1 Check battery power.
2.1.2 Check the wiring of solenoid coil switch and starter motor.
Possible malfunction causes

Result abnormal
1.) Depletion of battery
2.) Clean the (oxidized) connector on the solenoid coil switch.
3.) Solenoid coil switch
4.) Starter motor
Result normal

2.2 Obstructed or no rotation of engine
2.2.2 Check starter motor ring gear and flywheel.
1.) Starter motor
2.) Starter motor ring gear (Flywheel)
Result normal
2.3 Under-low starter motor speed (Normal battery voltage)
2.3.1 Check the starter motor current.
2.3.2 Clamp the starter motor power wires by current clamps.
2.3.3 Run the starter motor and measure the current.
Result abnormal
1.) If the current is too high, the starter motor is probably mechanically or
electrically malfunctioned.
2.) If the current is too low and the starter motor speed is too low, the contact
resistance in the starter motor wires is too high.
Result normal

7.7.3 Accelerator pedal
Preparations
The battery voltage is sufficient and the electric circuits are normal, including fuses, connectors, harnesses,
and main relay.
Related data stream
Accelerator pedal position (%) and voltage signals of accelerator pedals 1 and 2
Notice: There are two position sensors on the accelerator pedal.
Signal name Fully release the pedal Fully depress the pedal Note
Accelerator pedal opening
0% 100%
extent
Accelerator pedal sensor 1 0.76V 3.75V
Accelerator pedal sensor 2 0.38V 1.85V
1 Visually observe the accelerator pedal.
1.1 Check the fixing bracket of accelerator pedal for damage.
1.2 Check accelerator pedal for blockage by foot pad.
1.) Damage of accelerator pedal fixing bracket
2.) Blockage of accelerator pedal by foot pad
Result normal
2 Functional checking of accelerator pedal
2.1 Check accelerator pedal for obstruction or return failure when the accelerator pedal is depressed to the
dead end.
1.) Damage of accelerator pedal fixing bracket
2.) Obstruction of accelerator pedal (Such as damage of return spring or

blockage by impurities)
3.) Blockage of accelerator pedal by foot pad
Result normal

7.7.4 Cooling system
Preparations
The coolant level is normal, the battery voltage is sufficient, and the electric circuit connections are normal,
including fuses, connectors, harnesses, and main relay.
Related data stream
Coolant temperature and coolant temperature sensor voltage
Signal name Normal value Note

Coolant temperature sensor voltage 2.6~2.8V At 20°C coolant temperature
1 Visual observation of radiator hoses
1.1 Check the radiator hoses for leakage and cracking and check their connectors for secure connection.
Result abnormal
1.) Check radiator hoses for leakage and cracking and when necessary replace.
Result normal
2 Checking of radiator and radiator fan
2.1 Check the radiator for leakage and contamination.
2.2 Check the mechanical drive parts of radiator fan for damage.
2.3 Check the viscous drive fan for damage.
Result abnormal
1.) Impurities in radiator. Remove the impurities.
2.) Abnormal working of radiator fan. Check the mechanical drive parts of radiator fan and if necessary
replace.
Result normal
3 Checking of thermostat
3.1 Disassemble the thermostat and check it for damage.
3.2 Check the thermostat for normal working.

Result abnormal
1.) Thermostat malfunction. Replace.
Result normal
4 Checking of water pump
4.1 Check water pump for looseness.
4.2 During the idling of engine, check water pump for noise.
Result abnormal
1.) Water pump malfunction. Replace.
Result normal
5 Other checking items
5.1 Check for ingress of high pressure gas into the cooling system.
5.2 Check for ingress of engine oil into the water tank.
Result abnormal
1.) Ingress of high pressure engine gas into cooling system
2.) Damage of cylinder head or cylinder head gasket

7.7.5 Preheating System
Preparations
The battery voltage is sufficient and the electric circuits are normal, including fuses, connectors, harnesses,
and main relay.
Related data stream: Battery voltage
1 Checking of glow pug control circuit
1.1 Checking of glow plug power supply
1.1.3 Measure the voltage between glow plug power terminal and vehicle compartment ground.
1.1.4 After test, rotate the ignition switch to OFF and plug the coolant temperature sensor harness connector.
Result abnormal
1.) Damage of preheater relay (Check further with reference to trouble code - preheater relay in section
7.3.7.)
2.) Damage of preheater fuse. Replace.
Result normal
2 Checking of glow plug
2.1 Check the working current and resistance of glow plug.
2.1.3 Measure the total working current of glow plug:
Normal value: ~50±5A (At 12V)
2.1.4 After test, rotate the ignition switch to OFF and plug the coolant temperature sensor harness connector.
2.1.5 Unplug the connecting lug of glow plug and measure the resistance of every glow plug:
Normal value: 250mΩ~5Ω

Result abnormal
1.) Damage of glow plug. Replace.
Result normal

8 Disassembling and Installation Instructions of High

Pressure Parts
8.1 Safety precautions

The section 2.2.2 checking and repair of high pressure fuel system describes more safety related contents.
Please ensure to read carefully and thoroughly understand them before the further operations.
8.2 Disassembling and installation of fuel injectors
8.2.1 Precautions
Ensure the absolute cleanliness of fuel injectors during the handling and assembling of fuel injectors.
Keep clean the working site and tools used (Also keep clean the surrounding areas of cylinder head and fuel
injectors.).
During the assembling or storage of accessories, the accessories and the containers for placement of
accessories must also be kept clean.
Remove the protective caps only immediately before the assembling. After the disassembling, immediately
cover the connectors by protective caps. Ensure to prepare some spare clean protective caps. Any used
protective cap must be flushed by ultrasonic wave.
Before installation, all seal rings (O-rings) should be lubricated (By assembling oil, engine oil, or diesel).
To guard the fuel injector bodies and cylinder head against corrosion, it’s permissible to apply some grease to
the fitting portions of fuel injector fastening nuts and fuel injectors to ease the disassembling of fuel injectors.
If the fuel injectors are corroded within fuel injector mounting holes, the use of the following Bosch tools is
recommended:
Fuel injector disassembling and rotating tool: 0 986 611 481
Compression of fuel injectors: Tensioning device (0 986 612 782) with compressing device (0 986 612 727).
It’s prohibited to use any water-containing lubricant or sliding agent.
8.2.2 Electric precautions
All harness connectors must be plugged and unplugged under the OFF status of the ignition switch.
All harness connectors must be installed properly (Click sound).
Do not bend the harnesses forcibly. Ensure the secure fixing of harnesses.
8.2.3 Hydraulic precautions
During the installation and disassembling of fuel return pipe, do not use any tool.
To guarantee the internal space of fuel return pipe, ensure to prevent excessive bending, rotation, and
deformation of the fuel return pipe.
It’s prohibited to loosen or disassemble the fuel return plug on the fuel return hose. In event of above

symptoms, ensure to replace the whole fuel return pipe.
To prevent the loose high pressure connector, ensure to take special cautions during operations. While
disassembling the high pressure fuel pipes, ensure that no loosening torque is applied onto the high pressure
connector. If the high pressure connector is already loose, replace the whole fuel injector.
Once a fuel injector is disassembled, ensure to replace with one new copper seal ring and if necessary replace
the compression bolt.
It’s prohibited to rotate the fastening nuts of solenoid valve (For instance: During the installation or
disassembling of fuel injectors on engine).
8.2.4 Installation of fuel injectors
Remove the protective caps on the fuel injector nozzles, install copper seal ring to the sealing surface, and pay
attention to the coaxiality. The sealing washer must fit tightly with the sealing surface (This is not required for
the fuel injector with pre-fixed concentric sealing washer.).
Notice:
Avoid damaging the fuel injector orifices.
If required, fix the compression part onto the fuel injectors and then insert the fuel injectors into the cylinder
head.
Push the fuel injectors to the shaft shoulder by hand.
Carefully assemble the fastening bolts and nuts to the clampin g parts. If possible, carefully fix the fuel
injectors to the correct positions by hand and tighten to correct torque as per the drawing requirements.
Visual checking method: Compare the heights of fuel injectors to ensure there is no insufficient or excessive
copper sealing rings.
Remove the protective caps from the fuel injector high pressure connectors, lightly install the high pressure
fuel pipes by hand, and connect the fastening nuts on the fuel pipes to the threads of high pressure connectors
on the fuel injectors by hand.
Notice:
While installing the fuel injectors and high pressure fuel pipes, identify the fuel injector and high pressure
pipe for corresponding cylinders.
If one component is already loosened, the fastening nut on this component must be tightened before the final
tightening of high pressure pipe. Then, tighten the mounting nuts on the high pressure pipes from the fuel
injectors as per the tightening torque (Maximum 36N.m) of the drawing requirement. The tightening torque
shall not exceed 36N.m.
Remove the protective caps from the fuel return connectors of the fuel injectors.
O-rings must be slightly lubricated by special engine oil, assembling oil, or diesel.
Compress vertically the fuel return pipe plug into the fuel injector from the top by hand, till a proper
connection sound is heard, and push down the white plastic slot in place.
Ensure to pull the fuel return pipe by hand to check for correct installation.
While installing the harness connectors, ensure that a proper installation sound with the fuel injector harness
connector is heard.

Ensure to visually observe the fuel injector system for leakage.
Notice:
After replacement of fuel injector, ensure to re-write the IQA code of replacement fuel injector into the ECU.
8.2.5 Disassembling of fuel injectors
Before disassembling the fuel injector, ensure to disassemble the harness connector.
Loosen the fuel return pipe. If it’s necessary to loosen fuel return pipes of all fuel injectors, start from 1st
cylinder to last cylinder of engine in turn, in order to prevent generating tensile stress or compressive stress.
While disassembling the connectors of fuel return pipes, pull out the white plastic clampin g slot to the end by
hand, in order to prevent the blockage during upward pulling.
Ensure to immediately install the protective caps to the fuel injectors with fuel return connector disconnected.
While disassembling multiple fuel injectors, ensure to mark the cylinder number clearly on the fuel injector
and the corresponding high pressure fuel pipe by a waterproof pen.
Loosen the high pressure fuel pipe fastening nut on the fuel injector to be disassembled and the nut on the rail
and ensure that the high pressure connector of the fuel injector is not loose. If loose, the whole fuel injector
must be replaced.
Loosen the high pressure fuel pipe by hand, ensure to immediately protect the disconnected connector of fuel
pipe by protective caps, and mark the corresponding cylinder number.
Ensure to thoroughly remove the dirt, particles, and residual liquid from the fuel injector mounting holes of
cylinder head. If required, cover the fuel injector holes to guard against the ingress of dirt.
The expansion bolt/hexagon bolt on the fuel injector clampin g part must be loosened and disassembled and
can’t be reused.
Slightly and carefully rotate and pull/push the fuel injector by hand to take it out from the hole.
Ensure that the copper seal ring doesn’t fall into the cylinder head fuel injector hole. The seal ring can’t be
reused.
Disassemble all clampin g parts/systems of fuel injectors, protect the injector nozzles by protective caps, and
store the fuel injectors in an environment as clean as possible. Wrap around the fuel injectors with protective
fillers (Such as foam) and then place them into a package box.
8.3 Disassembling and installation of fuel rail
8.3.1 Precautions
During the running of engine and within 30s after the stop of engine, no disassembling or installation
operation is allowed, otherwise it will probably result in leakage of high pressure fuel.
Keep the working environment and tools as clean as possible.
Remove the protective caps only immediately before the installation of fuel rail. After the disassembling of
fuel rail, ensure to timely cover the fuel rail by protective caps.
It’s absolutely prohibited to use any water-containing lubricant.

8.3.2 Installation of fuel rail
Tighten the fuel rail onto the engine by bare hand.
Remove the protective cap from the fuel injector port of fuel rail and tighten the high pressure fuel pipe onto
the fuel injector and fuel rail by bare hand.
Tighten the high pressure fuel pipe nut on the fuel injector end to the final torque. The final torque is provided
by the high pressure fuel pipe supplier.
Install the fuel rail to the engine and tighten it to final torque. The final torque depends on the bolt sizes
(Including diameter, model, and friction coefficient).
Tighten the high pressure fuel pipe of fuel injector onto the fuel rail to final torque.
Remove the protective caps from fuel outlet port of high pressure fuel pump and corresponding port of fuel
rail. Tighten the high pressure fuel pipe to the fuel pump and fuel rail by bare hand.
Tighten the nuts on two ends of fuel pump and fuel rail to final torque. Follow the requirements of the
customer drawing for the tightening torque.
8.3.3 Disassembling of fuel rail
Loosen all nuts between fuel injectors and fuel rail.
Move aside the high pressure fuel pipe by bare hand and ensure to cover the protectors by protective caps.
Loosen the nuts of fuel pump and fuel rail.
Move aside the high pressure fuel pipe by bare hand and ensure to cover the protectors by protective caps.
Disassemble the fuel rail. Timely cover the fuel rail connectors by protective caps.
Wrap around the fuel rail with protective fillers (Such as foam) and then place it into a package box.
8.4 Disassembling and installation of CP1H fuel pump
8.4.1 Precautions
During the running of engine and within 30s after the stop of engine, no operation is allowed, otherwise it will
probably result in leakage of fuel.
Handle the fuel pump correctly to prevent destruction.
Keep the working environment and tools as clean as possible.
Remove the protective caps only immediately before the installation of fuel pump. After the disassembling,
ensure to timely cover it by protective caps.
All sealing devices (O-rings) must be lubricated (by engine oil or diesel) before installation.
It’s absolutely prohibited to use any water-containing lubricant.
8.4.2 Installation of CP1H fuel pump
Remove the protective caps. It’s preferable to degrease the drive shaft by clean testing oil, alcohol, glycol, or
propane.

Insert the drive shaft horizontally into the flange.
Tighten the drive shaft to final torque. The final torque is 70±5Nm (M14*1.5).
Remove the protective caps from fuel outlet port of high pressure fuel pump and corresponding port of fuel
rail. Tighten the high pressure fuel pipe to the fuel pump and fuel rail by hand.
Tighten the nuts on two ends of fuel pump and fuel rail to final torque. The final torque on fuel pump end is
CP1H: 20±2Nm.
Install the pipelines of fuel pump inlet port and outlet port.
Plug fuel metering unit harness connector.
Before start, ensure to fill 60mL diesel into the fuel pump for lubrication purpose.
o Loosen the ventilation port on the filter.
o Push down the manual pump, till the diesel flows out from the ventilation port.
o Tighten the ventilation port on the filter.
o Push down the manual pump again, till it can’t be pushed down further.
8.4.3 Disassembling of CP1H fuel pump
Unplug fuel metering unit harness connector.
Loosen the pipelines of fuel pump inlet port and outlet port and timely plug them by protective caps.
Loosen the high pressure fuel rail between fuel rail and fuel pump and timely plug the fuel pump ports by
protective caps.
Loosen the nut of drive shaft.
Loosen the fastening nuts of fuel pump.
Horizontally pull out the fuel pump.
Store the high pressure fuel tank into a plastic bag to prevent fuel leakage. Within the package box, fill the
surrounding area of the fuel pump by filler (Such as foam) for protection purpose, in order to guard the
protruding portions and parts on the pump body against damage during packaging, storage, and transport.

9 Daily Checking (Driver’s notice)

Inspection of vehicle exterior
Battery ....................................................................................... Secure connection and green indicator □

lamp
Fuel tank .................................................................................... Sufficient fuel level and securely □

tightened fuel tank cap.
Body bottom .............................................................................. Secure without looseness. □
Engine hood............................................................................... Closed and locked securely. □
Checking of engine
Engine Oil ................................................................................. Normal engine oil level □
Hydraulic steering fluid ............................................................. Normal steering fluid level □
Coolant ...................................................................................... Normal coolant level □
Water tank ................................................................................. Sealed without damage. □
Fuel-water separator .................................................................. Water level (Drainage) □
Air filter ..................................................................................... Clean and secure housing □
Diesel......................................................................................... Clean, water-free, and suitable trademark □

to working temperature.
Checking within cab
Indicator lamps and warning lamps ........................................... Normal working □
Play of steering wheel ............................................................... Within permissible range □
Pressure gauge ........................................................................... Normal working of pressure gauge □
Fuel tank level ........................................................................... Correct indication of fuel level □

10 Acronym
A Ampere
AP Acceleration pedal
BNC Bayonet Neill-Concelman
CB1H Common Rail Pump
CRI2.1 Common Rail Injector
CRS Common Rail System
ECU Electronic Control Unit
EDC Electronic diesel control
GTS Guided trouble shooting
HFM Hot-Film mass sensor
HP High pressure
hPa HectoPascals
HPP High pressure pump
mA Miliampere
MIL Malfunction Indicator Lamp
mg/H Milligram per hub
MeUn Metering unit
min Minute
MPa MegaPascals
Ω Ohm
kΩ Kiloohm
MΩ Megaohm
NEG Negative terminal
OEM Original equipment manufacturer
POC Particulate Oxidation Catalyst
POS Positive terminal
rpm Revolutions per minute

RPS Rail pressure sensor
TCD Technical customer documentation
Temp. Temperature
µs Microseconds
V Volt
°C Degree Celsius

11 Data Stream
The table below lists the important data steam and it’s strongly recommended to realize in the diagnostic unit.
Variable name Description
Epm_nEng Engine speed
RailP_pLin Current rail pressure
InjCtl_qCurr Current fuel injection volume
Brk_stRedRaw Auxiliary brake switch
Clth_stRaw Clutch switch
T15_stRaw Ignition switch
GlwLmp_st Preheater indicator lamp status
GlwPlg_st Glow plug output status
APP_uRaw1 Accelerator pedal 1 signal voltage
APP_uRaw2 Accelerator pedal 2 signal voltage
APP_rUnFlt Accelerator pedal opening extent
EnvP_p Atmospheric pressure
EnvP_uRaw Atmospheric pressure sensor signal voltage
CEngDst_uRaw Coolant temperature sensor signal voltage
CEngDst_t Coolant temperature
BattU_u Battery voltage
VehV_v Current vehicle speed
Air_uRawTCACDs Intake temperature sensor signal voltage
Air_tCACDs Intake temperature
IVPlaus_nCyl[0] 1st cylinder speed
IVPlaus_nCyl[1] 3rd cylinder speed
IVPlaus_nCyl[2] 4th cylinder speed
IVPlaus_nCyl[3] 2nd cylinder speed
IVPlaus_qFBCCyl[0] 1st cylinder FBC correction
IVPlaus_qFBCCyl[1] 3rd cylinder FBC correction

IVPlaus_qFBCCyl[2] 4th cylinder FBC correction
IVPlaus_qFBCCyl[3] 2nd cylinder FBC correction
MeUn_rPs_mp Fuel metering unit
MeUn_iActFlt_mp Fuel metering unit current
MeUn_uRaw_mp Fuel metering unit current sensor voltage
Epm_stSync Synchronization status
Rail_pDvt Rail pressure deviation
Rail_uRawMax Rail pressure sensor signal voltage
Brk_stMnRaw Main brake switch status
VehV_vSens Vehicle speed sensor signal voltage
InjUn_stStrt Start failure information
AFS_tiRaw Airflow sensor signal cycle
EnvT_t Environmental temperature
Fl_stWLvlSensRawVal Water-in-fuel sensor
AFS_mAirPerCyl Inhaled intake volume per cylinder
AirCtl_mDesVal Fresh air demand
Tra_numGear Current gear

12 Version Update Record

Date Version Update description
October 2017 V01 First draft

ZD30国五发动机电控故障诊断手册 EDC17C63 V6+SCR（第一版）-译文

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Diagnostic Guidebook

High pressure common rail fuel injection system of ZD30

Copyright statement and disclaimer

Copyright © Dongfeng Light Engine Co., Ltd.

No. 58, Xinjiang Road, Shiyan, Hubei, China

Postal code: 442003

First Edition in October, 2017

© Dongfeng Light Engine Co., Ltd. 2017 -2-

2.1 Document overview ..................................................................................................................... 9

2.2 Safety precautions ....................................................................................................................... 9

2.2.1 General safety precautions..................................................................................................... 9

2.2.2 Checking and repair of high pressure fuel system ................................................................. 9

2.2.3 Elevating of vehicle ............................................................................................................. 10

2.2.4 Parking of vehicle ................................................................................................................ 10

2.2.5 Service trench ...................................................................................................................... 10

2.2.6 Treatment of exhaust gas ..................................................................................................... 11

2.2.7 Rotating parts....................................................................................................................... 11

2.2.8 High temperature parts ........................................................................................................ 11

2.2.9 Inflammables and explosives (Such as diesel, gasoline, and detergent).............................. 11

2.3 Use of inspection equipment ..................................................................................................... 13

2.3.1 Basic preconditions for diagnosis ........................................................................................ 13

3 How to Use This Manual........................................................................................................................... 15

3.1 Malfunction checking and repair guidance................................................................................ 15

3.2 Precautions for malfunction diagnosis....................................................................................... 17

3.2.1 Preliminary judgment .......................................................................................................... 17

3.2.2 Read trouble codes............................................................................................................... 17

3.2.3 Diagnose by steps. ............................................................................................................... 17

4 System and Part Overview ........................................................................................................................ 18

4.1 Common rail fuel injection system ............................................................................................ 18

4.1.1 High pressure fuel pump (CP1H) ........................................................................................ 18

4.1.2 Common rail fuel injector (CRI2.1) .................................................................................... 20

4.1.3 High pressure fuel rail ......................................................................................................... 21

© Dongfeng Light Engine Co., Ltd. 2017 -3-

4.1.4 Rail pressure sensor (RPS) .................................................................................................. 21

4.1.5 Fuel filter ............................................................................................................................. 21

4.1.6 Fuel tank .............................................................................................................................. 22

4.1.7 Manual fuel pump................................................................................................................ 23

4.1.8 Electronic control unit (ECU) .............................................................................................. 23

4.1.9 Turbocharged pressure and temperature sensor................................................................... 24

4.1.10 Crankshaft signal sensor ...................................................................................................... 24

4.1.11 Camshaft sensor................................................................................................................... 24

4.1.12 Coolant temperature sensor ................................................................................................. 25

4.1.13 DOC differential pressure sensor......................................................................................... 25

4.1.14 Glow plug (GLP) ................................................................................................................. 25

4.1.15 Throttle ................................................................................................................................ 26

4.2 FAI-SCRL1.0 non-air assisted dosing system ........................................................................... 26

4.2.1 Supply module ..................................................................................................................... 28

4.2.2 Dosing nozzle ...................................................................................................................... 30

4.2.3 Dosing control unit (DCU) .................................................................................................. 32

4.2.4 AdBlue tank assembly ......................................................................................................... 33

4.2.5 AdBlue delivery pipe ........................................................................................................... 33

4.2.6 Water cutoff solenoid valve ................................................................................................. 34

4.2.7 NOx sensor .......................................................................................................................... 35

4.2.8 Exhaust gas temperature sensor ........................................................................................... 36

5 Checking and Repair Tools ....................................................................................................................... 38

5.1 Low pressure test suite .............................................................................................................. 38

5.2 Fuel injector fuel return volume test suite ................................................................................. 38

5.3 Transparent hose........................................................................................................................ 39

5.4 Protective cap ............................................................................................................................ 39

5.5 Measuring glass ......................................................................................................................... 39

5.6 Oscilloscope and parts ............................................................................................................... 40

5.7 Cylinder pressure test suite with adapter ................................................................................... 40

5.8 Manual pump ............................................................................................................................. 40