Common Malfunction Diagnosis Flow of Geely Automobile PDF

Common Malfunction Diagnosis Flow of
Geely Automobile
GEELY INTERNATIONAL CORPORATION

JUN. 2008
Common Malfunction Diagnosis Flow of Geely Automobile
Common Malfunction Diagnosis Flow Content of Geely Automobile
Engine ....................................................................................................................................... 1
No.001 Engine shuts off abnormally when driving..................................................................... 1
No.002 Engine surging .............................................................................................................. 3
No.003 Over idle speed when warm-up .................................................................................... 5
No.004 Idle speed fluctuation .................................................................................................... 7
No.005 Idle speed unstable or engine shut-off when opening AC or steering ........................... 9
No.006 Engine shuts off intermittently ..................................................................................... 11
No.007 Poor accelerating performance in cold condition ........................................................ 13
No.008 Spark plug non-sparking ............................................................................................. 15
No.009 Low idle speed during engine heating in cold condition .............................................. 17
No.010 Canister oil leaking...................................................................................................... 19
No.011 Fuel smells in vehicle .................................................................................................. 20
No.012 Engine vibration when operating................................................................................. 22
No.013 Engine noise over normal level ................................................................................... 24
No.014 Water temperature over normal value after AC activated............................................ 26
No.015 Oil pan leak ................................................................................................................. 27
No.016 Distributor oil leaking................................................................................................... 29
No.017 JL376/378 engine shut-off when sliding at neutral gear.............................................. 30
No.018 High idle speed when sliding at neutral gear, MK ....................................................... 32
No.019 Engine vibration .......................................................................................................... 33
No.020 Exhaust pipe pours black smoke ................................................................................ 34
No.021 Engine idle speed decreases when activating head beam or fan ............................... 36
No.022 Exhaust pipe blows water ........................................................................................... 38
No.023 Engine shuts off when accelerating ............................................................................ 39
No.024 Oil indicator is always on ............................................................................................ 41
No.025 Water temperature is over normal value when engine running with large load ........... 42
No.026 Canister electromagnetic valve sounds abnormal....................................................... 44
No.027 Engine fails to start ..................................................................................................... 45
No.028 Hard to start in cold condition...................................................................................... 47
No.029 Hard to stard engine when heating ............................................................................. 49
No.030 Idle speed unstable..................................................................................................... 51
No.031 Non-idle speed............................................................................................................ 54

No.032 Idle speed over normal value ...................................................................................... 56
No.033 Engine accelerates abnormal...................................................................................... 58
No.034 Water temperature over normal value......................................................................... 60
No.035 Oil existing in the water tank ....................................................................................... 62
No.036 There is water in the oil............................................................................................... 64
No.037 Abnormal sound of crankshaft bearing ....................................................................... 65
No.038 Abnormal sound of connecting rod bush..................................................................... 67
No.039 Camshaft with abnormal sound................................................................................... 69
No.040 Camshaft driving gear with abnormal sound ............................................................... 70
No.041 Cylinder knocking sound............................................................................................. 71
No.042 Oil pump with abnormal sound.................................................................................... 73
No.043 Crankshaft thrust piece with abnormal sound ............................................................. 74
No.044 Valve with abnormal sound ......................................................................................... 75
No.045 Engine with insufficient power.....................................................................................76
No.046 Oil consumption too large ........................................................................................... 78
No.047 Intake tempering ......................................................................................................... 83
No.048 Exhaust pipe bombs ................................................................................................... 85
No.049 Engine knocking.......................................................................................................... 86
No.050 Engine burning oil ....................................................................................................... 88
No.051 Cooling water unusually consumed ............................................................................ 89
No.052 Low engine oil pressure .............................................................................................. 90
No.053 Quick diagnosis for ECU............................................................................................. 91
No.054 Quick diagnosis for idling-speed governor EWD......................................................... 93
No.055 Quick diagnosis for knocking sensor........................................................................... 94
No.056 Quick diagnosis for stepper motor .............................................................................. 96
No.057 Quick diagnosis for ignition coil................................................................................. 100
No.058 Quick diagnosis for throttle valve position sensor ..................................................... 102
No.059 Quick diagnosis for inlet pressure temperature sensor ............................................. 104
No.060 Quick diagnosis for water temperature sensor.......................................................... 107
No.061 Quick diagnosis for canister solenoid valve .............................................................. 109
No.062 Fuel injector EV......................................................................................................... 111
No.063 Quick diagnosis for Hall sensor................................................................................. 113
No.064 Electric fuel pump EKP ............................................................................................. 115

No.065 Fuel pressure regulator DR....................................................................................... 117
No.066 Oxygen sensor LSH.................................................................................................. 119
No.067 JL376/378QE engines electric control system check ............................................... 121
No.068 Diagnosis and solution of common malfunctions of JL376/378QE engines electric
control system.......................................................................................................... 129
No.069 Flashing code list of M1.5.4 series............................................................................ 130
No.070 Malfunction code: P0107 "voltage of intake pressure sensor circuit too low"............ 132
No.071 Malfunction code: P0108 "voltage of intake pressure sensor circuit too high"........ 133
No.072 Malfunction code: P0112 "temperature indicated by intake temperature sensor too
low" .......................................................................................................................... 133
No.073 Malfunction code: P0113 "temperature indicated by intake temperature sensor too
high"......................................................................................................................... 134
No.074 Malfunction code: P0117 "temperature indicated by cooling liquid temperature sensor
too low" .................................................................................................................... 134
No.075 Malfunction code: P0118 "temperature indicated by cooling liquid temperature sensor
too high"...................................................................................................................135
No.076 Malfunction code: P0122 "voltage of throttle valve position sensor circuit too low"... 135
No.077 Malfunction code: P0123 "voltage of throttle valve position sensor circuit too high" . 136
No.078 Malfunction code: P0130 "signal circuit of upstream oxygen sensor malfunction" .... 137
No.079 Malfunction code: P0132 "voltage of upstream oxygen sensor circuit too high" ....... 137
No.080 Malfunction code: P0134 "upstream oxygen sensor signal malfunction" .................. 137
No.081 Malfunction code: P0135 "heating circuit of upstream oxygen sensor malfunction".. 138
No.082 Malfunction code: P0171 self-adapting of closed-loop control of air fuel ratio shall
exceed upper part................................................................................................... 138
No.083 Malfunction code: P0172 self-adapting of closed-loop control of air fuel ratio shall
exceed lower part ................................................................................................... 139
No.084 Malfunction code: P0201 "one-cylinder oil injector circuit malfunction"..................... 140
No.085 Malfunction code: P0202 "two-cylinder oil injector circuit malfunction" ..................... 140
No.086 Malfunction code: P0203 "three-cylinder oil injector circuit malfunction"................... 141
No.087 Malfunction code: P0204 "four-cylinder oil injector circuit malfunction"..................... 141
No.088 Malfunction code: P0230 "oil pump control circuit malfunction" ................................ 142
No.089 Malfunction code: P0325 "knock sensor circuit malfunction" .................................... 142
No.090 Malfunction code: P0335 crankshaft position sensor signal malfunction ................ 143
No.091 Malfunction code: P0336 crankshaft position sensor signal with unreasonable
malfunction ............................................................................................................. 143
No.092 Malfunction code: P0340 Phase sensor signal malfunction.................................... 144
No.093 Malfunction code: P0342 circuit voltage of phase sensor too low........................... 144
No.094 Malfunction code: P0343 circuit voltage of phase sensor too high ......................... 145
No.095 Malfunction code: P0443 "Malfunction of control circuit of driver stage of canister
control valve" ...........................................................................................................146
No.096 Malfunction code: P0444 "voltage of control circuit of driver stage of canister control
valve too low" ........................................................................................................... 146
No.097 Malfunction code: P0445 "voltage of control circuit of driver stage of canister control
valve too high" .........................................................................................................147
No.098 Malfunction code: P0480 "malfunction control circuit of cooling fan relay of AC
condenser"............................................................................................................... 148
No.099 Malfunction code: P0500 "unreasonable malfunction of speed signal" ..................... 148
No.100 Malfunction code: P0506 "idling speed lower than target speed value" .................... 149
No.101 Malfunction code: P0507 "idling speed higher than target speed value"................... 149
No.102 Malfunction code: P0508 "voltage of control circuit of idling speed governor too low"
................................................................................................................................. 149
No.103 Malfunction code: P0509 "voltage of control circuit of idling speed governor too high"
................................................................................................................................. 150
No.104 Malfunction code: P0511 "malfunction control circuit of idling speed governor"........ 150
No.105 Malfunction code: P0560 "unreasonable system voltage signal" .............................. 150
No.106 Malfunction code: P0562 "system voltage too low" ................................................... 151
No.107 Malfunction code: P0563 "system voltage too high" ................................................. 151
No.108 Malfunction code: P0601 "error of check code of electronic control unit".................. 152
No.109 Malfunction code: P0602 "error of identification code of diagnosis data of electronic
control unit" .............................................................................................................. 152
No.110 Malfunction code: P0645 "malfunction of relay control circuit of AC compressor"..... 152
No.111 Malfunction code: P0646 "voltage of relay control circuit of AC compressor too low" 153
No.112 Malfunction code: P0647 "voltage of relay control circuit of AC compressor too high"
................................................................................................................................. 154
No.113 Malfunction code: P1508 "voltage of control circuit of idling speed governor too high"
................................................................................................................................. 155
No.114 Malfunction code: P1651 "malfunction of control circuit of engine malfunction lamp
(SVS)" ...................................................................................................................... 155
No.115 Engine not running or slowly running while startup ................................................... 157
No.116 While startup, engine running, but unable to start ..................................................... 158
No.117 Difficult to start for hot startup.................................................................................... 159
No.118 Difficult to start for cold startup .................................................................................. 160
No.119 Difficulty startup at any time though with normal speed ............................................ 161
No.120 Normal startup with instable idling speed at any time ............................................... 162
No.121 Normal startup, with instable idling speed during warming up .................................. 163
No.122 Normal startup, with instable idling speed after warming up ..................................... 164
No.123 Normal startup, idling speed is instable or the vehicle will flame out when partially
loaded (such as: when air conditioner is on) ............................................................ 165
No.124 Normal startup, the idling speed is too high .............................................................. 166
No.125 Unable to rotating speed or flameout while accelerating........................................... 167
No.126 Slow reaction while accelerating ............................................................................... 168
No.127 Weak with poor performance while accelerating....................................................... 169
No.128 Malfunction code with EOBD system ........................................................................ 170
No.129 Malfunction code without EOBD system ................................................................... 174
Transmission ..................................................................................................... 176

No.130 Transmission hard to put into gear............................................................................ 176
No.131 Park position fails...................................................................................................... 177
No.132 Gear indicator lamp off sometimes ........................................................................... 178
No.133 Auto transmission with abnormal sound ................................................................... 179
No.134 Transmission shaking during driving ......................................................................... 181
No.135 Auto transmission case oil temperature rises, reverse gear fails .............................. 183
No.136 Auto transmission upshifts too late............................................................................ 184
No.137 Auto transmission unable to upshift .......................................................................... 186
No.138 Auto transmission unable to force downshift............................................................. 187
No.139 Engine shuts down after putting into gear ................................................................. 188
No.140 No forward gear ........................................................................................................ 189
No.141 Transmission oil easily deteriorate ............................................................................ 190
No.142 Auto transmission oil easily deteriorate..................................................................... 191
No.143 No reversing gear ..................................................................................................... 192
No.144 Trip stop of fourth gear of transmission case ............................................................ 193
No.145 Transmission with abnormal sound........................................................................... 195

No.146 Gear shifting lever swinging, hard to shift ................................................................. 197
No.147 Sounding when releasing throttle of third, fourth gears and decelerating ................. 198
No.148 Fifth gear not easily shifted up .................................................................................. 199
No.149 Fifth gear, first gear blocks, relieved only when the vehicle stops............................. 200
No.150 Hiss sound when put into gear during driving ........................................................... 201
No.151 Transmission gear runout ......................................................................................... 203
No.152 Hiss sound when second, third, fourth gear upshift .................................................. 204
No.153 Chug sound in transmission case at idling speed ..................................................... 205
No.154 Da-da sound in transmission at idling speed ............................................................ 206
No.155 Buzz sound during driving at high speed .................................................................. 208
No.156 Transmission with abnormal sound while shifting ..................................................... 210
No.157 Transmission gear disorder....................................................................................... 211
No.158 Shaking startup ......................................................................................................... 213
Chassis ................................................................................................................................. 215

No.159 Shaking startup ......................................................................................................... 215
No.160 Clutch slipping........................................................................................................... 217
No.161 Heavy clutch ............................................................................................................. 218
No.162 Not fully separated ....................................................................................................219
No.163 Clutch with abnormal sound...................................................................................... 221
No.164 Shock absorber with abnormal sound....................................................................... 223
No.165 Front wheel with abnormal sound when turning........................................................ 225
No.166 Heavy steering .......................................................................................................... 227
No.167 Steering wheel not well back to original position ....................................................... 229
No.170 Steering power insufficient (hydraulic) ...................................................................... 232
No.171 Power-assisted pump with abnormal sound ............................................................. 233
No.172 Direction running out................................................................................................. 235
No.173 Steering wander during normal driving...................................................................... 237
No.174 Front wheel tire abnormally worn .............................................................................. 239
No.175 Normally when driving straightly, but with abnormal sound while turning.................. 241
No.176 Braking wandering .................................................................................................... 242
No.177 Braking dragging.......................................................................................................244
No.178 Braking with abnormal sound.................................................................................... 246
No.179 Braking sideslipping, swerving .................................................................................. 248

No.180 Braking intermittently stiffening ............................................................................... 249
No.181 Braking ineffective..................................................................................................... 251
No.182 Brake fails ................................................................................................................. 253
No.183 Steering wheel with too large free stroke .................................................................. 255
No.184 Buzzing noise at rear wheel while driving at high speed........................................... 257
No.185 Braking force of brake master cylinder insufficient.................................................... 258
No.186 Stepping on pedal too heavily ................................................................................... 259
No.187 Common malfunction diagnosis and Solution for Geely automobile tire ................... 260
No.188 Causes analysis for common manufacturing defects of Geely automobile tire ......... 262
Electrics ...............................................................................................................................263
No.189 CD-player disk boot malfunction (without MP3) ........................................................ 263
No.190 CD-player fails to work when activating .................................................................... 265
No.191 CD-player keeps soundless under all modes............................................................ 265
No.192 CD-player/radio gains no power................................................................................ 267
No.193 A loudspeaker of CD-player/radio is soundless......................................................... 268
No.194 Onboard hand-free phone has no sound output (MK)............................................... 269
No.195 CD-player/radio button out of control ........................................................................ 271
No.196 CD-player/radio button indicator malfunction ............................................................ 271
No.197 CD-player/radio memory function malfunction .......................................................... 273
No.198 CD-player/radio no signal ......................................................................................... 273
No.199 CD-player/radio sound distortion at large volume ..................................................... 274
No.200 CD-player/radio tuner cant stop ............................................................................... 275
No.201 CD-player/radio has noise when receiving signal ..................................................... 276
No.202 CD-player fails to insert disk ..................................................................................... 277
No.203 CD-player fails to popup disk .................................................................................... 279
No.204 CD-player with poor vibration resistance performance ............................................. 280
No.205 USB interface of CD player malfunction (U-disk) (MK) ........................................... 281
No.206 CD-player burns out when connecting power source................................................ 283
No.207 CD-player consists back drop ................................................................................... 284
No.208 Cassette stuck or failed to popup.............................................................................. 286
No.209 Cassette speed abnormal, turned over automatically and chewed ........................... 287
No.210 Poor timbre, low volume or noise jump when playing CD ......................................... 289
No.211 Low loudspeaker volume........................................................................................... 291

No.212 Large loudspeaker noise........................................................................................... 293
No.213 Loudspeaker susurrates when pressing horn ........................................................... 295
No.214 Speedometer non-display ......................................................................................... 297
No.215 Freedom ship speedometer malfunction, indicates automatically when pressing horn
................................................................................................................................................. 299
No.216 Incorrect indication of speedometer .......................................................................... 301
No.217 Kilometrage on LCD of odometer will accumulate automatically after the engine starts
................................................................................................................................................. 303
No.218 Automatic movement of odometer pointer after start-up of engine ........................... 305
No.219 Incorrect indication or no indication of engine tachometer ........................................ 307
No.220 Incorrect indication (or no indication) of fuel gauge................................................... 309
No.221 No indication of water temperature gauge ................................................................ 311
No.222 Electric mirror cant work........................................................................................... 313
No.223 Always-On or failure of water temperature alarm indicator ....................................... 314
No.224 Safety & alarm indicator is always on or not on ........................................................ 315
No.225 Brake fluid level alarm indicator is always on or cant alarm..................................... 316
No.226 Oil alarm indicator is always on................................................................................. 317
No.227 Headlight is always on or not on ............................................................................... 318
No.228 Weak running of starter............................................................................................. 319
No.229 Starter cant work ...................................................................................................... 320
No.230 Idling of starter .......................................................................................................... 322
No.231 Abnormal sound during start-up of starter................................................................. 323
No.232 Over-high or over-low recharging voltage from generator......................................... 324
No.233 Generator cant work................................................................................................. 326
No.234 Charging indicator of generator is always on or not on ............................................. 328
No.235 Flashing of charging indicator of generator ............................................................... 329
No.236 Abnormal sound of generator.................................................................................... 331
No.237 Failure of battery storage .......................................................................................... 332
No.238 Weak running of blower ............................................................................................ 333
No.239 Blower cant work......................................................................................................334
No.240 Abnormal sound of blower ........................................................................................ 335
No.241 Continuous running of cooling fan............................................................................. 336
No.242 Cooling fan cant work............................................................................................... 337
No.243 Weak running of cooling fan...................................................................................... 338
No.244 Wiper cant work .......................................................................................................339

No.245 Wipe doesnt work at intermitting position ................................................................. 340
No.246 Electric fuel pump cant work .................................................................................... 341
No.247 Insufficient pressure of electric fuel pump ................................................................. 342
No.248 Positive pressure of fuel tank too high ...................................................................... 343
No.249 Failure of remote controller ....................................................................................... 344
No.250 Door lock is not self-locked after driving 30 feet........................................................ 346
No.251 Failure of central control locking while driving........................................................... 347
No.252 Flashing CGQ alarm indicator for speedometer........................................................ 348
No.253 Window lifter cant work ............................................................................................ 349
No.254 Blocking Door lock .................................................................................................... 350
No.255 Failure of door lock ................................................................................................... 351
No.256 If four doors of vehicle are not closed, the anti-theft alarm will be activated
automatically and central control will be locked automatically ................................. 352
No.257 Reversing radar cant work while reversing .............................................................. 353
No.258 Wrong information from the reversing radar.............................................................. 354
No.259 Sunroof cant move, including malfunction of automatic closing and anti-nip ........... 355
No.260 Abnormal sound and vibration of sunroof while operating ........................................ 356
No.261 Leaking of sunroof (water on internal decoration of roof).......................................... 357
No.262 Air-conditioner cant work.......................................................................................... 358
No.263 Normal suction pressure and too high exhaust pressure for AC compressor ........... 361
No.264 Too high suction pressure and exhaust pressure for AC compressor ....................... 362
No.265 Too high suction pressure and normal exhaust pressure for AC compressor ........... 363
No.266 Too low suction pressure and exhaust pressure for AC compressor......................... 364
No.267 Air conditioning has abnormal sound ........................................................................ 365
No.268 The air conditioning has no heating supply or the heating air is not warm................ 366
No.269 A/C compressor fails to start ..................................................................................... 368
No.270 The A/C control mechanism is hard to operate ......................................................... 370
No.271 The A/C evaporator is frosting................................................................................... 370
No.272 Constant malfunction and solution of A/C components ............................................. 372
No.273 Vehicle temperature sensor is in poor condition (code display 01)......................... 376
No.274 The vehicle exterior temperature sensor is in poor condition; (code display 02)....... 376
No.275 The evaporator temperature sensor is in poor condition. (code display 03) ........... 377
No.276 The temperature adjustment performer is in poor condition; (code display 04) ........ 377
No.277 The sun sensor is in poor condition.(code display 05) .............................................. 378
No.278 The fan governing module is in poor condition; (code display 06).......................... 378
No.279 The high speed relay is in poor condition; (code display 07) .................................... 379
No.280 The rear defrosting function is invalid ....................................................................... 379
No.281 The display screen has no display ............................................................................ 380
No.282 The internal and external circulation regulation is invalid.......................................... 380
No.283 The wind direction adjustment is abnormal ............................................................... 381
No.284 The blower is in poor operation................................................................................. 381
No.285 Vehicle interior air conditioning is in poor condition................................................... 382
No.286 Vehicle interior central heating is in poor condition ................................................... 383
No.287 Night light regulation function of the a/c controller is invalid...................................... 383
No.288 The compressor is out of service .............................................................................. 384
No.289 Effect of the air conditioning is in poor condition (check it per the content in the
following table) .........................................................................................................384
No.290 Installation and Commissioning of the Air Conditioning ............................................ 386
No.291 Line inspection of "EPS" indicating lamp (the "EPS" indicator does not light up when
the ignition switch is opened) ................................................................................... 397
No.292 Inspection to "EPS" indicator line ("EPS" indicator does not light up or keep on lighting
up when the cross-line connection is made between the diagnoses switch terminal and
the ground terminal)................................................................................................. 398
No.293 Main line of DTC11 torque sensor (the main line is broken or short circuit) .............. 398
No.294 DTC13 torque sensor (there is big difference between the auxiliary line outputs of the
main line and the torque sensor).............................................................................. 398
No.295 DTC14 torque sensor (power supply voltage of the torque sensor is too high or too low)
................................................................................................................................. 399
No.296 Auxiliary line of DTC15 torque sensor (the auxiliary line is disconnected or short circuit)
................................................................................................................................................. 399
No.297 DTC22 engine speed signal (no engine signal input)................................................ 399
No.298 Vss line(Vss line is disconnected or short circuit) ........................................................................401
No.299 DTC41 motor (the motor voltage is too high or too low)............................................ 401
No.300 DTC51 clutch line (the clutch line is disconnected or short)...................................... 401
No.301 Power circuit of DTC54 control module (low voltage of the battery) ....................... 402
No.302 DTC52 and DTC55 control modules (failure of control module)................................ 402
No.303 Voltage inspection.....................................................................................................402
No.304 Introduction of mechanical assembly ........................................................................ 403

No.305 Diagnoses to the ABS system failure ........................................................................ 405
No.306 Quick index list of malfunction clearance .................................................................. 406
No.307 Index of malfunction code free malfunction check list ............................................... 406
No.308 Malfunction check list of malfunction code................................................................ 407
No.309 The malfunction codes are 00283, 00285, 00290 and 00287 (mechanical malfunction)
................................................................................................................................................. 408
No.310 Malfunction codes: 00283, 00285, 00290 and 00287 ............................................... 409
No.311 Malfunction codes are 00283, 00285, 00290 and 00287 (electric failure) .............. 410
No.312 Malfunction code: 01044........................................................................................... 411
No.313 Malfunction code: 00668........................................................................................... 411
No.314 Malfunction code: 01130 ........................................................................................... 412
No.315 Malfunction check list of malfunction free code......................................................... 413
No.316 The ABS alarm lamp is normally open after the engine starts................................... 414
No.317 ABS is in abnormal operation.................................................................................... 414
No.318 The brake pedal stroke is too long ............................................................................ 416
No.319 Large force is required to stamp the pedal................................................................ 417
No.320 There is no diagnostic code output ........................................................................... 417
No.321 ABS system inspection ............................................................................................. 419
No.322 ECU code ................................................................................................................. 422
No.323 Fluid filling and air exhaust ....................................................................................... 423
Engine
No. 001 Engine shuts off abnormally when driving
Malfunction Cause Solution
Check the injection volume and the atomization of the injector, whether they are
normal, clean or replace the injector when necessary.
Low fuel pressure or
injector blockage Check fuel pressure. When idling the value shall correspond to 265~304 kPa, when
accelerating the value shall increase approximately 50 kPa. If fuel pressure is too
low, check fuel pressure controller, electric fuel pump and fuel filter etc.
Check engine ignition timing. When idling, the ignition advance angle shall be
Improper ignition
10~12. Otherwise, shall adjust engine initial advance angle. When accelerating,
timing, engine shuts
the ignition advance angle shall over 20~30, automatically adjusted. Otherwise,
off sometimes
shall replace ECU or maintain ignition controlling system.
Check valve clearance, whether it is too small. When heating, the clearance of air
Valve clearance too intake and exhaust valve shall be 0.200.05mm, otherwise, adjust it to prescribed
small or throttle body value according to maintenance manual.
too dirty Check throttle body, whether it is too dirty. Clean throttle body and idle speed
controller when necessary.
When applying poor quality fuel, the fuel pipe must be cleaned then replace
Fuel quality problem
standard gasoline, 93# or above.
Spark plug Check spark plug resistance, whether the value is 5~8K, as well as the clearance,
malfunction whether the value is 0.8~1.0mm. Otherwise, shall adjust or replace them.
Ignition coil Check ignition coil, the initial winding shall be 0.4~0.6, and the 2nd winding shall be
malfunction 11~15. Otherwise, shall replace ignition coil.
Spark plug wire If there is short or open circuit in spark plug wire, then shall replace it.
Idle speed control
Engine shuts valve or stepper motor When stuck, shall clean or replace it.
off in normal malfunction
driving, such
as geared Check the relay by multimeter, whether it is connected, as well as the coil
Fuel pump relay burnt
driving or resistance, whether the value is 75~90. Replace when necessary.
cornering Determine whether it is valve gumming, according to local and gasoline using
condition. Generally, the malfunction appears in cold condition, and will disappear
Valve gumming
after vehicle heated. It is recommended that driver shall clean engine without
components removing, meanwhile, replace qualified gasoline.
ECU harness pin poor Check ECU, whether it is poor contact, which results signal deviation when idling,
contact as well as abnormal shut-off. Fasten wire connector again, when necessary.
Three way catalytic Check three way catalytic converter, whether it is free-flowing, as well as the
converter damaged or housing, whether there is collision mark. Replace the converter assembly when
blocked necessary.
Temperature sensor part (pin disconnected) pin 1# and 2#: the rated resistance at
20 is 2.5K5%, and the value shall decrease when temperature raising.
Pressure sensor part (pin connected): black pen connects to earth; red pen
Pressure temperature
connects with pin 3# and 4# respectively. In idle condition, the reference voltage on
sensor malfunction
pin 3# shall be 5V, and the voltage on pin 4# shall be approximately 1.3V
(determined by vehicle). If the value abnormal, then the pressure temperature
sensor is damaged and shall be replaced.
Check main ECU wire harness connectors, whether they are fixed, as well as poor
connecting caused by rust and oxidation. Clean and fix it when necessary. Load
Poor ECU signal
data stream by K61 detector, and check the display value of ECU, whether it
coordinates to the standard. Replace ECU when necessary.
Check engine compression ratio and pressure, whether they are corresponding with
the standard value:
Insufficient engine
cylinder pressure 479Q 9.3: 1/1250kpa/250r/min; 479QA 9.8: 1/1440kpa/250r/min; 481Q9.4:
1/1360kpa/250r/min; JI376QE9.5: 1/1225kpa/350r/min; JL378QE 9.5: 1 /
1225kpa/350r/min; audit and maintain engine when necessary.
1
Engine shuts off abnormally when driving
Abnormal
Spark plug, ignition coil, spark plug wire
malfunction Replace
Normal Improper
Improper ignition timing Adjust
Normal
Abnormal
Valve clearance too small or throttle body too dirty Adjust and clean
Normal
Abnormal
Fuel quality problem Replace
Normal Abnormal
Three way catalytic converter damaged or Replace
blocked
Normal Burnt
Fuel pump relay burnt Replace
Normal Abnormal
Pressure temperature sensor failure Replace
Normal
Abnormal
Poor ECU signal Replace
Normal
Abnormal
Valve gumming Mainatain
Normal
Abnormal
Idle speed control valve or stepper motor Clean or replace
malfunction
Normal
Too low or bocked
Low fuel pressure or injector blockage
Check or replace
Normal
Abnormal
Inssuficient engine cylinder pressure Check engine
2
No. 002 Engine surging

Fuel fliter blockage Check fuel filter, whether it is blocked, and replace it when necessary.
Check charcoal canister, whether it contains gasoline, replace it if gasoline
Charcoal canister
contains.
Fuel injector blockage or Check the injection volume and atomization of injector, if they are abnormal,
poor atomized then shall clean and replace injector assembly.
Check fuel pressure, when idling, the pressure shall be in accordance with
regular value, 265~304kPa, and shall increase about 50kPa when
Low fuel pressure
accelerating. If fuel pressure is too low, shall check fuel pressure controller,
electric fuel pump and etc.
Test the actual pressure of manifold, whether it is in accordance with
standard.
Check intake manifold gasket whether it is damaged, as well as the gasket
Air intake system leakage between intake manifold and throttle.
Check the cylinder gasket, whether it is bent and damaged.
Check all hoses whether they are ageing and broken.
Tachometer
large vibrates Check spark plug applying condition, whether it operates well.
when engine Check cylinder wire, whether there is short or open circuit.
surging Poor ignition
Check the operating condition of ignition coil and distributor.
Check the connecting condition between ignition control and ECU.
Check idle motor, whether it is too dirty or stuck, clean or replace it when
Idle motor malfunction
necessary. Load data stream to confirm idle operation parameter status.
Check valve clearance: on 4-cylinder engine, the clearance of intake valve
shall be 0.200.05 mm, exhaust valve 0.300.05mm. On 3-cylinder engine,
Small valve clearance
the clearance of intake / exhaust valve shall be 0.200.05mm when heating,
0.120.04mm in cold condition. Otherwise, shall adjust it.
Check ignition advance angle, whether it is normal. In idle condition: on
4-cylinder engine, the advance angle shall be 10~12 before top dead
Improper ignition time
center. on 3-cylinder engine, the advance angle shall be 123.75 before top
dead center. Otherwise, shall adjust it.
Check exhaust system, whether it is blocked or damaged. Check timing,
whether it is misaligned. Check valve spring, whether it is damaged. Check
Engine mechanical parts
camshaft, cylinder head and piston, whether they are malfunction. Check
cylinder pressure, whether it is in normal condition.
3
Engine surging
Blocked
Fuel fliter blockage
Clean or replace
Normal
Poor
Check the injector whether it is blocked or poor
atomized Clean or replace
Normal
Low
Low fuel pressure
Maintain
Normal
Leak
Intake system leaking
Maintain
Normal
Poor
Poor ignition
Maintain or replace
Normal
Abnormal
Charcoal canister
Replace
Normal
Abnormal
Engine valve clearance Adjust
Normal
Abnormal
Engine ignition timing
Adjust
Normal
Abnormal
Idle motor Clean or replace
Normal
Abnormal
Engine mechanical parts Check
4
No. 003 Over idle speed when warm-up

Improper ignition time Adjust ignition time
Check fuel pressure, whether the value is 265~304kPa. If it is
Incorrect fuel pressure abnormal, shall check fuel pump and pressure controller, as well as
the balance fuel injection volume of each injector.
Throttle cable or inner
If throttle cable or inner damper fails to return origin position, sc.
damper fails to return origin
opening degree remains, shall check throttle cable and throttle.
position
Idle speed control valve or Check idle controller, whether there is over carbonization. Implement
stepping motor stuck clean and self-adaption value adjust when necessary.
Check intake system, whether it is leaking. Maintain or replace when
Intake system leak
necessary.
The sensitive resistance Check water temperature sensor, at each temperature, whether the
Idle speed raised temperature coefficient of operation resistance is in regulated range. For example, at 20 1
when warm-up water temperature sensor (temperature tolerance), the resistance shall be 2.27~2.73k.
indicates inaccurately Replace when necessary.
Check heater resistance of heated oxygen sensor (UAES 1~6,
Delphi 12, Polarsun 13.210%) , heater voltage (12V) and signal
Exhaust gas oxygen sensor voltage (0.1~0.9V), whether they are normal.
malfunction Check oxygen sensor, whether it is polluted or poisoned. When
oxygen senor outputs low voltage or signal error, then ECU will send
thick injection order, otherwise, replace the sensor.
Check A/C controlling system, whether it is normal.
A/C control signal error Check pressure switch current, whether it is normal.
Check AC system pressure, whether it is normal.
Check ECU, whether it is damaged. Replace ECU assembly when
ECU inner data unmatching
necessary.
5
Over idle speed when warm-up
Abnormal
Water temperature sensor malfunction
Replace
Normal
Abnormal
Oxygen sensor malfunction Replace
Normal
Abnormal
Intake system leaking Check
Normal
Stuck
Idle speed control valve or stepping motor stuck
Clean or replace
Normal
Abnormal
Incorrect fuel pressure Check
Normal
Abnormal
A/C control signal error
Check
Normal
Abnormal
Improper ignition time (too early)
Adjust
Normal
Abnormal
Throttle cable or damper malfunction Maintain
Normal
Abnormal
Replace
ECU inner malfunction
6
No. 004 Idle speed fluctuation

Throttle is stuck and Clean and check throttle sealing condition.
dirty
Check spark plug, whether it is dirty, cracked or tracking;
Check wire of each cylinder, whether they are ageing, tracking, short or open circuit;
Ignition maladjustment Check ignition timing, whether it is maladjustment. (ignition timing shall position at
10~12 before top dead center when idling. Adjust ignition timing advance angle if
necessary, when accelerating, the angle shall increase 20~30)
Check battery voltage, whether the value is 12~14.5V;
Voltage unstable Check generator, whether it operates normally;
Check body earth lead, whether it is fastened.
Check cooling temperature sensor, whether the resistance is according with the
standard in different temperatures.
Check intake temperature sensor, and replace it when necessary.
Check idle speed control valve or stepping motor, whether it is stuck or damaged,
Sensor and executive clean or replace it when necessary.
unit malfunction Check throttle position sensor, whether the bolts are over raised, and adjust them
when necessary.
Check oxygen sensor, whether it waves between 0.1V and 0.9V.
If injector sealing leaking, then replace injector assembly.
If spark plug operates poorly, then replace the plug.
Check canister, whether it is polluted and blocked.
Exhaust system
Check exhaust pipe, whether it is deformed and damaged.
malfunction
Check 3-way catalytic converter, whether it is damaged or blocked.
Poor tachometer Check instrument connector, whether it is poor contact. Fix it again when necessary.
sensitivity If it conducts normally, then replace the instrument panel.
Test the voltage between each 2 terminals of ECU, whether the value is in normal
range.
ECU malfunction
Check the connecting condition between ECU and wire.
Load data stream according to origin data.
Check the pressure difference between each cylinder, whether they are over normal
Engine mechanical range.
malfunction
Check the sealing condition of each cylinder.
7
Idle speed fluctuation
Stuck, dirty
Clean
Throttle is stuck and dirty
Normal
Abnormal
Adjust
Ignition maladjustment
Normal
Abnormal
Exhaust system malfunction Check or replace
Normal
Abnormal
Voltage unstable Check or replace
Normal
Abnormal
Sensor and executive unit malfunction
Replace
Normal
Abnormal
ECU malfunction Replace
Normal
Abnormal
Engine mechanical malfunction Check
8
No. 005 Idle speed unstable or engine shut-off when opening AC or steering
AC compressor over load (for example, coolant over filling, tube blocked,
Compressor or booster
condenser is dirty, and etc.), belt over tensioned, compressor inner stuck, as well
pump malfunction
as booster pump inner rotor stuck and results over load.
When intake manifold leaking, repair or replace relevant component. When valve
Intake system abnormal
clearance disalignment, adjust it. When air filter blocking, replace it.
Replace oil pump, when it operates abnormally. Fuel filter blocked, replace it.
Oil line pressure abnormal Fuel pressure controller operates abnormally, replace it. Oil pump relay poor
contact, maintain or replace it.
Idle speed AC switch or booster

When opening AC or steering, ECU doesn't receive loading signal, which results
unstable or pump oil pressure sensor
low idle speed and engine shut-off. Maintain or replace it.
engine malfunction
shut-off when
Idle speed controller or
openinig AC Check stepping motor, whether it is stuck or dirty. Clean or replace it when
stepping mortor
or steering necessary.
malfunction
When injector blocked or poor atomized, shall clean the injector, and replace it if
Injector malfunction
necessary.
Improper ignition timing or Check ignition timing, coil, wire and spark plug etc. and each connecting part,
weak jump-spark power whether they are damaged. Maintain or replace them.
ECU malfunction Check ECU and each connecting part, whether there are damage.
Low engine cylinder
Disassemble and maintain the engine.
pressure
9
Idle speed unstable or engine shut-off when

openinig AC or steering
Abnormal
Compressor or booster pump failure
Check or replace
Normal
Abnormal
Intake system abnormal Check
Normal
Abnormal
Oil line pressure abnormal Check or replace
Normal
Abnormal
AC switch or booster pump oil pressure sensor Replace
malfunction
Normal Abnormal
Clean or replace
Idle speed controller or stepping mortor malfunction
Normal Abnormal
Injector malfunction Clean or replace
Normal
Abnormal
Improper ignition timing or weak jump-spark power Adjust or replace
Normal Abnormal
Normal Abnormal
Insufficient engine cylinder pressure Check
10
No. 006 Engine shuts off intermittently

Adjust spark plug clearance: on 4-cylinder engine, 0.8~1.0mm. On
Spark plug clearance is
3-cylinder engine, 1.0~1.1mm. Replace the plug when there is current
abnormal or tracking
leaking.
Ignition wire tracking, short or
Replace ignition wire.
open circuit
Fuel pump relay conducting Check relay conducting point, whether it is burnt. Replace it when
point burnt necessary.
Check oil pressure and the atomization of each injector, whether they
Improper fuel pressure are normal. Check oil pump, oil pressure controller and fuel filter when
necessary. As well as clean and replace the injector.
Fuel pollution Check oil, whether it is polluted or mixed with water.
Check ignition coil, whether it is over heat or short circuit. Measure
primary winding, the resistance shall be 0.4~0.6, and secondary
Ignition coil malfunction
winding, the resistance shall be 11~15k. Otherwise, shall replace
ignition coil.
Check canister, whether it contains gasoline or it is blocked. Replace it
Canister oil leaking
when necessary.
Distributor malfunction Replace distributor assembly.
Engine shuts off
intermittently Check 3-way catalytic converter or exhaust pipe, whether it is bent or
Exhaust system blocked
when running at blocked. Replace it when necessary.
idle speed Check the valve clearance of each cylinder, whether the value is too
small. Adjust it to standard value when necessary. For 4-cylinder engine,
the intake valve clearance shall be 0.200.05mm, the exhaust valve
Improper valve clearance
clearance shall be 0.300.05mm. For 3-cylinder engine, the intake /
adjustment
exhaust valve clearance shall be 0.200.05mm when heating, and
0.120.04mm when in cold condition. Otherwise, shall adjust the
clearance.
Crankcase venting device Check PCV valve, whether it is blocked or stuck. Maintain or replace it
malfunction when necessary.
Check fuel tank, whether it contains inner vacuum. Replace tank cover
Fuel tank inner vacuum
or canister electromagnetic valve when necessary.
Check oxygen sensor, whether it is polluted or poisoned. Replace it
Oxygen sensor malfunction
when necessary.
Idle speed control valve or Check idle speed control valve or stepping motor, whether it is stuck or
stepping motor operates operating abnormal. Clean or replace idle speed control valve or
abnormal stepping motor when necessary.
Check ECU body, whether the heat condition and operating condition
ECU and connecting circuit are in according with manufacturer requirements. Replace ECU
malfunction assembly when necessary. Check engine computer wire harness
connector, whether it is loose, fix it again when necessary.
11
Engine shuts off intermittently
Abnormal
Improper fuel pressure
Maintain or replace
Normal
Burnt
Fuel pump relay conducting point burnt
Replace
Normal
Abnormal
Idle speed control valve or stepping motor is dirty or
stuck Check or replace
Normal
Abnormal
Fuel pollution Replace
Normal
Abnormal
Ignition coil malfunction Replace
Normal
Abnormal
Canister oil leaking Check or replace
Normal
Blocked
Check or replace
Normal
Abnormal
Replace
Normal
Abnormal
Adjust
Normal
Abnormal
Crankcase venting device malfunction
Check
Normal
Abnormal
Fuel tank inner vacuum Check
Normal Abnormal
Replace
Spark plug and ignition wire malfunction
Normal Abnormal
ECU and connecting circuit malfunction Check or replace
12
No. 007 Poor accelerating performance in cold condition

Improper gasoline quality Clean fuel pipe and replace clean gasoline, 93# or above.
Check filter, whether it is blocked. As well as fuel pressure
Low gasoline pressure controller, whether it operates normally, replace it when
necessary. Check gasoline pump pressure whether the value
is normal, maintain or replace it when necessary.
Air filter blocked Check air filter, whether it is blocked, clean or replace it when
necessary.
Check cylinder pressure, whether there is carbon deposit at
intake valve, as well as valve leaking and cylinder wearing
Low cylinder pressure
malfunction. Maintain or replace then according to the
malfunction.
Idle speed controlling valve or
Clean or replace idle speed control valve or stepping motor
stepping motor operates abnormal
Poor accelerating Check throttle body, whether it is stuck, clean or replace it
performance in cold Throttle malfunction
when necessary.
condition,
particularly in low Check ignition coil, wire and spark plug, whether they are
Ignition system malfunction
speed and middle malfunction, replace them when necessary.
speed.
Pressure sensor malfunction. Check the resistance and
Intake temperature pressure sensor voltage, whether the value is in normal range. Replace the
sensor when necessary.
Check oxygen sensor, whether the heating function is normal.
Oxygen sensor malfunction As well as the voltage signal, whether it varies between 0.1V
and 0.9V.
Check the vacuum, whether the value is in normal range.
Intake manifold leaking Check the connecting condition of each vacuum hose, as well
as intake/exhaust manifold gasket, whether it is damaged.
Check tachometer sensor signal and ignition datum, whether
Ignition timing maladjustment
they are normal.
Check ECU, whether it is malfunction. Check connecting wire,
ECU and connecting circuit
whether it is of poor contact. Maintain or replace it when
malfunction
necessary.
13
Poor accelerating performance in cold condition
Lack
Improper gasoline quality or low gasoline Check or replace
pressure
Normal
Blocked
Air filter blockage Clean
Normal
Low
Check
Normal
Stuck
Idle speed valve or throttle malfunction Check
Normal
Abnormal
Ignition system malfunction Check or replace
Normal
Abnormal
Intake temperature pressure sensor Replace
Normal
Abnormal
Replace
Normal
Abnormal
Intake manifold leaking
Check
Normal
Abnormal
Ignition timing maladjustment Check and adjust
Normal
Abnormal
ECU and connecting wire malfunction Check or replace
14
No. 008 Spark plug non-sparking

Measure the primary winding, the resistance shall be 0.4~0.6, and the
secondary winding, the resistance shall be 11~15k. Otherwise shall replace
Ignition coil malfunction
ignition coil. Check the coil, whether there is short or open circuit. Replace it
when necessary.
Check spark plug, whether it is leaking current, as well as the clearance of
Spark plug malfunction
electrode.
Distributor cover or distributor Check cover or distributor arm, whether there is current leaking, dielectric
arm malfunction puncture or damage. Replace it when necessary.
Check ignition wire, whether it is leaking current or open circuit. Replace it
Engine has Ignition wire malfunction
when necessary.
no start
symptom Measure sensor resistance (UAES 4-cylinder engine tacho sensor resistance
Tachometer sensor
and spark shall be 770~950, Delphi 540, Polarsun 53050), as well as the signal
malfunction or the Hall sensor
plug output and ECU wire, whether they are operating normally. Maintain it when
in distributor malfunction
non-sparking necessary.
Check EFI fuse, whether it is burnt or poor contact. Check main relay,
EFI fuse and relay malfunction whether it is burnt. Check the circuit, whether it is poor contact. Maintain
them when necessary.
ECU malfunction Check terminal input and output signal, whether they are normal.
Ignition control system circuit Check all connecting wires, whether they are poor contact or open circuit.
malfunction Maintain it when necessary.
Engine anti-thief control Check anti-thief controller and all connecting wires, whether they are normal
system malfunction connected, as well as the anti-thief status activated.
15
Spark plug non-sparking
Abnormal
Ignition coil malfunction Replace
Normal
Abnormal
Spark plug malfunction Adjust or replace
Normal
Abnormal
Distributor cover or distributor arm malfunction
Replace
Normal
Abnormal
Ignition wire malfunction Replace
Normal
Abnormal
Tachometer sensor failure or the Hall sensor in Replace
distributor malfunction
Normal
Abnormal
ECU malfunction
Replace
Normal
Abnormal
Ignition control system circuit malfunction Check
Normal
Abnormal
Engine anti-thief control system malfunction Replace
16
No. 009 Low idle speed during engine heating in cold condition
Check ignition coil, wire and spark plug, whether they are normal. Adjust or
Weak ignition spark
replace them when necessary.
Crankcase venting Check PCV valve, whether it is normal. Replace crankcase venting device when
device fails necessary.
Measure vacuum, check the connecting condition of manifold gasket, throttle
gasket, and all vacuum pipes.
Check thermostat, whether it is leaking, which results warm-up period over
Thermostat malfunction
normal value. Replace thermostat when necessary.
Measure the resistance (UAES idle speed valve 17.6, Delphi motor 53,
Idle speed valve
Polarsun motor 482.4) and voltage of idle motor, whether they are normal.
(steeping motor)
Check idle speed motor, whether it is dirty and stuck. Maintain and replace it
maladjustment
when necessary.
Adjust valve clearance: on 4-cylinder engine, the intake valve clearance shall
Improper valve be 0.200.05 mm, the exhaust valve clearance shall be 0.300.05mm. On
clearance 3-cylinder engine, the intake/exhaust valve clearance shall be 0.200.05mm
when warming-up, and 0.120.04mm in cold condition.
Check engine compression ratio and pressure, whether they are in accordance
Low idle speed with standard value. 479Q 9.3: 1/1250kpa/250r/min; 479QA 9.8:
during engine 1/1440kpa/250r/min; 481Q 9.4: 1/1360kpa/250r/min; JI376QE 9.5:
heating in cold Low cylinder pressure
1/1225kpa/350r/min; JL378QE 9.5: 1 / 1225kpa/350r/min; Inspemction the
condition cause, whether valve leaking or piston ring and cylinder wearing. Disassembly
and maintain the engine when necessary.
Check the resistance of water temperature sensor in cold condition (UAES
2.5k, at 20; Delphi 3.56~2.26k, at 20~30; Polarsun 2.5k, at 20),
Water temperature
whether they are in accordance with standard. Or measure the temperature of
sensor damaged
cold vehicle by scanner, whether it is in accordance with actual engine
temperature. Replace coolant fluid temperature sensor when necessary.
Check injector, whether it is blocked or stuck. Check atomization and implement
leak test. Clean or replace injector.
Check heat-type oxygen sensor heater resistance (UAES 1~6, Delphi 12,
Polarsun 13.210%), as well as heater voltage, 12V, and signal voltage,
Oxygen sensor
0.1~0.9V, whether they are in normal range. Check sensor surface, whether it is
malfunction
dirty and results voltage over normal value, as well as the fuel-air mixture is too
thin.
Check ignition time and calibrate ignition timing, in idle condition: on 4-cylinder
Ignition timing
engine, the ignition advance angle shall be 10~12 before top dead center. On
maladjustment
3-cylinder engine, the value shall be 123.75 before top dead center.
ECU malfunction Check connecting conditions of ECU and all wires.
17
Low idle speed during engine heating in cold

condition
Abnormal
Weak ignition spark Check and replace
Normal
Abnormal
Crankcase venting device failure Check
Normal
Damaged
Replace
Water temperature sensor damaged
Normal
Abnormal
Replace
Thermostat failure
Normal
Abnormal
Improper valve clearance Adjust
Normal
Abnormal
Check
Normal
Abnormal
Ignition timing maladjustment
Check
Normal Low
Check
Normal Abnormal
Idle speed valve (steeping motor) Clean and replace

maladjustment
Normal Abnormal
Clean and replace
Injector failure
Normal
Abnormal
Oxygen sensor malfunction Replace
Normal
Abnormal
18
No. 010 Canister oil leaking

Check the single check valve on fuel tank, whether it is damaged.
Check valve damage, on fuel tank
Replace fuel tank assembly when necessary.
Check the single check valve of fuel tank cover, whether it can open.
Fuel tank cover damage
Replace fuel tank cover when necessary.
Check the white venting pipe, to air, at the bottom of canister, whether it
There is fuel Canister venting (air) pipe blocked is blocked by silt and result oil leaking. Unplug or replace it when
under necessary.
vehichle
Check controlling canister inner charcoal and pipe export, whether they
when
are blocked. Replace them when necessary. Check canister, whether
parking, and Controlling canister malfunction
the mounting position is too low. Adjust the mounting height when
the engine
necessary.
speed is
unstable Vacuum pipe blocked, on top of Raise engine speed to 2000r/min, if vacuum pipe suction is low, then
when idling. canister shall check vacuum pipe system.
Check canister controlling valve resistance, which shall be 22~30 at
Canister control valve malfunction 20. Check controlling wire and valve element, whether they are in
normal condition. Maintain and replace them when stuck.
Check ECU and canister electromagnetic valve controlling circuit,
ECU malfunction
whether they are in normal condition.
Canister oil leaking
Damaged
Check valve damage, on fuel tank Replace
Normal
Damaged
Fuel tank cover damage
Replace
Normal
Damaged
Controlling canister malfunction
Replace
Normal
Blocked
Pipe blocked, on top of canister
Check
Normal
Damaged
Canister control valve malfunction
Replace
Normal
Abnormal
ECU malfunction
Replace
19
No. 011 Fuel smells in vehicle

When filling, fuel dropped around tank filling port and cover, then flows
Gas station man-made malfunction
into vehicle. Clean vehicle.
Fuel tank filling port and port cover Check or replace fuel tank filling port and cover.
leaking
Fuel pipe leak Check or replace leaking fuel pipe.
Fuel tank cracked and leaking Check fuel tank, whether it is leaking. Replace it when necessary.
Canister leak Check canister controlling system and venting system.
Fuel smells
in vehicle, Fuel tank inner pressure abnormal Replace fuel tank, check valve and fuel filling port cover etc.
when Controlling canister pipe malfunction Check canister pipe, whether it is dropped.
opening
window, it Canister controlling valve Check canister controlling valve, whether it is blocked, as well as the
smells even malfunction suction capacity, whether it is poor or fails to open.
worse Fuel pump and fuel sensor mounting Check or replace fuel pump and fuel sensor mounting sealing.
gasket leaking
Ignition timing maladjustment Maintain ignition timing, whether it is delayed.

Injector leak Check sealing of injector and pipe.
Engine operates abnormal Check engine operation, whether there is unavailable cylinder.
Measure the voltage of sensor, whether it is too low, as well as the
Oxygen sensor
fuel-air ratio, whether it is over normal value.
20
Fuel smelling strong in vehicle
Leak
Fuel pipe leakage
Check
Normal
Leak
Fuel tank leakage Replace
Normal Leak, blocked

Canister leak or block Replace or check
Normal Abnormal
Fuel tank inner pressure abnormal Check
Normal Leak
Injector leak Check
Normal
Abnormal
Engine oprates abnormal Check
Normal
Abnormal
Ignition timing maladjustment Check
Normal Abnormal
Canister controlling valve malfunction Replace
Normal
Abnormal
Canister pipe malfunction Replace
Normal Abnormal
Oxygen sensor Replace
21
No. 012 Engine vibration when operating

Check cylinder pressure, spark plug, ignition wire and
Engine operates with unavailable cylinder valve etc., whether they are abnormal. Replace the
malfunction part when necessary.
Incorrect ignition timing Adjust ignition time
Check electric fuel pump, fuel pressure controller and
Fuel pressure abnormal
Engine pipes
operates
Engine fuel grade doesn't in accordance with Replace qualified fuel
unstably and
standard
vibrations,
when running Injector malfunction Check injector fuel atomization and pulse width
in idle and low
speed, there Engine shock pad malfunction or mounting Adjust or replace relevant components
is tu-tu-tu bracket deformed
sound in
Cylinder gasket damage Replace cylinder gasket
exhaust pipe.
Clutch operates abnormal Maintain or replace relevant components
Gearbox or vehicle transmission accessories Adjust or replace relevant components
damage
According to sound position, maintain relevant
Crank link mechanism malfunction
components
22
Engine vibration when operating
Unavailable cylinder
Engine operates with unavailable cylinder Check
Normal Abnormal
Incorrect ignition timing Check
Normal Abnormal
Check
Fuel pressure abnormal
Normal Abnormal
Injector failure Check
Normal Abnormal
Check
Cylinder gasket damage
Normal
Abnormal
Engine fuel grade doesn't in accordance with Replace
standard
Normal Abnormal
Engine mounting bracket deformed
Check
Normal
Abnormal
Check
Crank link mechanism malfunction
Normal
Abnormal
Clutch operates abnormal Check
Normal
Abnormal
Gearbox or vehicle transmission accessories
Check
damaged
23
No. 013 Engine noise over normal level

Engine noise Exhaust system leaking or block Maintain leaking components, as well as replace blocking parts.
over normal
level, and Poor fuel quality, which results engine Replace qualified fuel that match Geely vehicle requirement.
vibration operating abnormal
when idling Engine operates abnormal When engine operating with unavailable cylinder, the malfunction
shall be excluded. When camshaft assembly and gear sound
abnormally, shall adjust or replace them. As well as the crankshaft
and piston link mechanism.
Generator water pump, booster pump Replace generator, water pump and booster pump assembly.
etc. sound abnormally
Water tank fan and AC fan sound Replace relevant components.
abnormally
Water temperature over normal value Maintain fan and cooling system, whether they operate normally.
Ignition timing maladjustment Maintain or adjust ignition timing.
Compressing ratio over normal value Maintain cylinder capacity, combustion chamber volume, as well as
the end surface of cylinder block and cylinder head, whether they
are normal.
Detonation sensor malfunction Maintain mounting condition of sensor and correct the voltage.
Poor lubrication Check oil pressure and quality.
Engine interferences with relevant Maintain and exclude the malfunction.
accessories
Intake system leak or block Replace relevant components when leaking. Unplug or replace
them when blocked.
24
Engine noise over normal level
Leaking or block
Exhaust system leaking or block
Check and replace
Normal
Abnormal
Engine operates abnormal Check
Normal
Abnormal sound
Generator water pump, booster pump etc. Check and replace
sound abnormally
Normal
Abnormal sound
Water tank fan and AC fan sound abnormally Check and replace
Normal
Abnormal Check
Water temperature over normal value
Normal Interferen
Engine interferences with relevant accessories Check
Normal Over normal value

Check
Compressing ratio over normal value
Normal Leak or block

Intake system leak or block Check
25
No. 014 Water temperature over normal value after AC activated

Insufficient coolant fluid Fill coolant according to requirements.
Radiator fan blade deformed and stuck. Replace radiator
Radiator fan operates abnormal
fan assembly when the fan speed is low.
Check refrigerant, whether it is too much, which increases
Too much refrigerant engine load and high water temperature. The refrigerant
shall be filled to standard level.
Condenser fan malfunction Maintain fan wire and motor.
AC system pressure over normal value Adjust system pressure to normal value.
Radiator over
heated after Too much furring contains in engine water pipe, which
AC activated The cooling and cycling performance of cooling results poor water cycling and cooling, and shall be
when driving system lower than normal level cleaned. Clean or replace the radiator, when it is dirty and
blocked.
Generator belt loose Adjust belt tightness according to requirement.
Water pump operates abnormal and results Maintain or replace pump assembly
poor cooling water recycles.
Thermostat fails to open Replace thermostat assembly
ECU malfunction Maintain ECU and all wire terminals
Engine operates abnormally Disassemble and maintain engine
Water temperature over normal value after AC

activated
Lack
Insufficient coolant fluid Add
Normal
Poor
Radiator fan operates abnormal Check and replace
Normal
Over normal value
Too much refrigerant Drain
Normal
Failure
Condenser fan malfunction Check and replace
Normal Over normal value

AC system pressure over normal value Check
Normal Not smooth

The cooling and cycling performance of cooling system lower than Check
normal level
Normal Poor
Poor cooling water recycles
Check
Normal
Abnormal
ECU failure
Replace
Normal Abnormal
Engine operates abnormally Check
26
No. 015 Oil pan leak

Fill oil according to standard. For 4-cylinder engine, dry, 3.5L; wet,
Too much oil 3.0L. For 4G18 engine, with oil filter, 4.0L; without oil filter, 3.8L. For
3-cylinder engine, 3.0L.
Oil pan gasket damage Replace oil pan gasket; tighten the bolts after sealant coated.
Rear end cover gasket leak Replace rear end cover gasket and coat with sealant.
Rear oil pipe capping leak Replace or maintain rear main oil pipe capping.
There is blow hole on rear end Maintain the blow hole on rear end.
Oil leak at rear end of Oil pan bolt loose Tighten oil pan retaining bolt or replace damaged bolt.
oil pan after vehicle Oil pan damaged or deformed Maintain or replace oil pan.
parked.
Oil pan retaining bolt adjust to 4.9NM, evenly.
Irregular assembly procedure
Coat sealant with proper quantity, otherwise, the gasket may slid and
move.
Unplug or replace gas exhaust system (PCV valve)
Inner engine pressure over
normal value Engine cylinder, piston ring and piston worn out. Maintain or replace
relevant component when necessary.
Crankshaft rear oil seal ageing Replace crankshaft rear oil seal.
or damage
27
Oil pan leaking
Too much
Fill oil according to standard
Too much oil
Normal
Damage
Oil pan gasket damage Replace
Normal
Irregular
Irregular assembly procedure
Remount
Normal
Damage
Oil pan damaged
Replace
Normal
Abnormal
Rear end panel deformed or seal gasket failure
Check and replace
Normal
Blocked
Rear oil pipe capping leaking Check and replace
Normal
Loose
Oil pan bolt loose
Tighten
Normal
Over normal value
Inner engine pressure over normal value Check
Normal Abnormal
Replace
Cranksahfe rear oil seal ageing or damage
28
No. 016 Distributor oil leaking

Too much oil Drain spare oil
Check crankcase intake pipe, whether it is blocked.
Poor crankcase venting
Clean and unplug intake pipe to exclude the malfunction.
Check distributor seal ring, whether it is ageing or
Distributor seal ring ageing and damage
damaged. Replace O-ring when necessary.
Engine stands
Check exhaust pipe and single check valve, whether
stil after
High inner engine pressure they are blocked. Unplug or replace them when
activated.
necessary.
There is
visible oil Check distributor rotating shaft, whether the loose
leaking at Distributor rotating shaft loose volume is in accordance with standard. Replace
distributor distributor assembly when necessary.
Check distributor gear, whether it is worn out. Replace
Distributor rotor gear wearing
distributor assembly when necessary.
Check oil leak of distributor sear and further determine the
Blow hole or crack on distributor processing accuracy of distributor. If there is blow hole or
crack, then shall replace distributor seat.
Distributor oil leaking
Y
Drain spare oil
Too much oil
N
Damage
Poor crankcase venting Check
Normal
Loose
Check
High inner engine pressure
Normal
Loose
Distributor seal ring ageing and damage Replace
Normal
Wearing
Distributor rotating shaft loose Replace
Normal
Over normal value
Distributor rotor gear wearing Replace
Normal
Poor
Blow hole or crack on distributor
Replace
29
No. 017 JL376/378 engine shut-off when sliding at neutral gear

Improper spark plag electrode Adjust or replace spark plug (spark plug clearance is 1.0~1.1mm)
clearance or spark plug current
leak and non-resistance
Improper valve clearance Adjust valve clearance, 0.200.05mm in hot condition, 0.120.05mm
adjustment in cold condition
Distributor malfunction Maintain and replace distributor assembly
Intake system leaking Maintain or replace relevant component
Idle speed controller (stepping Check stepping motor controlling wire, resistance and blocked. Clean
Engine operates motor) malfunction and replace then when necessary.
well when
Crankcase generates negative Check exhaust single check valve
accelerating
pressure
normally, while
shut-off when Fuel circuit stuck (when steering) Maintain fuel tank, whether there is impurity in it.
sliding at neutral
gear or steering. When fuel pipe is leaking, replace it When air filter is blocked, replace
Fuel pressure abnormal it. When fuel pump or fuel pressure controller, which value shall
between 264kPa and 305kPa, is damaged, replace it.
Fuel contains in canister Maintain and replace canister
Fuel contains in vacuum pipe Maintain oil pressure controller
Throttle shaft run-out Replace throttle body assembly
Wire malfunction Check wire circuit, whether it is poor contact.
Check cylinder pressure, whether the valve is leaking, as well as the
wearing condition of piston ring and cylinder.
30
JL376/378 engine shut-off when sliding at neutral gear
Improper
Improper spark plug and valve clearance Adjust
adjustment
Normal
Stuck
Fuel circuit stuck (when steering) Check
Normal
Abnormal
Idle speed controller (stepping motor) Clean and replace
Normal Abnormal
Fuel pressure abnormal Check
Normal
Abnormal
Distributor failure Replace
Normal
Leak
Maintain
Normal
Fuel contains
Fuel contains in vaccum pipe Maintain
Normal
Low
Low cylinder pressure Check
31
No. 018 High idle speed when sliding at neutral gear, MK

Improper ignition timing Adjust ignition timing
Throttle body or cable fails to return Clean throttle, adjust or replace throttle cable
Intake system leaking Maintain or replace relevant component
Improper valve clearance Adjust valve clearance
High idle
speed when Normal pressure: between 250kPa and 300kPa. When fuel
sliding at Improper fuel pressure pump, fuel filter and fuel pressure controller operating
neutral gear, abnormally, shall replace relevant component.
MK Stepping motor stuck, clean it. Throttle position sensor
sensitive poorly, adjust or replace it. Fuel injector leaking,
Electric injection unit operates poorly
replace it. Intake temperature pressure sensor malfunction,
replace it. (see the table above for details of check method)
Software malfunction, update it or check ECU, whether it is
ECU software malfunction or inner damage
damaged. Replace ECU when necessary.
High idle speed when sliding at neutral gear,

MK
Fails to return
Throttle body or cable fails to return Check and replace
Normal
Abnormal
Improper ignition timing
Check and adjust
Normal
Leak
Check
Normal
Abnormal
Adjust
Normal
Operates poorly
Electric injection unit operates poorly
Check and replace
Normal
Abnormal
ECU software failure or inner damage
Replace
32
No. 019 Engine vibration

Engine bracket or vehicle body deformed Replace engine bracket or correct vehicle body.
Check supply pressure of fuel system, whether it is too
low, while the normal value is between 250kPa and
Low fuel pressure 300kPa. Replace fuel pressure controller, fuel filter or
electric fuel pump and other relevant damaged
components.
Engine Generally, the malfunction is caused by unbalance fly
operating Clutch system malfunction
wheel or press plate etc. Replace relevant components.
unstably,
starting Spark plug, cylinder cable, valve, valve clearance,
slowly, with Engine operating with unavailable cylinder injector and cylinder sleeve worn out, and results
surge and unavailable cylinder. Exclude the malfunction.
vibration
Check idle speed stepping motor, whether it is too much
carbon deposit. Clean or replace it when necessary.
Electric injection unit malfunction
Check throttle opening degree, clean or replace throttle
sensor when necessary.
ECU damaged Check ECU integrated circuit, whether it is damaged.

Replace it when necessary.
Engine vibration
Check
Engine oprating with unavailable cylinder
Check
Normal
Low
Low fuel pressure
Check
Normal
Deform
Engine bracket or vehicle body deformed
Check and replace
Normal
Abnormal
Clutch system malfunction Check and replace
Normal
Damage
ECU damaged
Replace
33
No. 020 Exhaust pipe pours black smoke

Light smoke Air filter blocked Check and clean/replace air filter
when idling,
heavier when Low fuel quality Apply unleaded clean fuel, 93# or above, which is in accordance
accelerating with manufacturer requirements.
Fuel contains in vacuum pipe Check fuel pressure controller, whether it is damaged and leaking
High oil pressure Check fuel pump, pumping pressure and controller function.
Improper ignition timing Check and adjust ignition timing
Unavailable cylinder Implement cylinder cross firing test respectively, check the
performance of wire and spark plug.
Valve leaking Clean combustion chamber carbon deposit. Replace or grind
valve.
Injector leak or atomization abnormal Clean or replace malfunction injector
Throttle position sensor malfunction Measure the resistance and voltage of throttle, replace it when
necessary.
Oxygen sensor voltage abnormal Measure sensor voltage and resistance, replace it when
necessary.
Cylinder gasket damage Maintain or replace cylinder gasket.
ECU malfunction Check ECU and circuit whether they are normal.
Low cylinder pressure Disassemble and maintain engine.
34
Exhaust pipe pours black smoke
Blocked
Clean or replace
Air filter blocked
Normal Abnormal
Low fuel quality Replace
Normal Low
High oil pressure
Check and replace
Normal
Abnormal
Unavailable cylinder Check and replace
Normal
Abnormal
Improper ignition timing Adjust
Normal Abnormal
Oxygen sensor voltage abnormal Check
Normal
Leaking
Valve leaking Check and replace
Normal Abnormal
Cylinder gasket damage Replace
Normal
Abnormal
ECU failure Replace
Normal
Abnormal
Injector leak or atomization abnormal Clean or replace
Normal Abnormal
35
No. 021 Engine idle speed decreases when activating head beam or fan
Fuel quality is not in
Apply unleaded clean fuel, 93# or above.
accordance with requirement
Generator belt loose Adjust belt tension to 50NM, when pressuring downwards, and the
deflection shall be 10MM.
Earth lead loose Check gearbox, body earth lead and instrument earth lead, whether
they are loose. Tighten them when necessary.
Generator operates abnormal Check the electrical energy of generator, whether it is beneath 9V.
Replace generator voltage controller when necessary.
Battery open circuit Check the gravity of battery electrolyte, maintain or replace battery
Engine speed assembly when necessary.
decreases, with
vibration, when Idle speed controlling valve or Clean idle speed control valve or stepping motor. Replace it when
activating head stepping motor malfunction damaged.
beam or fan
Grouped switch short circuit Maintain grouped switch and relevant harness.
The power of head beam or the Check head beam, whether it applies the bulb requires the power over
load of fan is over normal value. standard value. Replace standard power bulb when necessary.
Replace fan motor or maintain the circuit.
Low generator charging current
Replace generator assembly, which supplies 90A charging current.
(75A)
Poor ECU signal Measure the voltage among terminals and wire connecting condition.
Maintain or replace them when necessary.
Engine operates abnormal Maintain engine
36
Engine idle speed decreases when activating

head beam or fan
Loose
Generator belt loose Adjust
Normal
Low
Earth lead loose Check
Normal
Open circuit
Generator operates abnormal
Check or replace
Normal
Battery open circuit Check
Normal
Idle speed controlling valve or stepping motor Abnormal
failure Clean and replace
Normal
Short circuit
Combined switch short circuit
Check and replace
Normal
Over load
The power of head beam or the load of fan is over normal value
Replace
Normal Poor
Replace
Poor ECU signal
Normal Abnormal
Check
Engine operates abnormal
37
No. 022 Exhaust pipe blows water

Check silencer inner water log. The tail water exhaust port of
Water log in silencer silencer is blocked, and blows large quantity of water when
accelerating. Punch a hole on silencer to drain water.
Throttle body water leak Maintain or replace throttle body.
Engine vibration when Gasket damaged Maintain cylinder and cylinder head surface, replace gasket.
idling, with abnormal
noise, and cooling Check cylinder head, whether there is crack or blow hole in it,
water is always which results coolant flow into cylinder. Remove cylinder head
Crack or blow hole in cylinder head
polluted. and inspect the crack in it, by magnaflux. Replace cylinder
head when necessary.
Check cylinder wall, whether there is crack or blow hole in it,
which results coolant flow into cylinder. Remove cylinder wall
Crack or blow hole on clinder wall
and inspect the crack in it, by magnaflux. Replace cylinder
head when necessary.
Exhaust pipe blows water
Water log
Water log in silencer Check
Normal Water leak

Replace
Throttle body water leak
Normal
Damage
Gasket damage Replace
Normal
Crack or blow hole
Crack or blow hole in cylinder head
Replace
Normal
Crack or blow hole
Replace
Crack or blow hole on clinder wall
38
No. 023 Engine shuts off when accelerating

Fuel tank lacks of fuel Fill fuel
Poor fuel quality Replace with standard fuel
Air filter blocked Clean or replace air filter
Vacuum sense port of intake pressure sensor is blocked by carbon
deposit. Clean it. Intake vacuum pipe cracked, and results vacuum
Low intake vacuum
decreased, mixture gas rarefied, as well as engine shut-off when
vehicle picking up.
Exhaust system partly blocked Check 3-way catalytic converter, whether it is dropped or blocked.
Check fly wheel signal rim, whether it operates correctly. Check
Engine shut-off tachospeed sensor, whether it is normal. Check valve timing,
when vehicle Ignition maladjustment
whether it is normal. Check ignition system, whether it contains
picking up ignition miss.
Positive electrode of oxygen sensor Check output voltage of oxygen sensor, in idle condition the value
short or open circuit. shall be about 4.5V. Otherwise, replace oxygen sensor.
Normal fuel pressure is between 250kPa and 300kPa. Check fuel
Fuel pressure decrease when
pump, fuel filter and fuel pressure controller etc. Replace them
accelerating
when necessary.
Throttle position sensor short or Check throttle position sensor, whether there is short or open
open circuit circuit. Replace it when necessary.
Check operation of each cylinder, whether it operates normal.
Disassemble and maintain engine when necessary.
39
Engine shuts off when accelerating
Lack
Fuel tank lacks of fuel Fill
Normal
Poor quality
Poor fuel quality
Replace
Normal
Blocked
Air filter blocked
Clean or replace
Normal
Low
Low intake vaccum
Check
Normal
Blocked
Check and replace
Normal
Abnormal
Ignition maladjustment Check
Normal
Decrease
Fuel pressure decrease when accelerating Replace
Normal
Positive electrode of oxygen sensor short or Abnormal
open circuit Replace
Normal Abnormal
Check
40
No. 024 Oil indicator is always on

Instrument Low oil quantity results low oil pressure Fill oil to standard level
warning
lamp is Low oil viscosity or oil deteriorated Replace required oil
always on The inner conducting point of oil pressure
after engine Oil pressure switch damage switch burnt seriously and results short circuit.
started Replace oil sensing plug.
The wire between oil sensing plug and grouped
instrument partly leads to earth at front wall,
Oil indicator circuit leads to earth partly
and results oil indicator lightening constantly
after circuit lead to earth.
Grouped instrument inner short circuit Replace grouped instrument
Maintain oil pump and oil pipe, whether it is
Low oil pressure blocked. Unplug it when necessary. Check oil
leaking condition and maintain it.
Large clearance results oil leaking and low oil
Large engine liner clearance, which results low oil pressure pressure. Normal value shall be 49kPa.
Replace relevant component.
Oil pipe leaking Maintain or replace relevant component.
Oil indicator is always on
Low
Low oil quantity results low oil pressure
Fill
Normal
Deteriorate
Low oil viscocity or oil deteriorated Replace
Normal
Damage
Oil pressure switch damage
Replace
Normal
Short circuit
Grouped instrumernt inner short circuit Replace
Normal Earth lead
Oil indicator circuit leads to earth partly Check
Normal
Low
Low oil pressure
Check
Normal
Large clearance
Large engine liner clearance, which results low oil pressure
Check
Normal Leak
Oil pipe leaking Check
41
No. 025 Water temperature is over normal value when engine running with large load
Lack of coolant fluid
Fill non-standard anti-freeze fluid Replace standard anti-freeze fluid
Fuel grade against requirement Apply specified fuel
Thermostat shall be fully opened when water temperature
Low thermostat open travel
reaches 82, otherwise, replace it.
Water pump belt loose Adjust tension rate
Water Radiator is too dirty inside or outside, and results
temperature Clean radiator, the dirt and water mark, replace water
low cooling performance, as well as water
is over normal tank when necessary.
temperature increased.
value when
diving in high Radiator fun operates abnormal (low speed or
Maintain fan circuit and replace fan.
speed, and is fails to work sometimes)
normal in low
Improper ignition timing Adjust timing
speed.
Engine water pipe rust Clean rust
Engine oxygen sensor damaged and results mixed gas
Engine mixed gas is too thick
viscosity misadjusted.
Low cylinder pressure, maintain it. Low clearance often
Improper piston fit clearance caused by applying non-standard piston, replace and
reassemble with proper piston.
Cylinder bolt loose or cracked
42
Water temperature is over normal value when engine running with

large load
Poor
Low cooling performance of rediator
Check and replace
Normal
Poor
Fan operates abnormal
Check and replace
Normal
Abnormal
Improper piston fit clearance
Check
Normal
Too thick
Engine mixed gas is too thick
Adjust
Normal
Too small
Low thermostat open travel
Replace
Normal
Loose
Water pump belt loose Adjust
Normal
Rust
Engine water pipe rust Clean
Normal
Against
Fuel grade againsts requiremen
Replace
43
No. 026 Canister electromagnetic valve sounds abnormal

Canister electromagnetic valve is dirty inside Clean it with carburetor detergent
Replace canister electromagnetic valve retaining rubber
Canister electromagnetic valve retaining rubber
seat and adjust the position, as far as possible with
Electromagnetic seat damage
vehicle body
valve sounds
abnormal when Serious fuel tank inner vacuum Replace fuel tank cap
idling
Over adjustment of canister electromagnetic Adjust canister electromagnetic valve according to
valve inner tube standard flow rate
Serious canister electromagnetic valve wearing Replace canister electromagnetic valve assembly
Canister electromagnetic valve sounds abnormal
Dirt
Canister electromagnetic valve is dirty inside
Clean and replace
Normal
Damage
Canister electromagnetic valve retaining rubber seat
Replace
damage
Normal
Vaccum
Serious fuel tank inner vaccum Maintain
Normal
Over normal value
Over adjustment of canister solenoid valve inner tube Adjust
Normal
Wearing
Serious canister solenoid valve wearing Replace
44
No. 027 Engine fails to start

No fuel Check fuel gauge and fuel level
Check battery voltage, whether it is normal, which shall above 11.5V. Charge or
replace battery when the value is too low. Check or replace circuit, if battery fails to
be charged as normal (check whether there is short circuit in inner/outer circuit,
Low battery voltage which results current leaking). Check battery circuit and all connections, whether
they are well conducted.
Check starter, whether it operates normally. Maintain or replace it when necessary.
Check starter, whether it operates normally. Check starter circuit, solenoid switch,
carbon brush, coil and rotor, whether there is short or open circuit, as well as poor
Starter malfunction conduction. Check one-way clutch whether it is slipping, as well as one-way clutch
and fly wheel tooth, whether they are damaged. Maintain or replace them when
necessary.
Ignition switch open Check circuit, fuse, ignition switch by multimeter, set to resistance range, whether
circuit and wire they are open circuit. To inspection the malfunction.
malfunction
Connect Geely special No. to check whether there is malfunction No.. And inspect
Electric control system
again if it shows malfunction No.. Then check relevant component and circuit
malfunction
according to the indication of malfunction No..
Check high voltage spark, if it operates normally, then check engine speed sensor,
ignition coil, ECU and relating circuit. Maintain or replace them when necessary.
(Connect two pins of primary winding respectively to multimeter, and the
resistance shall be 0.4~0.6 at 20. In same condition, the resistance of
Improper ignition secondary winding shall be 11~15k. Connect pin 2 and pin 3 of sensor to
timing or weak spark multimeter pen respectively, and at 20 the rated resistance shall be 86010%)
voltage
Check ignition timing, if it is improper, then check flywheel signal plate, whether it is
loose and malposition. Maintain or replace it when necessary.
Engine fails to
start Check high voltage spark energy, if it is weak, then check ignition coil, high voltage
resistance. Replace it when necessary.
Check spark plug electrode clearance and carbon deposit condition. Adjust or
replace it when abnormal.
Check timing belt, whether there is damage. Replace it when necessary.
Incorrect valve timing
Check timing belt, whether there is damage. Replace it when necessary.
Check air filter, whether it is blocked. Clean or replace it when necessary. Check
Air filter blocked or
intake system, particularly intake manifold, injector, vacuum pipe and connector,
intake system leaking
whether they are leaking. Exclude the malfunction when necessary.
Fuel pressure shall above 260kPa when idling. Otherwise, the fuel pressure is low,
Fuel system
and shall check fuel pump, fuel pressure controller and fuel pipe, whether there is
malfunction
malfunction.
Check engine signal plate, whether is it loose or moved. When necessary, shall
Engine signal plate
position it (20 teeth after point T for 4-cylinder, 16 teeth after point T for 3-cylinder)
loose or moved
first, then weld or replace engine signal plate.
Exhaust system Check or replace exhaust system blocking position
blocked
Measure cylinder pressure. Fill a few oil into cylinder to determine whether the
Low cylinder pressure cylinder or piston ring worn out, as well as valve sealing leaking. Adjust valve
clearance or disassemble engine when cylinder pressure is too low.
Check both ends of connector of each injector by oscillograph or multimeter,
whether there is pulse signal. If not, shall check parts of controlling circuit or ECU.
Otherwise, remove injector and check fuel injection quantity and atomization,
whether it is normal. Clean or replace it when necessary.
ECU malfunction ECU controller fails to input or output signal normally, replace it.
45
Engine fails to start
N
No fuel
Fill
Y
Lack
Low battery voltage
Charge
Normal
Abnormal
Starter failure Check and replace
Normal
Abnormal
Ignition switch open circuit and wire failure Check and replace
Normal
Abnormal
Electric control system failure
Check and replace
Normal
Abnormal
Improper ignition timing or weak spark voltage
Check
Normal
Abnormal
Spark plug failure Replace
Normal
Error
Incorrect valve timing Check
Normal
Blocked
Air filter blocked
Clean
Normal
Abnormal
Fuel system failure
Maintain
Normal
Low pressure
Low cylinder pressure Maintain
Normal
Abnormal
Exhaust system blocked Unplug
Normal
Abnormal
Injector failure
Clean and replace
Normal
Abnormal
Engine signal plate loose or moved Check or replace
Normal Abnormal
Replace
ECU inner short circuit
46
No. 028 Hard to start in cold condition

Check battery voltage whether it is normal. Charge or replace it when
necessary.
Check starter, whether it operates normally. Maintain or replace it when
Low engine speed when
necessary.
driven by starter
Check oil condition, whether it is too thick. Replace standard grade oil when the
oil is too thick, which results large inner engine friction and further causes low
engine speed.
Connect Geely special decoder to check whether there is malfunction code..
Electric controlling
And inspect again if it shows malfunction code. Then check relevant component
system malfunction
and circuit according to the indication of malfunction code.
Water temperature sensor fails to output signal or outputs incorrectly, which will
affect fuel injecting adjustment of engine ECU and results improper mixture gas
Cooling fluid temperature viscosity. And further causes engine fails to start, operates unstably, stop
sensor malfunction operating or running intermittently. Check cooling fluid temperature sensor. In
different temperatures, its resistance shall vary according to specified standard.
Replace it when necessary.
The spark plug clearance shall between 0.8mm and 1.2mm. If there is lots of
Spark plug operates fuel on spark plug surface, it indicates fuel fouling in cylinder. In this case, shall
abnormally remove all spark plugs, disconnect injector circuit, full open the throttle, and
start engine for several times to exclude the malfunction.
Check fuel pressure, if it is too low, shall check fuel pressure controller, electric
Low fuel pressure
fuel pump and fuel filter etc.
Incorrect oil grade, too Since oil grade is improper, which results large oil viscosity and hardly start, the
thick oil shall be replaced according to local temperature.
Hard to start in
cold condition Check valve timing, whether it is correct. Adjust it when necessary.
Check igniting operation, whether there is high voltage spark. If not, shall check
Improper ignition timing or engine speed sensor, ignition coil and related ECU circuit. Maintain or replace
weak spark energy them when necessary.
Check high voltage spark energy, if it is weak, then check ignition coil, high
voltage resistance. Replace it when necessary.
Exhaust system blocked Unplug blocked exhaust system
Over carbon deposit in intake manifold and valve, will cause low viscosity of
Over carbon deposit in
mixture gas in cold condition, and results hard to start. Shall clean the carbon
intake manifold or valve
deposit.
If the filter element is too dirty and blocked, the engine will be hard to start.
Remove the filter element and start engine, if it operates normally, then replace
Air filter blocked or intake the element.
system leaking
Check intake system, whether it is leaking. Particularly the intake mainfold
gasket, vacuum pipe and connector etc. Exclude the malfunction.
Injector blocked or fuel Remove injector, check fuel injection quantity and fuel atomization, whether
atomized abnormally they are normal. Clean or replace it when necessary.
Measure engine cylinder compressing pressure, if it is low, but will increase
after filled a few oil into the cylinder, then the cylinder or piston ring is worn out
Low cylinder pressure and need to replace or implement cylinder boring repair. If the pressure remains
at low value, then it indicates improper valve clearance, valve burnt or leaking.
Shall adjust valve clearance or replace valve.
ECU malfunction ECU controller fails to input or output signal normally, replace it.
47
Hard to start in cold condition
Abnormal
Low engine speed when driven by starter
Check
Normal
Abnormal
Electric controlling system short or open circuit
Check
Normal
Abnormal
Cooling fluid temperature sensor failure Replace
Normal
Poor
Spark plug operates abnormally Adjust and replace
Normal
Low
Low fuel pressure Check
Normal
Abnormal
Improper ignition timing or weak spark energy Maintain
Normal
Abnormal
Injector blocked or fuel atomized abnormally Clean and replace
Normal
Blocked
Air filter blocked Clean
Normal
Over carbon deposit
Over carbon deposit in intake mainfold or valve; exhaust Check
pipe blocked
Normal
Lack
Normal
Abnormal
48
No. 029 Hard to stard engine when heating

Check battery voltage, whether it is normal. If the value is
too low, shall charge and check charge circuit, as well as
related components.
Low starter speed or sliding Check starter, and maintain or replace it when starter coil is
heated and short circuit.
If motor idles, then the starter flywheel gear and motor gear
slide when match, which results engine hard to start.
Connect Geely special decoder to check whether there is
Electric controlling system malfunction code. And inspect again if it shows malfunction
malfunction code. Then check relevant component and circuit according
to the indication of malfunction code.
Check spark plug electrode clearance and carbon deposit
condition. Adjust or replace it when necessary.
Check heating operation, whether there is high voltage
spark. If not, check engine speed sensor, ignition coil, ECU
and relating circuit. Maintain or replace them when
Weak high voltage spark necessary.
Check high voltage spark energy. If it is weak, check ignition
coil, spark wire resistance. Replace them when abnormal.
Check cooling fluid temperature sensor. In different
Cooling fluid temperature sensor
temperatures, its resistance shall vary according to specified
malfunction
standard. Replace it when necessary.
Hard to start engine
when heating When heating, the expansion difference of valve seat and
element may affect injector pin valve and result valve
Injector malfunction seat and element stuck or leak, which relates with spark
plug drown and primary fuel pressure lose and cause hardly
to ignite. Check injector, replace it when necessary.
Check fuel, whether it is polluted, or contains other problem.
Fuel quality problem It is recommended that customers shall change the gas
station, where they often attend.
Engine cylinder, connect rod, crankshaft and camshaft
Engine cylinder, connect rod,
bearing fit pressure is over normal value, the expansion
crankshaft and camshaft bearing fit
when heating will result crankshaft stuck. Maintain relating
pressure is over normal value
part.
Engine speed sensor resistance or output signal and signal
tooth clearance abnormal, which results improper ECU
Speed sensor output signal abnormal
ignition timing, as well as engine hard to start. Shall adjust or
replace engine speed sensor.
Air filter blocked Clean or replace
Check fuel pressure, if it is too low, shall inspect fuel
Low fuel pressure
pressure controller, electric fuel pump, fuel filter and pipes.
Intake pressure temperature sensor Intake pressure temperature sensor is heated, which results
operates abnormally signal misalignment.
The triode in ECU controller is heated, and fails to input or
output signal normally. Shall replace ECU.
49
Hard to stard engine when heating
Low
Low starter speed or sliding Check and replace
Normal
Abnormal
Electric controlling system failure Check and replace
Normal
Abnormal
Spark plug failure Replace
Normal
Abnormal
Weak high voltage spark Check
Normal
Abnormal
Normal
Abnormal
Injector failure
Clean and replace
Normal
Abnormal
Fuel quality problem Replace
Normal
Over fitted
Engine fit pressure is over normal value Check
Normal
Abnormal
Speed sensor output signal abnormal Replace
Normal
Blocked
Normal
Lack
Normal
Abnormal
Intake pressure temperature sensor operates Replace
abnormally
Normal Abnormal
Replace
50
No. 030 Idle speed unstable

When idling, the action, such as open AC, operate steering wheel
or open front lamp, will increase engine load. ECU will add
injection quantity to remain engine running stably, as well as to
prevent engine shut-off when engine load increased. Disconnect
idle speed conducting point, while engine is not running in idle
condition, determined by ECU, and it will remain injection quantity
Improper throttle position sensor
instead of increase it. Therefore, the engine speed remains as
adjustment
before, and ECU will adjust idle speed according to the order of
oxygen sensor mixer. The malfunction is indicated by low engine
speed when open AC or operate steering wheel in idle condition.
When the throttle is closed totally, inspect idle switch of throttle
position sensor by Geely special deNo.r, whether it is normal.
Adjust or replace it when necessary.
Check throttle and idle speed by-pass pipe, whether they are
Idle speed by-pass pipe blocked blocked. Clean it when necessary to ensure free-flowing air
intake.
Engine idle speed According to engine speed, temperature, throttle open degree
unstable and AC signal etc., ECU will calculate and adjust idle speed
control valve or stepping motor, as well as by-pass pipe, to
decrease engine speed. If idle speed control valve delayed or
Idle speed control valve or stuck, as well as in the case of throttle malposition etc., ECU will
stepping motor malfunction fail to implement idle speed adjusting correctly, which results idle
speed unstable. Shall clean or replace relating parts, sc. replace
idle speed control valve and implement self-adaption on idle
speed control valve or stepping motor by deNo.r, series Geely,
when necessary.
Connect Geely special decoder to check whether there is
Electric controlling system malfunction code. And inspect again if it shows malfunction code.
malfunction Then check relevant component and circuit according to the
indication of malfunction code.
Check operating condition of each cylinder, whether there is
individual cylinder, which operating abnormal. Particularly the
Individual cylinder fails to work
spark plug, spark wire, cylinder pressure etc. Maintain or replace
then when malfunction cause was found.
51
Intake pipe leaking and results incorrect flow rate decision on

ECU, which will cause unstable idle speed. Check leaking
Intake pipe leak
position, particularly intake manifold gasket, injector seal ring,
vacuum pipe and connector etc.
It has not implement In case of replacing engine ECU, battery or disconnect battery
self-adaption, after engine ECU power for a long time, it shall implement self-adaption according
or battery was replaced. to Geely engine self-adaption procedure.
Check running engine, whether the output voltage of generator is
in normal value. If it is abnormal and results unstable idle speed,
Generator voltage abnormal
then check generator and relating circuit and parts. Maintain or
replace them when necessary.
If the injector is leaking or blocked, and fails to inject according to
ECU order, which results improper mixure gas viscosity, as well
Injector leak or block
as individual cylinder operating abnormal and unstable idle
speed, then shall replace the injector.
Gum deposit, carbon deposit, broken or such problems in 3-way
catalytic converter result partly or random blockage, which will
increase the backpressure when exhausting, as well as low
vacuum of intake pipe, which results abnormal engine exhaust
and intake performance, that relating with cylinder operating
performance directly. Replace 3-way catalytic converter.
Often appears on vehicle MR7131A, stepping motor gasket is too
Improper stepping motor gasket
thin caused by manufacture process, and results motor operating
thickness
abnormal. Exclude the malfunction by replacing gasket.
Intake temperature sensor Check sensor data and voltage, replace it when necessary.
malfunction
Measure fuel pressure, check electric fuel pump, pipes and circuit
Low fuel pressure when it is lower than normal value. Maintain or replace them when
necessary.
Improper spark plug and ignition Check spark wire cross firing condition, as well as ignition timing.
advance angle, which results Adjust or replace it when necessary.
unstable idle speed
Check vehicle, whether there is any sign of accident. Engine
Engine bracket cracked bracket cracked will cause engine vibration, and unstable idle
speed.
Oxygen sensor malfunction Check oxygen sensor signal, replace it when necessary.
Canister valve malfunction Check canister control valve, replace it when necessary.
52
Idle speed unstable
Improper adjusted
Improper throttle position sensor adjustment Adjust and replace
Normal
Blocked
Idle speed by-pass pipe blocked Clean
Normal
Abnormal
Idle speed control valve or stepping motor failure Clean and replace
Normal
Abnormal
Replace
Electric controlling system failure
Normal Fails to work
Individual cylinder fails to work

Check
Normal
Leak
Intake pipe leak Check
Normal
Abnormal
Voltage abnormal Check
Normal
Abnormal
Injector failure Clean and replace
Normal Blocked

Check and replace
Normal
Abnormal
Replace
Intake temperature sensor failure
Normal
Low
Normal
Cracked
Engine bracket cracked Replace
Normal
Abnormal
Oxygen sensor failure Replace
Normal
Fail
Canister valve failure Replace
53
No. 031 Non-idle speed

Check throttle and idle speed air pipe, whether they are blocked. Clean
Idle speed air pipe blocked
them if there is too much carbon deposit to ensure free-flowing intake.
Check idle speed stepping motor, whether it operates normally and flexibly.
Ilde speed stepping motor
Clean it if there is too much carbon deposit. Replace motor when
malfunction
necessary.
Loose throttle pedal and check throttle cable condition, adjust it if the
Improper throttle cable or clearance is improper.
thorttle position sensor When throttle is closed totally, inspect throttle position sensor idle speed
adjustment switch, by Geely special decoder, whether it operates normally. Adjust or
replace it when necessary.
Connect Geely special decoder to check whether there is malfunction code.
Electric controlling system
And inspect again if it shows malfunction code. Then check relevant
malfunction
component and circuit according to the indication of malfunction code.
Check cooling fluid temperature sensor. In different temperatures, the
Cooling fluid temperature
resistance of coolant temperature sensor shall vary according to regulated
Non-idle speed, sensor malfunction
standard. Otherwise, replace it.
engine shut-off
when pressing Check operating condition of each cylinder, whether individual cylinder
throttle pedal Indicidual cylinder fails to operates abnormally, particularly inspect the spark plug, spark wire and
work cylinder pressure etc. Maintain or replace relating parts when malfunction
cause was found.
Check running engine, whether the output voltage of generator is in normal
value. If it is abnormal and results unstable idle speed, then check
Engine voltage abnormal
generator and relating circuit and parts. Maintain or replace them when
necessary.
According to idle speed operating principle, vacuum pipe leaking will result
non-idle speed. Shall replace vacuum pipe.
Incorrect engine valve Timing belt loose and cause gear malposition, as well as similar condition
timing with non-idle speed. Shall adjust ignition timing.
Part of idle speed controlling circuit is ageing or affected by water, may
Circuit malfunction
result non-idle speed. Shall maintain circuit.
Pull out ECU engine connector, measure the resistance between each
Engine ECU malfunction terminal by multimeter, whether the value is corresponding to technical
requirements. Replace engine ECU when abnormal.
54
Non-idle speed
Blocked
Idle speed air pipe blocked Clean
Normal
Abnormal
Ilde speed stepping motor failure Clean and replace
Normal
Abnormal
Improper throttle cable or thorttle position sensor adjustment Clean and replace
Normal
Abnormal
Check
Normal
Abnormal
Normal
Fails to work
Indicidual cylinder fails to work Check
Normal
Abnormal
Engine voltage abnormal Check
Normal
Leak
Check
Normal Error
Check and adjust

Incorrect engine valve timing
Normal
Abnormal
Circuit failure Check
Normal
Abnormal
Engine ECU failure
Replace
55
No. 032 Idle speed over normal value

Improper throttle cable or throttle position Loose throttle pedal and check throttle cable condition.
sensor adjustment Adjust it when the clearance is improper.
Throttle contains too much carbon deposit, Check throttle, if there is too much carbon deposit, which
sc. it is stuck, which results the throttle fails results throttle fails to close as normal, then shall clean it.
to close normally.
Check idle speed stepping motor, whether it operates
Idle speed stepping motor malfunction flexibly. If it is stuck, caused by carbon deposit, and then
shall clean it. Replace stepping motor when necessary.
Intake pipe leaking, result incorrect decision to air flow
rate on ECU, and causes improper control, which leads
Intake system leaking to over idle speed. Check leaking position, particularly
the intake manifold gasket, fuel injector seal ring,
vacuum pipe and connector etc.
Connect Geely special decoder to check whether there
is malfunction code. And inspect again if it shows
Electric controlling system malfunction
malfunction code. Then check relevant component and
circuit according to the indication of malfunction code.
Idle speed over Check water temperature sensor, whether it can send
normal value temperature signal to ECU correctly. In normal condition,
the coolant temperature is applied to adjust fuel injecting
quantity, sc. mixture gas viscosity. In low temperature,
ECU controls injector to inject more fuel to increase
Cooling fluid temperature sensor
mixture gas viscosity, as well as idle speed. Check water
malfunction
temperature sensor, if it fails to measure temperature as
normal. In different temperatures, the resistance of
cooling temperature sensor shall vary according to
regulated standard. Otherwise, replace coolant
temperature sensor.
Check intake manifold pressure temperature sensor,
Intake pressure sensor malfunction
replace it when abnormal.
Measure oxygen sensor, if the voltage is low, beneath
0.5V, then will cause incorrect ECU order, which results
mixture gas viscosity increase, as well as idle speed.
Replace oxygen sensor when necessary.
Pull out engine ECU pin and measure the resistance
between each terminal of ECU, whether the value is
Engine ECU malfunction
accordance with technical requirements. Replace engine
ECU when abnormal.
56
Idle speed over normal value
Improper
Improper throttle cable or thorttle position sensor adjustment Adjust
Normal
Over normal value
Throttle contains too much carbon deposit

Clean
Normal
Abnormal
Idle speed stepping motor failure Clean and replace
Normal
Leak
Intake system leaking Check
Normal
Abnormal
Check
Normal
Abnormal
Temperature sensor failure Replace
Normal
Abnormal
Intake pressure sensor failure Replace
Normal
Abnormal
Normal
Abnormal
Engine ECU failure Replace
57
No. 033 Engine accelerates abnormal

Check air filter, whether it is blocked. Clean or replace when necessary.
Air filter blocked Check intake system, whether it is leaking. Measure intake manifold vacuum, the
value shall above 30kPa when idling. Otherwise, the intake system is leaking. Shall
check connectors and all hoses and vacuum pipes carefully.
Improper adjustment Press accelerate pedal fully, and check whether the throttle fully opens. Adjust
of throttle cable or throttle cable or pedal, if it fails to open fully.
throttle position Check throttle position sensor. During throttle varies from full close to full open, the
sensor, which results resistance between signal terminal and earth terminal shall increase constantly,
throttle fail to fully without interruption. Adjust or replace the sensor according to regulation, when
open. abnormal.
Check ignition timing. When idling, the ignition advance angle shall be 10~12.
Improper ignition Otherwise, shall adjust the primary ignition advance angle. When accelerating, the
timing or weak spark angle shall increase to 20~30 automatically. When abnormal, shall check ignition
energy. controlling system, including ignition coil, spark wire and spark plug etc., alternative
replace ECU.
Check fuel pressure. When idling, fuel pressure shall in accordance with regulation,
265~304kPa. When accelerating, fuel pressure shall increase about 50kPa. If fuel
Low fuel pressure
pressure is too low, then shall check fuel pressure controller, electric fuel pump, fuel
filter and etc.
Injector blocked or Remove injector and check injecting quantity and atomization quality, whether they
poor atomization are normal. When abnormal, clean or replace the injector.
Check battery voltage, whether it is normal. If the value is too low, when will cause
Low battery voltage fuel injecting quantity decrease, which results low engine power, as well as
Engine accelerating delay. In this case, shall check charging system or replace battery.
accelerates
abnormal Check coolant temperature sensor. In different temperatures, the resistance of the
Coolant temperature
sensor shall vary in accordance with regulated standard. Otherwise, shall replace
sensor malfunction
the sensor.
Intake pressure Check intake manifold pressure temperature sensor. Replace it when abnormal.
sensor malfunction
Clutch sliding Replace driven plate of clutch.
Low engine cylinder Measure the compressing pressure of engine cylinder. If it is too low, then shall
pressure adjust valve clearance, or disassemble and inspect engine.
In case of low power and accelerating performance, caused by poor flywheel and
Poor flywheel signal
signal wheel signal, shall replace flywheel assembly.
Crankshaft position In case of ECU order delay and low accelerating performance, caused by the sensor
sensor malfunction fails to indicate crankshaft position correctly, shall replace the sensor.
Incorrect engine valve Check engine valve timing, whether it is correct. Adjust it when incorrect.
timing
Check the operating condition of each cylinder, such as individual cylinder
Individual cylinder operating, whether it is abnormal. Particularly the spark plug, spark wire and cylinder
fails to work pressure etc. Determine the malfunction cause and maintain or replace relating
parts.
Check 3 way catalytic converter, whether it is blocked. The reverse interfere caused
Exhaust system
by blockage will result poor engine accelerating performance. In this case, replace
blocked
3-way catalytic converter.
Oxygen sensor It results indiscernible mixture gas rate, as well as low power.
malfunction
58
Engine accelerates abnormal
Blocked
Improper adjusted
Normal
Improper adjustment of throttle cable or throttle position sensor

Adjust
Normal Abnormal
Improper ignition timing or weak spark energy Check
Normal
Low
Low fuel pressure
Check
Normal
Blocked
Injector blocked
Clean and replace
Normal
Low
Low battery voltage
Charge
Normal
Abnormal
Cooling fluid temperature sensor failure
Replace
Normal
Abnormal
Intake pressure sensor failure Normal
Normal Sliding
Clutch sliding Replace
Normal
Low
Low engine cylinder pressure
Check
Normal
Poor
Poor flywheel signal Check
Normal
Abnormal
Crankshaft position sensor failure Replace
Normal
Error
Incorrect engine valve timing Check and adjust
Normal
Fails to work
Individual cylinder fails to work Check
Normal
Blocked
Exhaust system blocked Check and replace
Normal
Abnormal
59
No. 034 Water temperature over normal value

Check cooling system, whether there is enough
Lack of coolant coolant. Add coolant if it is lack of coolant, which will
affect cooling performance.
Water temperature meter and sensor Water temperature over normal value, virtually.
malfunction Replace relating components.
Check radiator cap and radiator, maintain or replace
Radiator leaking
leaking part.
Check upper and lower pipe temperature of radiator,
if there is high value difference, then shall remove
Thermostat fails to open as normal
thermostat and measure the activating temperature.
Replace thermostat if it fails to open normally.
Check water pipe, maintain leaking position and
Water pipe leaking
fasten loose clip
Check water pump driving belt, whether it is loose or
damaged. Adjust or replace when necessary.
Open radiator cap and start engine, to inspect
Water pump malfunction coolant flowing condition and determine whether the
water pump is working. If the coolant keeps still, then
remove and check water pump. Replace it when
Water temperature
blade wheel is damaged.
over normal value,
when engine Heater radiator leaking Check heater radiator, maintain or replace it.
operating
Check radiator cooling fan motor and fan blade,
whether they are damaged. Maintain or replace them
when necessary.
Check coolant temperature sensor. In different
temperatures, the resistance of coolant temperature
Radiator cooling fan fails to operate normally
sensor shall vary in accordance with regulated
standard. Otherwise, shall replace the sensor.
Check engine ECU and radiator cooling fan motor
controlling circuit. Maintain or replace them when
necessary.
Check radiator, whether there are bubbles nearby.
Cylinder head gasket damage Replace cylinder head gasket, may exclude the
malfunction.
Check radiator, whether it is blocked by mud or other
impurity. Clean or replace it, when cooling
Poor radiator cooling performance performance is affected by blockage.
Check furring condition in radiator. Clean or replace
it, when cooling performance is affected.
Part blockage in engine inner water cycling pipe Unplug or replace cylinder block
60
Water overheat
Insufficient
Insufficient coolant Fill
Normal
Failure
Water temperature gauge and sensor fails Replace
Normal
Abnormal
Thermostat can not open normally Replace
Normal
Water leaking
Water leakage in water Check
tank
Normal
Abnormal
Water pump trouble Replace
Normal
Water leaking
Water leakage in water pipe Replace
Normal
Water leaking
Water leakage in water tank of fan Replace it
heater
Normal
Radiator cooling fan can not run normally Overhaul and replace it
Normal
Cylinder head gasket damaged Replace it
Normal
Poor heat radiating of the radiator Check and replace
Normal
Partial clogging in engines Check and replace

internal circulating water pipe
61
No.035 Oil existing in the water tank
Oil enters cooling system during engine repair, and

oil enters water tank along with coolant after the
Man-made malfunction engine operates to normal water temperature. This
malfunction can be eliminated through replacing
coolant for several times;
Cylinder head gasket is slightly damaged or not

pressed tightly, after the engine starts, oil appears in
the water tank due to oil pressure higher than the
pressure of cooling system which causes oil entering
into cooling system along the damage of cylinder
Malfunction of cylinder head gasket
head gasket. In case of this malfunction ,
disassemble the engine to check cylinder head and
its gasket, cylinder block surface, repair or replace it
and then tighten it in accordance with standard
torque;
Oil appears in the water Check whether cylinder head or cylinder block is
tank during engine Cylinder head or cylinder block deforming
deformed, if any, repair or replace it;
operation
There is crack inside oil way of cylinder head, and

the crack is enlarged once heated, therefore oil
There is crack on the cylinder head enters into cooling system through it. In this case,
check carefully that there is any crank on the cylinder
head, use instrument if necessary, if any, replace it;
There is crack inside oil way of cylinder block, and

the crack is enlarged once heated, therefore oil
There is crack on the cylinder block enters into cooling system through it. In this case,
check carefully that there is any crank on the cylinder
block, use instrument if necessary, if any, replace it;
In case of this malfunction , the pipeline must be

Automatic transmission fluid and radiating
treated timely, the malfunction exists in automatic
pipe connect and oil enters
transmission type Geely Vehicle;
62
Oil existing in the water tank
Man-made trouble Replace
Malfunction of cylinder head Replace
Cylinder head or cylinder block Replace

deforming
There is crack on the Replace

cylinder head
There is crack on the cylinder Replace

block
Automatic transmission fluid and radiating pipe Replace

connect and oil enters
63
No. 036 There is water in the oil
During engine repairing, there is water mixed into crankcase, oil mixes with water
Man-made
and color changes after the engine operates to normal water temperature. This
malfunction
malfunction can be eliminated by changing oil;
Cylinder head gasket is slightly damaged or not pressed tightly, after the engine
starts, water enters into crankcase through cylinder head gasket. In case of this
Malfunction of
malfunction , disassemble the engine to check cylinder head and its gasket, cylinder
cylinder head gasket
block surface, repair or replace it and then tighten it in accordance with standard
torque;
There is water in
the engine oil
There is crack on cylinder head, and the crack is enlarged once heated, therefore
There is crack on the
water enters into crankcase through it. In this case, check carefully that there is any
cylinder head
crank on the cylinder head, use instrument if necessary, if any, replace it;
There is crack on cylinder block, and the crack is enlarged once heated, therefore
There is crack on the
water enters into crankcase through it. In this case, check carefully that there is any
cylinder block
crank on the cylinder block, use instrument if necessary, if any, replace it;
There is water in the oil
Man-made trouble Incorrect Check
Normal
Malfunction of cylinder head gasket Damaged Replace
Normal
There is crack on the cylinder head Crack Replace
Normal
There is crack on the Crack Replace

cylinder block
64
No. 037 Abnormal sound of crankshaft bearing
Oil filter blocked Replace the oil filter
Poor oil quality Change oil
Eliminate it in accordance with malfunction

Engine water temperature high
of high water temperature;
Check oil pressure, abnormality will also

Abnormal pressure of oil pump cause abnormal sound, if necessary,
change oil pump;
Check the matching clearance between

main bearing shell and main bearing
There is abnormal sound in journal, the value is 0.020mm-0.059mm, if
crankshaft bearing, sound is Matching clearance between main bearing shell and the clearance exceeds limit 0.1mm, it is
heavy in crankcase with main bearing journal too large necessary to select main bearing shell
toneless plump; the faster again according to measured diameter of
the engine speed, the louder main bearing journal and technical
the noise, and the noise is requirements (empirical value);
obvious particularly when
accelerating suddenly. When
serious, engine block Measure thrust clearance of crankshaft at
vibrates, lubricant pressure thrust washer, the value is
reduces; the noise does not Thrust clearance between thrust washers too large 0.087mm-0.177mm, if the value exceeds
change when engine limit 0.300mm, the thrust washer should be
temperature changes. changed; (empirical value)
Check crankshaft camber, if the camber

Crankshaft bending exceeds limit 0.1mm, the crankshaft should
be corrected or changed (empirical value);
Check that there is any peeling, ablation or

other abnormality on the surface of bearing
Main bearing shell is ablated and worn seriously
shell, if the bearing shell fails, it should be
changed;
If main bearing shell is just loose, tighten

Bolt on the cover of main bearing shell is loose the bolt on the cover of main bearing shell
by torque specified;
65
Abnormal sound of crankshaft

bearing
Poor
Poor oil quality Replace
Normal
Blocked
Oil filter blocked Replace
Normal
Water temperature high

Engine water temperature high Check
Normal
Bend
Crankshaft bending Replace
Normal
Wearing
Main bearing shell is ablated and worn Replace
seriously
Normal
Abnormal
Abnormal pressure of oil pump Check
Normal
Too large
Thrust clearance between thrust Check
washers too large
Normal
Matching clearance between main Too large

Check
bearing shell and main bearing journal
too large
Normal
Loose
Bolt on the cover of main bearing Check
shell is loose
66
No. 038 Abnormal sound of connecting rod bush
Poor oil quality Change oil
Oil filter clogged Replace the oil filter
Oil too diluents Change oil
When engine accelerates Abnormal pressure of oil Check oil pressure, abnormality will also cause abnormal sound, if
suddenly, obvious clear pump necessary, replace oil pump;
and short knocking is
produced and becomes Check the clearance between connecting rod bearing shells, the
louder as the loading value is 0.020mm-0.063mm, if the clearance exceeds limit 0.1mm, it
increases; creaking can be Shell clearance too large is necessary to select connecting rod bearing shell again according
heard by shaking throttle to measured connecting rod bearing diameter and technical
slightly; the noise does not requirements. (empirical value);
change obviously when
engine temperature
changes. Check that there is any peeling, wearing, ablation or other
Shell wearing excessively,
abnormality on the surface of connecting rod bearing shell, if the
loosing or breaking etc.
bearing shell fails, it should be changed;
If connecting rod bearing shell is just loose, tighten the bolt by torque
Connecting rod bolt is loose
specified;
67
Abnormal sound of connecting

rod bush
Poor oil quality Replace
Normal
Oil too diluent Replace
Normal
Normal
Abnormal pressure of oil pump Check
Normal
Halfshell clearance too large Adjust it
Normal
Connecting rod bolt loose Overhaul
Normal
Halfshell wearing excessively, Replace it

loosing or breaking
68
No. 039 Camshaft with abnormal sound

Malfunction Causes Solution
Engine with high water temperature Eliminate malfunction based on high water temperature;
Engine oil with poor quality Replace engine oil;
Oil filter blocked Replace filter;
When the engine is Camshaft cam is worn, causing

Check camshaft; repair or replace;
normal, sound similar abnormal sound
as resonance
Fit clearance between camshaft and Check fit clearance; if necessary, repair engine or replace
appears; when
camshaft bearing too large concerned malfunction parts;
severe, irregular noise
appears. Camshaft seat burnt and damaged Check it is burnt and damaged; repair the engine;
Hardness of internal spring of the
Replace the spring or assembly;
gear not enough
Check oil pressure, which will cause abnormal sound if abnormal;
Pressure of oil pump abnormal
if necessary, replace oil pump;
Camshaft with abnormal sound
Worn
Engine with high water temperature Repair
Normal
Not good
Engine oil with poor quality Replace
Normal
blocked
Normal
Burnt
Camshaft seat burnt and damaged Replace
Normal
Abnormal
Pressure of oil pump abnormal Repair
Normal
Stiffness
Hardness of internal spring of the Repair
gear not enough
Normal
Too large
Fit clearance between camshaft and wall Replace
Normal
Abnormal
Cam worn Replace
69
No. 040 Camshaft driving gear with abnormal sound

Lubricating oil with poor quality Replace lubricating oil
Strained clearance of driving gear not matched, causing
Fit clearance not matched
abnormal sound;
Check driving gear of admission camshaft and that of exhaust
Improper assembling
camshaft are correctly assembled; if not, reassemble;
Matching angle under stress not even Adjust angle of driving gear; if necessary, replace it;
Camshaft driving Hardness of internal spring of the gear not Replace the spring or assembly;
gear with enough
abnormal sound Check inlet filter screen of oil pump is blocked; if so, clean or
replace;
Engine oil pressure too low Check clearance between drive gear and driven gear of oil
pump. And check relief valve is blocked; if so, repair or replace;
Check lubricating system is leaking, and mainly check clearance
of connecting rod tile; if leaking, eliminate it;
check driving gear is with obvious metal damaging traces,
Driving gear worn
causing noises; if so, replace it;
Camshfat driving gear with abnormal sound
Improper
Improper Reassemble
assembling
Normal
Lubricating oil with poor Poor

Replace
quality
Normal
Unusual
Matching angle under stress not even Replace
Normal
Not matching
Fit clearance of gears not Repair
matching
Normal Stiffness
insufficient
Hardness of internal spring of the gear not
enough Replace
Normal
Too low
Engine oil pressure too Repair
low
Normal Worn
Replace
Driving gear worn
70
No. 041 Cylinder knocking sound

Put screwdriver at filler port, and put your ear against the
screwdriver lever, and carefully observe and listen;
Flame out for cylinders gradually; if sound of this cylinder weakens
or disappears, then it is confirmed that this cylinder has abnormal
sound;
Piston and cylinder wall severely
worn, with too large clearance To differentiate from other abnormal sound, fill in some lubricating
oil at spark plug hole of this cylinder; if the sound weakens or
disappears, then it is confirmed as piston knocking sound;
When knocking sound is very severe and filler port is smoking
externally, it is because that clearance between piston and cylinder
wall is too large;
When the engine
Fuel grade too low, with poor Check fuel quality, and confirm its grade; if not reaching specified
operates at idling speed,
quality requirements, replace it;
upper of cylinder body
generates clear and Check ignition timing. When the engine is at idling speed, ignition
rhythmical metal advance angle is 10--12; if not correct, adjust advance angle of
knocking sound Dang. Ignition time too early initial ignition of the engine. When accelerating, ignition advance
When cooling, the sound angle could automatically be increased to 20--30. If unusual,
becomes obvious. With check ignition control system or replace ECU;
rising engine
temperature and speed, Engine oil filter blocked Replace engine oil filter;
the sound becomes Check knock sensor; if piston knocking is caused due to damaged
smaller or disappears. Knock sensor malfunction
knock sensor, replace it;
Carbon deposit within the Check carbon deposit within the cylinder; if too many causing
cylinder too many glowing ignition and piston knocking, clean it;
Clearance of connecting rod tile
Check and repair the engine;
too large
Piston ring blocked Check operations of piston ring; if blocked, repair or replace it;
Check cylinder cover is grinding; if grinding too large causing
Compression ratio too large combustion chamber smaller, and compression ratio too large
causing piston knocking, replace cylinder cover;
Clearance of piston ring too
Check piston ring; if necessary, replace it;
large
71
Cylinder knocking
sound
Piston and cylinder wall severely worn its Worn Repair

clearance
Normal
Fuel grade too low, with poor quality Poor quality

Replace
Normal
Too early
Ignition time too early Adjust
Normal
Knock sensor malfunction Abnormal Replace
Normal
Carbon deposit within the cylinder Too many Repair

too many
Normal
Large clearance
Clearance of connecting rod tile Repair
too large
Normal
Piston ring blocked Blocked Replace
Normal
Filter element blocked Blocked Replace
Normal
Clearance of piston too large Too large Replace
72
No. 042 Oil pump with abnormal sound

Check oil level within crankcase; if too low, fill up to
Engine oil not sufficient
standard height;
Filter screen blocked Check filter screen is blocked; if so, clean or replace;
Clearance of driving gear of oil pump too large Check clearance; if necessary, replace it;
Engine bottom
When at idling speed, probably oil pan position
with regular
Oil pump sounding appearing with clear clattering; if necessary, replace
clattering
oil pump;
Valve blocked Check and clean;
Fit clearance between driving gear of oil pump and
Driving gear of oil pump sounding driving gear of camshaft changes, thus damaging
driving gear of oil pump;
JL376/378 driving chain sounding Replace driving chain;
Oil pump with abnormal
sound
Insufficient
Engine oil not sufficient Add
Normal
Poor
Engine oil with poor Replace
quality
Normal
Blocked
Filter screen blocked Clean
Normal
Clearance of driving gear of oil Large clearance Replace

pump too large
Normal
Oil pump sounding Sounding

Replace
Normal
Valve blocked blocked

Clean
Normal
Sounding
Driving gear of oil pump Repair
sounding
Normal
Sounding
Driving chain Replace
sounding
73
No. 043 Crankshaft thrust piece with abnormal sound

Engine oil not sufficient Check oil level within crankcase; if too low, fill up to standard height;
Check filter screen is blocked; if so, clean or replace;
Engine oil with too low pressure
Check clearance between drive gear and driven gear of oil pump.
Crankshaft thrust And check relief valve is blocked; if so, repair or replace;
piece with
abnormal sound Crankshaft and thrust piece severely Crankshaft and thrust piece severely worn, causing too large axial
worn play, and abnormal sound; disassemble the engine and repair;
Thrust piece burnt and damaged Check it is burnt and damaged; if necessary, replace thrust piece;
Measure thrust clearance at thrust piece, with standard value as
Thrust clearance too large 0.087mm-0.177mm; if exceeding limit value 0.300mm, replace
thrust piece. (empirical value)
Crankshaft thrust piece with
unusual noise
Insufficient
Engine oil not sufficient Add
Normal
Engine oil with poor Poor

Replace
quality
Normal
Too large
Engine oil with too low pressure Repair
Normal
Worn
Crankshaft and thrust piece severely worn Replace
Normal
Thrust piece burnt and Burnt and damaged

Replace
damaged
Normal
Large clearance
Thrust clearance too Repair
large
74
No. 044 Valve with abnormal sound

Remove valve chamber cover, and make the engine run at idling speed;
listen to the sound and observe splashing of lubricating oil, and make
preliminary judgment; insert feeler gage to suspected valve clearance; if the
Continuous, regular Valve clearance too large sound weakens or disappears, then it is this valve that is sounding; with the
and clear da-da engine under cold state, adjust valve clearance; when clearance of intake
sound is heard at valve is 0.12mm~0.15mm, corresponding exhaust valve clearance is
one side of valve 0.20mm~0.25mm. when adjusting, make the valve closed;
chamber. When the
engine is at idling, Engine oil not sufficient Check oil level within crankcase; if too low, fill up to standard height;
medium speed, the
sound becomes Cylinder cover deformed Replace cylinder cover;
obvious; when high Check oil screen is blocked; if so, clean or replace;
speed, the sound is
in disorder. This Engine oil with too low Check clearance between drive gear and driven gear of oil pump. And
sound is not pressure, poor lubrication check relief valve is blocked; if so, repair or replace;
affected by engine causing abnormal sound
Check clearance between crankshaft and connecting rod tile is too large
temperature and causing oil leaking too much and oil pressure too low;
flameout.
If abnormal sound still exists after adjustment of valve clearance, check and
Camshaft worn measure cam lobe is damaged or severely worn; if exceeding limit value
0.300mm, replace it. (empirical value)
Valve with abnormal
sound
Too large
Valve clearance too large Adjust
Normal
Engine oil not Insufficient

Add
sufficient
Normal
Deformed
Cylinder cover Replace
deformed
Normal
Poor
Engine oil with too low pressure, poor lubrication Repair
causing unusual noise
Normal
Worn
Camshaft worn Replace
75
No. 045 Engine with insufficient power

Check air filter is blocked; if so, clean or replace;
Check intake system is leaking. Measure degree of vacuum
Air filter blocked of intake manifold. When at idling speed, degree of vacuum
shall be larger than 30KPA; if too small, it indicates that intake
system is leaking; carefully check connection and each hose,
vacuum pipe;
Step on accelerator pedal to the bottom, and check throttle
valve is fully opened; if not, adjust its dragline or pedal;
Throttle valve tie-line or throttle valve
Check throttle valve position sensor. When throttle valve is
position sensor improperly adjusted, and
changed from fully closed to fully opened, resistance of its
could be fully opened
signal terminal and earthing terminal shall be increased
The engine is
continuously, without interruption; if unusual, adjust or replace it
basically running
accordingly;
normally without
load; but Check ignition timing. When the engine is at idling speed,
accelerating slowly ignition advance angle is 10--12; if not correct, adjust advance
Improper ignition timing or weak
and hard to grade angle of initial ignition of the engine. When accelerating, ignition
high-pressure spark
up with load; when advance angle could automatically be increased to 20--30. If
stepping on unusual, check ignition control system or replace ECU;
accelerator pedal
to the bottom, still Check fuel pressure. When at idling speed, fuel pressure
feels that power is shall conform to specified value 265~304kpa. When
not enough, Fuel pressure too low accelerating, fuel pressure shall increase about 50kpa. If too
rotating speed low, check fuel pressure adjuster, electric fuel pump, gasoline
could not be filter, etc;
increased, and Oil injector blocked or with poor Remove oil injector; check ejecting amounts and atomization
unable to reach atomization are normal; if not, clean or replace oil injector;
maximum speed.
Check battery voltage is normal; if too low, it will cause
reduced ejecting amounts, causing insufficient dynamic force,
Battery voltage too low
and slow acceleration; if too low, check charging system or
replace battery;
Check cooling liquid temperature sensor. Resistance of this
Cooling liquid temperature sensor
sensor could be changed according to specified standard under
malfunction
different temperatures; if not, replace this sensor;
Check intake manifold pressure temperature sensor; if
Inlet pressure sensor malfunction
unusual, replace it;
Measure compression pressure of engine cylinder; if too low,
Engine cylinder pressure too low
adjust valve clearance or remove the engine;
76
Engine with insufficient

power
Air filter blocked Blocked

Clean or replace
Normal
Leaking
Intake system leaking Repair leaks
Normal
Throttle valve opening abnormal Unusual Adjust
Normal
Throttle valve position sensor Unusual

Adjust or replace
malfunction
Normal
Improper ignition timing Abnormal Adjust advance angle of initial

ignition
Normal
Too low Repair
Fuel pressure too
low
Normal
Abnormal
Remove, clean oil
ejector Replace oil injector
Normal
Battery voltage too Abnormal

low Check charging system or replace
battery
Normal
Cooling liquid temperature Abnormal Replace cooling liquid

sensor malfunction temperature sensor
Normal
Unusual
Intake manifold pressure temperature Replace intake manifold pressure
sensor malfunction
Normal
Replace ECU contrast test Changes Replace ECU
No changes
Compression pressure of Unusual

Remove and repair engine
cylinder too low
77
No. 046 Oil consumption too large

Also the most common problem. The counselor shall explain to the
Driving habit problem
customer patiently and nicely, using euphemism;
Check oxygen sensor could correctly identify concentration of gas mixture;
if not, it will cause high oil consumption;
Clearance of spark plug too Clearance of spark plug is too large, causing poor ignition, which is one of
large reasons causing high oil consumption;
Check ignition timing; when the engine is at idling speed, ignition advance
Improper ignition timing angle shall be 10~12; if not correct, it may cause rising oil consumption;
adjust ignition advance angle of the engine;
Oil injector blocked or poor Remove oil injector; check ejecting amounts and sealing are normal; if not,
sealing clean or replace oil injector;
Check cylinder pressure, valve, etc. If individual cylinders are not working,
Cylinder poorly operating
repair it accordingly; replace or adjust parts causing unusual working;
Check cooling liquid temperature sensor. Resistance of this sensor could be
Cooling liquid temperature
changed according to specified standard under different temperatures; if
sensor malfunction
not, replace this sensor;
Check air filter is blocked; if so, it may cause poor intake and large oil
Air filter blocked
consumption; clean or repair it;
During using, oil
consumption of the Fuel with poor quality may cause this malfunction; recommend the
engine is a lot Poor fuel quality customer to replace it at filling station that he often uses;
higher than
standard value Tire obviously worn or Tire will cause increased friction force, balancing out partial engine power,
pressure severely insufficient causing increased oil consumption;
With sudden acceleration, speed counter of the engine is quickly increased,
but the vehicle speed is very slowly increased, which could be judged that
Clutch slipping
the clutch is slipping, causing idle running and increased oil consumption;
replace clutch pressure plate and driven disk;
For carburetor vehicle in old Geely model, the following malfunctions may
Temperature control system occur: temperature control switch and thermostat are damaged, causing
malfunction causing large oil increased oil consumption as these damages will cause reduced water
consumption temperature, and carburetor cold not work normally, causing poor gasoline
atomization and obviously increased oil consumption; replace it;
Fuel pipe leaking Check fuel pipe; replace leaking pipe;
Braking seizing Adjust front and rear braking; if necessary, burnish brake disk;
Oil tank cover not well sealed Poor sealing causes fuel evaporation;
Canister control non-return
Replace it;
valve damaged
Intake quantity not conforming to standard values, causing error control,
Inlet pressure and
and high oil consumption when the vehicle is driving; check it with computer
temperature sensor damaged
diagnosis instrument; if necessary, replace inlet pressure sensor;
Throttle valve position sensor
Unable to identify opening; replace sensor;
with broken circuit
Cementing within three-way catalyze blocked, with poor exhaust, causing
Three-way catalyzer blocked
high oil consumption; replace it;
Inlet pipe leaking Replace inlet pipe;
Check operations of each cylinder; if individual cylinders are poorly
Individual cylinders not
operating, mainly check spark plug, high tension line, cylinder pressure, etc.
working
Confirm causes and repair or replace;
Incorrect valve timing of the
Check valve timing is correct; if not, adjust it;
engine
Measure compression pressure of engine cylinder; if too low, check valve
Cylinder pressure too low
clearance or remove and repair engine;
Idling speed too large or too Eliminate one by one according to idling speed-related malfunction
78
small template, making idling speed reach normal state;

Eliminate one by one according to water temperature-related malfunction
Water temperature abnormal
template, making water temperature reach normal state;
79
Oil consumption too

high
Habit problem
Driving habit problem Drive correctly
Normal
Abnormal
Oxygen sensor Replac
malfunction e
Normal Too large
Clearance of spark plug too Adjust

large
Normal
Improper
Improper ignition timing Check and

adjust
Normal
Poor sealing
Oil ejector obstructed or poor sealing Clean
Normal
Repair
Cylinder poorly operating Repair
80
Normal
Abnormal
Cooling liquid temperature sensor Replace
malfunction
Normal
blocked
Normal
Poor
Poor fuel quality Replace
Normal
Unusual
Tire obviously worn or pressure severely insufficient Repair or replace
Normal
Slipping
Clutch slipping Replace
Normal
Abnormal
Temperature control system malfunction Repair
causing large oil consumption
Normal
Leaking
Fuel pipe leaking Repair
Normal
Braking seizing Seizing Replace
Normal
Not well sealed

Oil tank cover not well Replace
sealed
Normal
Damaged
Canister control non-return valve Replace
damaged
Normal
Abnormal
Inlet pressure and temperature sensor damaged
Replace
Normal
Open circuit
Throttle valve position sensor with open Replace
circuit
81
Blocked
Three-way catalyzer blocked Replace
Normal
Not working
Individual cylinders not Repair
working
Normal
Incorrect
Incorrect valve timing of the engine Repair
Normal
Too low
Cylinder pressure too low Repair
Normal
Abnormal
Idling speed too large or too small
Repair
Normal
Abnormal
Water temperature abnormal l Repair
82
No. 047 Intake tempering

Check ignition timing. When the engine is at idling speed, ignition advance angle
is 10--12; if not correct, adjust advance angle of initial ignition of the engine.
When accelerating, ignition advance angle could automatically be increased to
20--30. If unusual, check ignition control system or replace ECU;
Check valve clearance is normal; if not, adjust it; if the valve is burnt and
Valve not well closed
deformed and not well closed, replace the valve and re-furbish;
Oil injector blocked or with Remove oil injector; check ejecting amounts and atomization are normal; if not,
poor atomization clean or replace oil injector;
Inlet pressure sensor
Check intake manifold pressure temperature sensor; if unusual, replace it;
Intake malfunction
manifold with
Check throttle valve position sensor. When throttle valve is changed from fully
tempering
Throttle valve position sensor closed to fully opened, resistance of its signal terminal and earthing terminal shall
malfunction be increased continuously, without interruption; if unusual, adjust or replace it
accordingly;
Oil duct malfunction is caused by too low oil ejected, which is caused mainly as:
oil pressure is too low; oil injector blocked. Malfunction of intake system is
Gas mixture too thin
caused as intake amounts are too many, which is caused mainly as: sensor
controlling intake amounts are invalid; intake manifold leaking;
Engine valve timing error Check valve timing is correct; if not, adjust it;
Oil injection control program
Replace engines Electronically Controlled Unit (ECU);
malfunction within ECU
83
Intake tempering
Improper
Improper ignition timing Check and adjust
Normal
Not well closed
Valve not well closed Repair
Normal
Poor atomization
Oil ejector blocked or with poor Clean
atomization
Normal
Abnormal
Inlet pressure sensor malfunction Replace
Normal
Unusual
Throttle valve position sensor malfunction Replace
Normal
Too thin
Gas mixture too thin Repair
Normal
Error
Engine valve timing error Repair
Normal
Abnormal
Malfunction of oil injection control
program within ECU Replace
84
No. 048 Exhaust pipe bombs

Check ignition timing. When the engine is at idling speed,
ignition advance angle is 10--12; if not correct, adjust
advance angle of initial ignition of the engine. When
accelerating, ignition advance angle could automatically be
increased to 20--30. If unusual, check ignition control system
Exhaust pipe or replace ECU;
bombs Oil injector leaking, causing gas mixture
Check oil injector is leaking; if so, replace it;
too thick
Engine valve timing error Check valve timing is correct; if not, adjust it;
Oil injection control program malfunction
Replace engines Electronically Controlled Unit (ECU);
within ECU
Exhaust pipe bombs
Improper
Improper ignition timing Repair
Normal
Leaking
Oil injector leaking Clean
Normal
Error
Engine valve timing error Repair
Normal
Unusual
Oil ejection control program malfunction
Replace
85
No. 049 Engine knocking

Check fuel quality and confirm fuel grade; if not reaching
Fuel with low grade and poor quality
specified requirements, replace it;
Check ignition timing. When the engine is at idling speed,
ignition advance angle is 10--12; if not correct, adjust
advance angle of initial ignition of the engine. When
Ignition time too early
accelerating, ignition advance angle could automatically be
increased to 20--30. If unusual, check ignition control system
or replace ECU;
Engine overheating may cause this problem; check cooling
Cooling system malfunction
system;
Put screwdriver at filler port, and put your ear against the
screwdriver lever, and carefully observe and listen;
Flame out for cylinders gradually; if sound of this cylinder
weakens or disappears, then it is confirmed that this cylinder
has abnormal sound;
To differentiate from other abnormal sound, fill in some
Piston and cylinder wall severely worn, lubricating oil at spark plug hole of this cylinder; if the sound
with too large clearance weakens or disappears, then it is confirmed as piston knocking
sound;
When knocking sound is very severe and filler port is smoking
externally, it is because that clearance between piston and
Metal knocking sound cylinder wall is too large;
occurs when the
engine increases the After confirming knocking sound, check cylinder diameter and
load or grades up piston dimension; repair according to technical requirements or
replace it;
Causing too many intake amounts, and thin gas mixture
Intake manifold leaking causes engine knocking; check pipes; if abnormal, repair or
replace;
Oil pressure too low, causing too few ejecting amounts, and
Oil pressure too low thin gas mixture causes engine knocking; check fuel pump and
pipe; if necessary, replace it;
Oil injector blocked, causing too few ejecting amounts, and thin
Oil injector blocked gas mixture causes engine knocking; check and clean the oil
injector; if necessary, replace it;
Carbon deposit within the cylinder too Check carbon deposit within the cylinder; if too many causing
many glowing ignition and knocking, clean it;
Check cylinder cover is grinding; if grinding too large causing
Compression rate too large combustion chamber smaller, and compression ratio too large
causing piston knocking, replace cylinder cover;
Individual cylinders not working Eliminate it one by one
Causing too many intake amounts, and thin gas mixture
Intake manifold pressure temperature
causing engine knocking; check electrical signal of sensor; if
sensor invalid
abnormal, replace it;
Program malfunction within ECU Replace ECU assembly;
86
Engine knocking
Poor quality
Fuel with low grade and poor quality Replace
Normal
Piston and cylinder wall severely worn, with too large clearance Worn
Repair
Normal
Too early
Ignition time too early Repair
Normal
Too low Repair
Oil pressure too low
Normal
blocked
Oil ejector blocked Clean
Normal
Too much
Carbon deposit within the Repair
cylinder too many
Normal
Compression rate too large Too large Repair
Normal
Not working
Individual cylinders not Repair
working
Normal
Abnormal
Replace
Intake manifold pressure temperature sensor
invalid
Normal
Leaking Repair
Intake manifold leaking
Normal
Abnormal
Repair
Cooling system
malfunction
Normal
Abnormal
Program malfunction within Replace
ECU
87
No. 050 Engine burning oil

Check one-way throughout of PCV valve at upper of valve chamber
PCV valve invalid hood; if not, it will cause exhaust gas pressure too high within the
engine, thus burning engine oil; otherwise replace it;
Engine oil too much Reduce oil amounts;
Oil consumption Check valve oil seal is aged, without sealing, engine oil enters to
too much, tail gas combustion chamber through valve stem. Replace valve oil seal;
in blue Valve oil seal malfunction
Check clearance between valve stem and valve guide; if too large
caused by abrasion, replace it;
Check piston ring is broken and elasticity and end clearance, side
Valve oil seal malfunction
clearance, back clearance conform to requirements; if not, replace;
Check clearance between piston and cylinder bushing conforms to
Piston and cylinder severely worn
requirements; if not, repair the engine;
Engine burning oil
Invalid
PCV valve invalid Replace
Normal
Abnormal
Valve oil seal malfunction Repair
Normal
Too much
Engine oil too much Discharge
Normal
Poor
Engine oil with Replace
poor quality
Normal
Abnormal
Piston ring, piston and
Repair
cylinder malfunction
88
No. 051 Cooling water unusually consumed

Check water tank, water bottle, pipe, radiator, radiator cap, warm-wind
radiator are water leaking; repair or replace. (pay attention to unusual
Cooling system leaking
consumption of cooling water caused by deformed assembling of rubber ring
of radiator cap)
Cylinder ring is damaged or not pressed out. After startup of engine, water
enters to crankcase or combustion chamber through cylinder ring;
Cylinder ring malfunction combustion chamber is through with water duct; if there is bubble out or water
column spraying out of cooling water, it will cause unusual cooling water;
Cooling water of observe engine oil is emulsified; if so, replace cylinder ring;
the engine
consumed too Water without anti-freezing This malfunction is rare in higher temperature area, but still with possibility; in
much during efficiency, causing icing after case of this situation, replace anti-freezing liquid conforming to requirements;
using parking in winter
Cylinder cover with cracks, which will be increased under heating, and water
will enter to crankcase or combustion chamber through cracks. Under this
Cylinder cover with cracks
situation, check carefully cylinder cover is with cracks; if necessary, use
special instruments; in case of cracks, replace it;
Cylinder body with cracks, which will be increased under heating, and water
will enter to crankcase or combustion chamber through cracks. Under this
Cylinder body with cracks
situation, check carefully cylinder body is with cracks; if necessary, use
special instruments; in case of cracks, replace it;
Consumption of
cooling water
Leaking
Cooling system leaking Repair or

replace
Normal
Abnormal
Cylinder ring Replace

malfunction
Normal Icing
Water without antifreezing efficiency, causing icing after Replace

parking in winter
Normal
Cracks
Cylinder cover with cracks Replace
Normal
Cracks
Cylinder body with cracks Replace
89
No. 052 Low engine oil pressure

Insufficient lubricating oil Check engine oil; if necessary, replace or add lubricating oil;
Use engine oil with correct grade; at least above SG of summer
Oil viscosity too small
SAE10W-40/winter 5W-30
Check oil screen is blocked; if so, clean or replace;
Oil pump malfunction
Check clearance between drive gear and driven gear of oil pump. And
check relief valve is blocked; if so, repair or replace;
Clearance of connecting rod tile Check clearance of connecting rod tile is too large, causing oil leaking;
Engine oil with too too large, causing oil leaking if so, repair or replace;
low pressure when
engine is working Clearance of crankshaft tile too Check clearance of crankshaft tile is too large, causing oil leaking; if so,
large, causing oil leaking repair or replace;
Main oil duct blocked or leaking Analyze causes and repair accordingly;
Oil pressure sensor or indicator Check electrical signal of sensor and oil indicator lamp; if abnormal,
lamp damaged replace it;
Oil induction plug leaking Replace induction plug
Eliminate malfunction one by one according to relevant template,
High water temperature
making water temperature normal;
Low engine oil pressure
Insufficient
Insufficient lubricating oil Add
Normal
Too small
Oil viscosity too small Replace
Normal
Damaged
Oil pressure sensor or indicator lamp Repair
damaged
Normal
Too large
Clearance of connecting rod tile too large, Repair
causing oil leaking
Normal
Too large
Replace
Clearance of crankshaft tile too large, causing oil leaking
Normal
Blocked or leaking
Main oil duct blocked or leaking Repair or
replace
90
Quick diagnosis for M1.5.4 Electrical injection system components of

MR479 engine
No.053 Quick diagnosis for ECU
Power source:
Power supplied by the battery continuously via 18# pin; Power supplied while main relay is
turned on via 37# pin; power supplied while ignition switch is turned on via 27# pin. Earthing:
2#, 10#, 14#, 19#, 24#, 30#, 48# pin. Malfunction diagnosis interface:
55# pin, engine data K line. Call out malfunction information records within ECU via K line, or
manually input some instructions, such as clear malfunction information records, make idle
speed actuator self-learning, etc;
General causes:
1. Invalid caused by burnt and damaged parts and components within ECU due to electrical
overload of externally connected device;
2. ECU entered with water causing circuit board rusty, etc; Maintenance precautions:
1. Before removing ECU, remove battery cell firstly;
2. For welding on the vehicles, cut off ECU power source;
3. Close ignition switch firstly while startup with externally connected power source or as
externally connected power source;
4. Radio speaker could not approach the controller; Simple measuring method:
1 (connect the connector) Read engine malfunction records via engine data K line, and make
comparison based on engine system data and normal vehicle data, find out differences and
continue in-depth inquiry;
2 (Remove the connector) check ECU connections are complete, and mainly check ECU power
supply, earthing lines are normal;
3. Check external sensor is working normally, output signal is reliable, and its lines are complete;
4. Recommend the ECU replaced to be assembled in the normal vehicle, and simulate
malfunction malfunction, and further confirm the malfunction;
91
Diagnosis flowchart for voltage of M1.5.4 electrical injection system
92
Y 1. Switch on diagnosis instrument, and display voltage value of battery

cell; when the engine is running under normal operating temperature,
check voltage is higher than 15V?
2. When the engine is running under normal operating temperature, N

N check voltage displayed on the instrument is lower than 15V?.
3. Check voltage value of battery anode and earthing is higher than N

Y 15V?.
4. Check when the engine is running at 20001Vm, and switch on N Till malfunction elimination instructions
head lamp, air conditioner, voltage value of battery cell is higher than
15V?.
5. Repair or replace the engine; confirm it is repairable.
No.054 Quick diagnosis for idling-speed governor EWD
Function: provide idling-speed bypass air route, and control air quantity by changing
cross-section of the route, realizing closed-loop control over rotating speed while the engine is
under idling-speed condition; principle: one permanent magnet rotating freely on the shaft within
idling-speed governor is rigidly connected with one rotating slide block, and could rotating driven
by the coil, making slide block also rotating. Angular position of slide block determines opening of
bypass duct, and thus adjusting bypass air quantity. Angular position of slide block is controlled
by duty ratio of electrical pulse output by electronic controller;
Idle speed actuator
93
Definition of EWD3 pin:

#4# EWD3-1# pin;
2#26# EWD3-2# pin; Simple measuring method:
1. (Remove the connector) place digital multimeter to ohm position, and two pens are
respectively connected to 1#, 2# pins of governor; rated resistance is 17.60.6 under 20;
otherwise, replace it;
2. (Connect the connector) Start the engine, and make it rotate under idling speed; carefully put
the hands against EWD3, and you feel slight vibration (recommend oscillograph);
3. When the engine is rotating under idling speed, take off harness connector of idling-speed
governor, and rotating speed of the engine shall be changed, which indicates that idling-speed
governor is working normally;
4. Take out harness connector of idling-speed governor, and measure its terminal voltage via
multimeter or oscillograph. When the engine is rotating, terminal of harness connector of
idling-speed governor shall be output with impulse voltage, which indicates that control system
lines of ECU and idlings-peed governor are faul-free; if idling speed is still not stable at this point,
with large deviations from specified value, check idling-speed governor. If output without impulse
voltage, open the air conditioner and test again; if still not, it means that control system lines of
ECU and idlings-peed governor are malfunction.
If after installation of governor, too low idling speed, idling-speed-free appears, replace for the
pad with 0.3-0.5mm thick, and screw down bolt twice, with the first torque as 2NM, and 7NM for
the second, and maximum torque no larger than 7NM. If the torque is too large, it will cause
EWD casing deformed, and internal slide block and valve body blocked with above-mentioned
malfunctions;
No.055 Quick diagnosis for knocking sensor
Function: this sensor is for providing engine knocking information to electronic controller ECU for
knocking control.
Principle: knocking sensor is a vibration acceleration sensor, which is installed at engine cylinder
body. Only one or several sensors installed is ok. Its sensitive element is a piezoelectric crystal,
to which vibration of cylinder body is transferred via mass block within the sensor, and which will
generate voltage at two pole faces due to pressure generated from vibration of mass block, and
transforms vibration signal into voltage signal;
94
95
Definition of sensor pin:

1#11# Knocking signal output;
2#30# Earthing;
3#19# Earthing (shielded)
Simple measuring method:
respectively connected to 1#, 2# and 1#, 3# pins of sensor; resistance under normal temperature
shall be larger than 1M;
2. Place digital multimeter to MV position, and knock at knocking sensor slightly with a small
hammer; at this point, voltage signal shall be output;
Note: please check 3# shielded line is well earthed.
3. Communicate diagnosis instrument specified by complete vehicle plant with electrical injection
ECU, and read malfunction data within ECU, thus making judgment over throttle valve position
sensor;
No.056 Quick diagnosis for stepper motor
Function: provide idling-speed bypass air route, and control air quantity by changing
cross-section of the route, realizing closed-loop control over rotating speed while the engine is
under idling-speed condition;
Principle: stepper motor is actuall a miniature motor, and its stator is polyphase coil winding and
rotor is permanent magnet, through which one spiral axis is threaded, and these two are
contacted with thread. When stator coil is switched with current, the rotor will rotate towards
corresponding directions. As rotor and spiral axis are contacted with thread, angular
displacement of rotor is transformed into linear displacement of spiral axis. Bypass cross-section
could be changed by front and rear moving of spiral axis. If the rotor rotates fixed angle each
time, spiral axis will move a certain displacement, i.e. one step. Electronic controller could control
moving steps of stepper motor by changing coil energization phase to obtain corresponding
bypass air flow.
96
Idle speed actuator step motor
97
Maintenance precautions:
1. Do not apply any forces axially to press down or take out the axle;
Before idle speed governor with stepper motor is installed within throttle valve body, the axle
must be at completely holdback position;
3. Pay attention to cleaning of bypass air route;
4. After removing battery cell, manually trigger self-learning function of stepper motor duly by
using K line for malfunction diagnosis for earthing with three times, and earthing time equaling to
and larger than 2.5s each time, or self-learning by using diagnosis instrument;
respectively connected into AD, BC pins of regovernor, and rated resistance under 25 is
535.3; otherwise, replace it;
2. (Connect the connector) Start the engine, and make it rotate under idling speed; put hands
slightly against stepper motor, and you feel slight vibration at this point;
3. Read amount of step of idle speed stepper motor out of engine parameter with diagnosis
instrument, and start the air conditioner, and amount of step will increase. If rotating speed of the
engine is kept at 3000rpm for a certain time, check amount of step will continue to rise, till to
maximum opening value, which indicates that stepper motor is working normally;
4. If you cannot make judgment, recommend malfunction recurrence testing on malfunction-free
vehicle;
98
Diagnosis flowchart of idling speed stepper motor

1. Switch on diagnosis instrument, and start the engine, and observe its
Y idling speed is stable? Observe stepper motor is within normal working
range through idling speed status of diagnosis instrument?
N 2. Check bypass opening is clean and not obstructed?
3. Check control lines of stepper motor are with the following conditions? Y
Socket connector is tightly inserted or loosening; open circuited; shorted
to ground or shorted to voltage source; joint of stepper motor falls out. Repair
N 4. Check resistance of stepper motor coil is within 35-95ohm?

Note: this value is related to temperature.
N 5. Check resistance between terminal B and D, and A and C of idling

speed stepper motor is infinitely large?
Y
N
Y 6. Check joint terminal and earthing resistance is larger than
10000ohm?
7. Clean idling speed bypass opening with compressed air gun; drive
stepper motor with idling-speed initialization function of diagnosis Y
instrument, making valve stem slide to clean pollutants with compressed
air; confirm repairs are completed.
8. Replace idling-speed control stepper motor; confirm repairs are

completed?
9. Replace ECU, and confirm repairs are completed?
99
No.057 Quick diagnosis for ignition coil

Function: transform low-voltage direct current of the battery into high-voltage, and generate
spark through discharging of spark plug, causing gas mixture within the cylinder.
Principle: when earthing channel of primary winding is switched on, this winding is charged. If
circuits of primary winding are cut off by ECU, then charging is terminated, and meanwhile, high
voltage is inducted from secondary winding, making spark plug discharge. What is different from
ignition coil with distributor is that, secondary winding of ignition coil ZSK2 2 has spark plug each
connected to its two terminals, and these two plugs will ignite at the same time.
ignition coil
Ignition switch #90
Ignition coil ZSK-ROV has two pins at its low-voltage sides:

Pin with + is connected with the battery, and pin with - with ECU1#; High voltage side:
connected to center of distributor
Double-spark ignition coil
Ignition switch #90
100
Low-voltage side: 1# connected with ECU20# earthing channel of No. 1 coil primary winding;
2# connected with ECU1# earthing channel of No. 2 coil primary winding;
3# and 4# connected both to power source (+);
High-voltage side: 1, 2, 3, 4 respectively connected with spark plug of engine cylinder of same
numbering;
respectively connected to two pins of primary winding, resistance is 0.41-0.53 for Type ROV,
and 0.42-0.58 for Type 2X2 under 20; and for secondary winding, resistance is 7-9k for
Type ROV, and 11.2-14.8k for Type 2X2;
2. Take out spark plug within the engine, and connect with high voltage line, and make its casing
earthed; start the starting motor and observe flashover of spark plug;
Diagnosis flowchart for ignition coil

1. Check and confirm connection between ignition coil and ECU is loosening, Y
and terminal damaged?
2. Check ignition switch to terminal 1 is open circuited or shorted to ground?

Y
Check support of ignition coil is earthed?
3. Ignition switch closed; remove joint of ECU and ignition coil; and check ECU
Y
and ignition coil is shorted circuited to voltage source?
4. Check ignition coil terminal 2 to ECU terminal 1 is shorted to earth? Y
5. Check ignition coil terminal 2 to ECU terminal 1 is open circuited? Y

Repair
6. Replace ignition coil; confirm malfunction still exists after replacement?
7. Replace ECU
Completed
101
No.058 Quick diagnosis for throttle valve position sensor
Function: this sensor is for providing information about outer corner of throttle valve to ECU,
based on which, ECU could obtain information related to engine load, condition (such as startup,
idling speed, dragging, partial load, full load) and acceleration and deceleration.
Principle: this sensor is actually corner potentiometer with linear output characteristics. Rocker
arm of potentiometer is installed with throttle valve at the same axis; when throttle valve rotates,
it will make rocker arm slide to certain position; potentiometer will output voltage signal
proportional to throttle valve position.

1#30# earthing;
2#12# connected to 5V reference voltage;
3#53# sensor signal output
respectively connected to 1#, 2# pins of sensor, with its resistance as 2k20% under normal
temperature;
2. Two pens are respectively connected to 1#, 3# pins; rotate throttle valve, and its resistance
will increase as opening of throttle valve, and for 2#, 3# pins, the opposite condition will occur;
Note: while observing changes of resistance value, observe it jumps largely; if so, it indicates that
the signal has break point; then replace it;
3. (Connect the connector) Open ignition switch and do not start the engine, then place digital
multimeter to direct current voltage position, with black pen for earthing, and red pen for 2# pin;
which shall have 5V reference voltage at this point; connect 3# pin and measure signal output;
when throttle valve is fully closed, its voltage value is about 0.3V (specific value related to vehicle
model); when throttle valve is fully opened, its voltage value is about 3V (specific value related to
vehicle model).
102
Diagnosis flowchart for throttle valve position sensor

1. Switch on ignition switch, the engine not started
N
Change opening of throttle valve, and check it is indicated as C degree to
about 34 degree with diagnosis instrument?
Y 2. Close ignition switch; take out sensor joint; ignition switch switched on. Y
Opening of throttle valve is indicated as 10 degree?
N Y
3. Check signal circuit of the sensor (53-3) is shorted circuited or shorted to
earth with B+?
4. Check reference voltage circuit of the sensor (12-1) is open circuited, Y
shorted to earth or shorted to B+?
5. Check signal circuit of the sensor (53-3) is open circuited, shorted to earth Y
or shorted to B+?
Y
6. Check earth circuit of the sensor (30-2) is open circuited, shorted to earth
or shorted to B+?
7. Ignition switch closed; signal terminal 3 of sensor is shorted circuit to

N reference voltage terminal 12 of ECU; ignition switch turned on, opening of
throttle valve is fully opened 84 degree (about 5V)?
N 8. Ignition switch turned on; measure voltage between earth circuit (terminal
Repairs
2) and reference voltage (terminal 1) is 5V with the voltmeter?
9. Replace throttle position sensor Completed
10. Replace ECU
103
No.059 Quick diagnosis for inlet pressure temperature sensor
Function: this sensor is for measuring absolute pressure and inlet temperature of intake manifold,
and providing information related to engine load and inlet temperature. Principle: piezoelectric
transducer is for measuring inlet pressure, and will provide "load signal" to the controller
according to difference between atmospheric pressure and intake manifold pressure; provide 5V
via controller and feed 0-5V to the controller according to difference of inlet pressure. Type NTC
(negative temperature coefficient) sensor is for measuring inlet temperature, and resistance
changes by inlet temperature, and this sensor will transfer one voltage indicating changes of inlet
temperature to the controller.
air intake manifold absolute pressure and air

intake temperature sensor

#30# earthing;
2#44# temperature signal output;
3#12# connecting 5V reference voltage;
4#7# pressure signal output; Simple measuring method:
1. Read malfunction code via engine diagnosis instrument and check malfunction information by
referencing parameter of inlet temperature and inlet pressure. When the vehicle is not started,
inlet pressure is close to the local atmosphere pressure, generally as one atmosphere pressure;
after startup, pressure is reduced to 300400kpa, and inlet temperature is ambient temperature
at that time;
2. For temperature sensor, (remove the connector) place digital multimeter to ohm position, and
two pens are respectively connected to 1#, 2# pins of sensor, and rated resistance is 2.5k5%
under 20, and other corresponding resistance values could be measured from characteristic
curve above. When measuring, use simulation method, specifically, supply air to the sensor via
air blower (do not approach too closely), and observe changes of sensor resistance, which shall
be reduced at this point;
3. For pressure sensor, (connect the connector) place digital multimeter to DC voltage position,
with black pen for earthing and red pen respectively connecting with 3#, 4# pins. At idling speed,
3# pin shall have 5V reference voltage, and voltage of 4# pin is about 1.3V (specific value related
to vehicle model); under empty load, slowly open throttle valve, and voltage of 4# pin is not
greatly changed; quickly open throttle valve, and voltage of 4# pin could reach about 4V
104
immediately (specific value related to vehicle model), and then reduced to about 1.5V (specific
value related to vehicle model).
Diagnosis flowchart for inlet pressure temperature sensor (inlet temperature sensor)
1. Ignition switch closed; remove ECU joint and check earth circuit (30-1) of sensor
Y
is open circuited or shorted to B+?
2. Check signal circuit (44-2) of sensor is open circuited, shorted to earth or shorted
to B+? Y
Y
N
3. Plug in ECU joint, and take out sensor plug, ignition turned on. Check socket
connector terminal (2-1) has reference voltage of 5V?
N
Repairs
4. Replace intake temperature sensor
5. Replace ECU
Completed
105
Diagnosis flowchart for inlet pressure temperature sensor (inlet pressure sensor)
1. Any following conditions occur?
---Vacuum booster or fuel pressure-regulating valve hose loosening or
Y
damaged
--- Intake manifold vacuum leaking and throttle valve leaking
Y
2. Disconnect sensor joint, and connect diagnosis instrument, and ignition
turned on. Observe absolute pressure displayed on diagnosis instrument is
Y
N 3. Check lines between ECU terminal 7 of signal circuit of sensor and sensor
terminal 4 is shorted circuited to B+?
4. Check lines between ECU terminal 7 of signal circuit of sensor and Y

sensor terminal 4 is open circuited or shorted to earth?
5. Check lines between ECU terminal 12 of 5V reference voltage and sensor Y

terminal 3 is open circuited or shorted to earth or to power source?
N 6. Check absolute pressure displayed on diagnosis instrument is 1013hpa

after the following operations? Ignition switch closed; ECU terminal 7
shorted circuit to ECU terminal 3; ignition switch turned on
7. Check lines between ECU terminal 30 of earth circuit of sensor and

Y
sensor terminal 3 are open circuited, shorted to earth or to power source?
N 8. With ignition switch turned on, check voltage between earth

circuit (terminal 1) and reference voltage (terminal 3) is about 5V Repairs
9. Replace manifold intake pressure sensor
10. Replace ECU

Completed
106
No.060 Quick diagnosis for water temperature sensor
Function: this sensor is for providing information about engine cooling liquid temperature, so that
the controller could correct oil injection and ignition accordingly.
Principle: this sensor is a heat variable resistor of negative temperature coefficient (NTC), with its
resistance value reduced as the temperature rises, but not as linear relationship. This resistor is
installed within copper heat guiding sleeve.

1#45# temperature signal output;
2#30# earthing.
1. (remove the connector) place digital multimeter to ohm position, and two pens are respectively
connected to 1#, 2# pins of sensor, and rated resistance is 2.5k5% under 20, and other
corresponding resistance values could be measured from characteristic curve above. When
measuring, use simulation method, specifically, put working area of the sensor into boiling water
(soak time shall be sufficient), and observe changes of sensor resistance, which shall be
reduced to 300-400 (specific value up to temperature of boiling water);
2. Check water temperature parameter of engine diagnosis instrument is close to water
temperature at the time, also with obvious changes; make judgment according to value
displayed;
Serial No. Resistance Temperature
Temperature tolerance Temperature tolerance
Min. Max. Min. Max.
107
Diagnosis flowchart for cooling liquid temperature sensor

1. Ignition switch closed: take out ECU joint and check earth circuit of sensor (2 pin 30 pin)
Y
is open circuited or shorted to B+?
Y
2. Check signal circuit of sensor (1-45) is open circuited, shorted to B+ or shorted to ground? Y
3. Plug in ECU joint, turn on ignition and check there is 5V reference voltage between two
N terminals of sensor joint? Repairs
4. Replace cooling liquid temperature sensor of the engine
5. Replace ECU
Completed
108
No.061 Quick diagnosis for canister solenoid valve
Function: for controlling flow of regenerated air flow of fuel evaporation control system.
Principle: canister of fuel evaporation control system could absorb oil vapor of oil tank, till
saturation. After canister control valve by electronic controller is opened, fresh air and fuel vapor
saturated in the canister will form regenerated air flow, and reintroduce to engine inlet pipe. And
electronic controller will change duty ratio of impulse signal transferred to magnet coil of canister
control valve according to engines different conditions, thus controlling over flow of regenerated
air flow. In addition, this flow is affected by pressure difference at two s ides.
Definitino of TEV pin:

1# TEV driver stage pin;
2#5# TEV control pin;
Maintenance precautions:
1. When installing, airflow direction shall conform to specifications; 2. In case control valve
becomes invalid due to black particle within valve body, and needed to be replaced, check
canister; 3. During maintenance, avoid liquid such as water, oil from entering to valve; 4. To
avoid transfer of solid borne noise, recommend to hang up canister control valve and install it at
hose.
1. (remove the connector) place digital multimeter to ohm position, and two pens are respectively
connected to two pins of canister control valve; rated resistance is 26 under 20;
2. Remove canister control valve, and absorb the air inside and check; canister control valve
shall be stuffy; then apply battery voltage of 12V to two connecting terminals, and absorb the air
to control valve, and the valve shall be airing. If upon check, status of canister control valve is not
consistent with above check results, it indicates that it is malfunction, and replace it;
109
Diagnosis flowchart for canister control valve

1. Ignition switch closed: remove joint of canister control valve, and turn on
Y
ignition switch, but unable to start the engine. Measure there is 12V voltage
to ground at one terminal of socket connector?
Y
2. Check lines between main relay terminal 87 and canister control valve are
open circuited, shorted to ground or to power source?
N
3. Check resistance of canister control valve is 5-50?
N 4. Ignition switch closed: remove ECU joint: check lines between ECU and Y
Repairs
canister control valve are open circuited, shorted to ground or to power
source?
5. Replace canister control valve
6. Replace ECU, and confirm repairs are completed.
Repairs
110
No.062 Fuel injector EV
1. O ring
2. Filter screen
3. Ejector body with electric
plug
4. Coil
5. Spring
6. Valve needle with coil
Function: fuel injector ejects fuel within specified time according to instructions of ECU, and
provides fuel to the engine and make it atomized.
Principle: ECU supplies power to coil of fuel injector, forming magnetic field force; when this
force increases enough to overcome resultant of pressure of release spring, gravity of needle
valve and friction force, needle valve starts to rise, and fuel injection starts. When injection
impulse stops, pressure of release spring will make needle valve re-closed.
Mounting position: Intake manifold close to inlet valve.
Malfunction: Poor idling speed, poor acceleration, unable to startup (difficult startup), etc.
General causes: Colloid deposit within fuel injector due to lack of maintenance, causing it
ineffective.
Maintenance precautions: 1. There are many types of fuel injectors, and those with the same
appearance and which could be installed may not be the proper one. Part number for injector
during repairs must be the same with that of original injector. Do not mix up; 2. To ensure
convenient installation, apply clean silicon-free oil at surface of upper O ring connected with fuel
distribution pipe. Do not pollute inner of oil injector and jet orifice; 3. When removing and
reassembling fuel injector, replace O ring; do not damage sealing surface of fuel injector; 4. If
fuel injector has two slots, make it correct when installing clamps by referencing mounting
position of original parts; 5. Do not remove, and clean or replace filter screen without permission;
6. After removing, make sure fuel injector seat is clean. Avoid foreign substances entering to the
cylinder.
111

(remove the connector) Place digital multimeter to ohm position, and two pens are respectively
connected to two pins of oil injector, and rated resistance is 11-17 under 20.
Suggestions: thoroughly clean oil injector with special cleaning analyzer for each 20000kM.
Diagnosis flowchart for oil injector
1. Close ignition switch and disconnect joint of oil ejector; connect voltmeter
to No. 1 terminal of the first cylinder ejector and earth between; switch on
ignition switch, and observe voltage of No. 1 terminal of oil ejector is 12V
Y instantaneously? For other oil ejectors, same steps.
Y
2. Repair earthing, short circuit and open circuit between main relay, oil
pump relay, oil ejector
3. Check lines between oil ejector and ECU terminal (17-2) are open Y
circuited, shorted to ground or to power source? Repairs
4. Close ignition switch, and remove joint of oil ejector: measure resistance
N of each oil ejector is lower than 15.95 one by one with ohmmeter?
Y 5. Connect oil ejector joint of each cylinder and ground with ohmmeter;
measure resistance between each oil ejector and ground is larger than
1M?
6. Replace oil ejector
7. Replace ECU
Completed
112
No.063 Quick diagnosis for Hall sensor
Hall effect Principle of hall sensor

When the current IS passes
through semiconductor slice,
hall voltage UH will occur at
right-handed rotation direction,
which is proportion to
magnetic field induction B
(vertical to current IS) and
current. Hall voltage is
affected by induction strength
B.
Hall element at (ON) status Hall element at (LOCKED)
status
Low
High
level
level
UV UV
UA output voltage
UV input voltage
113
Diagnosis flowchart for Hall sensor (ignition distributor)

1. Remove hall sensor, and measure resistance between
N terminal C of sensor joint and ground is between 0-2?
2. Ignition switch turned on, but unable to start the engine:

N measure voltage between terminal 3 and ground is between
1.0-1.5V?
N 3. Close ignition switch and remove ECU joint; measure

resistance between terminal 1 of sensor joint and lines terminal
48 of ECU joint is between 0-2?
N 4. Measure resistance between terminal 1 of sensor joint and

ground is infinitely large?
5. Connect all joints, and clear malfunction code; as road testing, N Troubleshooting tip
malfunction code is displayed?
Y
6. Replace hall sensor, and confirm malfunction code still exists
after repairs are completed?
7. Repair open circuit of lines between sensor and ground, and

confirm repairs are completed?
8. Repair problems such as open circuit or shorted to ground of

lines between sensor and ECU, and confirm repairs are
completed?
9. Repair problems such as open circuit between sensor and ECU,

and confirm repairs are completed
10. Replace ECU
114
No.064 Electric fuel pump EKP
1. Oil pump end

cover
2. Armature
3. Oil duct
4. Impeller
Function: Transfer fuel from oil tank to the engine, and provide sufficient fuel pressure and rich
fuel.
Principle: Fuel pump is vane pump driven by DC motor, and placed within oil tank and
immerged by fuel, using fuel for heat emission and lubrication. The battery supplies power to
electric fuel pump through oil pump relay, which will only switch on lines of electric fuel pump
when started and the engine is running. When the engine stops running due to accidents, fuel
pump will stop running automatically.
Mounting position: Within fuel tank.
Malfunction: Large running noise, poor acceleration, unable to startup (difficulty startup), etc.
General causes: Due to uses of poor quality fuel, it will cause: 1. formation of insulating layer due
to colloid accumulation; 2. locking of oil pump bushing and armature; 3. corrosion of oil level
sensor elements, etc.
Maintenance precautions: 1. according to needs of the engine, electric fuel pump is with different
flows. Even mountable fuel pump with the same appearance is not proper. For maintenance,
number of part of fuel pump shall be consistent with original one; 2. to prevent damages of fuel
pump, do not operate it under dry condition for a long time; 3. if fuel pump is to be replaced,
clean fuel tank and pipes and replace fuel filter.
connected to two pins of fuel pump, and measure internal resistance, which shall not be zero or
infinite (i.e. non-short-circuited, off state).
(connect the connector) for oil return system, connect the fuel pressure gauge at oil sucker, and
start the engine, making it operate at idling speed status. Fuel pressure of the engine shall be
around 260kPa at this time; take out vacuum tube of fuel pressure regulator, and fuel pressure
shall be around 300kPa at this time.
115
Diagnosis flowchart of oil pump circuit

Y
1. Check fuse of oil pump relay is open circuited?
N 2. Close inigtion and remove fuel pump relay: ignition switched on, and
voltage of terminal 85, 30 of relay is larger than 10.7V?
N 3. Remove ECU joint, and measure resistance of lines between ECU

terminal 3 and fuel pump relay is lower than 0.5?
Y
N
4. Measure resistance between ECU terminal 3 and ground is infinitely
large?
Y
N 5. Measure resistance of relay coil (85-86) is about 80-90?
N 6. Check lines between fuel pump and fuse, and oil pump relay are
normally connected?
Y
7. Replace ECU and confirm repairs are completed.
8. Repair shorted to ground of fuse of fuel pump relay, and confirm Y

repairs are completed?
9. Repair malfunctions such as open circuit, short circuit of relay, fuse, Y

power supply, and confirm repairs are completed?
Y
10. Repair short circuit of lines between relay and ECU, and confirm
repairs are completed?
Y
11. Replace oil pump reay, and confirm repairs are completed? Repairs
116
No.065 Fuel pressure regulator DR
Function: For oil return system, fuel pressure regulator is used for regulating fuel pressure of
fuel system, making difference with pressure of intake manifold kept at a constant value.
Principle: This pressure regulator is diaphragm type overflow valve. when system fuel pressure
is increased, oil pressure within oil inlet exceeds resultant force of pre-tightening force of the
spring and air pressure within spring chamber, the diaphragm will be jacked, and valve will be
opened. Fuel is returned to fuel tank through oil return port in center of pressure regulator, and
fuel pressure dropped, till the valve is closed.
Mounting position: Installed at fuel distribution pipe for oil return system.
Malfunction: Fuel pressure too low or too high, difficult to startup, etc.
General causes: Due to uses of poor quality fuel, it will cause: 1. blocked filter screen; 2. foreign
substances causing large leakage. In addition, manually mechanical damages, etc. Maintenance
precautions: during maintenance: 1. do not impact diaphragm element by high pressure gas; 2.
do not clean it with strong corrosive liquid; 3. deformation is not allowed due to outside force.
Simple measuring method: For oil return system, connect fuel pressure gauge at oil sucker, and
start the engine, making it operate at idling speed status. Fuel pressure of the engine shall be
around 260kPa at this time; take out vacuum tube of fuel pressure regulator, and fuel pressure
shall be around 300kPa at this time.
117
Diagnosis flowchart of fuel regulation

1. With the engine running at 1200rpm under normal temperature,
N check voltage of oxygen sensor displayed is kept at lower than 0.275V
with the diagnosis instrument?
2. Remove joint of oxygen sensor, and check its voltage is between

0.35-0.55V with the engine under idling speed?
N Y
3. Check two lines connecting oxygen sensor (10-3; 28-4) are with
REPAIR
open circuit, shorted to ground or shorted to voltage source?
4. Check voltage of oxygen sensor displayed is kept larger than 0.75V

N
with the diagnosis instrument?
5. Remove joint of oxygen sensor, and its voltage is lower than 0.35V
Y
with the diagnosis instrument? To troubleshooting tip
6. Remove oxygen sensor
7. Repair short circuit or open circuit
Completed
118
No.066 Oxygen sensor LSH
1 cable conductor 2 disk washer, 3 insulating bushing,

4 protective sleeve, 5 clamping connector of heating
element
6 heating rod, 7 contact gasket 8 sensor seat, 9
ceramic probe, 10 protective tube
Function: Measure oxygen contents of engine exhaust, and determine gasoline and air are
fully burnt. And electronic controller realizes closed-loop control using excess air coefficient =1
as the goal according to this information, to ensure maximum conversion efficiency of three-way
catalytic converter on three pollutants such as HC, CO and Nox from the exhaust.
Principle: Sensing element is ceramic tube, to exhaust externally and to atmosphere internally.
When temperature of sensing ceramic tube reaches 350, it is with solid electrolyte. With this
feature, convert concentration difference of oxygen to potential difference, reaching output of
electrical signal. If mixture gas is too thick, concentration difference of oxygen in and out of
ceramic tube is high, and potential difference is also high. And a great amount of oxygen is
moved from inner side to outer side, and output voltage is high (close to 900mV); if mixture gas is
too thin, concentration difference of oxygen in and out of ceramic tube is low, and potential
difference is also low. And only a small amount of oxygen is moved from inner side to outer side,
and output voltage is low(close to 100mV).
Mounting position: Installed at front of exhaust pipe.
Malfunction: poor idling speed, poor acceleration, tail gas exceeding standard, oil consumption
too large, etc.
Installation torque: 40~60 NM
General causes: 1. wet water vapor enters to inner of sensor, and temperature changes
suddenly and probe is broken; 2. oxygen sensor poisoning.( Pb, S, Br, Si ).
Maintenance precautions: do not use cleaning liquid, oily liquid or volatile solid at oxygen sensor
during maintenance.
connected to 1# (white), 2# (white) pins of sensor, and resistance is 1~6 under normal
temperature.
(connect the connector) under idling speed status, when oxygen sensor reaches working
temperature of 350, place digital multimeter to DC voltage position, and two pens are
respectively connected to 3# (grey, 4# (black) pins of sensor, and voltage shall fluctuate quickly
between 0.1-0.9V.
119
Diagnosis flowchart of oxygen sensor
Y 1. Connect the diagnosis instrument, and start the engine to water temperature
80. Observe voltage of sensor signal is between 0.2-0.8?
N 2. Check two lines connecting oxygen sensor (sensor 4-ECU28, sensor 3-ECU10)
are with open circuit, shorted to ground or power source (1.098V for shorted to Y
power source, 0.092 for shorted to ground)
3. Close ignition, and plug in controller. Connect voltmeter to two white conductors of N
oxygen sensor, and the engine is started and running at idling speed, and check
value displayed at voltmeter is between 12-14V?
4. Close ignition and remove connection of socket connector of oxygen sensor.

N Connect two white conductors of oxygen sensor with multimeter, and check resistance
is between 0.5-20ohm? Note: this value is related to temperature.
5. Close ignition and remove connection of socket connector of oxygen sensor.

N Measure resistance of signal line (black) and signal cathode conductor (grey) of the
sensor is within the following range: 30M at -20; 10M at 350; 100K at
850.
6. Close ignition and take out controller plug. Remove connection of socket connector N
of oxygen sensor, and connect the multimeter, and check resistance of cathode
conductor is 0.5?
7. Steps same as 6; connect the multimeter to another terminal, andcheck resistance No

Repairs
of anode conductor is 0.5?
N 8. Close ignition, plug in controller, and remove connection of socket connector of

oxygen sensor. Connect black and central earthing with the voltmeter, with ignition
turned on. Observe reading of voltmeter is between 0.4-0.6V?
Replace oxygen sensor, and confirm repairs
Replace ECU
Completed
120
No.067 JL376/378QE engines electric control system check
Testing
Testing terminal Component, part check Preparations for testing conditions Rated value
step
Ignition closed, take out plug of controller, and intake pipe in front of throttle valve is sealed with
proper materials. Take out connecting pipe of canister control valve of throttle vavle body.
01 Sealing of intake system No generation of bulb
Apply compressed air, and make pressure within intake pipe as about 1-2bar. Check liquid
leaking, and check all sealing seams. After check, reassemble connecting pipe of canister
Ignition closed, take out plug of controller, and connect pressure gauge at fuel high-tension
loop. Take out fuel return pipe of the pressure regulator, and install auxiliary hose on the
02 Fuel device connector of pressure regulator. And auxiliary hose leads to one proper barrel (with capacity of
at least 2 liters). 46 and 3 pins on the controller are earthed at the same time, making oil pmp
rotate 30 seconds.
02.1 Oil supply of fuel pump Carry out same as step 02 700-1000ccm
02.2 Fuel pressure Carry out same as step 02 2.83 bar
Remove auxiliary hose, and connect return pipe to oil tank, and ignition is switched on, and 3
02.3 Oil return pipe and 46 terminals of controller plug are earthed (with auxiliary cable). Read out pressure of Max. 2.93.1 bar
pressure gauge, and disconnect earth connection, and ignition is closed.
After about 10 seconds, read pressure of the monograph again, and record dropped value of
02.4 pressure maintenance 0.2-0.3 bar
the pressure.
About 2.5 bar,

Plug in the controller, and the engine will start and operate at idling speed. Record fuel
pressure regulator
02.5 pressure at idling speed, and increase the throttle, and meanwhile observe pressure gauge,
function
and pressure must be increased
About 2.8 bar
Ignition closed, and take out controller plug, and connect the voltmeter to plug of fuel pump,
02.6 Power supply of fuel pump and make 3 and 46 terminals of controller plug earthed at the same time (with auxiliary cable). Min. 10.7V
And fuel pump must be operating, and read out power supply voltage.
121
Voltage drop of anode

02.7 Same as description of 02.6, but multimeter placed to another terminal. Max. 0.5V
side
Voltage drop of cathode

02.8 Same as description of 02.6, but multimeter placed to another terminal. Max. 0.5V
side
02.9 Total value of voltage drop Values calculated based on 02.7 and 02.8. Max. 0.8V
Earth connection of
03.0 constant anode to Ignition closed, take out controller plug and connect multimeter
controller
Constant anode, earthing

03.1 182 Carry out same as step 3.0 About 12V
terminal 2

03.2 18. 14 Carry out same as step 3.0 About 12V
terminal 14
03.3 18 19 Carry out same as step 3.0 About 12V
terminal 19
03.4 1824 Carry out same as step 3.0 About 12V
terminal 24
Anode to controller earth
04.0 connection, voltage drop Ignition closed, take out controller plug, load resistance and voltmeter connection 0.3V
ignition switch
04.1 B+ 18 Voltage drop terminal 18 Load resistance terminal 18 and 2 03V
04.2 B- 2 Earth wire terminal 2 Load resistance terminal 18 and 2 03V
04.6 B+ 27 Voltage drop terminal 27 Load resistance terminal 18 and 27, ignition turned on 03V
04.7 B+ 37 Voltage drop terminal 37 Load resistance terminal 18 and 37, ignition turned on 03V
05.1 Hall sensor 1...3 Power supply hall sensor Ignition closed, controller plug inserted. Connect voltmeter, and turn on ignition. About 5
122
Close ignition, insert controller plug and connect voltmeter. Take out socket connector of
When replacing shading
ignition coil with ignition switch, and take out distributor cover. With ignition turned on, slowly
05.2 Hall sensor 1...2 Hall sensor signal rotor, one voltage larger
rotate belt pulley of engine crankshaft manually, and observe shading rotor of measuring
than 2V must be displayed
instrument and hall sensor.
Hall sensor based on To anode conductor
05.3 Close ignition, take out controller plug and connect the multimeter. 0.5
terminal 12 and ECU connection of hall sensor
Hall sensor based on To cathode conductor

05.4 Same as Step 5.3, with multimeter connected to another terminal 0.5
terminal 48 and ECU connection of hall sensor
Connection from hall

Hall sensor based on
05.5 sensor to controller Same as Step 5.3, with multimeter connected to another terminal 0.5
terminal 49 and ECU
conductor
Pressure sensor terminal power supply from intake Ignition closed, and connect controller. Connect the voltmeter to plug of pressure sensor, and
06.1 5
3...1 pipe pressure sensor ignition turned on
Pressure sensor terminal Intake pipe pressure

06.2 Same as Step 6.1, with voltmeter connected to another terminal 38V 4.2V
4...1 sensor signal
Intake pipe pressure

Pressure sensor terminal 10.8V
06.3 sensor signal when the Same as Step 6.2, with engine running at idling speed
4...1 1.3
engine is no-load running
Intake pipe pressure
Pressure sensor terminal
06.4 sensor signal when Same as Step 6.2; step on the throttle, and observe voltmeter
4...1
increasing throttle
Anode conductor
06.5 connection to pressure Ignition closed, take out controller plug, and connect resistance and measure 0.5
3 and ECU terminal 12
sensor
Cathode conductor
06.6 connection to pressure Same as Step 6.5; connect multimeter 0.5
sensor
Pressure sensor terminal Signal conductor

06.7 Same as Step 6.5; connect multimeter 0.5
4 and ECU terminal 7 connection to controller
Pressure sensor terminal Power supply from intake Close ignition, connect controller plug, and take out connection of socket connector of pressure
07.1 About 5V
1...2 temperature sensor sensor, and connect voltmeter to plug of pressure sensor, ignition
Pressure sensor terminal Intake temperature sensor
07.2 Same as Step 07.1, connect plug of pressure sensor. Note: this value is related to temperature 0.53V
1...2 signal
Pressure sensor terminal Intake temperature sensor Close ignition, take out plug of pressure sensor. Connect multimeter of pressure sensor. Note:
07.3 At 20
1...2 resistance this value is related to temperature
123
Pressure sensor terminal Intake temperature sensor

07.4 Close ignition, take out controller plug, and connect multimeter 0.5
2 to controller terminal 44 signal conductor
Throttle position sensor Power supply from throttle
08.1 Close ignition, connect controller plug, and connect voltmeter, ignition turned on About 5V
terminal 1..2 sensor
Throttle sensor signal
Throttle position sensor voltage, throttle closed,
08.2 Same as Step 8.1, voltmeter connected to throttle, closed 0.10.9V
terminal 2..3 throttle sensor signal
voltage
Throttle position sensor
08.3 Throttle all opened Same as Step 8.2, whole throttle opened 3.04.8V
terminal 2..3
Throttle sensor signal
voltage inspection. Note:
Throttle position sensor Same as Step 8.2, but connect one oscillograph to replace voltmeter, with throttle quickly Oscillograph without
08.4 this inspection only
terminal 2..3 opened and closed sever voltage interference
possible with connecting
one oscillograph
Throttle position sensor Connection between
08.5 terminal 1 and ECU anode conductor to Close ignition, take out controller plug, and connect resistance and measure 0.5
terminal 12 throttle sensor
08.6 Throttle position sensor Connection between
terminal 2 and ECU cathode conductor to Same as Step 8.5, with multimeter connected to terminal 0.5
terminal 30 throttle sensor
08.7 Throttle position sensor
Signal conductor to
terminal 3 and ECU Same as Step 8.5, with multimeter connected to terminal 0.5
controller conductor
terminal 53
09.1 Knocking sensor terminal Cathode conductor to
Close ignition, take out controller plug, and connect multimeter 0.5
2 and ECU terminal 30 controller conductor
09.2 Connection between
Knocking sensor terminal
signal conductor to Same as Step 9.1 0.5
controller
09.3 Knocking sensor terminal Shielded conductor
Same as Step 9.1, with multimeter connected to another terminal 0.5
3 and ECU terminal 19 connection
09.4 Knocking sensor terminal Internal resistance of
Disconnect socket connector of knocking sensor, and connect multimeter 4.55.5V
12 knocking sensor
10.1 Oxygen sensor terminal Power supply for heating Close ignition, plug in controller, with voltmeter connected to two white conductors connecting
12...14V
12 element of oxygen sensor to socket connector of oxygen sensor, and start the engine to be running at idling speed
10.2 Oxygen sensor terminal Internal resistance of PTC Close ignition, and disconnect socket connector of oxygen sensor, and connect multimeter to
0.2...20
12 heating element two white conductors of oxygen sensor. Note: this value is related to temperature.
10.3 Oxygen sensor 12 Current consumption of Close ignition, ampere meter with suitable commutator conductor, connecting to one white
124
heating element of oxygen conductor. The engine is started and running at idling speed. Note: this value is related to
sensor temperature.
10.4 Oxygen sensor Insulated resistance of Close ignition, disconnect socket connector of oxygen sensor. Measure signal line (black) and 30M at -20; 10M
heating element to signal cathode conductor (grey) of oxygen sensor and two white conductors one by one with at 350; 100K at
primary element multimeter. Note: this value is related to temperature. 850.
10.5 Oxygen sensor Reference voltage of Close ignition, plug in controller, and disconnect socket connector of oxygen sensor, and
controller terminal 10 voltmeter connected to black wire and central earthing, with ignition turned on.
10.6 Oxygen sensor Signal voltage of oxygen Close ignition, and connect socket connector of oxygen sensor. Connect voltmeter to black and Display slowly between
sensor grey cables of oxygen sensor. The engine is started and running at idling speed, and observe 0.20.8V
display of measuring instrument after several minutes.
10.7 Oxygen sensor Close-cycle control of Same as Step 10.6. When swinging at display, take out vacuum hose with fuel regulator and Display stable within short
oxygen sensor, seal it. After inspection, plug in hose at pressure regulator. time. Then re-swing.
interference identification
of signal voltage
10.8 Grey cable Cathode conductor signal Close ignition, take out controller plug, and disconnect socket connector of oxygen sensor, and
connection connect multimeter/
10.9 Oxygen sensor Anode conductor signal Same as Step 10.8; connect multimeter to black cable. After inspection, connect socket
Black cable connection connector of oxygen sensor.
11.1 Cooling liquid temperature Supply voltage of cooling Close ignition, and turn on controller plug. Take out plug of cooling liquid temperature sensor. About 5V
sensor liquid temperature sensor Connect voltmeter and turn on ignition.
11.2 Cooling liquid temperature Note: this value is related Same as Step 11.1, but connecting plug of cooling liquid temperature sensor.
sensor to temperature
11.3 Cooling liquid temperature Connection between Close ignition, take out controller, and take out plug of cooling liquid temperature sensor. <0.5
sensor signal and controller Connect the multimeter.
conductor
11.4 Cooling liquid temperature Connection between Same as Step 11.3, with multimeter connected to another terminal. <0.5
sensor cathode conductor and
controller conductor
12.0 AC ready and AC Close ignition, and take out controller plug. Open knife type panel of controller plug. Plug in
compressor input controller, with voltmeter connected to the following terminals.
12.1 18...41 AC ready to input The engine is started and running at idling speed. Close air conditioner. About 12V
12.2 18...41 AC ready to input Same as step 12.1, but with air conditioner turned on. About 0V
12.3 18...40 AC compressor input Same as step 12.1, with voltmeter connected to another terminal, and air conditioner closed About 12V
12.4 18...40 AC compressor input Same as step 12.3, but with air conditioner turned on. About 0V
13.1 Ignition coil Power supply from ignition Close ignition, and take out controller plug. Connect voltmeter. Ignition turned on. About 12V
coil (ignition switch)
125
13.2 1...2 Ignition coil source input Same as Step 13.1, with voltmeter connected to another terminal. About 12V
13.3 Ignition coil connecting Power supply from ignition Close ignition, take out controller plug, and remove connecting conductor of ignition coil
conductor coil (with load) (ignition switch and terminal 1), and connect one load resistance to ignition switch and
connecting conductor of terminal 1. Make bridge connection at controller plug (from 2 to 1. )
13.4 B+ ignition coil Ignition coil voltage F drop Same as Step 13.3. with voltmeter connected to B+ and ignition switch (load resistance). <0.5V
(ignition switch)
13.5 ECU terminal 1 Cathode conductor Same as Step 13.3. with voltmeter connected to controller terminal 1. <0.5V
Ignition coil terminal 1 voltage drop of ignition coil
13.6 Ignition coil Close ignition, and connect connecting conductor of ignition coil. Connect controller plug, and Intense blue spark seen
remove conductor of ignition coil, and connect proper lightening distance, which is adjusted to during lightening
10mm. note: during inspection, do not hold or contact part 1 of ignition device with hands to
operate the starter.
14.1 Ignition coil Closed angle, closed Ignition closed, connect control plug. Connect conductor 4 of ignition coil. Turn on engine
angle control tester of ignition coil and adjust to closed angle for measurement. The engine is started and
running at idling speed. Read out closed angle (measured value of the tester).
14.2 Ignition coil Closed angle, closed Same as Step 14.1, but with rotating speed slowly increased to about 3000rpm. Display value becomes
angle selection larger
14.3 Ignition coil Voltage drop of ignition Same as Step 14.1, with engine tester converted to dynamic voltage drop for measurement.
final stage. Note: this
measurement is only valid
when using proper
measuring instrument.
14.4 Ignition coil Voltage drop of ignition Same as 14.2, but with engine slowly increased to about 3000rpm.
final stage. Note: this
measurement is only valid
when using proper
measuring instrument.
15.1 Ignition distributor Basic arrangement of Ignition closed, take out plug of hall sensor. The engine is placed at top dead center of the For basic adjustment, mark
distributor first cylinder (not rotating at camshaft). Take out ignition distributor cover, and evaluate marking on the distributor cover fit
position of distributor rotor. with distributor rotor center.
15.2 Ignition timing correction Distributor arrangement Ignition closed, connect plug of hall sensor, and install ignition distributor cover. optical disc Ignition time 6.75
of distributor lamp of tong sensor is connected to ignition conductor of the first cylinder. crankshaft angle (mark)
Note: when engine tester is with dead center sensor, tong sensor is not needed to connect.
With the engine under hot running, temperature of cooling liquid is larger than 80. Connect
the diagnosis instrument, and choose ignition correction function, and at this point idling speed
could be increased to about 1500rpm. If with ignition correction line (terminal 51), it could be
selected. Ignition correction line (terminal 51) is earthed.
15.4 Ignition conductor of Digital idling-speed With the engine under hot running at idling speed, measure ignition advance angle. And When electric instruments
induction thong (the first stabilization function connect electric instruments as much as possible, such as heating pad, high beam. And are turned on, adjust
cylinder) or top dead observe ignition mark or ignition angle display of engine tester. ignition timing quickly.
126
center sensor
16.1 Conductor connection of Close ignition, and take out controller plug. Remove fuse of oil pump and heating element of About 12V
oil injector of the first oxygen sensor. Bridge connection with terminal 14, 3 and 46. Connect 2 (-) and 17 (+) with
cylinder voltmeter.
16.2 Conductor connection of Same as 16.1, with voltmeter connected to 2 (-) and 16 (+). About 12V
oil injector of the second
cylinder
16.3 2...35 Conductor connection of Same as 16.1, connect 2 (1) and 35 (+) with voltmeter About 12V
oil injector of the third
cylinder
16.4 2...34 Conductor connection of Same as 16.1, connect 2 (1) and 34 (+) with voltmeter About 12V
oil injector of the fourth
cylinder
17.1 B+...+EVl Power supply under load Close ignition, and take out controller plug. Remove all plugs of oil injector. Connect load 0.5V
resistance to the first cylinder and terminal 14. voltmeter connects to positive connection of B+
and load resistance. Remove fuse of oil pump and heating element of oxygen sensor, with 2
bridge connected to 3 and 46.
17.2 B+...+EV2 Power supply under load Same as 17.1, switching with another terminal for load resistance and voltmeter to positive 0.5V
conductor (connecting plug for cylinder oil injector at cable side)
17.3 B+...+EV3 Power supply under load Same as above-mentioned, but for cylinder 3 0.5V
17.4 B+...+EV4 Power supply under load Same as above-mentioned, but for cylinder 4 0.5V
19.5 EV4+... Startup control Close ignition, and switch on controller plug. Connect closed angle tester to oil injector of fourth 25...35
Note: this measuring cylinder with switching conductor. Remove fuse of oil pump. Remove conductor of ignition coil 10...20
instrument could be used (ignition switch). Remove plug of cooling liquid temperature sensor and connect one resistance 58
at each oil injector. with 30 thousand ohm to replace NTC. Operate starter for about 15 seconds, and observe
display of closed angle tester. Display when startup:
Display after startup for about 5 seconds:
Display after startup for about 10 seconds:
20.1 4...26 Internal resistance of Close ignition, take out controller plug, and connect the multimeter. Note: resistance is related 3595 ohm
stepper motor to temperature.
20.2 21...29 Internal resistance of Close ignition, take out controller plug, and connect the multimeter. Note: resistance is related 3595 ohm
stepper motor coil to temperature.
20.3 4 stepper motor Conductor connection Same as 20.1, take out plug of stepper motor, with the multimeter switched to corresponding 0.3ohm
terminal B terminal.
terminal C terminal.
127
terminal D terminal.
terminal A terminal.
20.7 Stepper motor Control Close ignition, turn on controller plug and turn on speed counter. Connect the tester to stepper About
motor with switching conductor. The engine is started and running at idling speed. Display on 850rpm
the speed counter: 6080 step
Display on the closed angle tester:
20.8 Stepper motor Idling speed governing Same as 20.7, electric instruments such as heating pad shall be exact and turned on at the Rotating speed quickly
function same time. In case of servo steering, rotate to stopper and stop when the vehicle is at rest. reduced under the load,
Observe display on the speed counter and closed angle tester. then increased to starting
value
20.9 Stepper motor Basic governing of idling Same as 20.7, the engine is still warm, and close all current consumption instruments. Connect Adjusted value
speed diagnosis instrument and choose basic governing function. Choose maintenance connector
terminal. and make terminal 39 (controller) earthed. Observe display on the speed counter and
closed angle tester. Adjust bypass bolt. Running at idling speed.
21.1 51... Connection between Close ignition, take out controller plug and connect the multimeter. 0.5ohm
ignition correction
conductor to controller
(terminal 51) conductor
22.1 55... Connection between fuel Close ignition, take out controller plug and connect the multimeter. 0.50ohm
conductor to controller
(terminal 55) conductor
23.1 3...2 Fuel pump relay control, Ignition closed, take out controller plug. Take out casing of controller plug, and turn on About 12V
final stage controller plug, with voltmeter connected to terminal 1 and 2. ignition turned on, and starter
not started.
23.2 3...2 Fuel pump relay control, Same as 23.1, but engine started and running at idling speed. 0.5...2.0V
driver stage
128
No.068 Diagnosis and solution of common malfunctions of JL376/378QE engines electric control system
Serial No. Malfunction Display by diagnosis instrument Analytic procedure Causes Measures
After startup, flame out

after about 10s at idling integral quantity exceeding lower limit Obviously oil injection not normal; check ECU malfunction; malfunction
1. speed. Hard to start again, oil injection correction: -25% hardware of oil supply system is working disappears after replacement Replace ECU
and flame out when voltage of oxygen voltage is 800mv normally of ECU
throttling up the engine
Unable to startup (started Key placed to the second position, and

Diagnosis instrument ON, but unable to Fuse broken, causing ECU27
2. before); normally started check ECU27 pin is with 12V voltage, 19 Replace fuse
communicate with ECU pin without voltage
once during exhaust pin is connected to vehicle body
Electric injection system without power Fuse broken, causing ECU18

3. Unable to startup Diagnosis instrument without display supply pin without power supply Replace fuse
check ECUl8 pin is with 12V voltage, 19 voltage
pin is connected to vehicle body
Startup with burning, and Two malfunctions: Measure connections between

ECUl2 pin not ON with
flame out immediately after - Throttle valve position sensor shorted above-mentioned sensors and ECU, and
4. above-mentioned sensors, Replace harness
engines rotating speed to earth connections among them and with the
but ON with hall element
rises - Pressure sensor shorted to earth ground with multimeter.
Instable idling speed, but

5. actually operation very / / / /
normal
Instable idling speed,

Self-learning of stepper motor Flame out, wait for 10s, and
6. sometimes high and / Not malfunction
not completed re-start
sometimes low
Without malfunction. When the motor is

7. Unable to start working, diagnosis instrument displays Check hall element is working normally Hall element 48 pin broken Improve harness quality
that rotating speed of the engine is 0rpm
Oil pump relay is with closing sound, but Check fuse or lines from oil
8. Unable to start Without malfunction.
oil pump not working normally pump relay to oil pump
129
No.069 Flashing code list of M1.5.4 series
Serial Malfunction Malfunction

Designation of malfunction code Flashing code
No. type lamp
1 Knock sensor (zero measuring testing status) 1 1 1
2 Malfunction-free 11 - -
3 Temperature sensor of AC condenser 13 1 0
4 Throttle valve position sensor 14 1 1
5 Condensing sensor 15 2 1
6 Intake pressure sensor 16 1 1
7 oxygen sensor 17 1 1
8 Intake temperature sensor 18 1 1
9 Cooling liquid temperature sensor 19 1 1
10 Oil injector-4 cylinders 21 1 1
11 Oil injector-1 cylinder 22 1 11
14 Canister control valve 25 1 1
15 Correction coefficient of air fuel ratio control 31 2 0
16 Maximum speed limit of the engine 33 2 0
17 Electronic control unit 34 2 1
Addition correction self-learning of air fuel ratio control (work when

18 35 2 0
under idling speed range)
130
Multiplication correction self-learning of air fuel ratio control (work

19 36 2 0
when under driving conditions)
20 Addition correction self-learning of air leakage of air fuel ratio control 37 2 0
21 Battery 38 2 0
22 Vehicle speed signal 41 2 0
23 Cooling fan relay 42 1 1
24 Cylinder signal 43 2 0
25 Malfunction indicating lamp 45 1 0
26 Speed governor driver stage 1 61 1 1
27 Speed governor driver stage 2 62 1 1
Malfunction type: : 1 broken circuit or short circuited to ground or power source 2 signal
overrun
Malfunction lamp: : 1ON 0 OFF
Steps for reading flashing code:
1. Switch on ignition switch of the engine, but unable to start the engine.
2. Connect K line (ECU-55# or OBD diagnosis connector -7#) to earth, and the time exceeds
2.5 seconds.
3. Malfunction stored in the malfunction memorizer is output in flashing mode through
malfunction indicating lamp.
4. Each flashing code is made up of 2 numbers, and each number is made up of 0 or 1-9.
5. Number 0 flashes ten times, and numbers 1-9 flash respectively 1-9 times; interval of two
numbers pauses (one second) when flashing, and neighboring malfunction code will pause for
long time (3 seconds).
6. The same malfunction code flashes continuously for 3 seconds. And all malfunction codes
flash continuously, till the engine is started or reading action of malfunction terminates.
7. If there is no malfunction stored within malfunction memorizer, then without malfunction
flashes, i.e. 11.
131
Diagnosis flowchart of M7.9.7 system of 479Q/QA/481Q according

to malfunction code
Description: 1. check the following only when confirmed as current stable status malfunction;
otherwise it will cause incorrect diagnosis.
2. Multimeter mentioned hereinafter refers to digital multimeter. Do not use pointer type
multimeter to check lines of electric injection system.
3. Check vehicles with burglary protection system. If ECU to be replaced in the Follow-ups,
make programming to ECU after replacement.
4. For this project: When P0171, P0172, P0335, P0336, P1651 malfunction codes exist,
engines malfunction lamp is not ON.
5. If malfunction code indicates voltage of certain circuit is too low, it means that this circuit may
be shorted to ground; if malfunction code indicates voltage of certain circuit is too high, it means
that this circuit may be shorted to power source; if malfunction code indicates certain circuit is
malfunction, it means that this circuit may be opened or there is malfunction to many lines.
Diagnosis help: 1. Malfunction code could not be eliminated, malfunction is stable status
malfunction; if chance failure, mainly check harness connector is loosening.
2. No unusual conditions are found after inspection according to above-mentioned steps;
3. During inspection, pay attention to effect of automobile maintenance, cylinder pressure,
mechanical ignition timing on the system;
4. Replace ECU and test it. If malfunction code could be eliminated at this point, then malfunction
part is located in ECU; if not eliminated, replace for original ECU, and repeat the flowchart, and
recheck it.
No.070 Malfunction code: P0107 "voltage of intake pressure sensor
circuit too low"
Serial
Operation steps Results Follow-ups
No.
1 Switch on diagnosis instrument and commutator, and place ignition switch to ON. Next step
Observe inlet pressure of data flow, and check value is around 101kpa (specific Yes To step 5
2
value related to the air pressure at that time).
No Next step
Take out the connector of intake pressure sensor of the harness, and check voltage Yes To step 5
3
between 3# and 1# pins of this connector is around 5V with multimeter.
No Next step
Repair or replace
Yes
Check lines respectively between 17#, 33#, 37# pins of ECU and 1#, 3#, 4# pins of harness
4
sensor connector are shorted to ground.
No Next step
Start the engine and make it operate at idling speed. Step the throttle slowly to be
close to full opening, and observe changes of value of inlet pressure on the Yes Diagnosis help
5 diagnosis instrument, and values shall not be largely changed at this time; step the
throttle quickly to be close to full opening, and value shall reach above 90kpa
No Replace sensor
immediately at this time.
132
No.071 Malfunction code: P0108 "voltage of intake pressure sensor

circuit too high"
Serial
No.
1 Switch on diagnosis instrument and commutator, and place ignition switch to ON. Next step
Yes To step 5
Observe inlet pressure of data flow, and check value is around 101kpa (specific
2
value related to the air pressure at that time).
No Next step
Yes To step 5
Take out the connector of intake pressure sensor of the harness, and check voltage
3
between 3# and 1# pins of this connector is around 5V with multimeter.
No Next step
Repair or
Yes
Check lines respectively between 17#, 33#, 37# pins of ECU and 1#, 3#, 4# pins of replace harness
4
sensor connector are opened or shorted to power source.
No Next step
Start the engine and make it operate at idling speed. Step the throttle slowly to be Yes Diagnosis help
close to full opening, and observe changes of value of inlet pressure on the
5 diagnosis instrument, and values shall not be largely changed at this time; step the
throttle quickly to be close to full opening, and value shall reach above 90kpa
immediately at this time. Replace sensor
No
No.072 Malfunction code: P0112 "temperature indicated by intake

temperature sensor too low"
Serial No. Operation steps Results Follow-ups
Switch on diagnosis instrument and commutator, and place ignition switch

1 Next step
to ON.
Observe intake temperature of data flow, and check it is equal to Yes To step 5
temperature within air inlet pipe (specific value related to engine
2
temperature at that time). Note: if value is -40 at this point, then
disconnection malfunction may occur to lines. No Next step
Take out connector of intake temperature sensor of the harness, and check Yes Next step
resistance between 1# and 2# pins of sensor is suitable to its temperature
3
with multimeter (for details, refer to related parts of this maintenance
manual). No Replace sensor
Take out connector of intake temperature sensor of the harness, and check Yes To step 5
4
voltage between 1# and 2# pins of this connector is around 5V.
No Next step
Repair or replace
Check lines between 17#, 40# pins of ECU and 1#, 2# pins of sensor Yes harness
5
connector are opened or shorted to power source.
No Next step
Start the engine, and make it operate at idling speed. Observe changes of
6
values of intake temperature on the diagnosis instrument, and values shall Yes Diagnosis help
rise as temperature of cooling liquid of the engine rises at this time
133
No Replace sensor
No.073 Malfunction code: P0113 "temperature indicated by intake

temperature sensor too high"

1 Next step
to ON.
Observe intake temperature of data flow, and check it is equal to Yes To step 5
temperature within air inlet pipe (specific value related to engine
2
temperature at that time). Note: if value is -40 at this point, then
disconnection malfunction may occur to lines. No Next step
Take out connector of intake temperature sensor of the harness, and check Yes Next step
resistance between 1# and 2# pins of sensor is suitable to its temperature
3
with multimeter (for details, refer to related parts of this maintenance
manual). No Replace sensor
Take out connector of intake temperature sensor of the harness, and check Yes To step 5
4
voltage between 1# and 2# pins of this connector is around 5V.
No Next step
Repair or replace
Yes
harness
Check lines between 17#, 40# pins of ECU and 1#, 2# pins of sensor
5
connector are shorted to ground.
No Next step
Yes Diagnosis help

Start the engine, and make it operate at idling speed. Observe changes of
6 values of intake temperature on the diagnosis instrument, and values shall
rise as temperature of cooling liquid of the engine rises at this time.
No Replace sensor
No.074 Malfunction code: P0117 "temperature indicated by cooling

liquid temperature sensor too low"

1 Next step
to ON.
Observe temperature of cooling liquid of data flow, and check it is equal to

Yes To step 6
2 engine temperature (specific value related to engine temperature at that
time). Note: if value is -40 at this point, then disconnection malfunction
may occur to lines. No Next step
Take out connector of temperature sensor of cooling liquid of the harness, Yes Next step
and check resistance between 1# and 2# pins of sensor is suitable to its
3
temperature with multimeter (for details, refer to related parts of this
maintenance manual). No Replace sensor
4 Take out connector of temperature sensor of cooling liquid of the harness,

and check voltage between 1# and 2# pins of this connector is around 5V. Yes To step 6
134
No Next step
Repair or replace
Yes
harness
Check lines between respectively 39#, 35# pins of ECU and 1#, 2# pins of
5
sensor connector are opened, or shorted to power source.
No Next step
Start the engine, and make it operate at idling speed. Observe changes of Yes Diagnosis help
values of temperature of cooling liquid on the diagnosis instrument, and
6
values shall rise as temperature of cooling liquid of the engine rises at this
time. No Replace sensor
No.075 Malfunction code: P0118 "temperature indicated by cooling

liquid temperature sensor too high"

1 Next step
to ON.
Yes To step 6
Observe temperature of cooling liquid of data flow, and check it is equal to
engine temperature (specific value related to engine temperature at that
2
time). Note: if value is -40 at this point, then disconnection malfunction
may occur to lines. No Next step
Yes Next step

Take out connector of temperature sensor of cooling liquid of the harness,
and check resistance between 1# and 2# pins of sensor is suitable to its
3
temperature with multimeter (for details, refer to related parts of this
maintenance manual). No Replace sensor
Yes To step 6
Take out connector of temperature sensor of cooling liquid of the harness,
4
and check voltage between 1# and 2# pins of this connector is around 5V.
No Next step
Repair or replace
Check lines between respectively 39#, 35# pins of ECU and 1#, 2# pins of Yes harness
5
No Next step
Start the engine, and make it operate at idling speed. Observe changes of Yes Diagnosis help
values of temperature of cooling liquid on the diagnosis instrument, and
6
values shall rise as temperature of cooling liquid of the engine rises at this
time. No Replace sensor
No.076 Malfunction code: P0122 "voltage of throttle valve position

sensor circuit too low"

1 Next step
to ON.
135
Yes Next step

Observe "absolute opening of throttle valve" of data flow, and value is
2
between 4%-10% (specific value depends on vehicle model).
No To step 5
Yes Next step

Step the throttle to full opening and observe "absolute opening of throttle
3 valve" of data flow, and value will be increased to about 85-95% as opening
of throttle valve is increased (specific value depends on vehicle model).
No To step 5
Yes Replace sensor

Repeat Step 3, and observe "absolute opening of throttle valve" of data
4
flow, and value is abruptly changed during changes.
No Next step
Repair or replace
Yes
Take out connector of throttle valve position sensor of harness, and check harness
5 lines between respectively 17#, 32#, 16# pins of ECU and 1#, 2#, 3# pins of
No Next step
Yes Replace sensor

Check voltage between 1# and 2# pins of this connector is around 5V with
6
multimeter.
No Diagnosis help
No.077 Malfunction code: P0123 "voltage of throttle valve position

sensor circuit too high"

1 Next step
to ON.
Yes Next step

Observe "absolute opening of throttle valve" of data flow, and value is
2
between 4%-10% (specific value depends on vehicle model).
No To step 5
Yes Next step

Step the throttle to full opening and observe "absolute opening of throttle
3 valve" of data flow, and value will be increased to about 85-95% as opening
of throttle valve is increased (specific value depends on vehicle model).
No To step 5
Yes Replace sensor

Repeat Step 3, and observe "absolute opening of throttle valve" of data
4
flow, and value is abruptly changed during changes.
No Next step
Repair or replace
Yes
Take out connector of throttle valve position sensor of harness, and check harness
5 lines between respectively 17#, 32#, 16# pins of ECU and 1#, 2#, 3# pins
of sensor connector are opened, or shorted to power source.
No Next step
Yes Replace sensor

Check voltage between 1# and 2# pins of this connector is around 5V with
6
multimeter.
No Diagnosis help
136
No.078 Malfunction code: P0130 "signal circuit of upstream oxygen

sensor malfunction"
(Note: following diagnosis flowchart is applied when P0135 does not occur at the same time; if P0135
malfunctions exist at the same time, deal with P0135 malfunctions, and then check according to the following
flowchart.)

1 Next step
to ON.
Yes Diagnosis help

Start the engine, and make it operate at idling speed, till temperature of
cooling liquid reached normal value. Observe changes of value of voltage
2
of oxygen sensor on the diagnosis instrument, and the value shall be
changed quickly between 100mV~900mV at this time. No Next step
Repair or replace
Check lines respectively between 36#, 18# of ECU and A# (opposed to Yes harness
3 grey connecting line of oxygen sensor), B# (opposed to black connecting
line of oxygen sensor) of sensor connector are shorted to ground.
No Next step
A. Check admission system is severely leaking; Yes Repair accordingly

B. Oil injector is blocked;
4 C. Spark plug is with too large clearance;
D. Resistance of sub live wire is too large;
E. Tube of intake valve is worn; etc. No Diagnosis help
No.079 Malfunction code: P0132 "voltage of upstream oxygen sensor

circuit too high"
flowchart.)

1 Next step
to ON.
Start the engine, and make it operate at idling speed, till temperature of Yes Diagnosis help
2
Yes Repair or replace

Check lines respectively between 36#, 18# of ECU and A# (opposed to
line of oxygen sensor) of sensor connector are shorted to power source. No Diagnosis help
No.080 Malfunction code: P0134 "upstream oxygen sensor signal

malfunction"
flowchart.)
137

1 Next step
to ON.
Start the engine, and make it operate at idling speed, till temperature of Yes Diagnosis help
2
Repair or replace
Yes
Check lines respectively between 36#, 18# of ECU and A# (opposed to harness
line of oxygen sensor) of sensor connector are opened.
No Diagnosis help
No.081 Malfunction code: P0135 "heating circuit of upstream oxygen

sensor malfunction"

1 Next step
to ON.
Take out connector of oxygen sensor of harness, and check voltage Yes Next step
between C# (opposed to white connecting line of oxygen sensor), D#
2
(opposed to white connecting line of oxygen sensor) pins of this connector
is around 12V with multimeter. No To step 4
Yes Next step

Check resistance between C# (white), D# (white) pins of oxygen sensor is
3
between 2~5 under 20 with multimeter.
No Replace sensor
Yes Replace fuse

4 Check 8A fuse of heating circuit of oxygen sensor is blown.
No Next step
Repair or replace
Check lines respectively between 1# pin of ECU, 87# pin of main relay and Yes harness
C# (opposed to white connecting line of oxygen sensor), D# (opposed to
5
white connecting line of oxygen sensor) of sensor connector are opened, or
shorted to power source or ground. No Diagnosis help
No.082 Malfunction code: P0171 self-adapting of closed-loop control

of air fuel ratio shall exceed upper part
(Note: following diagnosis flowchart is applied when malfunction codes such as admission pressure sensor,
canister control valve, oxygen sensor do not occur at the same time; if relevant malfunction codes exist at the
same time, deal with other malfunctions, and then check according to the following flowchart.)
138

1 Next step
to ON.
Yes Next step

cooling liquid reached normal value. Under full condition, observe changes
2
of value of voltage of oxygen sensor on the diagnosis instrument, and
check the value is around 100mV under some conditions for a long time.
No Diagnosis help
Yes Next step

Switch on fuel pressure gauge at oil inlet pipe of fuel system, and observe
3
pressure is around 350kPa under full condition.
No Repair fuel system
Repair or replace
Check lines respectively between 36#, 18# pins of ECU and A# (opposed to Yes harness
line of oxygen sensor) of sensor connector are shorted to power source.
No Next step
A. Check admission system is severely leaking;

Yes Repair accordingly
B. Oil injector is blocked;
5 C. Spark plug is with too large clearance;
D. Resistance of sub live wire is too large;
E. Tube of intake valve is worn; etc. No Diagnosis help
No.083 Malfunction code: P0172 self-adapting of closed-loop control

of air fuel ratio shall exceed lower part
(Note: following diagnosis flowchart is applied when malfunction codes such as admission pressure sensor,
canister control valve, oxygen sensor do not occur at the same time; if relevant malfunction codes exist at the
same time, deal with other malfunctions, and then check according to the following flowchart.)

1 Next step
to ON.
Yes Next step

cooling liquid reached normal value. Under full condition, observe changes
2
of value of voltage of oxygen sensor on the diagnosis instrument, and
check the value is around 900mV under some conditions for a long time. No Diagnosis help
Yes Next step

Switch on fuel pressure gauge at oil inlet pipe of fuel system, and observe
3
pressure is around 350kPa under full condition.
No Repair fuel system
Check lines respectively between 36#, 18# pins of ECU and A# (opposed to
4 grey connecting line of oxygen sensor), B# (opposed to black connecting Yes Repair or replace
line of oxygen sensor) of sensor connector are shorted to power source. harness
139
No Next step
A. Oil injector is leaking; Yes Repair accordingly

5 B. Exhaust pipe is leaking;
C. Ignition timing is incorrectly; etc.
No Diagnosis help
No.084 Malfunction code: P0201 "one-cylinder oil injector circuit

malfunction"

1 Next step
to ON.
Take out connector of one-cylinder oil injector of harness, and check Yes To step 4
2 voltage between 1# pin of this harness and cathode of power source is
around 12V.
No Next step
Repair or replace
Yes
Check lines between 1# pin of connector of one-cylinder oil injector and harness
3
main relay are opened or shorted to ground.
No Next step
Yes Next step

Check resistance between 1# and 2# pins of one-cylinder oil injector is
4
No Replace oil injector
Check voltage between 2# pin of one-cylinder oil injector connector and Yes Diagnosis help
5
cathode of power source is around 3.7V with multimeter.
No Next step
Repair or replace
Yes
Check lines between 2# pin of one-cylinder oil injector connector and 27# harness
6
pin of ECU are opened or shorted to power source or ground.
No Diagnosis help
No.085 Malfunction code: P0202 "two-cylinder oil injector circuit

malfunction"

1 Next step
to ON.
Yes To step 4
Take out connector of two-cylinder oil injector of harness, and check voltage
2
between 1# pin of this harness and cathode of power source is around 12V.
No Next step
Repair or replace
Yes
Check lines between 1# pin of connector of two-cylinder oil injector and harness
3
No Next step
Yes Next step

Check resistance between 1# and 2# pins of two-cylinder oil injector is
4
140
Yes Diagnosis help

Check voltage between 2# pin of two-cylinder oil injector connector and
5
No Next step
Repair or replace
Check lines between 2# pin of two-cylinder oil injector connector and 6# pin Yes harness
6
of ECU are opened or shorted to power source or ground.
No Diagnosis help
No.086 Malfunction code: P0203 "three-cylinder oil injector circuit

malfunction"

1 Next step
to ON.
Take out connector of three-cylinder oil injector of harness, and check Yes To step 4
2 voltage between 1# pin of this harness and cathode of power source is
around 12V. No Next step
Repair or replace
Yes
Check lines between 1# pin of connector of three-cylinder oil injector and harness
3
No Next step
Yes Next step

Check resistance between 1# and 2# pins of three-cylinder oil injector is
4
Check voltage between 2# pin of three-cylinder oil injector connector and Yes Diagnosis help
5
No Next step
Repair or replace
Yes
Check lines between 2# pin of three-cylinder oil injector connector and 7# harness
6
No Diagnosis help
No.087 Malfunction code: P0204 "four-cylinder oil injector circuit

malfunction"
Switch on diagnosis instrument and commutator, and place ignition switch to

1 Next step
ON.
Take out connector of four-cylinder oil injector of harness, and check voltage Yes To step 4
2 between 1# pin of this connector and cathode of power source is around 12V
with multimeter.
No Next step
Repair or replace
Yes
Check lines between 1# pin of connector of four-cylinder oil injector and main harness
3
relay are opened or shorted to ground.
No Next step
4 Check resistance between 1# and 2# pins of four-cylinder oil injector is

Yes Next step
141
Yes Diagnosis help

Check voltage between 2# pin of four-cylinder oil injector connector and
5
No Next step
Repair or replace
Yes
Check lines between 2# pin of four-cylinder oil injector connector and 47# pin of harness
6
ECU are opened or shorted to power source or ground.
No Diagnosis help
No.088 Malfunction code: P0230 "oil pump control circuit malfunction"


1 Next step
to OFF.
Yes To step 4
Take out oil pump relay, and place ignition switch at ON. Check power
2 supply terminal of oil pump relay, i.e. voltage between 30#, ,, , 86#
pins of relay and cathode of power source is around 12V.
No Next step
Repair or replace
Yes
Check lines at power supply terminal of relay are opened or shorted to harness
3
ground.
No To step 2
Replace oil pump

Yes
Check control terminal of oil pump relay with multimeter, i.e. voltage relay
4
between 85# pin of relay and cathode of power source is around 3.7V.
No Next step
Repair or replace
Yes
harness
Check control terminal of relay, i.e. lines between 85# pin of relay and 69#
5
No Diagnosis help
No.089 Malfunction code: P0325 "knock sensor circuit malfunction"

1 Next step
to OFF.
Yes Next step

Take out connector of knock sensor of harness, and check resistance
2 between 1# and 2# pins of knock sensor is larger than 1Mwith the
multimeter.
No Replace sensor
Check lines respectively between 1#, 2# of knock sensor connector and Repair or replace
3 Yes
19#, 20# of ECU are opened, or shorted to power source or to ground. harness
142
No Next step
Yes Diagnosis help

According to the specification, replace knock sensor. Start the vehicle and
4 make rotating speed of the engine exceed 2200 revolutions per minute.
Recheck malfunction code P0325 will appear again. Check as chance
No
failure
No.090 Malfunction code: P0335 crankshaft position sensor signal

malfunction

1 Next step
to OFF.
Yes Next step

Take out connector of speed sensor of harness, and check resistance
2 between 2# and 3# pins of speed sensor is between 770~950 under 20
with the multimeter.
No Replace sensor
Repair or replace
Yes
Check lines respectively between 2#, 3# of speed sensor connector and harness
3
34#, 15# of ECU are opened, or shorted to power source or to ground.
No Next step
Yes Diagnosis help

4 Check signal panel of flywheel is good.
Replace signal
No
panel
No.091 Malfunction code: P0336 crankshaft position sensor signal

with unreasonable malfunction

1 Next step
to OFF.
Yes Next step

Take out connector of speed sensor of harness, and check resistance
2 between 2# and 3# pins of speed sensor is between 770~950 under 20
with the multimeter.
No Replace sensor
Repair or replace
Yes
harness
Check lines respectively between 2#, 3# of speed sensor connector and
3
34#, 15# of ECU are opened, or shorted to power source or to ground.
No Next step
4 Check signal panel of flywheel is good. Yes Diagnosis help
143
Replace signal
No
panel
No.092 Malfunction code: P0340 Phase sensor signal malfunction

1 Next step
to ON.
Yes To step 4
Take out connector of phase sensor of the harness, and check voltage
2
between 3# and 1# pins of phase sensor connector is around 12V.
No Next step
Repair or replace
Yes
Check lines between 3# pin of phase sensor and 87# pin of main relay are harness
3 opened or shorted to earth;
Check 1# pin of phase sensor is poorly earthed.
No Next step
Yes To step 6
Check voltage between 2# pin of phase sensor connector and cathode of
4
power source is about 9.9V.
No Next step
Repair or replace
Yes
harness
check lines between 2# pin of phase sensor connector and 79# pin of ECU
5
are opened or shorted to power source or earth;
No Next step
Yes Diagnosis help

6 Check signal panel of camshaft is good.
Replace signal
No
panel
No.093 Malfunction code: P0342 circuit voltage of phase sensor too

low

1 Next step
to ON.
Yes To step 4
2
No Next step
Repair or replace
Yes
No Next step
144
Yes To step 6
4
No Next step
Repair or replace
Yes
check lines between 2# pin of phase sensor connector and 79# pin of ECU harness
5
No Next step
Yes Diagnosis help

Replace signal
No
panel
No.094 Malfunction code: P0343 circuit voltage of phase sensor too

high

1 Next step
to ON.
Yes To step 4
2
No Next step
Repair or replace
Yes
No Next step
Yes To step 6
4
No Next step
Repair or replace
Yes
harness
check lines between 2# pin of phase sensor connector and 79# pin of ECU
5
No Next step
Yes Diagnosis help

Replace signal
No
panel
145
No.095 Malfunction code: P0443 "Malfunction of control circuit of driver

stage of canister control valve"

1 Next step
to ON.
Yes To step 4
Take out connector of canister control valve of the harness, and check
2 voltage between 1# pin of this connector and cathode of power source is
around 12V with the multimeter.
No Next step
Repair or replace
Yes
Check lines at power supply terminal of canister control valve are opened or harness
3
shorted to ground.
No To step 2
Yes Next step

Check resistance between 1# and 2# pins of canister control valve is
4
between 22~30 under 20with the multimeter.
Replace control
No
valve
Yes Diagnosis help

Check voltage between 1# pin of connector of canister control valve and
5
cathode of power source is around 3.7V with the multimeter.
No Next step
Repair or replace
Yes
Check lines between 2# pin of connector of canister control valve and 46# harness
6
pin of ECU are open shorted.
No Diagnosis help
No.096 Malfunction code: P0444 "voltage of control circuit of driver

stage of canister control valve too low"

1 Next step
to ON.
Yes To step 4
No Next step
Repair or replace
Yes
harness
Check lines at power supply terminal of canister control valve are opened or
3
shorted to ground.
No To step 2
146
Yes Next step

4
Replace control
No
valve
Yes Diagnosis help

5
No Next step
Repair or replace
Yes
harness
Check lines between 2# pin of connector of canister control valve and 46#
6
pin of ECU are shorted to ground.
No Diagnosis help
No.097 Malfunction code: P0445 "voltage of control circuit of driver

stage of canister control valve too high"

1 Next step
to ON.
Yes To step 4
No Next step
Repair or replace
Yes
harness
Check lines at power supply terminal of canister control valve are opened or
3
shorted to ground.
No To step 2
Yes Next step

4
Replace control
No
valve
Yes Diagnosis help

5
No Next step
Repair or replace
Yes
harness
Check lines between 2# pin of connector of canister control valve and 46#
6
pin of ECU are shorted to power source.
No Diagnosis help
147
No.098 Malfunction code: P0480 "malfunction control circuit of cooling

fan relay of AC condenser"

1 Next step
to OFF.
Yes To step 4
Take out cooling fan relay of AC condenser, and place ignition switch at
2 ON, and check voltage between power supply terminal of this relay, i.e.
30# and 85# pins of relay and cathode of power source is around 12V.
No Next step
Repair or replace
Yes
Check lines at power supply terminal of cooling fan relay of AC condenser harness
3
are opened or shorted to ground.
No To step 2
Yes Replace relay

Check voltage between control terminal of cooling fan relay of AC
4 condenser this relay, i.e. 86# pin of relay and cathode of power source is
around 3.7V.
No Next step
Repair or replace
Yes
harness
Check lines between 86# pin of control terminal of relay and 50# pin of ECU
5
are opened or shorted to power source or ground.
No Diagnosis help
No.099 Malfunction code: P0500 "unreasonable malfunction of speed

signal"

1 Next step
to OFF.
Yes Repair ABS system

If vehicle is equipped with ABS system, check ABS system has
2
malfunction code.
No Next step
Yes Next step

3 Check pointer of odometer works normally.
Repair instrument
No
lines
Yes Next step

4 Check speed sensor works normally.
Replace speed
No
sensor
148
Repair or replace
Yes
harness
Check lines between sensor signal line and 59# pin of ECU are opened or
4
shorted to power source or ground.
No Diagnosis help
No.100 Malfunction code: P0506 "idling speed lower than target speed
value"

1 Next step
to OFF.
Yes Next step

Check adjusting screw, throttle dragline and condition of throttle work
2
normally. Repair and
No maintain as
necessary
Yes Next step

3 Check idling speed governor works normally. Repair and
No maintain as
necessary
A. Check pressure of oil supply system is too low; Repair as

Yes
4 B. Check oil injector is blocked; necessary
C. Check the system is well exhausted.
No Diagnosis help
No.101 Malfunction code: P0507 "idling speed higher than target speed
value"
Switch on diagnosis instrument and commutator, and place ignition

1 Next step
switch to OFF.
Yes Next step

Check adjusting screw, throttle dragline and condition of throttle
2
work normally. Repair and maintain as
No
necessary
Yes Next step

3 Check idling speed governor works normally.
Repair and maintain as
No
necessary
Yes Repair as necessary

A. Check the system is exhausted; B. Check oil injector is blocked;
4
C. Check pressure of oil supply system is too high.
No Diagnosis help
No.102 Malfunction code: P0508 "voltage of control circuit of idling

speed governor too low"
149

1 Next step
to ON.
Yes Next step

Take out connector of idling speed governor, and check resistance between
2
A and D, B and C pins is around 535.3 under 20 with the multimeter.
Replace stepper
No
motor
Repair or replace
Yes
Check lines among A, B, C D pins of idling speed governor and 65#, 66#, harness
3
67#, 64# pins of ECU are shorted to ground.
No Diagnosis help

speed governor too high"

1 Next step
to ON.
Yes Next step

2
A and D, B and C pins is around 535.3 under 20 with the multimeter. Replace stepper
No
motor
Repair or replace
Check lines among A, B, C D pins of idling speed governor and 65#, 66#, Yes harness
3
67#, 64# pins of ECU are shorted to power source.
No Diagnosis help
No.104 Malfunction code: P0511 "malfunction control circuit of idling

speed governor"

1 Next step
to ON.
Yes Next step

2
A and D, B and C pins is around 535.3 under 20 with the multimeter.
Replace stepper
No
motor
Repair or replace
Yes
harness
Check lines among A, B, C D pins of idling speed governor and 65#, 66#,
3
67#, 64# pins of ECU are opened.
No Diagnosis help
No.105 Malfunction code: P0560 "unreasonable system voltage signal"

1 Next step
to OFF.
Yes Next step

2 Check battery voltage is around 12V with the multimeter.
No Replace battery cell
150
Repair or replace
Check lines among 44#, 45#, 63# pins of ECU and 87# pin of main relay Yes harness
3
are opened or shorted to ground.
No Next step
Start the engine, and check charging voltage of generator is between 9-16V Yes Next step
4
within different speed range.
No Replace generator
Yes Diagnosis help

5 Check earth point of engine harness is good.
Repair or replace
No
harness
No.106 Malfunction code: P0562 "system voltage too low"

1 Next step
to OFF.
Yes Next step

Repair or replace
Yes
harness
Check resistance of lines between 44#, 45#, 63# pins of ECU and 87# pin
3
of main relay are too large.
No Next step
Yes Next step

Start the engine, and check charging voltage of generator is between 9-16V
4
Yes Diagnosis help

Repair or replace
No
harness
No.107 Malfunction code: P0563 "system voltage too high"

1 Next step
to OFF.
Yes Next step

151
Yes Next step

Start the engine, and check charging voltage of generator is between 9-16V
3
Yes Diagnosis help

Repair or replace
No
harness
No.108 Malfunction code: P0601 "error of check code of electronic

control unit"
1 Switch on diagnosis instrument, and place ignition switch at ON. Next step
Yes Next step

Eliminate malfunction code, and reconfirm this malfunction is stable status
2
malfunction.
No System normal
3 Replace ECU. End
No.109 Malfunction code: P0602 "error of identification code of

diagnosis data of electronic control unit"

1 Next step
to ON.
Yes Next step

Eliminate malfunction code, and reconfirm this malfunction is stable status
2
malfunction.
No System normal
3 Replace ECU. End
No.110 Malfunction code: P0645 "malfunction of relay control circuit of

AC compressor"

1 Next step
to OFF.
152
Yes To step 4
Take out relay of AC compressor, and place ignition switch at ON. Check
2 voltage of power supply terminal of relay, i.e. 30# and 85# pins and cathode
of power source is around 12V.
No Next step
Repair or replace
Yes
harness
Check lines at power supply terminal of relay are opened or shorted to
3
ground.
No To step 2
Yes Replace relay

Check voltage of control terminal of AC compressor relay, i.e. between 86#
4 pin of relay and cathode of power source is around 3.7V with the
multimeter.
No Next step
Repair or replace
Yes
Check lines of control terminal of AC compressor relay, i.e. 86# pin of relay harness
5
and 70# pin of ECU are opened.
No Diagnosis help
No.111 Malfunction code: P0646 "voltage of relay control circuit of AC

compressor too low"

1 Next step
to OFF.
Yes To step 4
No Next step
Repair or replace
Yes
Check lines at power supply terminal of relay are opened or shorted to harness
3
ground.
No To step 2
Yes Replace relay

multimeter.
No Next step
153
Repair or replace
Yes
harness
Check lines of control terminal of AC compressor relay, i.e. 86# pin of relay
5
and 70# pin of ECU are shorted to ground.
No Diagnosis help
No.112 Malfunction code: P0647 "voltage of relay control circuit of AC

compressor too high"

1 Next step
to OFF.
Yes To step 4
No Next step
Repair or replace
Yes
harness
Check lines at power supply terminal of relay are opened or shorted to
3
ground.
No To step 2
Yes Replace relay

multimeter.
No Next step
Repair or replace
Yes
harness
Check lines of control terminal of AC compressor relay, i.e. 86# pin of relay
5
and 70# pin of ECU are shorted to power source.
No Next step
Yes Diagnosis help
6 Check electromagnetic clutch of AC compressor works normally.

Repair or replace
No electro-magnetic
clutch
154

speed governor too high"

1 Next step
to ON.
Take out connector of idling speed governor (EWD) of the harness, and Yes To step 4
2 check voltage between 2# pin of this connector and cathode of power
source is around 12V with the multimeter.
No
Next step
Repair or replace
Yes
Check lines at power supply terminal of idling speed governor (EWD) are harness
3
opened and shorted to ground.
No Next step
Yes Next step

Check resistance between 1# and 2# pins of idling speed governor (EWD)
4
is around 17.6 under 20 with the multimeter.
No Replace EWD
Repair or replace
Yes
harness
Check lines between 1# pin of connector of idling speed governor (EWD)
5
and 26# pin of ECU are shorted to power source.
No Diagnosis help
No.114 Malfunction code: P1651 "malfunction of control circuit of

engine malfunction lamp (SVS)"

1 Next step
to ON.
Carry out action testing on malfunction lamp of the engine via actuator Yes Next step
2 action testing of the diagnosis instrument, and observe it is at OFF status
or ON status.
No System normal
Repair or replace
Yes
Check lines at power supply terminal of malfunction lamp of the engine is harness
3
open circuited or shorted to ground.
No Next step
Repair or replace
Yes
Check lines between pin of control terminal of malfunction lamp and 28# pin harness
4
of ECU is open circuited or shorted to power source or the ground.
No Next step
Yes Diagnosis help

5 Check bulb of malfunction lamp is working normally.
No Replace bulb
155
Diagnosis flowchart of M7 system based on malfunction

Before executing steps of malfunction diagnosis based on malfunction of the engine, carry out
preliminary inspection:
1. Confirm malfunction indicator lamp of the engine is working normally;
2. Check and confirm there is no malfunction information recorded with the malfunction diagnosis
instrument;
3. Confirm malfunction claimed by the vehicle owner exists and confirm conditions why this
malfunction appears. Appearance inspection:
1Check fuel pipe is leaking;
2Check vacuum pipe is broken, kinked, or correctly connected;
3Check inlet pipe is blocked, air leaking, squashed or damaged;
4Check high tension line of ignition system is broken, aging, and ignition sequence is correct;
5Check earthing location of harness is clean, firm;
6Check connector of each sensor, actuator is loosening or poorly contacted. Important: in
case of above-mentioned malfunctions, carry out care and maintenance accordingly, otherwise it
will affect following malfunction diagnosis and maintenance.
Diagnosis help: 1. Confirm the engine is free of malfunction records;
2. Confirm malfunction that is claimed exists;
3. Carry out according to above-mentioned steps and find out nothing unusual;
4. Pay attention to the effect of automobile maintenance, cylinder pressure, mechanical ignition
timing, fuel conditions on the system during inspection;
5. Replace ECU and test it.
If malfunction is eliminated at this time, then malfunction part is in ECU; if malfunction still exists
at this point, replace for original ECU, and repeat the flowchart, and re-inspect.
156
No.115 Engine not running or slowly running while startup

General malfunction part: 1. battery; 2. startup motor; 3. harness or ignition switch; 4. mechanical
parts of the engine. General diagnosis flowchart:
Yes Next step

Check voltage between two binding posts of battery is around 8-12V
1
while the engine is started with the multimeter.
No Replace battery
Yes Next step

With ignition switch at starting position, check binding post of anode of
2
startup motor is with voltage above 8V with the multimeter.
Repair or replace
No
harness
Repair or replace
Yes
Remove startup motor, and check its working conditions. Mainly check it starting motor
3
is open circuited or jammed due to poor lubrication.
No Next step
Replace for
Yes lubricating oil with
If malfunction only occurs in winter, check resistance of startup motor is proper grade
4
too large due to improper selection of lubricating oil and gear case oil.
No Next step
Check internal
Yes resistance of
Check internal mechanical resistance of the engine is too large, causing engine
5
startup motor not running or slowly running.
No Diagnosis help
157
No.116 While startup, engine running, but unable to start

General malfunction part: 1. oil tank without oil; 2. fuel pump; 3. speed sensor; 4. ignition coil; 5.
mechanical part of engine. General diagnosis flowchart:
Yes Next step

Connect fuel pressure gauge (access point is front end of oil sucker of
1 fuel distribution pipe assembly), and start the engine, and check fuel
pressure is around 350kPa. Repair oil supply
No
system
Yes Next step
Connect diagnosis instrument of electric injection system and observe

2
engine speed. Start the engine and observe speed signal is output.
Repair speed
No
sensor lines
Yes Next step
Take out line of one cylinder, and connect spark plug, making spark plug
3 electrode about 5mm away from engine body. Startup the engine and
check there is high pressure spark.
Repair ignition
No
system
Eliminate
Yes
mechanical failure
Check pressure of each cylinder of the engine, and observe engine
4
cylinder is with insufficient pressure.
No Next step
Yes Diagnosis help

Connect commutator of electric injection system, and open ignition
5 switch, and check power supply of 12#, 13#, 44#, 45#, ,63# pins are
normal; check bonding of 3#, 51#, 53#, 61#, 80# pins are normal.
Repair
No
corresponding lines
158
No.117 Difficult to start for hot startup

General malfunction part: 1. fuel containing water; 2. fuel pump; 3. cooling liquid temperature
sensor; 4. fuel pressure regulator vacuum pipe; 5. ignition coil.
General diagnosis flowchart:
Yes Next step

pressure is around 350kPa. Repai r oil supply
No
system
Yes Next step

Take out line of one cylinder, and connect spark plug, making spark plug
check there is high pressure spark.
Repair ignition
No
system
Repair lines or
Take out connector of cooling liquid temperature sensor, and start the Yes replace sensor
engine. Observe the engine is successfully started at this point. (or
3 connect one 300ohm resistance in series at connector of this sensor to
replace cooling liquid temperature sensor and observe the engine is
successfully started at this point.)
No Next step
Yes Repair or replace

4 Check fuel pressure regulator vacuum pipe is loosening or air leaking.
No Next step
Yes Replace fuel

Check fuel condition and observe malfunction is caused just after
5
refueling.
No Next step
Yes Diagnosis help

normal; check bonding of 3#, 51#, 53#, 61#, 80# pins are normal. Repair
No
corresponding lines
159
No.118 Difficult to start for cold startup

General malfunction part:1. fuel containing water; 2. fuel pump; 3. cooling liquid temperature
sensor; 4. oil injector; 5. ignition coil;
6. throttle valve body and idling speed bypass duct; 7. mechanical parts of engine. General
diagnosis flowchart:
Connect fuel pressure gauge (access point is front end of oil sucker of Yes Next step
pressure is around 350kPa. Repai r oil supply
No
system
Take out line of one cylinder, and connect spark plug, making spark plug Yes Next step
check there is high pressure spark. Repair ignition
No
system
Take out connector of cooling liquid temperature sensor, and start the Repair lines or
Yes
engine. Observe the engine is successfully started at this point. (or replace sensor
3 connect one 300ohm resistance in series at connector of this sensor to
replace cooling liquid temperature sensor and observe the engine is No Next step
successfully started at this point.)
Clean throttle valve
Yes and idling speed
4 Step on the throttle lightly, and observe it is easily started. duct
No Next step
Replace
Remove oil injector, and check it is leaking or blocked with special Yes malfunctiony ones
5
cleaning and analysis instrument.
No Next step
Yes Replace fule

6
refueling.
No Next step
Eliminate
Yes
mechanical failure
Check pressure of each cylinder of the engine, and observe engine
7
No Next step
Yes Diagnosis help

normal; check bonding of 3#, 51#, 53#, 61#, 80# pins are normal.
Repair
No
corresponding lines
160
No.119 Difficulty startup at any time though with normal speed

General malfunction part: 1. fuel containing water; 2. fuel pump; 3. cooling liquid temperature
sensor;4. oil injector; 5. ignition coil;
6. throttle valve body and idling speed bypass duct; 7.intake duct; 8. ignition timing; 9. spark
plug;10. mechanical parts of engine. General diagnosis flowchart:
Repair air intake

Yes
system
1 Check air filter is blocked, and intake duct is air leaking.
No Next step
pressure is around 350kPa. Repair oil supply
No
system
Take out line of one cylinder, and connect spark plug, making spark plug Yes Next step
check there is high pressure spark. Repair ignition
No
system
Yes Next step

Check spark plug of each cylinder, and observe its type and clearance
4
conform to the specifications.
No Adjust or replace
Repair lines or
Yes
Take out connector of cooling liquid temperature sensor, start the engine replace sensor
5
and observe it is successfully started at this time.
No Next step
Clean throttle valve

Yes and idling speed
6 Step on the throttle lightly, and observe it is easily started. duct
No Next step
Replace
Yes
Remove oil injector, and check it is leaking or blocked with special malfunctiony ones
7
No Next step
Yes Replace fuel

8
refueling.
No Next step
Eliminate
Yes
Check pressure of each cylinder of the engine, and observe engine mechanical failure
9
No Next step
Yes Next step

Check ignotion sequence and ignition timing of the engine conform to the
10
specifications. Repair ignition
No
timing
Connect commutator of electric injection system, and open ignition Yes Diagnosis help
No
corresponding lines
161
No.120 Normal startup with instable idling speed at any time

General malfunction part:1. fuel containing water; 2. oil injector; 3. spark plug; 4. throttle valve
body and idling speed bypass air duct; 5. intake duct; 6. idling speed regulator; 7. ignition timing;
8. spark plug; 9. mechanical parts of the engine.
Repair air intake

Yes
system
No Next step
Yes Clean or replace

2 Check idling speed regulator is jammed.
No Next step
Yes Next step

3
Check throttle valve body and idling speed bypass air duct is with carbon Yes Clean
4
deposit.
No Next step
Replace
Yes
Remove oil injector, and check it is leaking or blocked, or flow with out of malfunction ones
5
tolerance with special cleaning and analysis instrument.
No Next step
Yes Replace fuel

6
refueling.
No Next step
Eliminate
Yes
Check pressure of each cylinder of the engine, and observe cylinder mechanical failure
7
pressure has too large differences.
No Next step
Yes Next step

Check ignition sequence and ignition timing of the engine conform to the
8
specifications.
Repair ignition
No
timing
Yes Diagnosis help

No
corresponding lines
162
No.121 Normal startup, with instable idling speed during warming up

General malfunction part: 1. fuel containing water; 2. cooling liquid temperature sensor; 3. spark
plug; 4. throttle valve body and idling speed bypass air duct; 5. intake duct; 6.idling speed
regulator; 7. mechanical parts of engine.
Repair air intake

Yes
system
No Next step
Yes Next step

2
Clean concerned
Yes
Remove idling speed regulator, and check throttle valve body, idling parts
3
speed regulator and idling speed bypass air duct are with carbon deposit.
No Next step
Repair lines or
Yes
4
and observe the engine's idling speed is instable during warming up.
No Next step
Replace
Yes
Remove oil injector, and check it is leaking or blocked, or flow with out of malfunctiony ones
5
No Next step
Yes Replace fuel

6
refueling.
No Next step
Eliminate
Yes
7
No Next step
No
corresponding lines
163
No.122 Normal startup, with instable idling speed after warming up

General malfunction part:1. fuel containing water; 2.cooling liquid temperature sensor; 3. spark
plug; 4. throttle valve body and idling speed bypass air duct; 5.intake duct;6. idling speed
regulator; 7. mechanical parts of engine.
Repair air intake

Yes
system
No Next step
Yes Next step

2
Clean concerned
Yes
parts
Remove idling speed regulator, and check throttle valve body, idling
3
No Next step
Repair lines or
Yes
4
and observe the engine's idling speed is instable during warming up.
No Next step
Replace
Yes
Remove oil injector, and check it is leaking or blocked, or flow with out of malfunctiony ones
5
No Next step
Check fuel condition and observe malfunction is caused just after Yes Replace fuel
refueling.
6
No Next step
Eliminate
Yes
7
No Next step
Yes Diagnosis help

No
corresponding lines
164
No.123 Normal startup, idling speed is instable or the vehicle will flame
out when partially loaded (such as: when air conditioner is on)
General malfunction part: 1. air conditioning system; 2idling speed regulator; 3. oil injector.
Serial
No.
Clean concerned
Remove idling speed regulator, and check throttle valve body, idling speed Yes parts
1
regulator and idling speed bypass air duct are with carbon deposit.
No Next step
Yes To step 4
Observe output power of the engine is increased while air conditioner is on, i.e.
2 observe changes of ignition advance angle, oil injection pulse width and air input
with diagnosis instrument of electric injection system.
No Next step
Yes Next step

Connect commutator of electric injection system, and disconnect connecting line of
3 75# pin of electronic control unit. Check there is high level signal at harness end
when air conditioner is on. Repair air
No conditioning
system
Yes Next step
Check pressure of air conditioning system, electromagnetic clutch of air
4 Repair air
compressor and AC compression pump are normal.
No conditioning
system
Replace
Remove oil injector, and check it is leaking or blocked, or flow with out of tolerance Yes malfunction ones
5
with special cleaning and analysis instrument.
No Next step
Yes Diagnosis help

Connect commutator of electric injection system, and open ignition switch, and
6 check power supply of 12#, 13#, 44#, 45#, ,63# pins are normal; check bonding
of 3#, 51#, 53#, 61#, 80# pins are normal. Repair
No
corresponding lines
165
No.124 Normal startup, the idling speed is too high

General malfunction part: 1. throttle valve body and idling speed bypass air duct; 2. vacuum pipe;
3. idling speed regulator; 4. cooling liquid temperature sensor; 5. ignition timing.
Yes Adjust
1 Check throttle cable is jammed or too tightening.
No Next step
Repair air intake

Yes
2 Check vacuum pipe of intake system and connection is leaking. system
No Next step
Remove idling speed regulator, and check throttle valve body, idling Yes Clean concerned parts
3
No Next step
Repair lines or replace

Take out connector of cooling liquid temperature sensor, start the engine Yes sensor
4
and observe the engine's idling speed is too high at this time.
No Next step
Yes Next step

5 Check ignition timing of the engine conforms to the specification.
No Repair ignition timing
Yes Diagnosis help

Connect commutator of electric injection system, and open ignition switch,
6 and check power supply of 12#, 13#, 44#, 45#, ,63# pins are normal;
check bonding of 3#, 51#, 53#, 61#, 80# pins are normal.
Repair corresponding
No
lines
166
No.125 Unable to rotating speed or flameout while accelerating

General malfunction part:1. fuel containing water; 2. intake pressure sensor and throttle valve
position sensor; 3. spark plug; 4. throttle valve body and idling speed bypass air duct; 5.intake
duct; 6. idling speed regulator; 7. oil injector; 8. ignition timing; 9. exhaust pipe. General
diagnosis flowchart:
Yes Repair air intake system

1 Check air filter is blocked.
No Next step
Yes Next step

pressure is around 350kPa during accelerating.
No Repair oil supply system
Yes Next step

3
Yes Clean concerned parts

4
No Next step
Yes Next step

Check intake pressure sensor, throttle valve position sensor and its lines
5
are normal.
No
sensor
Replace malfunction
Yes
Remove oil injector, and check it is leaking or blocked with special ones
6
No Next step
Yes Replace fuel

7
refueling.
No Next step
Yes Next step

Check ignotion sequence and ignition timing of the engine conform to the
8
specifications.
Yes Next step
9 Check exhaust pipe is smoothly exhausted.

Repair or replace
No
exhaust pipe
Yes Diagnosis help

normal; check bonding of 3#, 51#, 53#, 61#, 80# pins are normal. Repair corresponding
No
lines
167
No.126 Slow reaction while accelerating

position sensor; 3. spark plug;4. throttle valve body and idling speed bypass air duct; 5.intake
duct;6. idling speed regulator; 7. oil injector; 8. ignition timing; 9. exhaust pipe. General diagnosis
flowchart:
Repair air intake

Yes
system
1 Check air filter is blocked.
No Next step
pressure is around 350kPa during accelerating. Repair oil supply
No
system
Yes Next step

3
Yes Clean concerned parts

4
No Next step
Yes Next step

Check intake pressure sensor, throttle valve position sensor and its lines
5
are normal.
No
sensor
Replace malfunction
Yes
Remove oil injector, and check it is leaking or blocked with special ones
6
No Next step
Yes Replace fuel

7
refueling.
No Next step
Yes Next step

Check ignition sequence and ignition timing of the engine conform to the
8
specifications.
Yes Next step

Repair or replace
No
exhaust pipe
normal; check bonding of 3#, 51#, 53#, 61#, 80# pins are normal. Repair corresponding
No
lines
168
No.127 Weak with poor performance while accelerating

position sensor;3. spark plug;4. ignition coil; 5. throttle valve body and idling speed bypass air
duct; 6. intake duct;7idling speed regulator; 8 oil injector; 9. ignition timing; 10. exhaust pipe.
Check there are malfunctions such as clutch skidding, low tire Yes Repair
1 pressure, braking dragging, incorrect tire dimension, incorrect
positioning of four wheels, etc. No Next step
Repair air intake
Yes
2 Check air filter is blocked. system
No Next step
Connect fuel pressure gauge (access point is front end of oil sucker Yes Next step
3 of fuel distribution pipe assembly), and start the engine, and check
fuel pressure is around 350kPa during accelerating. Repair oil supply
No
system
Take out line of one cylinder, and connect spark plug, making spark Yes Next step
4 plug electrode about 5mm away from engine body. Startup the
engine and check strength of high pressure spark is normal.
No Repair ignition system
Check spark plug of each cylinder, and observe its type and Yes Next step
5
clearance conform to the specifications.
Remove idling speed regulator, and check throttle valve body, idling Yes Clean concerned parts
6 speed regulator and idling speed bypass air duct are with carbon
deposit. No Next step
Yes Next step

Check intake pressure sensor, throttle valve position sensor and its
7
lines are normal. Repair lines or replace
No
sensor
Remove oil injector, and check it is leaking or blocked with special Yes Replace malfunction
8
No Next step
Check fuel condition and observe malfunction is caused just after Yes Replace fuel
9
refueling.
No Next step
Yes Next step

Check ignition sequence and ignition timing of the engine conform to
10
the specifications.
Yes Next step

Repair or replace
No
exhaust pipe
switch, and check power supply of 12#, 13#, 44#, 45#, ,63# pins
12
are normal; check bonding of 3#, 51#, 53#, 61#, 80# pins are
Repair corresponding
normal. No
lines
169
No.128 Malfunction code with EOBD system
Malfunction
NO Malfunction code Description
level
1 P0030 Open-circuit of heating control circuit of upstream oxygen sensor 3
2 P0031 Short-circuit to earth of heating control circuit of upstream oxygen sensor 3
Short-circuit to power source of heating control circuit of upstream oxygen

3 P0032 3
sensor
4 P0036 Open-circuit of heating control circuit of downstream oxygen sensor 3
5 P0037 Short-circuit to earth of heating control circuit for downstream oxygen sensor 3
Short-circuit to power source of heating control circuit for downstream oxygen

6 P0038 3
sensor
7 P0053 Unreasonable heating internal resistance, upstream oxygen sensor 3
8 P0054 Unreasonable heating internal resistance, downstream oxygen sensor 3
9 P0105 Unchanged signal (icing) of intake pressure sensor 3
10 P0106 Intake pressure sensor unreasonable 3
11 P0107 Intake pressure sensor short circuit to earth 3
12 P0108 Intake pressure sensor short circuit to power source 3
13 P0112 Too low signal voltage of intake temperature sensor 3
14 P0113 Too high signal voltage of intake temperature sensor 3
15 P0116 Unreasonable temperature signal of engine coolant 3
16 P0117 Too low circuit voltage of temperature sensor of engine coolant 3
17 P0118 Too high circuit voltage of temperature sensor of engine coolant 3
18 P0122 Circuit voltage exceeding minimum value, throttle position sensor 3
19 P0123 Circuit voltage exceeding maximum value, throttle position sensor 3
20 P0130 Unreasonable signal upstream oxygen sensor 3
21 P0132 Circuit voltage too high, upstream oxygen sensor signal 3
22 P0133 Upstream oxygen sensor aging (signal slows down) 3
170
23 P0134 Circuit signal malfunction, upstream oxygen sensor 3
24 P0136 Unreasonable signal of downstream oxygen sensor 3
25 P0138 Circuit voltage too high, downstream oxygen sensor signal 3
26 P0140 Circuit signal malfunction, downstream oxygen sensor 3
Unreasonable self-learning of closed-loop control of air fuel ratio for off-line

27 P0170 7
test
28 P0171 Over-thin of self-learning of closed-loop control of air fuel ratio for off-line test 7
29 P0172 Lower cable inspection air/fuel ratio closed circuit self-adaptation too thick 7
30 P0201 Open circuit of 1st cylinder fuel injector controlling circuit 3
31 P0202 Open circuit of 2nd cylinder fuel injector controlling circuit 3
32 P0203 3rd cylinder fuel injector controlling circuit open circuit 3
33 P0204 Open circuit of 4th cylinder fuel injector controlling l circuit 3
34 P0261 Short circuit to earth of 1st cylinder fuel injector controlling circuit 3
35 P0262 Short circuit to power supply of 1st cylinder fuel injector controlling circuit 3
36 P0264 Short circuit to earth of 2nd cylinder fuel injector controlling circuit 3
37 P0265 Short circuit to power supply of 2nd cylinder fuel injector controlling t circuit 3
38 P0267 Short circuit to earth of 3rd cylinder fuel injector controlling circuit 3
39 P0268 Short circuit to power supply of 3rd cylinder fuel injector controlling circuit 3
40 P0270 Short circuit to earth of 4th cylinder fuel injector controlling circuit 3
41 P0271 Short circuit to power supply of 4th cylinder fuel injector controlling circuit 3
42 P0300 Several cylinders misfire 2
43 P0301 1st cylinder misfire 2
171
44 P0302 2nd cylinder misfire 2
45 P0303 3rd cylinder misfire 2
46 P0304 4th cylinder misfire 2
47 P0318 Damaged circuit inspection accelerating sensor signal failure 3
48 P0321 Crankshaft signal error 3
49 P0322 No engine speed sensor pulse signal (open or short circuit) 4
50 P0324 Knock signal processing chip and other circuit malfunction 6
51 P0327 Knock sensor signal circuit voltage lower than normal value 3
52 P0328 Knock sensor signal circuit voltage over normal value 3
53 P0340 Improper phase sensor mounting position 3
54 P0341 Poor phase sensor conduction 3
55 P0342 Phase sensor short circuit with earth 3
56 P0343 Phase sensor short circuit with power supply 3
57 P0420 3 way catalytic converter ageing (emission over standard level) 3
58 P0444 Canister valve controlling circuit open circuit 3
59 P0458 Canister valve controlling circuit voltage lower than normal value 3
60 P0459 Canister valve controlling circuit voltage over normal value 3
61 P0480 Cooling fan relay controlling circuit open circuit (low speed) 5
62 P0481 Cooling fan relay controlling circuit open circuit (high speed) 5
63 P0501 Vehicle speed sensor signal unreasonable 3
172
64 P0506 Idle controlling speed lower than target 3
65 P0507 Idle controlling speed higher than target 3
66 P0508 Stepping motor driving pin short circuit with earth 3
67 P0509 Stepping motor driving pin short circuit with power supply 3
68 P0511 Stepping motor driving pin failure 3
69 P0560 System battery voltage signal unreasonable 5
70 P0562 System battery voltage lower than normal value 5
71 P0563 System battery voltage over normal value 5
72 P0602 Electrical Control Unit (ECU) code error 3
73 P0627 Pump relay controlling circuit open circuit 3
74 P0628 Short circuit to earth of pump relay controlling circuit 3
75 P0629 Short circuit to power supply of pump relay controlling circuit 3
76 P0645 Open circuit of A/C compressor relay controlling circuit 5
77 P0646 Short circuit to earth of A/C compressor relay controlling circuit 5
78 P0647 Short circuit to power supply of A/C compressor relay controlling circuit 5
79 P0650 MIL lamp driving circuit failure 3
80 P0691 Short circuit to earth of cooling fan relay controlling circuit (low speed) 5
81 P0692 short circuit to power supply of cooling fan relay controlling circuit (low speed) 5
Air/fuel ratio closed circuit self-adaptation over upper limit (middle loading
82 P2177 11
area)
Air/fuel ratio closed circuit self-adaptation below lower limit (middle loading
83 P2178 11
area)
173
84 P2187 Air/fuel ratio closed circuit self-adaptation over upper limit (low loading area) 11
85 P2188 Air/fuel ratio closed circuit self-adaptation below lower limit (low loading area) 11
86 P2195 Upper oxygen sensor ageing (signal deviation over upper limit) 3
87 P2196 Upper oxygen sensor ageing (signal deviation below lower limit) 3
88 P2270 Lower oxygen sensor ageing (over upper limit) 3
89 P2271 Lower oxygen sensor ageing (below lower limit) 3
No.129 Malfunction code without EOBD system
Malfunction
NO Description
code
1 P0107 Low circuit voltage of intake pressure sensor
2 P0108 High circuit voltage of intake pressure sensor
3 P0112 Low signal of intake temperature
4 P0113 High signal of intake temperature
5 P0116 Incorrect water temperature signal
6 P0117 Water temperature signal too low
7 P0118 Water temperature signal too high
8 P0120 Malfunction of throttle position sensor circuit
9 P0130 Signal voltage too low, upstream oxygen sensor
10 P0132 Signal voltage too high, upstream oxygen sensor
11 P0134 Malfunction of upstream oxygen sensor signal (0.4Vusvk_w0.6V)
12 P0135 Malfunction of heating circuit of oxygen sensor
13 P0201 Malfunction of one-cylinder oil nozzle circuit
14 P0202 Malfunction of two-cylinder oil nozzle circuit
15 P0203 Malfunction of three-cylinder oil nozzle circuit
16 P0204 Malfunction of four-cylinder oil nozzle circuit
174
17 P0230 Malfunction of oil pump control circuit
18 P0325 Malfunction of knock sensor circuit
19 P0335 Reference point signal malfunction, crankshaft position sensor
20 P0443 Malfunction of canister control valve driver-stage control circuit
21 P0444 Voltage too low, driver-stage control circuit of canister control valve
22 P0445 Voltage too high, driver-stage control circuit of canister control valve
23 P0480 Malfunction of cooling fan relay of AC condenser control circuit
24 P0500 Unreasonable speed signal
25 P0506 Idling speed lower than target idling speed value
26 P0507 Idling speed deviated from target value
27 P0508 Short-circuit to earth,of control circuit idling speed governor
28 P0509 short circuit to power supply of idle speed adjustor controlling circuit
29 P0511 Open circuit of idle speed adjustor controlling circuit
30 P0560 System voltage signal unreasonable
31 P0562 System voltage lower than normal value
32 P0563 System voltage over normal value
33 P0601 Electrical Control Unit (ECU) check code error
34 P0602 Electrical Control Unit (ECU) programming error
35 P0630 Vehicle Identification Number (VIN) discode or mismatch - Electrical Control Unit
(ECU)
36 P0645 AC compressor relay controlling circuit failure
37 P0646 AC compressor relay controlling circuit voltage lower than normal value
38 P0647 AC compressor relay controlling circuit over normal value
39 P0650 MIL controlling circuit malfunction
175
Transmission
No. 130 Transmission hard to put into gear
1. Check the pedals free clearance, keeping at 1-3mm;

clearance between release bearing and clutch pressure plate
better at 2-3mm; if too large, adjust it within range above
(empirical data);
2. Check whether crankshaft has too large play; if unusual,

repair the engine to make play accurate;
Clutch not fully separated
3. Clutch pressure plate spring too soft; replace it;
4. Clutch disk excessively worn; replace it;
5. Clutch pressure plate and flywheel surface warped and

deformed (replace it if deformed amounts above 0.5 mm)
1. Upper, lower play of gear shifting lever kept at 1-2mm, if too

large, replace gear shifting lever assembly;
Gear shifting lever incorrectly adjusted 2. Check whether rubber pillar of support base is broken;
replace gear shifting lever assembly if so;
3. Check whether cover at connections of shift lever and

transmission is too loose; replace the cover if so;
1 Check whether quantity of transmission gear oil reaches oil

ansmission hard to filler; add it if not enough;
put into gear
2Check whether gear oil within transmission turns black or white,
Check transmission oil which indicates deterioration if so. Replace it and clean
transmission;
3 Check viscosity of gear oil within transmission, and replace for

those suitable for local weather;
1. Check whether shift shaft within transmission bends, and

could reach maximum stroke by drawing front and back, without
jamming; replace shift shaft if so;
2. Check whether support shaft falls or deforms, and replace it if

so;
Shifting parts block within transmission
3. Check whether interlocking slide block abrades, and moving left
and right within interlocking is smooth. burnish it if jamming;
4. Check whether interlocking groove of shifter fork shaft is too

deep, whether its depth fits for extruded part of interlocking block.
If too deep, burnish it;
Check whether clearance on the gear pressed by synchronizer

Check synchronizer in transmission ring of each gear is between 0.85-1.45. If clearance less than
0.5mm, replace synchronizer ring;
176
Transmission hard to put into gear
Abnormal
Clutch not fully separated Adjust and repair
Normal
Abnormal
Shift bar incorrectly adjusted Adjust and repair
Normal
Abnormal
Transmission oil Check and replace
Normal
Shifting parts block within Abnormal Adjust and replace

transmission
Normal
Synchronizer within transmission Abnormal Adjust and replace
No. 131 Park position fails
Check whether gear cable is drawn to P gear; adjust cable

position if not so, making shifting bar below transmission
Gear cable incorrectly adjusted
reach the furtherest point. Manual shift ball placed at
P-position fastening blot;
If manual brake released at P-position and this vehicle

moved to-and-fro freely, it is assumed locking device of
Parking gear fails P-position locking device fails or broken
P-position fails, or P locking plate wears, ruptures.
Replace locking plate or repair locking device;
Check whether P-position tie rod within transmission

Auto transmission malfunction bends or deforms; check whether P-position locking block
ruptures, making it unable to lock output shaft;
177
Parking gear fails
Incorrectly
Gear cable incorrectly adjusted
Adjust
Normal
Ruptures
P-position locking device fails or broken Replace
Normal
Abnormal
Auto transmission malfunction
Repair
No. 132 Gear indicator lamp off sometimes
Take out N-position switch plug, short-connected N-position or

P-position tie-line, with long-time check; check whether
position lamp short-connected is normal. If malfunction exists,
Combined instrument malfunction check whether tie-line of N-position switch and combination
instrument is normal; replace combination instrument if
normal; shake combination instrument properly, and check
normal or not; replace combination instrument if abnormal
(other positions and the like)
Gear indicator Check contact on A/T switch, and replace A/T switch if
lamp off A/T switch malfunction necessary; check earth wire is falsely connected; fix earth
sometimes wire.
Remove oil drip pan; check gear contact sheet is poorly

Gear contact sheet within transmission
contacted;
Check line is worn or broken, and earth wire is poorly

Line malfunction
contacted;
178
Gear indicator lamp off

sometimes
Abnormal
Combination instrument Replace
malfunction
Normal
Abnormal
A/T switch malfunction Replace
Abnormal
Line malfunction Repair
No.133 Auto transmission with abnormal sound
Oil filled between 2-4 holes of dip stick. Oil is too much, causing abnormal
sound with parts rotation. Oil too little, and each friction pair lack of
Oil quantity and quality lubrication, causing abnormal sound. Check idling speed is normal and
engine temperature is normal. For N-position, check oil level is normal,
and fill transmission oil if not sufficient. If dirty, replace transmission oil.
Check abnormal sound of transmission is in front or at rear. If in front,

<engine side> start vehicle, step on brake, and put into driving position. If
noise too large, check turbo pulley within torque converter works
Torque converter malfunction
normally. Listen carefully unusual noise is from crankshaft rear,
transmission front, and if noise is wheezy, it is abnormal sound of torque
converter; replace torque converter assembly;
Auto transmission
Abnormal sound in middle, slow shifting, oil pressure insufficient. Check
with abnormal
Oil pump malfunction clearance between oil pump rotor and casing, plate, which shall be within
sound
standard range;
Check planet gear mechanism is worn or broken, and thrust bearing,

Planet gear mechanism
thrust disc is damaged. Replace it if so.
Check meshing mark of output shaft and gear ring is normal; replace
output shaft and gear ring if abnormal; check whether differential bearing
Out shaft axle differential with is loosening. Shaking with hands shall be without loosening sound, and
abnormal sound ball bearing track not flaked; replace differential bearing if abnormal;
check differential planet gear, shaft could grind step. Replace differential
assembly if worn.
179
Auto transmission with

abnormal sound
Abnormal
Oil quantity and quality Check or repair
Normal
Torque converter Abnormal Replace
Normal
Oil pump Abnormal Replace
Normal
Abnormal Repair
Planet gear mechanism
Normal
Abnormal
Outshaft axle differential Repair
with abnormal sound
180
No.134 Transmission shaking during driving
Engine power output not balanced; some cylinder not working;

Engine malfunction
check operations of each cylinder through cylinder breaks;
Check each cushion of suspension deforms, ages, ruptures;

Engine suspension malfunction
change cushion if any.
Check ball cage inside and outside the drive shaft is

excessively worn or loosening, drive shaft bends, and upper
Drive shaft malfunction
and lower runout within 2mm; replace drive shaft assembly if
Transmission too large.
shaking during
driving
Check tire is bubbling, line broken, and upper and lower
Tire or steel ring malfunction runout is within 1-3mm. replace tire, steel ring, front hub if too
large;
Check whether tooth of driving gear and driven gear of each

position falls out individually; check meshing clearance of
driving gear and driven gear of each position is too deep, and
Transmission inner malfunction
check meshing mark and ensure middle part is well meshed;
check tooth of output shaft and differential gear ring falls out
individually;
181
Transmission shaking
during driving
Abnormal
Engine Repair
Normal
Engine suspension Abnormal Replace
Normal
Drive shaft Abnormal Replace
Normal
Abnormal Dynamic balancing or

Tire or steel ring replace
Normal
Abnormal
Within transmission Repair
182
No. 135 Auto transmission case oil temperature rises, reverse gear fails
Check manual shifting valve is worn, or blocks. If

abnormal, replace control valve plate assembly or grind
control valve, making it normal;
Control valve plate fails
Check each relevant control valve is leaking; replace

valve body assembly if abnormal;
Auto transmission case oil
temperature rises, reverse
gear fails Check piston seal of control brake is damaged, leaking;
replace seal if abnormal;
Reversing control brake malfunction
Check reversing control piston blocks; adjust or replace

piston if abnormal;
Auto transmission case oil

temperature rises, reverse
gear fails
Control valve plate fails Fails Replace
Normal
Reversing control brake Abnormal Repair

malfunction
183
No. 136 Auto transmission upshifts too late
1. Check throttle tie-line, and step to the end, and throttle shall at
maximum position. If not possible, adjust throttle tie-line;
Throttle tie-line malfunction

2. Check tie-line of throttle position of auto transmission; there shall be
2-8mm clearance between tie-line bottom and pedestal, and adjust it if
not so;
Check each control valve is worn, or blocks; if abnormal, grind it or

Control valve plate malfunction
replace control valve assembly;
Check speed control valve blocks or leaks; if abnormal, repair or

Governor valve malfunction
replace governor valve;
Check friction disk clearance is normal; if not, replace friction disk or

Friction disk skids
flange, and adjust it normally;
Auto transmission 1. Check filter is obstructed; if abnormal, clean or replace;

upshifts too late
Oil pressure insufficient

2. Check main adjusting valve; if abnormal, check oil pump gear
clearance and strength of relief spring inside the oil pump conforms to
requirement; if abnormal, replace oil pump;
Check throttle valve blocks or is worn, leaking; if abnormal, grind it or

Throttle valve malfunction
replace valve plate assembly;
Check shifting valve blocks, or is worn, leaking; if abnormal, grind it or

Shifting valve malfunction
replace it;
Check accumulator blocks, or is worn, leaking; check accumulator

Accumulator malfunction spring conforms to requirement; if abnormal, adjust or replace seal or
spring;
184
Auto transmission upshifts too late
Abnormal
Throttle tie-line Adjust
Normal
Abnormal
Control valve plate Repair or replace
Normal
Abnormal Repair or replace
Governor valve
Normal
Abnormal
Friction disk skids Replace
Normal
Abnormal
Oil pressure insufficient Repair
Normal
Throttle valve Abnormal Repair
Normal
Abnormal
Shifting valve Replace
Normal
Abnormal
Accumulator Replace
185
No. 137 Auto transmission unable to upshift
Check auto transmission oil is too little, and oil level shall
Auto transmission oil be between 2-4 holes of dipstick; if too little, it will not
generate oil pressure, making it unable to upshift;
Check throttle tie-line, and step to the end, and throttle

shall at maximum position. If not possible, adjust throttle
Throttle tie-line malfunction tie-line; Check tie-line of throttle position of auto
transmission; there shall be 2-8mm clearance between
tie-line bottom and pedestal, and adjust it if not so;
Check speed control valve blocks or leaks or fails; if

Governor valve malfunction
Auto transmission abnormal, repair or replace governor valve;
unable to upshift
Check auto shifting valve blocks or leaks; if abnormal,

Auto shifting valve malfunction
adjust or replace valve plate assembly;
Check accumulator blocks, or is worn, leaking; check

Accumulator malfunction accumulator spring conforms to requirement; if abnormal,
adjust or replace seal or spring;
Check drive-gear clutch piston blocks or leaks; if

Drive-gear control valve malfunction
abnormal, adjust or replace drive-gear clutch parts;
Auto transmission unable to upshift
Abnormal
Auto transmission oil liquid Check and fill
Normal
Throttle tie-line Abnormal

Adjust
Normal
Governor valve Abnormal

Repair
Normal
Abnormal Repair
Auto shifting valve
Normal Abnormal
Replace
Accumulator
Normal
Abnormal Repaiar or replace

Drive-gear control valve
186
No. 138 Auto transmission unable to force downshift
Check throttle tie-line, and step to the end, and throttle

shall at maximum position. If not possible, adjust throttle
Throttle tie-line malfunction tie-line; Check tie-line of throttle position of auto
transmission; there shall be 2-8mm clearance between
tie-line bottom and pedestal, and adjust it if not so;
Check control valve plate blocks or leaks inside; if

Control valve malfunction
abnormal, repair or replace;
Auto transmission Governing valve severely worn, causing pressure relief,

unable to force Governing valve malfunction thus unable to downshift; replace governing valve
downshift assembly;
Check forced downshift switch is ok; if abnormal, replace

it, and if normal, check tie-line from downshift switch to
Forced downshift switch malfunction
control unit is normal, and if so, check control unit is ok,
and if not so, replace it;
Check solenoid valve switch is damaged; by referencing

Forced-gear solenoid valve damaged circuit drawing, check there is open circuit, short circuit;
replace solenoid valve;
Auto transmission unable to force

downshift
Abnormal
Throttle tie-line Adjust
Normal
Abnormal
Control valve Repaiar or replace
Normal
Abnormal
Forced downshift switch
Replace
Normal
Abnormal
Forced-gear solenoid valve
damaged Replace
187
No. 139 Engine shuts down after putting into gear
Idling speed too low or clutch too low; Clean idling motor or replace, and adjust clutch height, or
throttle blocks replace throttle tie-line;
Idling motor poorly operates Clean or replace idling motor;
Check signal panel loosens; repair or replace parts and

components;
Rotating signal panel loosens or engine
unusually operates
Repair the engine, making it normal or replace damaged
parts and components;
Engine shuts down
after putting into Gear inside transmission worn, damaged or Disassemble gear inside transmission; adjust or replace
gear jammed, blocked damaged parts and components;
Clutch disk and flywheel locked or not fully Repair or replace parts and components; repair and separate
separated fully or replace damaged parts and components;
With power on, test locking clutch solenoid valve is normal;

check resistance of control solenoid valve is up to standard; if
Torque converter (with locking clutch) not so, replace solenoid valve; if so, check tie line of solenoid
malfunction valve and control unit is normal; if so, check control unit is ok;
if not so, replace it; if solenoid valve and control unit tie-line,
control unit are all normal, clean or replace torque converter;
Engine shuts down after putting into gear
Abnormal
Idling speed too low or clutch too low; throttle Repair
blocks
Normal
Idling motor poorly operates

Abnormal
Clean or replace
Normal
Rotating signal panel loosens or engine Abnormal

unusually operates Repair
Normal
Gear inside transmission worn, damaged or Abnormal

jammed, blocked Repair
Normal
Abnormal
Torque converter
Replace
188
No. 140 No forward gear
1. Check oil pressure of drive gear, which shall be within standard

value. If oil pressure too low, check whether oil pressure valve is
Forward gear clutch malfunction
jammed, and clutch oil plug is damaged;
2. Check clutch friction disk is excessively worn;
1. Check drive-gear clutch oil pressure;

Forward gear brake malfunction 2. Check drive-gear brake friction disk is excessively worn;
3. Check brake driving piston is jammed;
No forward gear Forward gear one-way clutch

Check one-way clutch is damaged, and functionally abnormal;
malfunction
Check valve body of control valve plate is worn, leaking or blocked;

Control valve malfunction
if abnormal, clean, adjust or replace valve plate assembly.
Check governing valve is blocked, worn or leaking; if abnormal,

Governing valve malfunction
adjust or replace governing valve assembly;
No forward gear
Unusual
Forward gear clutch Replace
Normal
Unusual
Forward gear brake Replace
Normal
Abnormal
Forward gear one-way clutch Replace
Normal
Abnormal
Control valve Replace
Normal
Abnormal
Governing valve Replace
189
No. 141 Transmission oil easily deteriorate
Transmission must be filled with qualified gear oil (degree

Transmission oil quality problem
of API GL-4, SAE 80W-85 viscosity);
Oil level flush with lower plane of oil filler bolt; quality of
gear oil not good, and its quantity severely insufficient,
causing poor heat emission and excessive wearing of the
Transmission oil severely insufficient bearing. Mating surface of constant meshing gear falls out
due to high temperature causing transmission oil turning
black and deteriorating; replace damaged parts and
components and clean transmission, and replace gear oil;
Transmission oil Vent hole falls out, causing entry of dust and moisture
easily deteriorate Transmission vent hole falls out from the atmosphere, and turning transmission oil white or
dirty;
Check meshing clearance of each gear pair within

transmission is too small, which shall be between
Transmission inner malfunction 0.1-0.35. If too small, it will cause transmission oil
temperature too high, thus facilitating gear oil
deteriorating;
Disassemble transmission, and remove oil sludge and

Gear oil not replaced according to specified
foreign substance. Clean scraps on the gear and bearing
time for a long time causing too much oil
thoroughly. Refill gear oil with specified model, and
sludge, and oil easily deteriorates
replace it according to specified time and mileage.
190
Transmission oil easily deteriorate
Normal
Abnormal
Transmission oil quality problem Refill accordingly
Normal
Abnormal
Transmission oil severely insufficient Refill accordingly
Normal
Abnormal
Transmission vent hole falls out
Repair
Normal
Abnormal
Repair transmission
Transmission inner malfunction
Normal
Gear oil not replaced according to Abnormal

Replace oil
specified time
No. 142 Auto transmission oil easily deteriorate
Auto transmission must be filled with qualified ATF

Transmission oil quality and quantity problem (degree of DEXRON or DEXRON ). Oil level shall
be between the third or fourth hole of dipstick;
Torque converter inner malfunction Replace torque converter assembly;
Auto transmission
oil easily Check ablation of each clutch and brake within auto
deteriorate Transmission inner malfunction transmission, making auto transmission oil deteriorate;
replace clutch and brake friction disk;
Check heat-removal oil tank of auto transmission leaks,

and there shall be no auto transmission oil within water
Auto transmission heat-removal system tank; if any, replace radiator assembly; check
malfunction heat-removal control valve is jammed, making
transmission oil unable to remove heat circularly. Too high
oil temperature will cause easy deterioration;
191
Transmission oil easily

deteriorate
Normal
Abnormal
Transmission oil quality problem Replace
Normal
Abnormal
Torque converter inner Replace
Normal
Abnormal
Repaiar or replace
Transmission inner
Normal
Abnormal
Auto transmission heat-removal Repair
system
No. 143 No reversing gear
Shifting operation mechanism incorrectly Adjust shifting operation mechanism (gear shifting lever or shift
No reversing adjusted tie-line);
gear, reversing
not possible or Reversing locking mechanism worn, Check reversing shift fork is severely worn, or fails; if abnormal,
automatic damaged replace swing link support;
jump-out while
reversing
Reverse gear malfunction Check reverse gear ruptures or fails; if abnormal, replace gear;
192
No reversing gear
Shifting operation mechanism

Abnormal
incorrectly adjusted Adjust
Normal
Reversing locking mechanism Abnorma

worn, damaged
Replace
Normal
Reverse gear malfunction Abnormal

Replace
No. 144 Trip stop of fourth gear of transmission case
Adjust shifting operation mechanism (gear shifting lever o

Shifting operation mechanism incorrectly adjusted
shift tie-line);
Check adapting of synchronizer ring and drum of third,

fourth gear loosens, and replace it if abnormal; check
Synchronizer of third, fourth gear loosens
slide block of synchronizer of third, fourth gear is
excessively worn, and replace it if abnormal;
Auto trip stop of Check self-locked groove of shift fork shaft of

fourth gear of synchronizer of third, fourth gear and transmission
transmission housing are incorrectly positioned; check shift fork shaft if
Shift fork shaft of third, fourth gear self-locked,
case abnormal; check grooving position of self-locked groove is
interlocking mechanism poor
correct; replace shift fork shaft if abnormal; check position
of transmission housing hole is up to standard; replace
transmission housing if abnormal;
Shift fork of third, fourth gear excessively worn Check shift fork shaft is deformed or worn; replace it if
(4-gear end face) abnormal;
Fourth-gear of output, input shaft worn, appearing

Replace fourth-gear of output, input shaft;
severe taper
193
Trip stop of fourth gear of transmission

case
Abnormal
Shifting operation mechanism incorrectly
adjusted Adjust
Normal
Unusual
Synchronizer of third, fourth gear loosens Repaiar or replace
Normal
Abnormal
Shift fork shaft of third, fourth gear self-locked, interlocking Repair
mechanism poor
Normal
Abnormal
Shift fork of third, fourth gear excessively Replace
worn
Normal
Fourth-gear of output, input shaft worn, Abnormal Replace

appearing severe taper
194
No. 145 Transmission with abnormal sound
Check viscosity of transmission oil is too small, and quantity is too

Poor transmission oil quality, quantity little. Fill in API GL-4 SAE and oil level is flush with lower plane
of oil filler;
If any gear is sounding and park gear not sounding during driving,
check each bearing within transmission is worn or loosening, and
Bearing within transmission worn
bearing shall move stably without abnormal sound. Shaking with
hands shall be without loosening sound;
Meshing clearance of each gear pair within transmission is too

large or too small, which shall be within 0.1-0.35mm. Measure it
Gear worn
with several points, with measuring error at different positions not
exceeding 0.15mm;
If any gear is sounding, and clutch disappears, check bearing is

Transmission with damaged; replace it if abnormal; check input shaft and output
abnormal sound Input shaft or bearing malfunction
shaft is bent and measured with dial indicator, and with upper and
lower runout no more than 0.1mm;
Check chamfer of reversing cock wheel and driving and driven

gear of the second gear is too small, making reverse gear scratch
driving and driven gear of the second gear, and grind chamfer to
Gear moving interfere
make it larger; push reverse gear to the highest position with
hands, making it not scratch driving and driven gear of the second
gear;
If any gear is sounding during driving, and park gear not

sounding, check differential bearing or planet gear mechanism is
Differential malfunction
damaged or clearance incorrect; if damaged, adjust or replace
parts concerned; check bearing is damaged, and replace it if so;
195
Transmission with abnormal

sound
Abnormal
Transmission oil quality, quantity Replace or add
poor
Normal
Abnormal
Bearing within transmission worn Replace
Normal
Abnormal
Gear worn Replace
Normal
Abnormal
Input shaft or bearing Replace
Normal
Gear moving interfere Abnormal Repair
Normal
Abnormal Adjust or replace

Differential
196
No. 146 Gear shifting lever swinging, hard to shift
Gear shifting lever loosens, shifting Check nylon cover of gear shifting lever is unusually worn; if
Gear shifting incorrect; so, replace it;
lever swinging,
hard to shift
Gap between shift ball head and swing lever
Check shift ball head and swing lever loosen; if so, replace it;
too large, shifting incorrect;
Gear shifting lever swinging, hard to shift
Shift bar loosens, shifting incorrect Abnormal Repair
Normal
Clearance between shift ball head and swing Repaiar or replace

Abnormal
lever too large, shifting incorrect
197
No. 147 Sounding when releasing throttle of third, fourth gears and decelerating
Check viscosity of transmission oil is too small, and quantity is

Transmission oil quality, quantity too little. Fill API GL-4 SAE 80W-85, and oil level shall be
flush with lower plane of oil filler.
Check driving gear and driven gear of third, fourth gear.

Abrasion of tooth shall not exceed 30% of original tooth length,
Gear clearance of third, fourth gear too large and abrasion of its depth no more than 0.5mm. Meshing area
of gear shall be no less than 2/3 of working surface; meshing
clearance no larger than 0.5mm; change gear pair if too large;
Sounding when
releasing throttle
of third, fourth Mainly check abrasion of bearing of input shaft 6205 (without
gears and slot), output shaft 6305 (with slot). And the bearing shall be
decelerating Bearing with abnormal sound(major operating without abnormal sound or jamming. Ball track with
inspection) the bearing shall not be fallen. Shaking with hands shall be
without loosening sound. In case of above-mentioned
problems, change bearing;
If play of one shaft is too large, check bearing of one shaft is

Large play of one shaft
loosening; replace it if so;
Check synchronizer of third, fourth gear is loosening; replace it

Synchronizer malfunction
if so;
Sounding when releasing throttle of third,

fourth gears and decelerating
Abnormal
Transmission oil quality, quantity Fill up accordingly
Normal
Abnormal
Gear clearance of third, fourth gear too Repair
large
Normal
Abnormal
Bearing with unusual noise Replace
Normal
Abnormal
Large play of one shaft Repair
Normal
Abnormal
Synchronizer malfunction Repaiar or replace
198
No. 148 Fifth gear not easily shifted up
Check gear shifting lever is bent or deformed, rubber sleeve is

Shift lever malfunction
aging, loosening
Check swing link support is worn, loosening or deformed, and shift

Transmission shift operation shaft and device of fifth gear is smoothly put into gear; if not, replace
mechanism malfunction swing link support assembly; check shift fork of fifth gear is vertical
to shift fork shaft; if not, replace shift fork of fifth gear;
1. Toothed ring of fifth-gear synchronizer is excessively worn, and

clearance of toothed ring pressed at gear no less than 0.5mm, with
Fifth gear not specified value between 0.85-1.45; area of joint face of fifth-gear
easily shifted up synchronizer and gear shall be larger than 80%; replace
synchronizer ring if not;
Synchronizer assembly of fifth gear
2. Check height of slide block of synchronizer is no less than 5mm;
malfunction
replace slide block of synchronizer if less than 5mm;
3. Check synchronizer hub and cover is too loosening or too
tightening. Hub shall be assembled within the cover freely. Joint part
of cover and gear shall be triangular. Replace synchronizer
assembly if damaged, worn, or its edge angle turning round;
Transmission input, output shaft

Replace transmission input, output shaft fifth-gear;
fifth-gear malfunction
199
Fifth gear not easily shifted up
Abnormal
Shift lever Replace
Normal
Unusual
Transmission shift operation Repair
mechanism
Normal
Abnormal
Fifth-gear synchronizer Replace
Normal
Abnormal
Transmission input, output shaft Repair
fifth-gear
No. 149 Fifth gear, first gear blocks, relieved only when the vehicle stops
Check gear shifting lever is bent or deformed, rubber cover

Gear shifting lever malfunction
is aging or loosening;
Check free clearance of pedal is at 1-3mm; clearance of

bearing and pressure plate is better at 2-3mm; if too large,
adjust accordingly; (empirical data)
Clutch not fully separated If clutch spring is too soft, replace it;
If clutch friction disk is excessively worn, replace it;
Check clutch plate and flywheel surface is bent, deformed
(replace it if amount of deformation is above 0.5mm);
Fifth gear, first
gear blocks, Check swing link support, right-angle shaft is deformed,
relieved only loosening. Right angle is 90 degree by visual measurement,
when the vehivle and if bending angle diminishes, replace swing link support;
stops Check fifth-gear synchronizer, and cover within hub is too
loosening and slanted around; if too loosening, replace
synchronizer assembly;
Check height of slide block of synchronizer; if less than
Transmission inner malfunction 5mm, replace slide block;
Check soldered tooth of driven gear of one gear is too far
from engaging tooth of another gear, and clutch collar may be
too deep inside. Press soldered tooth by forcing machine;
Check clearance between rear end plate of fifth gear
synchronizer and hub is too large; after fifth-gear is put, slide
block turns up, and blocks when to be relived. clearance shall
be within 2mm; if too large, replace rear end plate;
200
Fifth gear, first gear blocks, relieved only when the vehivle
stops
Abnormal
Check gear shifting lever Replace
Normal
Abnormal
Clutch not fully separated Repair
Normal
Abnormal
Transmission inner malfunction Repair
No. 150 Hiss sound when put into gear during driving
Check tightening torque at connections of gear

shifting lever and transmission is too tightening, and
Gear shifting lever malfunction
rubber cover is not isolating vibration, making sound
introduced to cab;
Hiss sound when Check working face of fourth-gear shift shaft and
put into gear fork is vertical; if not, replace fourth-gear fork. Check
Fourth-gear shift shaft and fork malfunction
during driving working face of fork is worn unilaterally; if so, replace
fourth-gear fork;
Check fourth-gear synchronizer spring and ring

Fourth-gear synchronizer malfunction are damaged; if conical surface turns small or
deformed, replace synchronizer toothed ring;
201
Hiss sound when put into gear during

driving
Abnormal
Check shift bar Repair
Normal
Abnormal
Fourth-gear shift shaft and fork Replace
Normal
Abnormal
Check fourth-gear synchronizer Replace
202
No. 151 Transmission gear runout
Fixed bolt of transmission

Check fixed bolt of transmission; fasten it if loosening;
loosens
Gear shifting lever deforms Gear shifting lever deformed causing gear abnormally or not well jointed;
1. If gear runout found at any gear, gear lever is switched to this gear,
then remove transmission cover and check gear meshing; if normal,
check locking mechanism of shift fork shaft;
Shift fork within transmission is 2. Push positioning device of shifting fork with hands; if poor, remove shift
excessively worn, self-locked fork shaft and check positioning ball and spring; if the spring is too soft or
spring breaks or too softens; broken, replace it. If groove of shift fork shaft is excessively worn, repair
During driving, replace self-locked spring and or replace it;
gear lever fork 3. Check screws of fixing plate of shifting fork are loosening, and
automatically clearance between fork end and gear groove is too large; correct it if
jumps to neutral shifting fork bends; if lower end of shifting fork is worn and sliding gear
position, which groove is too loosening, remove and repair it;
may occur when
driving at medium, Axle head of swing link support
high speed, load within transmission is
Weld up shaft end of swing link support, and grind it to stand dimension;
suddenly changes excessively worn, making all
or automotive is gears not well positioned
vibrating severely,
and most trip stop Bearing and shaft unusually Check abrasion of bearing and shaft; if the shaft is severely worn, bearing
during at high worn is loosening or shift shaft plays axially, then remove, repair or replace;
speed.
Spline clearance between
transmission clutch collar and
spline hub too large; clearance Check operation of synchronizer; if malfunction found, repair or replace it;
between clutch collar and tooth
of put gear too large
Soldered tooth bent or deformed, Check meshing of gear; if not fully meshed, check gear is worn or in
abrasion smaller taper; replace it if severely worn;
203
Transmission gear runout
Abnormal
Fixed bolt of transmission loosens
Fasten
Normal
Abnormal
Shift fork within transmission worn Replace
Normal
Abnormal
Swing link support within transmission Repair
Normal
Abnormal
Unusual abrasion of bearing and shaft Replace
Normal
Abnormal
Synchronizer clutch collar and spline hub
Replace
Normal
Abnormal
Soldered tooth bent, deformed, worn Replace
No. 152 Hiss sound when second, third, fourth gear upshift
check back clearance of synchronizing ring of second, third,

Second, third, fourth gear synchronizing ring fourth gear is not proper; if not normal, check end face of
malfunction synchronizing ring is excessively worn; if abnormal, replace
Hiss sound when synchronizing ring;
second, third,
fourth gear upshift
Contact face of gear end face and synchronizing ring is

Second, third, fourth gear malfunction excessively worn; if abnormal, replace gear;
204
Hiss sound when second, third, fourth gear upshift
Second, third, fourth gear synchronizing ring

Abnormal
Repaiar or replace
Normal
Second, third, fourth gear Abnormal Repaiar or replace
No. 153 Chug sound in transmission case at idling speed
Clearance between hub and torsional spring within clutch friction

disk is too large. Concentricity of transmission one shaft and
engine crankshaft is out of true. Clutch friction disk and hub bent
Clutch malfunction
and deformed, and rotated causing abnormal sound. Connecting
plane of transmission and engine shall be adjusted with adjusting
pad;
Chug sound in
transmission Bearing within transmission is excessively worn; clearance
case at iding driving and driven gear of first, second gear is too large. Meshing
speed Transmission malfunction clearance at 0.1-0.15; adjusting pad of output shaft is broken,
making output shaft move forward; first gear scratches and
differential generating abnormal sound;
Check lubricating oil is poor or deteriorating. If abnormal,

Lubricating oil malfunction
supplement or replace lubricating oil;
Chug sound in transmission case at iding

speed
Check clutch Abnormal Repair
Normal
Abnormal
Check transmission Repair
Normal
Unusual
Check transmission lubricating oil Fill or replace
205
No. 154 Da-da sound in transmission at idling speed
Gap between spline hub and one shaft spline within clutch
Clutch malfunction friction disk is too large; replace clutch friction disk and one
shaft;
Check bearing ball of input shaft is crushed; tooth of

driving and driven gear of first, second gear of input shaft
is fallen individually; chamfer of reversing middle wheel
and second-gear driving and driven gear is too small,
Da-da sound in
making reversing gear scratch second-gear driving and
transmission at
driven gear; grind chamfer to make larger, and push
idling speed Transmission inner malfunction
reversing gear to the highest position with hands, making it
not scratch second-gear driving and driven gear; check
whether reversing gear and transmission housing collide; if
abnormal, repair transmission housing. Check swing link
support is loosening, causing reversing gear collide with
transmission housing; if abnormal, replace support;
Lubricating oil malfunction check lubricating oil is insufficient; if not sufficient, fill up;
206
Da-da sound in transmission at idling speed
Check clutch Abnormal Repair
Normal
Abnormal
Check transmission Repair
Normal
Check transmission lubricating oil

Unusual
Add or replace
207
No. 155 Buzz sound during driving at high speed
Check viscosity of transmission oil is too small, and

Viscosity of transmission oil too small, quantity too
quantity is too little. Fill in API GL-4 SAE 80W-85
little
and oil level is flush with lower plane of oil filler;
Check tightening torque at connections of gear shifting

Tightening torque at connection of transmission lever and transmission is too tightening, and rubber
lever cover is not isolating vibration, making sound
introduced to cab;
Mainly check meshing mark of differential gear ring and

output shaft, which is adjusted between 0.1-0.15mm.
Meshing mark shall be in middle of tooth, with area no
Meshing mark of differential gear ring and output
less than 80%. Meshing point not falling out; differential
shaft abnormal, and differential bearing worn
bearing worn or loosening. Ball, track within bearing
not falling out. Inner and outer cover not obviously
loosening while shaking bearing.
Buzz sound during
driving at high check cone bearing is adjusted too tighten; if not
speed Transmission cone bearing incorrectly adjusted
normal, adjust and check differential;
Toothed ring of synchronizer is excessively worn.

Clearance on the gear pressed by synchronizer ring is
no less than 0.5mm. Specified value is between
0.85-1.45. Area of joint face of fifth-gear synchronizing
ring and gear shall be larger than 80%; if lower, replace
synchronizing ring;
Check fit clearance of hub, cover, which shall be no
Transmission synchronizer malfunction
obvious clearance while shaking from left to right. Hub
shall be assembled within the cover freely. Joint part of
cover and gear shall be triangular. Replace
synchronizer assembly if damaged, worn, or its edge
angle turning round;
Check height of slide block of synchronizer; if less
than 5mm, replace slide block;
208
Buzz sound during driving at high speed
Transmission oil viscosity, quantity Abnormal

Fill up accordingly
Normal
Tightening torque at connection of

transmission lever Abnormal
Tighten the torque
accordingly
Normal
Meshing mark of differential gear ring

and output shaft, and differential Abnormal
bearing abrasion Adjust or repair
Normal
Abnormal
Adjust according to
Transmission cone bearing adjustment standard gap
Normal
Transmission synchronizer, hub, cover,

slide block Abnormal
Repaiar or replace
209
No.156 Transmission with abnormal sound while shifting
Clutch tie-line (improved version) having too small bending; while

Clutch tie-line malfunction shifting, clutch sound introduced to cab via tie-line; replace old
version of clutch tie-line;
Check tightening torque at connections

of gear shifting lever and transmission is
Tighten connections of gear shifting lever and transmission
too tightening, and rubber cover is not
according to standard torque;
isolating vibration, making sound
introduced to cab;
Transmission
with abnormal Toothed ring of synchronizer is excessively worn. Clearance on
sound while the gear pressed by synchronizer ring is no less than 0.5mm.
shifting Specified value is between 0.85-1.45. Area of joint face of fifth-gear
synchronizing ring and gear shall be larger than 80%; if lower,
replace synchronizing ring;
Synchronizer gear ring, hub, cover Check fit clearance of hub, cover, which shall be no obvious
excessively worn or clearance clearance while shaking from left to right. Hub shall be assembled
incorrectly within the cover freely. Joint part of cover and gear shall be
triangular. Replace synchronizer assembly if damaged, worn, or its
edge angle turning round;
Check height of slide block of synchronizer; if less than 5mm,
replace slide block;
Transmission input, output shaft bearing, gear severely worn, or

Transmission inner malfunction long-term impact causing burr at meshing of gear; replace damaged
parts;
210
Transmission with abnormal sound while

shifting
Check clutch tie-line Abnormal Replace tie-line
Normal
Abnormal
Check tightening torque at connection of Tighten
transmission lever accordingly
Normal
Abnormal
Check transmission synchronizer gear ring, hub, cover, slide block Replace
Normal
Abnormal
Check transmission gear, shaft and bearing, etc. Replace damaged
parts
No. 157 Transmission gear disorder
Lock frame, pin of interlocks deformed or Replace interlock ball, pin and spring of
severely worn. transmission
When clutch not fully separated, put

into gear at start or shifting during Lower end of gear lever (automotive) is not
driving; not switched to the gear sufficient in length, and working face of
Replace shift operation mechanism
needed; unable to return to neutral lower end greatly worn or fork, guide block
position after put into gear; put into greatly deformed, worn.
two gears while vehicle is static.
Location pin of gear lever ball head worn,

loosening broken, or ball head, hole greatly Replace gear lever assembly
worn.
211
Gear disorder
Put into different gear. Hold gear lever Try to put into gear but Yes
with hands and shake around. Check cannot or try to shift down
swing angle of gear lever (automotive) but cannot?
No Malfunction caused
as shifting swing
Yes Swing or not lever falls out from
Put into two gears at fork groove, such as
the same time? No severely worn lever
No or groove
No
Yes
But swinging angle of
Malfunction caused by gear lever exceeds
broken or leaked normal range Malfunction caused by
location pin damaged locking
device, such as
severely deformed,
worn lock pin, frame
Malfunction caused by
loosening mating of location
pin and slot or severe abrasion
of ball head and seat
Interlocjing
End
212
No. 158 Shaking startup
1. Get off the vehicle and check flywheel,

flywheel casing, transmission connection is
Inner end of releasing lever not within the loosening, engine support is fixed, bolt is
same plane loosening? If loosening, fasten it; 2. check
pressing spring or circlip of release bearing is
broken; replace it;
When the vehicle starts at low 1. Check if any large abrasion sound is heard
speed, release clutch gradually during rotation, even rotating resistance is
according to operation rules, and Driven disk or clutch plate deformed or larger?
slowly step down accelerator warped; end face of flywheel severely 2. A. Check cushion sheet on clutch plate is
pedal. Clutch could not jointed jumps broken, damping spring is fatigue or broken; B.
stably and cause shaking, even friction rivet on clutch plate is loosening;
buffeting to whole vehicle. Repair or replace it if malfunctions exist.
Check driven disk is with uneven depth, oil

Friction disk of driven disk with uneven
sludge, scorching, uneven surface, hardened
depth, oil sludge, scorching, uneven
surface, exposed rivet head, loosening or
surface, hardened surface, exposed rivet
broken rivet
head, loosening or broken rivet
Replace it if exist.
213
214
Chassis
No.159 Shaking startup
(1) Clutch pedal has too large free stroke, diaphragm spring
force fully or partially acting on operation mechanism, making
Adjust free stroke of clutch;
driven disk unable to well separated with flywheel and clutch
plate;
(2) Clutch housing or transmission housing loosening Fasten loosening parts;
(3) Rivet on driven disk loosening or driven disk too thick; Clinch or replace driven disk;
Malfunction: while
startup, clutch
(4) Driven friction disk, clutch plate and flywheels working face Replace warped driven disk, clutch plate
could not be
warped, deformed; or flywheel;
jointed stably,
causing shaking.
(5) Spring annealing, diaphragm spring fatigue, with uneven
Replace clutch plate assembly;
and insufficient elastica, or broken;
(6) Fixed screws for clutch plate and flywheel loosening; Fasten bolt;
(7) Space between release bearing sleeve and its guide pipe
Clean guide pipe;
with oil sludge, dust or blocked, unable to return;
215
Diagnosis flowchart of shaking startup
216
No. 160 Clutch slipping
(1) Free stroke of clutch pedal too small or zero,

When releasing diaphragm spring force fully or partially acting on
clutch, the vehicle operation mechanism, making driven disk Adjust free stroke of clutch;
could not be started; unable to well pressed with flywheel and clutch
during accelerating, plate;
rotating speed of
engine rises, and (2) Driven disk with oil sludge, causing reduced Remove oil sludge and eliminate oil
vehicle speed not its surface friction force or its hardened; leaking; or replace driven disk;
rising accordingly;
when going against (3) Working face of driven friction disk, clutch
long slope, clutch plate and flywheel severely worn, thickness Replace driven disk;
smoking with pasting reduced;
smell. When pulling (4) Spring annealing, diaphragm spring fatigue
Replace clutch plate assembly;
on parking brake for or broken;
startup test, engine (5) Fixed screws for clutch plate and flywheel
Fasten bolt;
shall stall; if not, it loosening;
indicates that the
(6) Space between release bearing sleeve and
clutch slips. Clean guide pipe;
its guide pipe with oil sludge, dust or blocked,
unable to return;
Diagnosis program for clutch driving, slipping
217
No. 161 Heavy clutch
1. Clutch drive mechanism deformed, Check drive mechanism is deformed or jammed; correct and
jammed; repair if so;
2. Clutch tie-line jammed; Clean or replace clutch tie-line;
Feel heavy and 3. Clutch master cylinder damaged, Check clutch master cylinder is damaged, blocked; replace it
hard when blocked; if so;
stepping down
clutch pedal
Check clutch wheel cylinder is damaged, blocked; replace it if

4. Clutch wheel cylinder damaged, blocked;
so;
4. Foreign substances or rust at pivoting of Check any foreign substances or rusts at pivot; clean them or
diaphragm spring of clutch plate; lubricate rusts if so;
Heavy clutch
Unusual
Clutch drive mechanism deformed, jammed Correct and repair
Normal
Unusual
Clutch tie-line jammed or fouling Clean or replace
Normal
Damaged
Clutch master cylinder damaged, blocked Replace
Normal
Damaged
Clutch wheel cylinder damaged, blocked Replace
Normal
Unusual
Foreign substances or rust at pivoting of diaphragm spring of clutch plate Clean or lubricate
218
No. 162 Not fully separated
(1) Free stroke of clutch too large, diaphragm spring force fully or partially
acting on operation mechanism when stepping down the pedal, making
Adjust it;
diaphragm spring not fully compressed, and driven disk unable to well
separated with flywheel and clutch plate;
Malfunction: when
the engine is (2) Clutch plate diaphragm uneven, not within the same plane; Replace clutch plate;
operating at idling
speed, step on
clutch pedal, (3) Driven disk incorrectly installed, causing friction between driven disk
Reassemble;
impact sound of and flywheel;
gear occurs when
put into gear at (4) Driven disk warped, deformed, causing friction between driven disk
Correct driven disk;
original position, and flywheel or clutch plate;
and hard to put into
gear; if severe, replace driven disk of standard
engine will stall (5) Clutch driven disk too thick;
thickness;
(6) Spline hub of driven disk not flexibly moved at one shaft (output shaft)
of transmission, causing friction between driven disk and flywheel or Replace driven disk;
clutch plate, and making clutch not fully separated;
219
Diagnosis program for not fully separated clutch
220
No. 163 Clutch with abnormal sound
1. Fixed screws of clutch operation mechanism Check fixed screws of clutch operation mechanism are
loosening or damaged; loosening or damaged; fasten or replace it if any;
Check clutch release bearing is worn, damaged;

2. Clutch release bearing worn, damaged;
replace it if any;
Abnormal sound
when stepping on 3. Torsion spring of clutch plate loosening or Check torsion spring of clutch plate is loosening or
clutch pedal broken; broken; replace it if any;
4. Check spline hub of clutch plate is worn, loosening;

4. Spline hub of clutch plate worn, loosening;
replace it if any;
5. Check fixed screws of clutch housing are loosening;

5. Screws of clutch housing loosening;
fasten it if any;
221
Clutch with abnormal

sound
Abnormal
Fixed screws of clutch operation mechanism loosening or damaged Fasten or replace
Normal
Abnormal
Clutch release bearing worn, damaged Replace
Normal
Abnormal
Torsion spring of clutch plate loosening or broken Replace
Normal
Abnormal
Spline hub of clutch plate worn, loosening Replace
Normal
Abnormal
Screws of clutch housing Fasten screws
loosening
222
No. 164 Shock absorber with abnormal sound
Check fixed bolts are loosening or damaged; fasten or

1. Fixed bolts loosening or damaged;
replace if any;
Check upper and lower rubber covers are damaged;

2. Upper and lower rubber covers damaged;
replace if any;
Vehicle bumping
with abnormal 3. Buffer block damaged; Check buffer block is damaged; replace if any;
sound
4. Oil leaking; Check it is oil leaking; replace it if any;
5. Spring too soft or broken; Check spring is too soft or broken; replace it if any;
6. Internally worn, loosening; Check it is oil leaking; replace it if any;
223
Shock absorber with

abnormal sound
Normal
Fasten or
Fixed bolts loosening or damaged Abnormal replace
Normal
Damaged Replace
Upper and lower rubber covers damaged
Normal
Damaged
Buffer block aged, damaged Replace
Normal
Oil leaking
Oil leaking
Replace
Normal
Abnormal
Spring too soft or broken Replace
Normal
Abnormal
Internally worn, loosening, core axle warped, not straight, friction face warped, uneven Replace
224
No. 165 Front wheel with abnormal sound when turning
Check front suspension bolt is loosening or damaged;

1. Front suspension bolt loosening or damaged;
fasten or replace it if any;
Check ball head of tie rod, lower swing arm are

loosening; replace it if any;
2. Ball head of tie rod, lower swing arm loosening;
Check ball head of lower swing arm is loosening;
Abnormal sound replace it if any;
occur to front
wheel when
turning, while 3. Rubber cover of lower swing arm damaged; Check rubber cover of lower swing arm is damaged;
normally when replace it if any;
driving straightly
4. Pressure bearing of front wheel lack of Check pressure bearing of front wheel lacks of
lubricating oil or damaged; lubricating oil or damaged; lubricate or replace it if any;
Check outer ball cage of front wheel is worn, loosening;

5. Outer ball cage of front wheel worn, loosening;
replace it if any;
225
Front wheel with

abnormal sound when
turning
Abnormal
Front suspension bolt loosening or damaged? Fasten or replace
Normal
Loosening
Ball head of tie rod, lower swing arm loosening Replace
Normal
Rubber cover of lower swing arm Damaged

Replace
damaged
Normal
Abnormal
Pressure bearing of front wheel lack of lubricating oil or Lubricate or
damaged replace
Normal
Abnormal
Outer ball cage of front wheel worn, loosening Replace
226
No.166 Heavy steering
(1) Ttire pressure not enough; Tire inflation
(2) Fixed screws of steering knuckle loosening or

Re-fasten
falling out;
(3) Inner, outer tie rod ball head adjusted too

Adjust their matching clearance or lubricate
tighten or lack of oil;
(4) Bearing of drive part of steering gear having

too large pretightening force, or driven part and Adjust clearance
lining matched too tighten;
Driver feels heavy
and difficult while
turning steering (5) Meshing of drive, driven parts adjusted too
wheel to left or Adjust gap
tighten;
right during driving;
when the vehicle is
turning corner or (6) Steering gear is oil-free or lack of oil; Fill up lubricating oil
turning around at
low speed, hard or
even unable to turn
steering wheel. (7) Thrust bearing of steering knuckle lack of oil or
Replace thrust bearing
damaged;
(8) Steering shaft bent or its sleeve collapsed

Replace steering gear
causing scratchin;
(9) Kingpin rear inclination or inclination too large

Four wheels positioning
or front wheel with negative outer inclination;
(10) Vehicle frame deformed causing incorrect

Correct vehicle frame or four wheels positioning
positioning of front wheel.
227
Fig 4 Diagnosis chart for heavy steering
228
No. 167 Steering wheel not well back to original position
Check tire pressure is too low; if so, add pressure to

1. Tire pressure too low;
specified scope;
Check tie-rod ball head is rusty, jammed; if so, lubricate

or replace it;
2. Tie-rod ball head, and ball head of lower swing
arm rusty, jammed;
Check ball head of lower swing arm is rusty, jammed; if
so, lubricate or replace it;
Steering wheel not 3. Pressure bearing lack of lubrication or Check pressure bearing is lack of lubricating oil or
well back to damaged; damaged; if so lubricate or replace it;
original position
4. Meshing clearance of steering gear too small; Check meshing clearance is too small; if so, adjust it;
Check steering column is bent or blocked; if so, correct

5. Steering column bent or blocked;
or replace it;
Check positional parameter of front wheel is incorrect;

6. Positional parameter of front wheel incorrect
if so, adjust it;
229
Steering wheel not well back to

original position
Too low
Tire pressure too low
Fill
Normal
Unusual
Lubricate or
Tie-rod ball head, and ball head of lower swing arm rusty, jammed replace
Normal
Unusual
Pressure bearing lack of lubrication or damaged Lubricate or replace
Normal
Too small
Meshing clearance of steering gear Adjust
too small
Normal
Damaged
Correct or
Steering column bent or blocked, cracked, too soft
replace
Normal
Unusual
Positional
Positional parameter of front wheel
adjustment
incorrect
230

Check power steering pump belt is too
Shaking steering 1. Power steering pump belt too loosening;
loosening; if so, adjust it.
2. Lack of steering oil; Check it is lack of steering oil; if so, add it;
Check power steering pump is damaged; if so,
3. Power steering pump damaged;
replace it
Abnormal sound while
4. Power steering gear clearance too large or Check power steering gear clearance is too
steering
damaged large or damaged; if so, adjust or replace it;
Check ball head is rusty or jammed; if so,
5. Ball head of lower swing arm malfunction
lubricate or replace it;
Power steering with
abnormal sound
Too loosening
Power steering pump belt too loosening Adjust
Normal
Lack of power steering oil? Lack Fill
Normal
Damaged
Power steering pump damaged Replace
Normal
Abnormal
Power steering gear clearance too large or damaged Adjust or replace
Normal
Ball head of lower swing Abnormal

Replace
arm faulty
231
1. Connecting screws of front suspension Check connecting screws of front suspension loosening or
loosening or damaged; damaged; if so, fasten or replace it;
2. Wheel and wheel parts abraded while Check wheel and wheel parts are abraded while steering; if
steering so, adjust and repair it;
Steering wheel
shaking while
steering during
driving 3. Steering gear looseningly installed; Check steering gear is looseningly installed; if so, fasten it;
4. Front wheel incorrectly positioned; Check front wheel is incorrectly positioned; if so adjust it;
5. Electric power assisted steering motor

Replace steering column with motor assembly;
shaking
No. 170 Steering power insufficient (hydraulic)

1. Power-assisted steering pump belt too Check power-assisted steering pump belt is too
loosening or damaged; loosening or damaged; if so, adjust or replace it;
2. Lack of power steering oil; Check it is lack of power steering oil; if so, add it;
Steering wheel not 3. Power steering pump damaged; Check power steering pump is damaged; if so, replace
well back to it;
original position
4. Hydraulic booster system with air Empty the air inside the hydraulic booster system;
5. Hydraulic pipe distorted, scrimped or cracked,

Repair abnormal parts;
oil leaking;
6. Power steering gear damaged; Check power steering gear is damaged; if so, replace it;
232
Steering power insufficient
Abnormal Adjust or replace

Power-assisted steering pump belt too loosening or
damaged
Normal
Lack of power steering oil Lack Fill
Normal
Power steering pump damaged Damaged

Replace
Normal
Power steering gear damaged Damaged Replace
No. 171 Power-assisted pump with abnormal sound
1. Power-assisted oil insufficient Check power-assisted oil is insufficient; if so, add it;
Check power-assisted pump belt pulley is loosening; if

2. Power-assisted pump belt pulley loosening
so, replace it;
Power-assisted
pump with
abnormal sound 3. Power-assisted pump belt loosening or severely Check power-assisted pump belt is loosening or
after vehicle worn severely worn; if so, adjust or replace it;
started; and
worsen when
steering Check screws of power-assisted pump are loosening; if
4. Screws of power-assisted pump loosening
so, fasten them.
5. Power-assisted pump worn or damaged Check power-assisted pump is worn or damaged

internally; internally; if so, replace it.
233
Power-assisted pump with

abnormal sound
Lack
Power-assisted oil insufficient Add
Normal
Loosening
Fixed screws of power-assisted pump Fasten
loosening
Normal
Damaged
Power-assisted pump belt pulley loosening or Replace
worn
Normal
Damaged
Power-assisted pump belt loosening or worn Replace
Normal
Damaged
Power-assisted pump severely worn internally Replace
234
No. 172 Direction running out
(1) Front wheels rotating mass (including tire, hub,

Dynamic balancing of front wheel
brake drum or disk, hub, etc.) imbalanced;
(2) Front wheels radial circle or end face circle running Positional adjustment for tire, dynamic balancing of
out too large; the wheel
(3) Front wheel using retread tire; Replace tire
(4) Front wheels camber angle too small, toe-in too

Adjust toe-in or four-wheel positioning
large, kingpin negative caster or caster angle too large;
(5) Kingpin caster angle or kingpin angle inconsistent

Four-wheel positioning
for two front wheels;
When the vehicle (6) Front beam or front suspension bent, distorted,
is running within Correct front body or replace front suspension
deformed;
certain low or high
speed range,
(7) Action of steering system and front suspension Correct toe-in; adjust tie-rod; replace tie-rod, ball
sometimes angular
interferes each other; head
oscillation occurs
around kingpin at
two front wheels, (8) Steering systems rigidity too low (including
Replace steering tie-rod, lower swing arm;
as called front steering tie-rod, lower swing arm, etc.);
wheel yawing;
especially when (9) Meshing clearance of drive, driven parts or bearing
Adjust clearance;
yawing at high clearance of steering engine too large;
speed, two front
wheels are (10) Gear rack of steering engine matched
severely Adjust matching clearance;
looseningly;
pendulating left to
right, and hands
holding steering (11) Ball head of inner and outer steering tie-rods
Replace ball head;
gear feels sense of connected looseningly;
numbness, or even
whole nose is seen (12) Front support loosening or deformed; Fasten or replace front support
to be shaking from
the cab.
(13) Front wheel hub bearing loosening; Replace bearing
(14) Steering engine looseningly connected at the

Fasten or adjust
frame;
(15) Vibration damper of front suspension fails or its

Replace vibration damper
efficiency at left and right different;
(16) Front suspension height or rigidity (thickness,

length, or extent of new, old of spring surface) Replace spring
inconsistent;
(17) Road roughness too large; when blow frequency

of road surface on the wheel is inconsistent with
natural frequency of angular oscillation of front beam, Drive on favorable road surface
yawing of front wheel is caused under gyroscope
effect;
235
Diagnosis flowchart of front-wheel yawing
236
No. 173 Steering wander during normal driving
Tire pressure of two front wheels not equal, diameter not

Inflate the tire, adjust loading;
equal or ca loading uneven;
One of tire or hub of two front wheels deformed Replace deformed tire or hub;
One ball head of steering tie-rod loosening or jammed Replace loosening or jammed ball head;
Toe-in too large or negative toe-in Correct toe-in;
Replace loosening or jammed ball head

one ball head of lower swing arm loosening or jammed
of lower swing arm;
Front spiral spring at two sides with unequal height or

Replace spring;
elasticity;
One lower swing arm bent or lining loosening Replace lower swing arm assembly;
Automatically run to
Lower joist of front suspension deformed Replace lower joist of front suspension;
another side during
driving. Straight driving
only ensured with
hands forcibly holding Wheelbase of two sides of frames unqual Adjust wheelbase at two sides of frame;
steering wheel
Hub bearing or oil seal of two front wheels with unequal Adjust degree of tightness of hub bearing
degree of tightness or oil seal of two front wheels;
Wheels at two sides of front, rear axles with braking or Correct breaking of wheels at two sides
dragging at one side; of front, rear axle;
Correct camber angle of two front

camber angle of two front wheels, kingpin caster angle or
wheels, kingpin caster angle or kingpin
kingpin toe-in angle unequal;
toe-in angle
Front beam, rear axle tube or frame with bending with Correct front beam, rear axle tube or
horizontal plane; frame;
Camber of paving too large or with cross wind. Choose road for driving;
Electric power-assisted steering pitch sensor incorrectly Adjust or replace steering column
adjusted assembly;
237
Automatic steering wandering diagnosis flow chart
238
No. 174 Front wheel tire abnormally worn
(1) Tire pressure not conforming to requirements; Inflate or discharge to the standard
(2) Tire not changed for long time; Replace the tire
(3) Front wheel incorrectly positioned, especially

Make four-wheel positioning
toe-in and camber incorrectly matched
(4) Hub bearing loosening Replace the bearing
(5) Steering inner, outer tie-rod or steering engine

Replace ball head or fasten screws
loosening;
(6) Radial circle or end face circle of front wheel

Balance the tire or replace tire
with too large runout;
(7) Rotating quality of front wheel imbalanced; Balance the tire
(8) Front wheel yawing; Fasten nuts of tie-rod ball head, replace the tire
(9) Longitudinal center line of front axle and frame

not vertical, or wheelbase at two sides of frame Correct or adjust frame and wheelbase
Tire increasingly unequal;
worn, with unusual
tread shape
(10) Front axle or frame bent, deformed; Correct or adjust frame and wheelbase
(11) Front axle with insufficient rigidity; Replace front axle
(12) Steering tie-rod or ball joint with insufficient

Replace steering tie-rod
rigidity;
(13) Front wheel unbracing, braking slowly back,

Adjust braking
or braking dragging;
(14) Tire bolt loosening; Fasten screws
(15) Overloading, uneven loading, startup too fast,

turning or braking at high-speed with too strong Reduce loading or reduce braking
rush;
(16) Often drive on the road with larger camber; Reduce driving on unfavorable road
(17) Turning angle unable to ensure pure rolling of

Eliminate incorrect driving behaviors
each wheel, with too much or insufficient steering;
(18) Poor tire quality; Choose high-quality tire
239
Diagnosis flowchart of unusual abrasion of front wheel
240
No. 175 Normally when driving straightly, but with abnormal sound while turning
Check wheel is abraded with body parts while turning; if

Wheel abraded with body parts while turning;
so, adjust and repair it;
Normally when Outer cage of two front wheels without lubricating Check outer cage of two front wheels are with
driving straightly, oil or damaged; lubricating oil or damaged;
but with abnormal
sound while
turning Pressure bearing lack of lubricating oil or Check pressure bearing is lack of lubricating oil or
damaged; damaged; if so, lubricate or replace it;
Thrust bearing of slide column lack of lubricating

Lubricate or replace thrust bearing of slide column;
oil or with damaged ball;
Normally when driving straightly, but

with unusual noise while turning
Abnormal Adjust and repair

Wheel abraded with body parts while turning
Normal
Outer cage of two front wheels without lubricating Abnormal

Fill up oil or replace
oil or damaged
Normal
Oil leaking
Pressure bearing lack of lubricating oil or
Lubricate or
damaged
replace
241
No. 176 Braking wandering
(1) Materials for friction disk of brake shoe of left, right

wheels not the same or degree of new, old not the Replace brake disk and brake drum
same;
(2) Closing area, position of friction disc of brake shoe

and brake drum (disk) of left, right wheels not the same Adjust the clearance
or braking clearance not the same;
(3) Technical conditions for left, right wheel cylinders not

Replace left, right wheel cylinders
the same, causing different action time or opening size;
(4) Pulling force of release spring of brake shoe of left,

Replace release spring of brake shoe
right wheels not the same;
(5) Tire of left, right wheels with different pressure,

While braking, wandering different diameter, different pattern, or different pattern Adjust tire, and charge the tire
occurs to driving direction; depth;
while emergency braking,
swerving occurs.
(6) Brake drum of left, right wheels with different

thickness, diameter, extent deformation, and roughness Replace brake drums of left, right wheels
of working surface;
(7) Brake pipe at single side collapsed, blocked or oil

Clean brake oil pipe
leaking;
(8) Brake pipe at single side or wheel cylinder with air

Replace brake oil
resistance;
(9) Brake shoe at single side and support pin closely Adjust clearance of brake shoe or remove
matched or rusty; dust
(10) Frame, axle bent within horizontal plane, and

wheelbase at two sides of frame unequal, or rigidity of Adjust frame, wheelbase or replace spring
front plate spring unequal.
242
243
No. 177 Braking dragging
(1) Brake pedal without free stroke; Adjust free stroke of brake pedal
(2) Matching between brake pedal and other axles lack of

Apply oil, remove dust, or solve other
oil, rusty, or release spring of pedal falls out, snapped off,
problems accordingly;
or with too small pulling force, etc.;
(3) Release spring of master cylinder piston ruptured or Replace release spring of master cylinder
with too small pretightening force; piston;
(4) Master cylinder piston, leather cup with too large length
Replace master cylinder piston, leather cup
or leather cup bloating, sticking;
(5) Compensation hole of master cylinder obstructed by

Clean pollutants;
pollutants;
After releasing brake (6) Leather cup of wheel cylinder bloating, sticking, or
Replace wheel cylinder leather cup
pedal, braking actions piston blocking;
on individual or all
wheels could not be
fully released, thus
(7) Release spring of brake shoe falling out, snapped off or
affecting re-startup, Replace release spring of brake shoe;
with too small pulling force;
accelerating driving or
free running of
vehicles.
(8) Brake shoe and support pin rusty; Repair brake shoe and support pin;
(9) clearance between brake shoe and brake drum (disk)

Adjust clearance between brake shoe and
incorrectly adjusted; after releasing brake, local abrasion
brake drum (disk);
still exists;
(10) Oil pipe through wheel cylinder collapsed or

Clean oil pipe of wheel cylinder
obstructed;
(11) While not braking, center hole of auxiliary cylinder Repair center hole of auxiliary cylinder
piston of supercharger could not be opened; piston of supercharger
(12) Brake hose distorted, deformed or partially obstructed Replace brake hose
(13) Hub bearing loosening; Fasten hub bearing
244
245
No. 178 Braking with abnormal sound
Fixed screws for suspension connection of Check fixed screws for suspension connection of brake
brake system loosening or damaged; system are loosening or damaged; if so, fasten or replace;
Fixed bolt of front brake tongs loosening or with

Fasten or replace front brake tongs assembly;
worn lining;
Check vacuum booster is internally damaged; if so,

Vacuum booster internally damaged;
replace it;
Braking with
abnormal sound
Brake disk severely worn; Check brake disk is severely worn; if so, replace it;
while vehicle is
driving normally
Check material of brake disk is too hard; if so, grind or

Material of brake disk too hard;
replace it;
Brake hub or disk severely worn with groove; Replace brake hub or disk;
Rubber cover of front and rear suspensions

Replace rubber cover of front and rear suspensions;
loosening, aging;
246
Braking with
unusual noise
Unusual
Material of brake disk too hard Grind or replace
Normal
Abnormal
Vacuum booster internally damaged Replace
Normal
Abrasion
Brake disk severely worn Replace
Normal
Abnormal
Fixed bolt of front brake tongs loosening or with worn
lining Grind or replace
Normal
Abnormal
Brake hub or disk severely worn with Grind or replace
groove
Normal
Abnormal
Rubber cover of front and rear
Replace
suspensions loosening, aging
Normal
Abnormal
Check fixed screws for suspension connection of brake system are Fasten or replace
loosening or damaged;
247
No. 179 Braking sideslipping, swerving
Tire worn smoothly Check tire is worn smoothly; if so, replace it;
Tire of the same axle not consistent Check tire of the same axle is consistent; if not, adjust it;
Check tire pressure is too low or too high; if so, adjust to specified
Tire pressure too low or too high
pressure;
While braking,
vehicle slips to one Brake shoe, brake disk with oil sludge; Check brake shoe, brake disk are with oil sludge; if so, clean it;
side or swerves
Air in the pipeline; Check air is in the pipeline; if so, empty it;
Pressure dividing valve incorrectly Check pressure dividing valve is incorrectly adjusted; if so, readjust
adjusted it;
Rubber cover of chassis suspension Check rubber cover of chassis suspension is loosening; if
loosening necessary, replace rubber cover;
248
Braking sideslipping, swerving
Replace
Abnormal
Check tire is worn smoothly
Normal
Abnormal
Check tire of the same axle is consistent Adjust or
replace
Normal
Abnormal
Check tire pressure is too low or too high Adjust
Normal
Abnormal
Check brake shoe, brake disk are with oil sludge Clean
Normal
Abnormal
Check air is in the pipeline Empty the air
No. 180 Braking intermittently stiffening
Vacuum tube of vacuum booster with cracks, or air Check vacuum tube of vacuum booster is with cracks,
leakage or air leakage; if so, replace it;
Check non-return valve of booster is obstructed or

When stepping on Non-return valve of booster obstructed or blocked blocked; if so, clean or replace it;
brake pedal,
sometimes normal,
sometimes
stiffening Vacuum booster damaged Check vacuum booster is damaged; if so, replace it;
Check machinery parts of brake pump are blocked; if

Machinery parts of brake pump blocked
so, repair;
Brake pipe obstructed Check brake pipe is obstructed; if so, unclog it.
249
Braking intermittently stiffening
Abnormal
Check vacuum tube of vacuum booster is with Replace
cracks, or air leakage
Normal
Abnormal
Check non-return valve of booster is obstructed or Clean or replace
blocked
Normal
Abnormal
Check vacuum booster is damaged
Replace
Normal
Abnormal
Check machinery parts of brake pump are Repair
blocked
Normal
Abnormal
Check brake pipe is obstructed Unclog the pipe
250
No. 181 Braking ineffective
(1) Master cylinder, wheel cylinder, pipe or pipe

Eliminate oil leaking or fasten joint screws
joint with oil leakage;
(2) Master cylinder liquid chamber (tank) with

Add brake liquid
insufficient oil or without oil;
(3) Brake liquid deteriorates (thinning down or

thickening) or fouling within inner pipe wall too Replace brake liquid or clean brake pipe
thick;
(4) Air inside the brake liquid; Empty the air
(5) Master cylinder leather cup, piston or cylinder Replace leather cup piston or replace brake master
severely worn; cylinder
(6) Wheel cylinder leather cup, piston or cylinder

Replace brake wheel cylinder
severely worn;
(7) Oil inlet, compensation hole of master cylinder

Clear obstructed substances
or vent hole of liquid chamber (tank) obstructed;
While braking, the (8) Delivery valve, spill valve of master cylinder or
driver feels pretightening force of piston release spring too Replace master cylinder
deceleration small;
insufficient; while
emergency
braking, braking (9) Through hole at front end of master cylinder
distance too long. Replace master cylinder
piston obstructed or leather cup sticking, bloating;
(10) Leather cup of wheel cylinder sticking,

Replace wheel cylinder
bloating;
(11) Supercharger or booster with poor efficiency

Replace supercharger
or ineffective;
(12) Oil pipe collapsed or hole inside the hose

Unclog the pipe
obstructed;
(13) Brake pedal with too large free stroke; Adjust free stroke
(14) Friction disk of brake shoe and brake drum

(disk) not favorably closed or brake clearance Replace brake disk and brake drum or adjust clearance
incorrectly adjusted;
(15) Friction disk of brake shoe with poor quality,

or hardened surface, scorching, oil sludge or Replace friction disk of brake shoe
exposed rivet head during uses,
(16) Brake drum severely worn or deformed while

Replace friction disk and brake drum
braking;
251
Diagnosis flowchart of ineffective braking
252
No. 182 Brake fails
(1) Severely insufficient brake liquid or without

Add brake liquid
brake liquid;
When stepping (2) Leather cup of master cylinder severely Replace leather cup of master cylinder or eliminate oil
on brake pedal, ruptured or severe leakage of brake system; leakage
the vehicle is not
decelerating;
even with
stepping on (3) Brake hose or metal pipe ruptured; Replace brake hose or metal pipe;
continuously, not
obviously
decelerating.
(4) Connection between brake pedal and master
Repair brake pedal;
cylinder falls off.
253
254
No. 183 Steering wheel with too large free stroke
(1) Drive, driven meshing part of steering gear

Adjust drive, driven meshing part of steering gear or
loosening or bearing of drive, driven parts
bearing clearance of drive, driven parts;
loosening;
(2) Connecting parts of steering gear and steering Adjust clearance of connecting parts of steering gear
shaft loosening; and steering shaft;
When the vehicle
keeps driving (3) Ball joint of steering gear loosening; Replace ball joint of steering gear;
straightly, shaking
steering gear to
and fro slightly, it
(4) Connecting part of tie-rod ball head loosening Fasten or replace tie-rod ball head;
feels play angle
very large.
Fasten or replace ball head of lower swing arm
(5) Ball head of lower swing arm loosening
assembly;
(6) Steering thrust bearing loosening Replace steering thrust bearing;
(7) Hub bearing loosening Adjust clearance of hub bearing;
255
256
No. 184 Buzzing noise at rear wheel while driving at high speed
Check bearings of two rear wheels are worn, damaged;

Bearings of two rear wheels worn, damaged
if so, replace;
Buzzing noise at
rear wheel while Check positioning of rear wheel is misadjusted; if so,
driving at high Positioning misadjustment of rear wheel make positioning adjustment;
speed
Check pressure of two rear wheels is normal; if

Pressure of two rear wheels normal
abnormal, adjust it to standard value;
Buzzing noise at rear wheel while driving at high speed
Bearings of two rear wheels worn, damaged Abnormal

Replace
Normal
Abnormal
Positioning misadjustment of rear Positioning
wheel adjustment
Normal
Abnormal
Pressure of two rear wheels normal Adjust
257
No. 185 Braking force of brake master cylinder insufficient
Check if the air exists; empty the air at exhaust hole of

Gas within brake pipe
wheel cylinder;
Check if leakage occurs, usually at connections;

Brake pipe with leakage
properly increase torque.
Brake pedal with

too long stroke; After uses for a certain time, due to increase of foreign
when stepping on Brake master cylinder valve with poor sealing substances within brake liquid and abrasion of valve,
the pedal, no sealing of valve becomes poor; thus replace the valve.
obvious braking
effect, with braking After long-time uses and abrasion with cylinder body,
distance larger Main leather ring of brake master cylinder worn main leather ring of brake master cylinder is worn; thus
than standard replace main leather cup;
Due to long-time uses and sanitation within the vehicle,

brake master cylinder body is filled with hard
substances such as sandstone. During working, inner
Brake master cylinder body ragged
wall of cylinder body is ragged, causing poor sealing
with leather ring, and internal leakage; replace brake
master cylinder.
Braking force
insufficient
Leakage
Pipe with leakage Eliminate leakage
No
Brake master cylinder valve with poor

sealing
Poor sealing
Replace valve
Poor
Main leather ring of brake

master cylinder worn Worn
Replace main leather
ring
No
Main leather ring of brake

master cylinder worn Worn
Replace main leather
ring
No
Inner wall of brake master

cylinder body ragged
Ragged
Replace brake master
cylinder
258
No. 186 Stepping on pedal too heavily
As near to the engine, rubber hose is increasingly aged

due to its high temperature, easily causing cracks,
(1) Vacuum connecting hose leaking;
leaking vacuum, and reducing degree of vacuum of
vacuum booster, making function of booster ineffective.
As non-return valve of booster is the valve from the

engine to booster, if non-return valve is ineffective, then
vacuum chamber of the booster is equal to vacuum
Stepping on pedal (2) Non-return valve of booster ineffective;
source pressure, when the engine is with low revolution,
too heavily, with
degree of vacuum will be insufficient, and causing
ineffective or
booster semi-effective.
semi-ineffective
booster function
Connection between booster and brake master cylinder
is one important sealing point of booster, as O-ring
(3) Leakage at connection of brake master
sealing. After uses for long time, O-ring is aging, with
cylinder
reducing sealing performance, causing function of
booster ineffective.
As the booster has generally rubber sealing parts

(4) Leakage of booster assembly; inside, leakage will easily occur, causing function of
booster ineffective.
Stepping on pedal too heavily
Leaking
Vacuum connecting hose leaking Eliminate leakage
No
Non-return valve of booster Ineffective

ineffective Replace non-return
valve
No
Leakage at connection of brake master Air leakage

cylinder Replace O ring
No
Leakage of booster Air leakage

assembly Replace booster
259
No. 187 Common malfunction diagnosis and Solution for Geely

automobile tire
Serial
Malfunction symptom Causes Prevention
No.
1. After the tire crown is damaged by sharp articles, the

steel wire is rusty and snapped off, with reduced
Drive on favorable
Tire tread torn, blown strength.
1 Bar blows up road or drive at low
up And under impact of outside force, it is blown up; also
speed
blown up under strong impact during driving at high
speed.
Steel wire of bracing

Tire tread ply of tire tread rusty, Steel wire of bracing ply damaged by sharp articles on
2 Avoid sharp articles
deformed and tire casing the road, causing rusty and deformed tire casing.
deformed.
Tire sidewall bulges

out under charging Cord thread broken as tire is under strong impact of road
Avoid barriers or
3 Bar cracked status, and barriers, etc. causing low power at this point, and the
drive at low speed
corresponding inner surface is bulging out.
cord thread broken.
Tire is cut through

Cut through Tire stabbed by sharp articles on the road; repairs
4 from outside, and Avoid sharp articles
(repair) needed.
with repair marks
Tire crown rubber Drive on favorable

Pattern Tire stabbed by sharp articles on the road, and rubbing
5 and casing torn, and road or drive at low
bruising with the road surface if continue driving.
fallen out speed
Tire crown rubber as

in soybean curd Tire is running under low temperature in winter. As
Spongy
residue type, and temperature is too low, rubbers performance is reduced,
6 surface of Replace winter tire
rubber is squeezed and also squeezed with broken stone on the road,
the pattern
with broken stone causing cracks of rubber.
inside
Racially cracked,
Tire sidewall cord thread broken, Drive on favorable
7 stabbed or or even blown up if Tire stabbed (cut through) by sharp articles. road and avoid
cut through severe with bruising sharp articles
marks.
With being placed for long time under charging status,

Avoid direct sun
Rubber Rubber surface with ultraviolet radiation, erosion by ozone and heat, rubber
8 shining, ozone,
chapped turtleback cracks. surface of the tire is cracked, but tire structure is not
heat source
damaged, which could be used later.
Rubber between tire Keep standard

Driving under lower pressure, excess flections caused by
Tire bead bead and sidewall pressure inside the
10 frequent steering, braking with a rush, it causes cracks
cracked cracked, and cord tire, and have good
with fatigue.
thread broken. driving habits
260
Tire fabric and tire Apply lubricating oil

Tire bead bead slip off; if Incorrect assembling: damage tire bead during while assembling,
11
prized up severe, steel wire assembling. and avoid barbaric
could be seen. behaviors
Use improper hub or tire seat. Rim is not effectively

Lubricate
Tire beads Steel wire cracked in lubricated. When assembling, tire bead is not fully closed
effectively, and
steel wire order, and those at with rim. To complete assembling, charge too high
12 avoid charging too
cracked, cracks having its pressure, causing high shear force locally at tire bead,
high pressure and
blown up radius reduced. making its steel wire broken in order, and tearing the tire
forced assembly
sidewall, even causing severe accidents.
Tire casing deformed,

While driving under insufficient pressure or pressure
tire cavity with high
loss, causing contact surface of the tire too large, and
Worn and temperature Keep normal
13 unusual heating, and also causing reduced tire
damaged scorching, and tire pressure
performance and rolling, till blown up; if severe,
sidewall
accidents may occur.
circumferentially
With obvious rolling

traces and
scorification of cord
thread; if severe, cord
thread and tire casing
rolled and cracked.
Pattern of one side of

Unusual A. Toe-in too large or positive camber angle too large,
tire crown is
abrasion and tire shoulder of outer side is worn. B. Toe-in too large Correct toe-in or
14 circumferentially
(one side at or negative camber angle too large, and tire shoulder of camber angle
worn too quickly than
shoulder) inner side is worn.
other parts
Local pattern of tire

Unusual crown is When emergency braking or braking locking, tire is
Avoid emergency
15 abrasion circumferentially instantly abraded with road surface locally, causing local
braking
(local) worn more quickly abrasion too quick.
than other parts
Check mechanical
Local pattern of tire system of the
Unusual Caused by driving habit of mechanical system (caster
16 crown is worn as in vehicle, and avoid
abrasion angle too large, hub eccentric)
lumpy rapid steering,
braking, startup
Pattern at two sides

Unusual
of tire crown is Check pressure
abrasion
17 circumferentially Driving under relatively low pressure and use standard
(two sides at
worn too quickly than pressure
shoulder)
other parts
261
No. 188 Causes analysis for common manufacturing defects of Geely

automobile tire
Serial
Malfunctions Malfunction Causes
No.
1. Steel wire of bracing ply not well bound

with tire casing; ply separation may occur.
2. While driving at high-speed for long time
Bracing ply Tire casing not stabbed, but cord thread loosens with with low pressure, frictional force between
1
separates tire casing. tire and road surface increases, and tire
crown unusually heats up, causing reduced
adhesive force among parts, and ply
separation may occur.
Surface layer between tire sidewall rubber and Tire rubber and sidewall not well bound
2 Joint slips off
rubber cracked during manufacturing.
Tire sidewall Side bulged out; foreign substances inside while Other substances mixed during
3
loosening dissecting. manufacturing
1. Inner lining or cord plies and tire casing

ply not well bound during manufacturing.
2. While driving at high-speed for long time
with low pressure, frictional force between
4 Inner loosening Cord plies bulged out, loosened with tire casing.
tire and road surface increases, and tire
crown unusually heats up, causing reduced
adhesive force among parts, and ply
separation may occur.
262
Electrics
No. 189 CD-player disk boot malfunction (without MP3)
Inspect +B and GND, which normal value shall be 10V to 14V.
When ACC and GND ignition switch locating at ACC or ON, the
voltage shall be 10V to 14V. If it indicates no powers supply, then
Power source malfunction
check whether the fuse is burnt or not, and replace it if necessary.
In common condition, GND and vehicle earth lead shall be
conducted.
Check if the disk is inserted in wrong direction, and correct it if
CD inserted in wrong direction
necessary.
Firstly inspect the disk format, and change disk if necessary. Then
Wrong CD format or too dirty
check whether it contains dirt or scratch mark and replace it if
disk
necessary.
CD-player disk
CD not reset yet Press RESET button to reset CD-player
Boot malfunction
Shock proof screw not
Remove the shock proof screw on housing
removed
The laser head is too dusty and dirty, which affect reading ability of
the lens. And it needs to be cleaned. Clean method: clean with
The laser head of CD-player is special disk.
too dirty or aged and too high
resistance Laser head ageing, this results low laser power. That is, the beam
from laser head can not focus correctly, which causes reading
ability reduction or losing. Replace CD-player assembly.
Internal CD-player circuit
Replace CD-player assembly.
malfunction
263
CD-player disk boot failure (without MP3)
Normal
Using non-CD disk Abnormal

Please use CD disk, rather than VCD,
DVD or PC disk etc.
Normal
Dust on CD laser head Abnormal Clean laser head
Normal
Dirt on disk Abnormal Clean disk
Normal
Inspect +B and GND, which normal value shall be 10V to 14V.
Abnormal When ACC and GND ignition switch locating at ACC or ON, the
Power source malfunction
voltage shall be 10V to 14V. Inspect and replace the fuse.
Normal
Abnormal
CD-player not reset Press RESET button to reset CD-player
Normal
Abnormal
CD inserts in wrong direction Correct the disk direction
Normal
Abnormal
Disk contains scrapes or deformation
Replace disk
abnormal
Normal
Not removed
Shockproof screw not removed Remove the shockproof screw on
housing
Normal
Abnormal
Internal CD-player malfunction Replace CD-player assembly
264
No. 190 CD-player fails to work when activating

Inspect +B and GND, which normal value shall be 10V to 14V. When ACC
Power source circuit and GND ignition switch locating at ACC or ON, the voltage shall be 10V to
malfunction or fuse 14V. In common condition, GND and vehicle earth lead shall be conducted. If
damaged; it indicates no powers supply, then check whether the fuse is burnt or not,
CD-player fails to and replace it if necessary.
work when
CD-player power switch Check the power switch on CD panel; operate the power switch by hand, if
activating
malfunction or damage there is no response then replace the CD-player
Internal CD-player power
Check the voltage of internal CD-player power source end, if the value is
source circuit
between 10~14V as normal, then replace the CD-player assembly
malfunction
CD-player fails to work when activating
Abnormal Inspect the circuit and replace the fuse

External CD-player power
source
Normal
Abnormal Replace CD assembly

CD-player switch
Normal
Abnormal Replace CD assembly

Internal CD-player power source circuit
No. 191 CD-player keeps soundless under all modes

Inspect +B and GND, which normal value shall be 10V to 14V. When ACC and
CD-player power GND ignition switch locating at ACC or ON, the voltage shall be 10V to 14V. If it
source malfunction indicates no powers supply, then shall confirm whether the fuse is burnt or not,
and replace it if necessary.
Check whether the appearance of loudspeaker is damaged, as well as the coil
whether it is burnt.
Loudspeaker
Method: Measure the resistance by multimeter setting at ohms range, and the
malfunction
value shall be 4 Ohm, if it indicates to infinite, then the loudspeaker is burnt and
CD-player keeps need to be replaced.
soundless under all
modes Check loudspeaker and CD-player connection whether there is open/short
circuit. Measure two ends of same colour respectively by multimeter setting to
Wires and Ohms range, and the value shall be 0 which means conducted. Check
connector CD-player rear plug whether it is loose, and the power source voltage whether
it is normal. In generally condition, GND and body earthlead shall be
conducted.
Check whether CD-player sound controller is damaged, and track adjustment
CD-player sound
whether it is correct, as well as sound adjusting variable voltage regulator
controller damaged whether it is badly worn. Replace CD-player assembly.
265
CD-player keeps soundless under all modes
Check LCD screen illumination
Abnormal
Normal
Check wires, connector and Abnormal
power source voltage. CD player power Check and replace the fuse
source malfunction
Normal
Abnormal Replace loudspeaker

Check loudspeaker
Normal
Replace CD-player assembly

Check CD-player sound Abnormal
adjusting button
Normal

Internal CD-player circuit Abnormal
266
No. 192 CD-player/radio gains no power

Vehicle ignition switch closed Turn ignition device to ON or ACC position
Fuse burnt Replace fuse of same specification
Replace it with new connector of same

Power source output line loose
specification if abnormal
Clean the conducting point with special cleaning
Dirt in connector conducting point.
solution or replace it with a new one.
CD-player gains no power Check loudspeaker output line with multimeter

Connector wire core disconnected
when pressing POWER whether it is disconnected, replace it with new
(open circuit)
button, after the ignition connector of same specification if necessary
switch opened,
Connect vehicle battery earthlead and speaker
housing by lead wire, if CD-player regains normal
Poor fuse contact (open circuit
operation, which indicates the earth lead open
sometimes)
circuit, then replace it with new connector of same
specification.
Replace it with new connector of same
Connector earth lead open circuit
specification
Internal CD-player/radio short circuit Replace CD-player/radio assembly
CD-player/radio gains no power
Abnormal
Vehicle ignition switch closed Turn to ON or ACC position
Normal
Abnormal
Fuse burnt
Replace with fuse of same specification
Normal
Abnormal
Power source output line loose Replace with fuse of same specification
Normal
Abnormal
Clean or replace connector with same
Dirt in connector conducting point
specification
Normal
Abnormal Replace connector with same specification
Connector wire core disconnected (open circuit)
Normal
Abnormal
Poor fuse contact (open circuit Replace connector with same specification
sometimes)
Normal
Abnormal
Replace connector with same specification
Connector earth lead open circuit
Normal
Short circuit
Internal CD-player/radio short circuit Replace CD-player/radio
assembly
267
No. 193 A loudspeaker of CD-player/radio is soundless

Panel function setting inaptitude In SEL menu, on panel, BAL and FDA shall be set to 0
Replace loudspeaker of same specification. (Note: Firstly,
connect the output line of front right loudspeaker to the other
Loudspeaker damaged
one, and check the sound output, which can indicate whether
the loudspeaker is broken.)
Loudspeaker output line wrong Check output line connection whether it is correct. (Please
A loudspeaker is connected refer to the connecting method shows on nameplate.)
soundless when CD/FM Connector conducting point and
operating Clean the connector with special cleaning solution or replace
output line connection containing
it with a new one of same specification.
dirt or oxide.
Measure loudspeaker output line by multimeter, whether it is
disconnected. And replace it with a new one of same
(open circuit)
specification when necessary.
Internal CD-player/radio
Replace CD-player/radio assembly
loudspeaker output disconnected
A loudspeaker of CD-player/radio is
soundless
Abnormal
Loudspeaker output line wrong Please refer to the connecting method shows on
connected nameplate
Normal Abnormal
Panel function setting inaptitude In SEL menu, on panel, BAL and FDA shall be set to 0
Normal Abnormal
Loudspeaker damaged Replace a new loudspeaker of same specification
Normal
Abnormal
Loudspeaker outputline Clear the oxide or replace with new outputline of
connection oxide same specification
Normal
Abnormal Clean the connector or replace it with a new one of
Dirts on connector conducting
point same specification
Abnormal
Normal
Connector wire core disconnected (open Replace with new connector of same specification
ciercuit)
Normal Disconnected
Internal CD-player/radio Replace CD-player/radio assembly
loudspeaker output
268
No. 194 Onboard hand-free phone has no sound output (MK)

Low sound volume set Set it louder
Replace it with cell phone or interface matching with

Unmatch cell phone type or interface
the vehicle
Phone mute outputline switch or Remove phone mute outputline to inspect the
external controlling circuit damaged damaged part, internal or external controlling circuit
Clean conducting point by special cleaning solution or
Dirt on connector conducting point
replace with new connector of same specification.
Measure loudspeaker outputline by multimeter, to
No sound output when check whether it is disconnected. Replace with new
(open circuit)
using onboard hand-free connector of same specification.
phone
Measure the connection between phone mute
Short circuit between phone mute outputline and earthlead by multimeter, to check whether
there is short circuit. (Remove phone mute outputline to
outputline and earthlead
inspect the damaged part, internal or external controlling
circuit)
Internal CD-player malfunction Replace CD-player assembly
Onboard hand-free phone controller

Replace onboard hand-free phone controller
malfunction
269
No sound output when using onboard

hand-free phone
Abnormal
Low sound volume set Set it louder
Normal
Phone mute outputline switch or external Abnormal

controlling circuit damaged Replace switch or external controlling
circuit
Normal
Abnormal
Dirts on connector conducting point Clean or replace with new connector of
same specification
Normal
Abnormal
Cell phone or interface unmatch Replace with cell phone matching with
vehicle
Normal
Abnormal Check phone mute outputline external controlling circuit
Short circuit between phone mute outputline whether it is short circuit.normal
and earthlead
Normal
Abnormal
Controller wire core disconnected (open Replace with new connector of same
circuit) specification
Normal Normal
Abnormal
Internal CD-player failure Replace CD-player assembly
Normal
Abnormal
Onboard hand-free phone controller Replace onboard hand-free phone
failure controller
270
No. 195 CD-player/radio button out of control

CD-player/radio button out Button stuck Rock around of the button until it senses normal
of control
Improper operation Press RST button by sticker to reset the player,

then it will be recovered.
CD-player/radio inner malfunction Replace CD-player/radio assembly
CD-player/radio button out of control
Rock around of the button until it senses normal

Button stuck
Abnormal
Normal
Abnormal Press RST button by sticker to reset the player, then it will be
Improper operation recovered
Normal
Abnormal
CD-player/radio inner malfunction
No. 196 CD-player/radio button indicator malfunction

Fuse disconnected Replace fuses
Lamp controlling line loose Fix the wire
Directly connect the lamp controlling outputline

Lamp controlling switch fails or not to positive pole of vehicle battery, for inspecting
locates at ON position. the switch. If the lamp lightened then the switch
damaged. The switch shall turn to ON position.
CD-player/radio button Measure lamp controlling outputline with
indicator malfunction Lamp controlling wire core disconnected multimeter, to check whether it is disconnected. If
(open circuit) there is open circuit, replace connector of same
specification.
Check dirt on connector conducting point, and
Dirt on connector conducting point
clean it if necessary.
CD-player/radio inner circuit short
connected
271
CD-player/radio button lamp

malfunction
Abnormal Replace fuse

Fuse disconnected
Normal
Lamp controlling line loose Abnormal

Fix lamp controlling line
Normal
Abnormal
Lamp controlling switch fails or not Replace switch with same specification or turn lamp controlling
locates at ON position. switch to ON position.
Normal
Abnormal
Lamp controlling wire core Replace connector with same specification
disconnected (open circuit)
Normal
Abnormal
Dirts on connector conducting point
Clean or replace with new connector of same
specification
Normal
Abnormal
CD-player/radio inner circuit Replace CD-player/radio
short/open circuit assembly
272
No.197 CD-player/radio memory function malfunction

Power outputline B+ (memory line) and Check power source outputline B+ (memory
ACC (ignition line) wrong connected to line) and ACC (ignition line), whether they are
each other wrong connected, and correct it when necessary.
Check power source output line B+ (memory
CD-player/radio memory
Power outputline B+ (memory line) line) whether it is connected on ACC (ignition
function malfunction line), and correct it when necessary. (Note: please
connected on ACC (ignition line )
connect according the method showing on
nameplate)
CD-player/radio inner memory circuit
Replace CD-player/radio assembly. `
short or open
CD-player/radio memory function failure
Power outputline B+ (memory line) and ACC Abnormal

(ignition line) wrong connected to each other Correct B+ (memory line) and ACC (ignition line)
Normal
Power outputline B+ (memory line) Abnormal

connected on ACC (ignition line ) Connect B+ (memory line) back to memory power end
Normal
Abnormal
CD-player/radio inner memory short or
open circuit
No. 198 CD-player/radio no signal

Antenna cable disconnected Check antenna cable whether it is disconnected
Clean conducting point with special cleaning

Dirt on antenna cable conducting point
solution
CD-player/radio no signal Antenna cable deformed and results poor Replace with new antenna assembly of same
conduct specification
CD-player/radio inner antenna cable
short circuit, open circuit
273
CD-player/radio no signal
Abnormal Check antenna cable whether it is disconnected

Antenna cable disconnected
Normal
Dirts on antenna cable conducting point Abnormal Clean conducting point with special cleaning solution
Normal
Abnormal
Antenna cable deformed and results poor contact Replace antenna assembly with same specification
Normal
Abnormal Replace CD-player/radio assembly

CD-player/radio inner antenna cable short circuit
No.199 CD-player/radio sound distortion at large volume

Check loudspeaker retaining screws whether they

Loudspeaker retaining screw loose
are loose, and tighten them when necessary.
Check loudspeaker diaphragm whether it is deglue,

Loudspeaker diaphragm deglue
and repair or replace loudspeaker when necessary.
CD-player/radio sound
distortion at large volume Loudspeaker damage or disable to sustain
Replace loudspeaker or turn down the volume
high power
A loudspeaker rectifier burnt Replace damaged loudspeaker
CD-player/radio inner short or open circuit Replace CD-player/radio assembly
CD-player/radio sound distortion

at large volume
Abnormal
Loudspeaker retaining screw loose
Tighten the screws
Normal
Abnormal
Loudspeaker damaged or disable to sustain
Replace loudspeaker or turn down the
high power
volume
Abnormal Replace CD-player/radio assembly
CD-player/radio inner short or open circuit
274
No. 200 CD-player/radio tuner cant stop

Antenna cable disconnected Check antenna cable whether it is disconnected
Clean conducting point with special cleaning

Dirt on antenna cable conducting point solution. (Note: May clean with soft cloth, but neve
CD-player/radio tuner use solvents such as benzene or alcohol )
cant stop
Antenna cable deformed and results poor

Replace antenna assembly of same specification
conduct
CD-player/radio inner antenna cable short

or open circuit
CD-player/radio tuner cant stop
Abnormal
Antenna cable disconnected Connect antenna cable
Normal
Dirts on antenna cable conducting point Abnormal Clean or replace antenna cable with same specification
Normal
Replace new atenna cable of same specification

Antenna cable deformed and results poor Abnormal
conduct
Normal
CD-player/radio inner antenna cable short Abnormal Replace CD-player/radio assembly

or open circuit
275
No. 201 CD-player/radio has noise when receiving signal

Check antenna cable earth lead whether it is loose, replace i

Antenna cable earth lead loose or
of same specification or clean earth lead conducting point with
poor contact
special clean solution if necessary.
Poor local radio signal Change channel and test
Antenna cable earth lead deformed

CD-player/radio has Replace with new antenna cable of same specification
and results poor conduct
noise when receiving
signal
Check antenna cable retainig screws whether they are loose,
Antenna retaining screw loose
and tighten them if necessary.
Check loudspeaker, circuit and connector, and remove the

Loudspeaker malfunction
malfunctions according to different appearances.
CD-player/radio has noise when

receiving signal
Abnormal
Antenna cable earth lead loose or Replace antenna cable with same
poor contact abnormal specification
Normal
Poor local radio signal Abnormal

Change channel and test
Normal
Abnormal
Check and maintain loudspeaker and circuit
Loudspeaker malfuction
Normal
Abnormal
Tighten the screws
Antenna retaining screw loose
Normal
Abnormal
276
No. 202 CD-player fails to insert disk
Another disk in CD-player Press popup button and insert another disk
Two disk inserted It can insert one disk only.
Disk coating is too thin (transparent) to catch infrared

Disk coating is too thin signal. The photod on CD core is over conducted and
results CPU out of control.
If disk coating scuffed seriously where aligning to

Disk coating scuffed seriously photod, then fault will appear, that is, CPU out of
control
CD-player fails to insert Dont press two buttons at same time when
disk operating the panel, which may result CPU out of
Function improper operated control sometimes. When it appears, press RST button
by sticker to reset CD-player and remove the
malfunction.
Dont operate CD-player when CD hatch exposures

Sun or glare projectivity causes CD
under sun or glare projectivity. Replace CD-player
hatch deformation
assembly.
Disk broken Broken disk can not be applied, please replace disk.
Shockproof screw not removed Remove the shockproof screw on housing.
CD -player inner circuit malfunction Replace CD-player assembly
277
CD-player fails to insert

disk
Abnormal
Another disk remains in Press popup button and insert another disk
CD-player
Normal
Two disks inserted

Abnormal It can insert one disk only
Normal
Abnormal
Disk coating is too thin Replace disk
Normal
Disk coating scuffed seriously Abnormal

Replace disk
Normal
Function improper operated Abnormal

Press RST button by sticker to reset CD-player and
remove the failure.
Normal
Sun or glare projectivity

causes CD hatch deformation Abnormal Dont operate CD-player when CD hatch exposures
under sun or glare projectivity. Replace CD-player
assembly.
Normal
Disk broken Abnormal

Replace disk
Normal
Abnormal
Shockproof screw not Remove the shockproof screw on
removed housing
Normal
Abnormal
CD -player inner circuit failure Replace CD-player assembly
278
No. 203 CD-player fails to popup disk
Disk with improper type Replace with disk of proper type, matching
CD-player
If disk coating scuffed seriously where aligning to

Disk coating scuffed seriously photod, then CPU will be out of control. Replace
disk.
When CPU is out of control, press RST button by

CD-player fails to popup Function improper operated sticker to reset CD-player and press popup button for
disk a while.
Sun or glare projectivity shines on CD hatch Dont operate CD-player when CD hatch exposures
directly under sun or glare projectivity.
Disk broken Broken disk can not be applied, please replace disk
CD player inner circuit malfunction Replace CD-player assembly
CD-player fails to popup

disk
Abnormal Replace with disk of proper type, matching CD-player

Disk with improper type
Normal
Abnormal Press RST button by sticker to reset CD-player and press

Function improper operated popup button for a while.
Normal
Sun or glare projectivity Abnormal Dont operate CD-player when CD hatch exposures
shines on CD hatch directly under sun or glare projectivity.
Normal
Disk broken or disk coating Abnormal Replace disk

scuffed seriously
Normal
Abnormal
CD player inner circuit Replace CD-player assembly
malfunction
279
No. 204 CD-player with poor vibration resistance performance
CD player vibration resistance switch Press SEL button over 3 sec, until menu popup and
improper set select ESP 12/45, 45s is better.
CD-player with poor

vibration resistance Ensure each fix position is mounted according to
performance, and fails to Mounting bracket screws loose dimension drawings, and tightened the retaining
work on rough road screws.
CD player inner poor welded Replace CD-player assembly
CD-player with poor vibration

resistance performance
CD player vibration resistance Press SEL button over 3 sec, until menu popup and
switch improper set Abnormal select ESP 12/45, 45s is better.
Normal
Mounting bracket screws loose Abnormal Tighten retaining screws, as well as CD-player
normal
CD player inner poor welded Abnormal Replace CD-player assembly
280
No. 205 USB interface of CD player malfunction (U-disk) (MK)
No music stores in U-disk Copy MP3 music to U-disk
No MP3 music stores in U-disk Check music format on PC, whether it stores MP3 files.
Static or pulse voltage, appears when insert U-disk

repeatedly, results CPU error. (Don't pull out U-disk
Improper operation when playing music. It must turn to other MODE first.)
Press RST button by sticker to reset CD-player and
remove malfunction.
U-disk broken Check U-disk by applying another normal U-disk.
Insert U-disk until the indicator lightened. (The flat

USB interface of CD U disk improper inserted surface of U-disk shall be upwards, and the groove
player malfunction surface shall be downwards.)
(U-disk)
Clean with special clean solution (Note: may clean

Dirt on U-disk interface conducting
with soft cloth, never use solvent such as benzene or
point
alcohol.)
CD player interface contacting point

deformed
U-disk malfunction results data loss and affects music

Data loss play, inspect with another normal U-disk on same
CD-player. Replace U-disk when necessary.
CD-player inner program

Replace CD-player assembly, including USB
malfunction, which affects USB loading
281
USB interface of CD player

failure (U-disk)
Abnormal Copy MP3 music to U-disk

No music stores in U-disk
Normal
Abnormal
No MP3 music stores in U-disk Copy MP3 music to U-disk
Normal
Abnormal Press RST button by sticker to reset CD-player and remove

Improper operation
failure.
Normal
U-disk broken Abnormal Replace with U-disk of same specification
Normal
Abnormal Insert U-disk until the indicator lightened.

U disk improper inserted
Normal
CD player interface conducting Abnormal Clean interface contacting point

point deformed
Normal
Dirts on U-disk interface Abnormal Replace CD-player assembly

conducting point
Normal
Data loss Abnormal Replace U-disk with same specification
Normal
Abnormal
CD-player inner program failure, Replace CD-player assembly,
which affects USB loading including USB
282
No. 206 CD-player burns out when connecting power source
CD-player power source or Check CD-player power source, whether the voltage is between 12V and
circuit malfunction 14V. If the voltage is over normal standard, then check generator and
external power source, whether they operating normally.
Check the resistance value between the positive pole of CD-player power
supply circuit and CD-player housing, with multimeter, whether the value is
between 5kOhm and 10kOhm. If the circuit is conducting and the resistance
value is 0, then it indicates there is short circuit between positive pole of
power source and CD-player housing.
CD-player burns CD-player short circuit
out when between housing and earth
Check CD-player inner stabilized voltage supply and all components of
connecting protective circuit, whether there is short circuit. The principle inspecting
power source points are as follows: the inductive choke of stabilized voltage supply end,
the dynatron of controlling switch power supply and protective diode.
Check the components above, whether they were burnt out, and replace
them or the CD-player when necessary.
Connect multimeter to positive pole of CD-player, and set to current

measure mode. Turn on CD-player and operate in common condition, test
CD player over load current whether it is over normal value. Check power source circuit and
corresponding loads one by one, whether they are over load or consist
leakage.
CD-player burns out when connecting power

source
Over load
Check CD-player power supply voltage Inspect and maintain
generator
Normal
Abnormal
Check the resistance value between the Inspect and maintain stabilitized
positive pole of CD-player inner power power source circuit
source and CD-player housing.
Normal
CD-player over load

Abnormal
Inspect and maintain power
amplifying circuit
Normal
283
No. 207 CD-player consists back drop
Check disk surface, whether it consists scuffing or

wearing seriously, which results fuzziness sound when
playing.
CD player disk malfunction
Check whether there is problem of disk quality.
Check engine high voltage wire, whether it is

Engine high voltage wire or other electric
damaged. As well as the resistance value, whether it is
appliances
normal. Replace when necessary.
Check shield wire between CD-player housing and

earth lead, whether it consists disconnection or loose.
CD-player shield wire malfunction
Check the connection condition between radio

antenna pin and CD-player housing.
CD-player consists
back drop when Check the transfer switch between CD-player and
operating radio, whether it consists virtual link, or in place.
The alternation switch of CD-player and
Inspect the mechanical part of corresponding
radio not in place.
connection or replace CD-player assembly when
necessary.
Check the filter in CD-player stabilized circuit. For

the filters with inductive choke, shall inspect leakage.
CD-player stabilized power source Replace CD-player when necessary.
components and loudspeaker circuit
components
Check the capacitor in circuit, whether it is damaged.

Replace CD-player when necessary.
Check power source, if it is low power, which results

CD player inner malfunction CD-player inner components operate abnormally.
Replace CD-player assembly when abnormal.
284
CD-player consists back drop when

operating
Abnormal
Check enigne high Check CD disk Replace disk
voltage wire or other
electric appliances
Normal
Check CD shield wire Abnormal Check and

maintain, bonding
again
Normal
Check the transfer switch Abnormal

between CD-player and Adjust or
radio replace
Normal
Check CD-player stabilitized Normal Adjust or

power source and loudspeaker
replace
circuit
Normal
285
No. 208 Cassette stuck or failed to popup
Check cassette surface, whether it is damaged or deformed, and

Cassette deformed or damaged
Check the hatch, whether it is deformed. As well as the track, whether it

Hatch mechanism stuck or consist dirt. Maintain them when necessary.
contains dirt Check hatch track, whether it is too dusty, which results mechanism
stuck. Clean and lubricate when necessary.
Cassette stuck or
failed to popup
Press and check hatch button, whether it is functional. Inspect the

Cassette hatch button EJECT
button, whether it is cracked or dropped from loader. Replace radio
malfunction or damaged
assembly when necessary.
Press hatch popup button, inspect the operating condition of hatch

link mechanism and loader. Remove radio cover, press popup button
Loader stuck or damaged
and indicate the malfunction position. Replace radio assembly when
necessary.
Cassette stuck or failed to popup
Abnormal
Check cassette whether it is deformed Replace cassette
Abnormal
Hatch mechanism stuck or contains
dirts Adjust or replace
Abnormal
Check hatch button EJECT
Replace radio assembly
Abnormal
Check link mechanism of loader Replace radio assembly
Replace radio assembly
286
No. 209 Cassette speed abnormal, turned over automatically and chewed
Check external power supply, whether the voltage is over load and
Power supply malfunction results inner appliances operating unstably. The normal value shal
between 12V and 14V approximately.
Sentus or deformation on cassette housing affects cassette

Sentus or deformation on
operating and results low speed, unstably or chewed. Check and
cassette housing
replace the cassette.
Button switch not in place, resulting all the link mechanism

operating unreliably, and further causes cassette speed unstably or
Button switch not in place
chewed. Check operating conditions of all buttons and link
mechanism, and implement modification.
Drive gear worn seriously, resulting clearance increased between

each gear, and further causes speed differential. As a result the
Drive gear worn
cassette speed becomes abnormal, and may turn over automatically
or chewed. Replace recorder assembly.
Cassette speed
abnormal, Drive belt skid or dropped, that is, the friction reduced between belt
turned over and motor/flywheel, which results motor speed lowered and unstably.
Drive belt skid or dropped
automatically Check drive belt, whether it is loose or dropped, and replace recorder
and chewed assembly when necessary.
Drive motor brush worn seriously and fallen graphite powder results
partly short circuit between the copper plates of commutator, and
Drive motor brush worn seriously. further causes motor speed lowered. Check the clearance and
wearing condition between brushes, and replace recorder assembly
when necessary.
Guide pulley low pressure or deformed, wearing or poor bearing

Guide pulley low pressure or lubrication will cause cassette speed lowered and unstably. Check
deformed guide pulley wearing and operating condition, and lubricate or replace
recorder assembly when necessary.
The resistance of speed regulator potentiometer, electric governor,

increased or decreased, as well as delayed diode open circuit or short
Speed regulator potentiometer of circuit will result motor voltage raised or reduced, which causes motor
electric governor damaged speed unstable. Check the speed regulator potentiometer of electric
governor circuit, whether it is damaged, and replace recorder
287
Cassette speed abnormal, turned over

automatically and chewed
Normal
Abnormal
Power supply Maintain power supply
Normal
Abnormal
Cassette housing, damaged or not Replace cassette
Normal
Abnormal
Recorder button, damaged or not Inspect and replace
Normal
Abnormal
Drive gear wearing condition Replace recorder
Normal
Abnormal
Drive belt, loose or not Replace recorder
Normal
Abnormal
Drive motor wearing condition Replace recorder
Normal
Abnormal
Inspect guide pulley operating condition Inspect and replace recorder
Normal
Inspect speed regulator potentiometer electric Abnormal

governor circuit Inspect and replace recorder
Normal
288
No. 210 Poor timbre, low volume or noise jump when playing CD
Check CD disk surface, if it is too dirty or scuffed, then must be

replaced.
CD disk is too dirty or poor quality
Check CD disk quality, if it is deformed or piratic, then must be
replaced.
Check loudspeaker exterior, whether it is damaged, as well as

coil, whether it is burnt. Method: Measure the resistance by
Loudspeaker poor contact or
multimeter, and the normal value shall be 4 Ohm. If the value
damaged
shows as infinite, then the loudspeaker was burnt and must be
replaced.
Check CD player volume controlling knob, whether it is

damaged. As well as track controlling, whether it operates
Volume controlling knob damaged correctly. And variable potentiometer of volume controller,
whether it is seriously worn, Replace CD-player assembly when
necessary.
Poor timbre,
low volume or Check voltage of CD-player power supply, generally +B and
noise jump GND voltage shall between 10V and 14V. When ACC and GND
when playing ignition switch locating at ACC or ON position, the value shall
Power supply unstable between 10V and 14V.
CD
Check CD-player laser head serve motor driving voltage,
whether it is in normal range. Maintain it when necessary.
After CD disk was inserted, inspect by infrared illuminator,

load motor action, when the disk positioned survey up/down
Laser head is too dirty or aging focus action of laser head, whether it radiates red/blue beam.
Check laser head component, clean laser head or replace
CD-player assembly when abnormal.
Power amplifier is a component of the vehicle sonic equipmen

with most malfunction rate. It is mostly caused by integrated
package puncture.
CD-player inner power amplifying
circuit malfunction Check power amplifier circuit supply voltage and load, as well
as the transient peak voltage generated by motor, whether they
are under normal value. Maintain and replace CD-player
289
Poor timbre, low volume or

noise jump when playing CD
Abnormal
Check CD disk, whether it is too Replace CD disk
dirty
Normal
Abnormal
Check loudspeaker, whether it is
poor conducted Maintain, modify or replace
Normal
Abnormal
Check volume adjusting
knob Replace CD-player assembly
Normal
Abnormal
Check CD-player supply Maintain, modify
voltage
Normal
Abnormal
Check laser head, whether it is too
dirty or aging Clean or replace CD-player
assembly
Normal
Abnormal
Check the voltage between each pin of Inspect and maintain circuit or replace
power amplifier CD-player assembly
normal
290
No. 211 Low loudspeaker volume
Loudspeaker poor performance, magnetic of alnico

reduced. The sensitivity of loudspeaker is mainly
determined by the magnetic of permanent magnet, the
Loudspeaker poor performance quality of cone diaphragm and the level of assembly
process. Contact alnico with ferromagnetic and
estimate the magnetism, replace loudspeaker when
necessary.
Check loudspeaker and CD-player external

connection, whether they are damaged. Measure with
multimeter, the resistance shall be 0 Ohm, disconnect
the connectors on both ends, and measure the
resistance between connection and body (earth lead),
of which value shall be infinite. If not, the circuit shall
Loudspeaker circuit poor contact or short circuit. be maintained or replaced.
Check loudspeaker exterior, whether it is damaged,

as well as coil, whether it is burnt. Measure the
resistance by multimeter, and the normal value shall
be 4 Ohm. If the value shows as infinite, then the
loudspeaker was burnt and must be replaced.
All or single
loudspeaker low
volume Check CD disk quality, whether it is piratic. Replace to
genuine CD disk.
CD disk damaged
Check disk format or surface wearing level, and
replace timely when necessary.
Measure the resistance between both ends of

volume controlling potentiometer. Connect multimeter
Volume controlling potentiometer worn or and rotate potentiometer slowly, meanwhile survey the
damaged resistance variation, if there is no change or shows as
infinite, which indicates damage, then shall replace
CD-player
Check power amplifying circuit, measure the voltage

between each pin by multimeter. Check the signal from
front amplifying circuit. Mainly inspect the capacitance,
CD -player inner power amplifier open or short resistance of power amplifying circuit, as well as the
circuit circuit and integrated package of circuit panel, whether
they are burnt. Replace CD-player when necessary.
power amplifying circuit, measure the voltage between
each pin by multimeter.
291
Loudspeaker low volume
Abnormal
Replace loudspeaker
Loudspeaker poor performance
Normal
Loudspeaker connecting wire poor Abnormal

Check and maintain
conducted or short circuit
loudspeaker circuit
Normal
Abnormal
Poor CD disk quatily Replace CD disk
Normal
Abnormal
Volume controlling potentiometer damaged Replace volume
potentiometer
Normal
CD-player assembly inner short circuit or open Abnormal Replace CD player

circuit
292
No. 212 Large loudspeaker noise
Check loudspeaker magnet clearance and cone diaphragm,

Dirts in loudspeaker magnet
whether there is dirt in the clearance or the diaphragm cracked. With
clearance or cone diaphragm
that problems voice will be distortion when voice coil vibrating, and
cracked.
results raucity voice.
Check loudspeaker circuit, whether it is damaged or short circuit

to earth, as well as virtual connection between circuit and
CD-player/loudspeaker. Maintain or replace it when necessary.
Loudspeaker circuit poor contact Pull out the pins of CD-player and loudspeaker, measure the
resistance by multimeter, the value between both ends of circuit
shall be 0 Ohm, the resistance to earth shall be infinite, and the
resistance of loudspeaker shall be 4 Ohm. Inspect or replace when
necessary.
Check the appliances in engine cabin, high voltage wire for

example, mainly inspect the electromagnetic frequency, generated
External appliances affection
when the appliances operating, which may affect the normal
operation of CD-player and loudspeaker.
Large
loudspeaker
noise
Check the filter of CD-player stabilized voltage, some may equips
with inductive choke filter, then shall check current leakage in
inductive choke. Replace CD-player when necessary.
CD player stabilized voltage supply Check capacitor of circuit, whether it is damaged. Remove the
components malfunction capacitor and measure it by multimeter setting at voltage range,
survey value variation between straight polarity and reverse polarity.
If the variation range is too narrow, which indicates the capacitor is
damaged, then replace CD-player.
Most malfunctions in voice circuit appear on capacitor, cause

CD player voice circuit short or current leakage or sealing-off always affect voice affection when
damaged playing, with load noise. Measure it by multimeter, replace
CD-player or implement welding when necessary.
Check power amplifying circuit, measure the voltage between

each pin by multimeter, survey the signal from front amplifying
CD player power amplifying circuit
circuit, mainly inspect the capacitor, resistance, circuit and
short or damaged
integrated package on circuit panel, whether there are evidences of
burning. Replace CD-player when necessary.
293
Large loudspeaker noise
Abnormal
Replace loudspeaker
Dirts in loudspeaker magnet
clearance or cone diaphragm
cracked.
Normal Abnormal
Maintain loudspeaker circuit
Loudspeaker circuit poor

contact
Normal
Abnormal Maintain modify replace
External appliances affection
Normal
Abnormal
CD player stabilized voltage supply Replace CD-player
components malfuction
Normal
Abnormal
CD player voice short Replace CD-player
circuit or damaged
Normal
Abnormal
CD player power Replace CD-player
amplifiying circuit short or
damaged
Normal
294
No. 213 Loudspeaker susurrates when pressing horn
Check whether loudspeaker cone diaphragm is cracked.

Check whether the loudspeaker retaining screws are loose.
Since the vehicle horn mounting at front cross member, body
Loudspeaker damaged or screws loose will be vibrated when pressing horn, meanwhile, cracked
diaphragm or loose screws will result CD-player loudspeaker
voice distortion, as well as voice raucity when pressing horn.
Solution: replace horn and tighten loudspeaker retaining screw.
Check loudspeaker circuit, whether it is damaged or short

circuit to earth, as well as short circuit between loudspeaker
Loudspeaker short circuit circuit and horn circuit. Measure the resistance between
loudspeaker and earth, whether it is under normal range.
Maintain or replace it when necessary.
Check the screws of CD-player earth lead, horn earth lead

and body connecting position, whether they are loose. When
pressing horn, earth lead will be virtually conducted, because
The screw of CD-player and horn earthlead
screws loose, the friction between body and earth lead will
loose
cause weak spark and generates interfering signal, which
results loudspeaker raucity. Solution: Clean earth leads, and
tighten the retaining screws.
Loudspeaker Check the resistance between terminal A3, at CD-player pin,

susurrates when and body. Disconnect CD-player pin and rear view mirror pin,
pressing horn measure the resistance from A3 terminal to fuse by multimeter,
the value shall be infinite, that is under non-conduction.
CD-player short circuit Otherwise, shall maintain CD-player power supply circuit.
When pressing horn, loudspeaker susurrates, then shall

mainly inspect short circuit between horn circuit, earth lead
connecting with CD-player earth lead, and CD-player circuit.
Maintain circuit when necessary.
Check CD-player power supply circuit and inner stabilitized

power supply, whether there is burnt or short circuit. Mainly
inspect the capacitor between power supply and circuit,
whether there is current leakage or damage. Maintain or
Check anti-interference or wireharness direction on

CD-player inner magnet interference may
CD-player. As well as screen condition of CD-player, whether it
result loudspeaker noise
is interfered by screen wire damage. Maintain or replace it
when necessary.
Check CD-player high frequency receiving circuit, whether

there is damaged component, short circuit in circuit, or current
leakage in high frequency capacitor. Maintain circuit or replace
CD-player assembly when necessary.
295
Loudspeaker susurrates
when pressing horn
Normal
Abnormal
Loudspeaker damage or screws
loose Maintain, tighten and replace
Normal
Abnormal
Replace loudspeaker
Loudspeaker short circuit
Normal
The screw of CD-player and horn Abnormal

earthlead loose
Maintain and tighten
Normal
Abnormal
Horn and CD-player short circuit Maintain and replace
Normal
Abnormal
CD-player inner short circuit or burnt
Maintain and replace CD-player
296
No. 214 Speedometer non-display
Lift vehicle with two-post lift then start enginegeared, and

accelerate, survey sensor pulse signal by oscilloscope. If
there is no pulse signal on display screen, then the sensor is
malfunction and must be replaced. Measure the voltage
Speed sensor poor operation between both ends of speed sensor, open ignition switch,
and rotate wheel slowly. The voltage between speed sensor
pin 1 and pin 3 shall be 0.5~9V, between pin 2 and pin 3
shall be 8V approximately. Otherwise, shall inspect speed
sensor circuit.
Measure the resistance between pin 2 of speed sensor and

body, earth end, by multimeter, the value shall be 0 Ohm, sc.
Speed sensor connecting circuit conducted. Set ignition switch to ON position, measure the
malfunction voltage between pin 3 and body, earth end, the value shall
be 7.5~9V. Otherwise, shall maintain circuit or replace
instrument assembly.
Lift vehicle with two-post lift, then turn shift lever to neutral
gear and set ignition switch at ON position. Rotate front
Speed sensor power supply circuit
wheel slowly, measure the voltage between pin 1 and pin 2
malfunction
by multimeter, the value shall between 0.5V and 9V.
Speedometer Otherwise, replace speed sensor.
non-display, sc.
odometer non-display
Lift vehicle with two-post lift, then start engine, geared, and
accelerate. Survey sensor pulse signal by oscilloscope, if
there is no pulse signal on display screen, then shall inspect
Speed sensor drive or driven gear speed sensor firstly. If it finds no damage in sensor
damaged inspection, then shall remove driven gear from speed sensor
rear end, as well as drive gear from gearbox output shaft,
and survey whether it appears gear hit and miss. Replace it
when necessary.
Open fuse box and check CLUSTER (10A) AM1 (30A) and
fuse MAIN (80A), whether they are burnt. Replace them
when necessary. Disconnect connector from grouped
LCD odometer power supply and
instrument assembly, measure the resistance between B7
instrument connecting circuit
(GND) and body (earth end) by multimeter, as well as the
malfunction
resistance between B8 (GND) and body (earth end), and the
value shall be 0 Ohm, sc. conducted. Otherwise, shall
maintain connecting circuit.
Grouped instrument inner short and

Replace grouped instrument
open circuit
297
Speedometer
non-display
Survey instrument indicating

condition
Abnormal Normal
Maintain instrument power Lift vehicle with two-post lift,

supply fuse and fuse box. then start engine, geared, and
Check CLUSTER (10A) accelerate. Survey sensor pulse
AM1 (30A) and fuse MAIN signal by oscilloscope
(80A), whether they are
burnt.
Abnormal Normal
Lift front wheel and rotate Check instrument operating

slowly, then measure the condition. Maintain instrument,
voltage between speed sensor speed sensor connecting
pin 1 and pin 2 by multimeter, harness and connecting pin
the value shall be 0.5~9V. etc.
Normal
Abnormal
Measure the resistance between speed

sensor pin 2 and body by multimeter, the Maintain speedometer Abnormal Replace
value shall be 0 Ohm. Measure the sensor speedometer
voltage between pin 3 and body (earth sensor
end), the value shall be 7.5~9V.
Replace drive or driven

gear
Replace instrument
assembly
298
No. 215 Freedom ship speedometer malfunction, indicates automatically when pressing horn
Battery positive pole wire poor Check battery positive pole pin, whether it is poor contacted. Clean
contact and tighten it when necessary.
Set multimeter to voltage range, connect the red probe to terminal A11
on instrument panel pin, the black probe to body earth lead, turn ignition
switch to ON position, press horn button, and survey the variation of
voltage indicator. If the indicator swings greatly, which indicates short
circuit between speedometer and center integrated controlling circuit,
Instrument connecting cable short then shall implement maintaining work.
circuit
Pull out instrument pin and center integrated controller pin, measure
the resistance between two ends of wire harness and earth lead, of
which value shall be infinite, sc. non-conducted. Otherwise, shall
maintain or replace wire harness.
Check center integrated controller surface, whether it is burnt. Smell

center integrated controller, whether there is burnt taste. Replace center
integrated controller when necessary.
Disconnect center integrated controller and speedometer connecting

pin, measure the resistance respectively between terminal A11 on
Freedom ship Center integrated controller inner instrument connector and terminal A3 of center integrated controller, the
speedometer short circuit or damage value shall be 0 Ohm, sc. conducted. And the resistance between any
malfunction, terminal and earth shall be infinite. Otherwise, shall replace wire
indicates harness
automatically Set multimeter to voltage range, turn ignition switch to ON position,
when pressing connect the red probe to terminal A3 on center integrated controller, the
horn black probe to body earth lead, then press horn button and survey the
variation of multimeter indicator. Maintain center integrated controller or
Since the horn button switch is integrated in grouped switch on

Freedom ship; therefore, once there is short circuit between horn button
and grouped switch, they will affect each other.
Disconnect center integrated controller and grouped switch connector,

measure the resistance between A21 and A2, as well as A22 and A3, by
multimeter, and the value shall be 0 Ohm. Measure the resistance
Horn button cable and grouped between any terminal and body earth lead, the value shall be infinite.
switch inner short circuit
Check circuit between grouped switch and horn button, whether there
is short circuit. Disconnect center integrated controller connector, and
measure it by multimeter. The resistance between C6 and A21, C6 and
A22, C6 and B11, C6 and B22 shall be infinite, sc. non-conducted. Press
horn button, the multimeter indicator shall stand still. Otherwise, it
indicates grouped switch inner short circuit or burnt, and shall be
replaced.
Grouped instrument inner circuit Replace instrument assembly
299
speedometer moves automatically

when pressing the horn (CK)
Check instrument connecting wire. Check center integrated controller inner circuit, Check horn button circuit and grouped
whether there is short circuit or damage switch.
Pull out instrument connector and center integrated Check center integrated controller, whether Disconnect center integrated controller and grouped switch
controller pin; inspect the harness by multimeter, it is burnt. connector, measure the resistance between A21 and A2,
whether there is short circuit. as well as A22 and A3, by multimeter.
Abnormal
Abnormal Inspect, maintain, replace
Inspect, maintain, replace Abnormal Inspect, maintain, replace
Connect multimeter to terminal A11 on instrument Connect multimeter to terminal A3 on center Measure the resistance between C6 and A21, C6 and
panel connector, set ignition switch to ON position, integrated controller, set ignition switch to ON A22, C6 and B11, C6 and B22, by multimeter, press
press horn button, and survey the variation of position, press horn button, and survey the horn button, and survey the variation of multimeter
voltage indicator. variation of voltage indicator. indicator.
Swing Swing
Inspect and maintain speedometer and Swing
center integrated
controller connecting wire, whether Replace grouped switch assembly
there is short circuit.
Replace center integrated controller
when necessary.
300
No. 216 Incorrect indication of speedometer

1) Lift the vehicle with double props lifter, and shift the gear to
accelerate; view the waveform of the pulse signal from sensor
by oscilloscope; if the pulse signal is disconnected, then the
speed sensor should be replaced;
2) While measuring the voltage between terminals of speed
sensor, place igniting switch to ON and turn the wheel slowly;
Speed sensor fails or damaged the voltage between #1 and #3 terminal of speed sensor
should be varied from 0.5 to 9 V and voltage between #2 and
#3 should be about 8 V; #2 terminal is earthing wire; the
resistance between #2 terminal and body (earth) measured by
Ohm grade of multi-meter is zero, which is in conducting state;
if all the measured values are in normal range, speedometer
sensor should be replaced.
3) Lift the vehicle with double props lifter, and shift the gear to
accelerate; view the waveform of the pulse signal from sensor
by oscilloscope; if the pulse signal is disconnected or broken
Drive or driven gear of speedometer is down, then the speedometer should be checked first for
worn out broken sensor; the final driven gear in speed sensor and drive
gear of transmission output shaft should be dismantled and
checked if there is broken tooth; if yes, the gear should be
replaced.
4) Check the cable of speed sensor connection and instrument

loop if there is broken sleeve resulting in short-circuit; if yes,
harness should be repaired or replaced;
5) Remove plugs of speed sensor instrument PCB and
Conducting state or poor contact between
measure their resistance separately with multi-meter; the
speed sensor connection and instrument
resistance between #2 terminal of speed sensor and A9
loop
terminals of instrument plug should be zero as conducting
Incorrect indication
state; so as the resistance between #3 terminal of speed
of speedometer
sensor and A10 of instrument plug, and between #1 terminal
of speed sensor and A11 of instrument plug;
6) Check the rear connections of instrument panel, please

re-connect or replace if there is loose or poor contact;
Measure voltage of terminal B4 for normal 12V; instrument
Fluctuation of power supply for instrument
connectors B7 and B8 are bond straps; place igniting switch to
loop
ON position, measure the voltage between A10t A9, which
should be about 8V; connector A9 is bond strap and A11 is
signal cable for speedometer.
7) Check PCB of speedometer for signs of sealing-off or

burning. Because the electronic circuit of speedometer
converts the frequency signal from wheel speed sensor to
useful voltage signal to control circuit of speedometer and
drive the motor of odometer, if there is sealing-off or poor
Malfunction of internal electronic circuit for contact, the discontinuous power supply for electronic circuit
speedometer or stuck actuating will result in unstable speedometer due to irregular swing of
mechanism speedometer pointer. Test the combined instrument with
testing bench;
8) Check the internal actuating mechanism of speedometer for
dropping off or check the drive motor and pointer for blocking
by dirt, which may result in blocked or damaged speedometer;
if yes, clean or replace instrument assembly.
The types of tyres for front wheels are

Replaced with tyres of same specification as original
different.
301
Incorrect indication of
speedometer
Lift the vehicle with lifter, and shift the gear to

accelerate the engine; connect oscilloscope to #1
pin of speed sensor to view the waveform of the
pulse signal
Abnormal Normal
Measure the voltage between terminals of speed sensor, place Check the rear connections of
igniting switch to ON and turn the wheel slowly; the voltage instrument panel and power supply
between #1 and #3 terminal of speed sensor should be varied of instrument
from 0.5 to 9 V
Check, adjust and

repair
Yes
No
Check if there is conducting state or break

Check if between speed sensor connection and
speedometer is instrument loop
damaged Replace speed
sensor
Check drive or driven

gear of speedometer
Normal Abnormal
Check malfunction of internal Repair connection or

electronic circuit for speedometer or replace harness
Replace drive or stuck actuating mechanism
driven gear of
speedometer
Replace instrument
assembly
302
No. 217 Kilometrage on LCD of odometer will accumulate automatically after the engine starts
1) Check PCB of speedometer whether it is burnt or of

short-circuit; because the electronic circuit of
speedometer converts the frequency signal from wheel
speed sensor to useful voltage signal to control circuit of
speedometer and drive the motor of odometer; if the
Short-circuit of instrument PCB PCB is short-circuit, will result in discontinuous power
supply for electronic circuit and then affect to
speedometer;
2) Check PCB of instrument for short-circuit due to
soldering sealing-off of dropping-off; if yes, check and
repair or replace instrument assembly;
3) Place igniting switch to ON position, measure with

voltage grade of multi-meter if voltage of odometer drive
motor is in normal range; measure if resistance of drive
Short-circuit of odometer drive motor circuit motor is in normal range; check if short-circuit of drive
circuit results in abnormal working of odometer motor
and moving of odometer kilometrage; repair drive circuit
or replace drive motor;
4) Check centralized controller for always-ON" of A3

speed signal to instrument due to internal short-circuit or
burn-out, which will result in automatic moving of
Kilometrage on odometer kilometrage;
LCD of odometer 5) Switch multi-meter to voltage grade and igniting switch
will move Short-circuit of centralized controller to ON; connect red probe to A3 terminal of centralized
automatically after controller and black probe to bond strap of body; the
start-up of engine voltage measured should be between 0.5 9 V; start up
engine and view pointer of multi-meter; there will be no
obvious variation; otherwise, check and repair
centralized controller or replace centralized controller;
6) Besides odometer, the pulse signal from speed sensor

is also provided for centralized controller and EPS, so
the normal working of speedometer will be affected by
damage or short-circuit of any module of them;
7) Firstly, check speedometer under normal working
condition: Lift the vehicle with double props lifter, and
Internal short-circuit or damage of ECU for EPS
shift the gear to accelerate the engine; view the
(Electrical Power-assisted Steering)
waveform of the pulse signal from sensor by
oscilloscope; if speedometer works normally, remove
plugs of speed sensor and centralized controller, start up
engine and view if there is pulse signal on oscilloscope; if
yes, the ECU internal circuit for EPS is broken and
should be replaced.
Wrong connection of harness Connect the harness again;
Malfunction of speed sensor Replace speed sensor
303
Kilometrage on LCD of odometer will

accumulate automatically after
start-up of engine
Lift the vehicle with lifter, remove speed

sensor and start up engine; connect
oscilloscope on signal wire (#1 terminal) of
speed sensor and view the signal from
sensor
With signal Wrong connection of Without signal

harness
Malfunction of speed
Check centralized controller; remove plugs of Check PCB of instrument and sensor
speed sensor and EPS; switch multi-meter to odometer drive motor circuit
voltage grade and igniting switch to ON; for short-circuit due to
connect red probe to A3 terminal of centralized Connect the soldering sealing-off of
controller and black probe to bond strap of harness again dropping-off
body; measure if there is pulse signal Replace speed
sensor
Replace instrument
With signal Without signal assembly
Replace Check EPS ECU internal circuit for

centralized short-circuit or break
control module
Replace EPS ECU
304
No. 218 Automatic movement of odometer pointer after start-up of engine

1) Remove plugs of speed sensor and instrument plug;

measure wire resistance between terminals by
multi-meter separately; the resistance between #1
terminal of speed sensor and A11 terminal of instrument
Conducting state or poor contact plug should be zero as conducting state; the resistance
between speed sensor connection and measured by the multi-meter should be infinite,
instrument loop, poor contact between otherwise, there is short-circuit and should be repaired;
instrument PCB and bond strap 2) Check connection cable of instrument panel; Measure
voltage of terminal B4 by multi-meter for normal 12V;
instrument connectors B7 and B8 are bond straps; check
fixing screws of B7 and B8 earth wire and body for
loosing; if yes, tighten it firmly;
3) Check PCB of instrument for short-circuit due to

soldering sealing-off of dropping-off; if yes, check and
repair or replace instrument assembly;
4) Check tachometer for normal working; if there is
Short-circuit of internal electronic circuit
internal short-circuit or break for tachometer, the
of instrument or tachometer circuit
connection between tachometer and speedometer on
PCB should be checked for short circuit or wrong
transmission signal which results in fault of odometer and
instrument assembly should be replaced;
5) Remove plugs of centralized controller, EPS and
speedometer sensor, etc , start up engine and connect
Automatic moving of
oscilloscope on A11 terminal of instrument plug wire or
odometer pointer after
ECU of engine #9 terminal of engine ECU to view waveform; if there is
start-up of engine
still waveform of signal after removing plugs, the engine
ECU fails internally and should be replaced;
6) Switch multi-meter to voltage grade and igniting switch
to ON; connect red probe to A3 terminal of centralized
controller and black probe to bond strap of body; the
voltage measured should be between 0.5 9 V; start up
Short-circuit of centralized controller engine and view pointer of multi-meter; there will be no
obvious variation; otherwise, should check and repair
centralized controller loop and instrument connection or
replace centralized controller;
7) Firstly, check speedometer under normal working
condition: Lift the vehicle with double props lifter, and
shift the gear to accelerate the engine; view the
waveform of the pulse signal from sensor by
Internal short-circuit or damage of EPS oscilloscope; if speedometer is working normally, remove
ECU plugs of speed sensor and centralized controller, start up
engine and view if there is pulse signal on oscilloscope; if
yes, the ECU internal circuit for EPS is broken and
should be replaced.
Internal short-circuit of speed sensor Replace speed sensor assembly
Wrong connection of harness Check and sort out the harness connection again.
305
Automatic movement of
odometer pointer after
start-up of engine
Remove plug of speed sensor; lift the vehicle with double props lifter, and
start up the engine; connect oscilloscope on A11 terminal of instrument
harness to view for signal
No Yes
Short-circuit of internal Check if there is conducting state or bad

electronic circuit of Wrong contact of bond strap between speed sensor
connection Internal short-circuit of
instrument or tachometer connection and instrument loop speed sensor
circuit of harness
Connect the
harness Replace speed sensor
again assembly
Replace instrument
assembly Normal Abnormal
Check engine ECU for internal Check, repair and

short-circuit or break replace
Abnormal Normal
Replace engine Check centralized controller for internal short-circuit or

ECU damage
Abnormal Normal
Replace centralized Check EPS

controller
Replace EPS module (ECU)
306
No. 219 Incorrect indication or no indication of engine tachometer

1) Open fuse unit and check if CLUSTER(10A) AM1(30A)
and MAIN(80A) in fuse unit is broken; replace if necessary;
2) Place igniting switch to ON and measure voltage of
instrument connector B4 with voltage grade of multi-meter;
the voltage should be equal to the voltage of battery
Malfunction of power supply circuit for (standard voltage: 12V); measure resistance of instrument
instrument connectors B7 and B8 to bond strap; the resistance should
be zero because B7 and B8 are bond straps of instrument; if
power supply voltage for B4 and resistances for B7 and B8
are different from normal values, circuit should be checked
and repaired or fuse should be replaced;
3) Check PCB of tachometer for short-circuit due to soldering
Conducting state or break of tachometer PCB sealing-off of dropping-off; if yes, check and repair or replace
instrument assembly;
4) Remove engine ECU connecting harness and instrument
harness; measure by resistance grade of multi-meter
between #54 terminal or engine ECU and B11 connector of
Short-circuit or poor contact of engine ECU
Incorrect indication connecting harness, power supply and instrument board; the resistance should be zero as
or failure of engine tachometer connecting wire conducting state; and measure resistance between engine
tachometer #54 or B11 on instrument board and body (bond strap); the
resistance should be infinite, otherwise there must be
short-circuit in this loop.
5) Check tachometer coil for blow-out or break; check if
hairspring blocks with panel while rotating and if there is
Blocked mechanical part of tachometer
break of hairspring of tachometer coil; if yes, tachometer or
6) Dismantle combined instrument assembly with connectors
connected; connect oscilloscope on B11 terminal of
Internal malfunction of tachometer instrument connector; start up engine and view if the
displayed waveform of pulse signal is correct; if yes, the
tachometer should be checked, repaired or replaced;
7) Check rotating speed output signal of engine ECU;
dismantle engine ECU with connectors connected; connect
oscilloscope on #54 terminal and start up engine to view if
Malfunction of engine control system the displayed waveform of pulse signal is correct; if without
pulse display, engine control system should be checked and
repaired or engine ECU should be replaced;
307
Incorrect indication or no indication of engine

tachometer
Start up engine and view if pointer of tachometer

is swinging
Without swinging swinging
Check power supply loop for Check tachometer coil for blow-out
instrument; measure voltage of B4 or break; check if hairspring blocks
instrument connector for normal with panel while rotating and if there
about 12 V with voltage grade of is break of hairspring of tachometer
multi-meter; check fuse for burn-out coil
Abnormal
Replace fuse of
instrument
Check tachometer PCB for Replace tachometer or instrument

short-circuit or break assembly
Abnormal
Check, repair and
replace
Check connecting harness of

engine ECU and tachometer
for short-circuit or break
Abnormal
Check, repair and
replace
Connect oscilloscope on B11 terminal of

instrument connector; start up engine and
view if the displayed waveform of pulse
signal is correct
Abnormal
Normal
Connect oscilloscope on #54 terminal; start up engine

Check, repair or replace and view if the displayed waveform of pulse signal is
tachometer normal
Check and repair engine control

system or replace ECU
308
No. 220 Incorrect indication (or no indication) of fuel gauge

1) Open fuse unit and check if CLUSTER(10A) AM1(30A) and
MAIN(80A) in fuse unit is broken; replace if necessary;
2) Place igniting switch to ON and measure voltage of instrument
connector B4 with voltage grade of multi-meter; the voltage should be
1) Malfunction of power supply equal to the voltage of battery (standard voltage: 12V); measure
circuit for instrument resistance of instrument connectors B7 and B8 to bond strap; the
resistance should be zero because B7 and B8 are bond straps of
instrument; if power supply voltage for B4 and resistances for B7 and
B8 are different from normal values, circuit should be checked and
repaired or fuse should be replaced;
3) Dismantle instrument panel and then switch on igniting switch;
check output voltage between +12V and - terminals of instrument
2) Malfunction of stabilizing circuit
stabilizer for normal 11.5 12.5 V; if the voltage is lower than 11.5 V
for fuel gauge
or higher than 12.5 V or no voltage output, the stabilizer should be
replaced;
4) Check fuel gauge condition: disconnect sensor of fuel gauge and
open igniting switch; using external resistor instead of resistor of
sensor for detection and identification, the fuel gauge will indicate out
Incorrect indication 3) Fuel gauge in poor operation of fuel with 110 resistor, one-fourth tank of fuel with 75 resistor,
(or no indication) of half tank of fuel with 40 resistor, three-fourth tank of fuel with 20
fuel gauge resistor and full of fuel with 3 resistor; if the results indicated by fuel
gauge are different from above values, fuel gauge or instrument
assembly should be replaced;
5) Disconnect fuel sensor and combined instrument; measure
resistance of connecting wire between fuel gauge sensor and
4) Short-circuit or break of
combined instrument with multi-meter and the standard is 0 Ohm; the
connecting wire between fuel
resistance between the wire and bond strap should be infinite as
gauge sensor and combined
break status; otherwise the wire is short-circuit or broken and should
instrument
be replaced;
6) Floater of fuel sensor is blocked: check if there has been crash on
bottom of tank and if there is bulge or other object which prevents
5) Floater of fuel sensor is blocked floater from moving upward and downward, so that the fuel gauge is
incorrect; if yes, clear, repair or replace it;
7) Check fuel gauge sensor with resistance grade of multi-meter: the
resistance measured by multi-meter should be 32 when floater of
6) Fuel gauge sensor in poor sensor is at full position, and 32.53 for middle (1/2 position) of tank,
operation 1106 for out of fuel position; if measured results for floater of
sensor are different from standard values, fuel gauge sensor should
be replaced;
309
Incorrect indication (or no indication) of

fuel gauge
Disconnect sensor of fuel gauge and open igniting switch; use

external resistor instead of resistor of sensor to detect and
view if fuel gauge actuate
Yes No
Check if pointer position of fuel gauge is Check if there is short-circuit or break of

met with external resistors connecting wire between fuel gauge
sensor and combined instrument Check, repair or replace
No Check power supply loop for instrument; open fuse

Yes Abnormal
unit and check fuse for burn-out; measure voltage
of B4 instrument connector for normal voltage of
Replace fuel gauge or Check if fuel gauge sensor is Replace fuse
battery
instrument assembly blocked
Yes No
Check fuel stabilizing circuit;
dismantle instrument panel and
Check bottom of tank for distortion and Replace fuel gauge then switch on igniting switch;
internal surface of tank for bulge or sensor check output voltage between
other blocking +12V and - terminals of
instrument stabilizer
Clear or replace Abnormal

Replace fuel gauge or Replace
instrument assembly stabilizer
310
No. 221 No indication of water temperature gauge

Check water temperature gauge condition: disconnect
sensor of water temperature gauge and open igniting switch;
using external resistor instead of resistor of sensor for
detection and identification, the water temperature gauge will
Water temperature gauge in poor operation indicate around C area with 165 resistor, around 1/2 C
area with 56 resistor, around H area with 28.7 resistor; if
the results indicated by water temperature gauge are
different from above values, water temperature gauge or
Place igniting switch to ON and measure voltage of
instrument connector B4 with voltage grade of multi-meter;
the voltage should be equal to the voltage of battery
(standard voltage: 12V); measure resistance of instrument
connectors B7 and B8 to bond strap; the resistance should
be zero because B7 and B8 are bond straps of instrument; if
Malfunction of power supply circuit for power supply voltage for B4 and resistances for B7 and B8
instrument are different from normal values, circuit should be checked
and repaired or fuse should be replaced;
Dismantle instrument panel and then switch on igniting
No indication of switch; check output voltage between +12V and
water temperature - terminals of instrument stabilizer for normal 11.5 12.5 V;
gauge if the voltage is lower than 11.5 V or higher than 12.5 V or no
voltage output, the stabilizer should be replaced;
5) While checking water temperature sensor, the sensor can
be dismantled from engine and put into coolant or water with
certain temperature, in the meantime, check if the resistance
value is met with standard value. When temperature of
coolant is 60, the resistance of water temperature sensor
Water temperature gauge sensor in poor is 164.55; and when temperature of coolant is 90, the
operation resistance of water temperature sensor is 563; when
temperature of coolant is 115, the resistance of water
temperature sensor is 28.72; if measured resistance
values of water temperature sensor are different from
standard values, water temperature sensor should be
replaced;
4) Disconnect water temperature sensor and combined
instrument; measure resistance of connecting wire between
Short-circuit or open-circuit of connecting water temperature gauge sensor and combined instrument
wire between water temperature gauge with multi-meter and the standard is 0 Ohm; the resistance
sensor and combined instrument between the wire and bond strap should be infinite as break
status; otherwise the wire is short-circuit or broken and
should be replaced;
311
No indication of water
temperature gauge
Disconnect sensor of water temperature gauge and open igniting

switch; use external resistor instead of resistor of sensor to detect
and view if water temperature gauge actuate
Yes No
Check if pointer position of water Check if there is short-circuit or break Abnormal

temperature gauge is met with of connecting wire between water Check, repair or
external resistors temperature gauge sensor and replace
combined instrument
Yes No
Check power supply loop for instrument; open fuse unit
Check water temperature sensor with multi-meter and check fuse for burn-out; measure voltage of B4
Replace water temperature gauge or Abnormal
to measure resistances in different temperatures instrument connector for normal voltage of battery Replace
instrument assembly
fuse
Normal Abnormal
Check water temperature gauge stabilizing circuit; dismantle
instrument panel and then switch on igniting switch; check output
Check connecting wire of Replace water voltage between +12V and - terminals of instrument stabilizer
water temperature sensor temperature sensor
or replace instrument
assembly
Abnormal
Replace water temperature Replace
gauge or instrument assembly stabilizer
312
No. 222 Electric mirror cant work

Check contacts of mirror control switch and contacts of left and right adjusting
Switch parts of mirror switches for circuit break due to burn-out or too dirty; if yes, clean them or
damaged replace switch parts; Check left and right adjusting switches for blocking; if yes,
switch parts should be replaced.
Poor contact, short-circuit
or open circuit of harness, Check connector of mirror switch parts for loosing or dropping-off; Check
connecting wire and connector of mirror motor for loosing or dropping-off;
connectors
Disconnect connectors of mirror switch parts and measure voltage of its power
supply; find power supply wire and measured voltage should be 12 14 V; if
Electric mirror there is no voltage, fuse should be checked for burn-out; check if the resistance
cant work Power supply for mirror between bond strap at mirror switch parts and body should be zero, otherwise
look for the line or tighten it up again; check if there is break between points of
harness connection and measure the resistance; it should be zero as conducting
state.
Check mirror motor for sign of burn-out and measure by multi-meter if the
resistance of motor is in normal range; if the resistance is infinite, thus the motor
is burnt or broken internally and should be replaced; check with power on:
Malfunction of mirror motor disconnect connector of mirror motor; connect positive and negative poles of
external power supply to connectors of motor output and view if motor is
actuating; if not, it shows that motor has been broken internally and the electric
mirror should be replaced.
Electric mirror cant work
Abnormal
Switch of mirror damaged
Replace fuse
Normal
Abnormal
Poor contact, short-circuit or break of
Replace switch part
harness, connecting wire and connectors
Normal
Abnormal
Short-circuit or open circuit of power supply for Check, repair and replace
mirror
Normal
Replace motor of electric mirror
313
No. 223 Always-On or failure of water temperature alarm indicator

Check cooling system for sufficient coolant and normal recirculation of
Malfunction of cooling system
coolant;
Water temperature
The water temperature sensor is negative thermostat-type; measure its
alarm indicator is Malfunction of water resistance variation under different temperature and working condition and
temperature sensor compare them to standard values; check, repair or replace water
always on or isnt temperature sensor;
on Malfunction of wire 2) Check, repair or replace electric harness;
Internal malfunction of
3) Check, repair or replace combined instrument;
combined instrument
Water temperature alarm indicator is not on or
always on
Is electric fan working?

Abnormal
Cooling system
Normal
Abnormal
Measure with multi-meter for
Malfunction of water resistance variation
temperature sensor
Normal
Abnormal
Malfunction of wire
Check, repair or replace electric
harness;
Normal
Abnormal
of Check if instrument is
Malfunction
broken
combined instrument
314
No. 224 Safety & alarm indicator is always on or not on

Safety & alarm Seat belt unlocked (always-on) Snap-on the seat belt
indicator is always
on or not on Break (not on) or short-circuit (always-on) of 1) Check and repair internal circuit board for seat belt
internal circuit board for seat belt snap-on lock snap-on lock, or replace seat belt assembly
Malfunction of loop 3) Check if switching loop for snap-on lock of seat belt
is broken or short-circuit;
Internal fault of combined instrument 2) Check, repair or replace instrument assembly;
Safety & alarm indicator is not on or always on
GAUGE insurance, combined

Safety & alarm indicator for driver is not on Abnormal instrument and front-left belt lock
assembly
Normal
Alarm indicator is always on Normal

function Snap-on seat belt
Abnormal
Check loop or replace seat belt

lock assembly
315
No. 225 Brake fluid level alarm indicator is always on or cant alarm
Insufficient brake fluid results in always-on of brake
Fill sufficient brake fluid
fluid level alarm indicator
Short-circuit or open circuit of brake fluid level
Replace brake fluid level sensor
sensor
Short-circuit or open circuit of connection between
Failure of brake fluid level brake fluid level sensor and instrument results in Short-circuit of brake fluid level alarm indicator results in
alarm indicator is always always-on of brake fluid level alarm indicator always-on of its indicator.
on or cant alarm
Break of circuit for brake fluid level alarm indicator or failure of
Brake fluid level alarm indicator cant alarm
buzzer for alarm circuit
Internal fault of combined instrument Check, repair or replace combined instrument.
Fault of ABS system (indicated together with ABS
Repair ABS system
fault indicator)
Brake fluid level alarm indicator is always on

or cant alarm
Insufficient brake fluid Insufficient oil Check if oil is sufficient and fill sufficient brake fluid
Normal
Short-circuit or open circuit of brake fluid Broken

Brake fluid level
level sensor sensor
Normal
Short-circuit or
break
Short-circuit or open circuit of
Repair the connection
connection between brake fluid
level sensor and instrument
Normal
Short-circuit of combined Broken Replace combined

instrument instrument
Normal
Broken
Malfunction of ABS system Repair ABS system
316
No. 226 Oil alarm indicator is always on

Check and eliminate oil leakage and fill lubricating oil
Insufficient lubricating oil
according to specification
Dismantle oil pressure sensor and insert a flat bar to internal
diaphragm of sensor. Open start-up switch, if oil pressure
Block of lubricating oil tube
gauge actuates normally, thus the lubricating oil tube is
blocked;
Oil pressure alarm Connect terminal of oil pressure sensor to bond strap with
indicator is always on or Oil pressure sensor damaged wire, if the oil alarm is normal, then oil pressure sensor is fault
cant alarm and may be replaced;
Break or short-circuit of connecting Check the break or short-circuit of connecting wire for oil
wire for oil pressure alarm indicator pressure alarm indicator with multi-meter and repair it;
Remove the fault according to diagnosis process in engine
Over-low oil pressure
section;
Internal fault of combined instrument Replace combined instrument
Oil alarm indicator is always on or

cant alarm
Insufficient
Insufficient lubricating oil
Fill lubricating oil
Normal
Blocked
Block of lubricating oil tube Repair
Normal
Blocked
Oil pressure sensor damaged Replace
Normal
Over-low
Check and repair
Over-low oil pressure
Normal
Abnormal
Break or short-circuit of connecting wire for oil Check and repair
pressure alarm indicator
Normal
Abnormal
Short-circuit of combined Replace combined
instrument instrument
317
No. 227 Headlight is always on or not on

Broken fuse for headlights Check if fuse is broken and replace it if necessary;
Burn-out of headlight Replaced burnt headlight
If fuse is intact, check if headlight relay is poor contact or
Headlight relay is broken
burnt off and repair or replace it according to condition.
Check combined switch for headlight; measure
conductivity of switch with multi-meter; if the resistances
Broken combined switch for headlight are both infinite when switch is placed on either lower
All headlights cant work; beam or main beam position, thus the switch for headlight
all headlights is always on is broken and should be replaced;
or not on
Broken harness or poor contact with Check circuits section by section to eliminate short-circuit
bond strap or break;
If fuse is normal, check if headlight lamp holder is poor
Burnt bulb or poor contact of lamp
contact or if filament is burnt out and repair or replace it
holder
according to condition.
Internal fault of centralized controller
Replace centralized controller
(CK and MK)
Failure of light controller (Vision) Replace light control module;
Headlight is always on or not on
Burnt out
Broken fuse for headlight Replace
Normal
Burnt out
Headlight relay is broken Replace
Normal
Burnt out
Broken switch for headlight Replace
Normal
Abnormal
Broken harness or poor contact with bond Repair or replace
strap
Normal
Abnormal
Broken bulb or poor contact of lamp socket Repair or replace
Normal
Abnormal
Malfunction of centralized controller or Replace centralized controller or light
light controller controller
318
No. 228 Weak running of starter

Malfunction of battery Check if the voltage of battery reaches to 12.5 12.9V, if not, charge or replace the battery;
Check the connecting end of starter harness for fine contact, if it's abnormal, the starter harness
Malfunction of harness
should be checked and repaired;
Check if the internal bearing bush of starter is over-worn and thus results in fractional drag
between rotator and stator and subsequent Weak running of starter; then bearing bush or starter
Measure length of internal brush of starter with vernier caliper; the standard length of brush
should be 15.5 mm and the minimum worn length is 10 mm; if the brush is shorter than the
minimum value, the brush or starter assembly should be replaced;
Weak running of
starter Internal malfunction of Check if the no load current of starter is smaller than 90A under 11.5V; if it's abnormal, then
starter starter assembly should be replaced;
Check the grounding situation of starter commutator; check connection between armature coil
and spindle with Ohm meter; it should be disconnected, if its connected, the commutator or
starter should be replaced;
Check if the undercutting depth of commutator should be 0.60 mm and the minimum depth
should be 0.20 mm. if the depth is smaller than the minimum value, then the commutator or
starter assembly should be replaced;
Check if the crankshaft of engine can be rotated or if its run heavily, if its abnormal to cause
Malfunction of engine
Weak running of starter, the engine should be checked and repaired internally;
Weak running of starter
Too low
Voltage of battery Charge or replace battery
Normal
Does starter work normally? Abnormal Check, repair or replace starter
Normal
Bad contact Repair or replace

Malfunction of starter harness
Normal
Abnormal
Engine works abnormally Repair or replace
319
No. 229 Starter cant work

Malfunction of Check if the voltage of battery reaches to 12.5 12.9V, if not, recharge or replace the
battery battery;
Malfunction of
Check the fuse of starting loop for break and replace fuse if its broken;
fuse
Malfunction of Check if internal contacts of starter relay is conducting with power on, and replace the
starter relay relay if its broken;
Malfunction of Check the harness of starter for short-circuit or poor contact, if it's abnormal, the starter
harness harness should be checked and repaired;
Check if the coil of electromagnetic switch for starter is OK, and replace the
electromagnetic switch if the coil is broken;
Check the stator coil of starter for break or short-circuit, and replace starter assembly if
the coil is abnormal;
Starter cant work Measure length of internal brush of starter with vernier caliper; the standard length of
brush should be 15.5 mm and the minimum worn length is 10 mm; if the brush is shorter
Internal than the minimum value, the brush or starter assembly should be replaced;
malfunction of
starter Check the condition of commutator: 1. Check with Ohm meter if its connected between
two commutators, and replace commutators or starter assembly if one of them is
disconnected. 2. Check the grounding situation of starter commutator; check connection
between armature coil and spindle with Ohm meter; it should be disconnected, if its
connected, the commutator or starter should be replaced. 3. Check if the undercutting
depth of commutator should be 0.60 mm and the minimum depth should be 0.20 mm. if
the depth is smaller than the minimum value, then the commutator or starter assembly
should be replaced. Check connecting condition of exciting coil: 1. Check with Ohm meter
if its connected between conductor and exciting coil brush, and replace starter assembly
if its disconnected. 2. Check the grounding condition of exciting coil; it should be
disconnected between end of exciting coil and magnetic pole armature frame measured
by Ohm meter, and replace starter assembly if its connected.
Internal
Check if the crankshaft of engine can be rotated normally, if its blocking or blocked, the
malfunction of
engine should be checked and repaired.
engine
320
Starter cant work
Low voltage of battery Charge or replace battery

Too low
Normal
Broken fuse of starter Broken Change starter fuse
Normal
Malfunction of starter relay Change starter relay

Abnormal
Normal
Open circuit or poor contact of connector loop for starter Abnormal Check and repair
starter loop
Normal
Blocking or incapable rotating or crankshaft for Check and repair

engine Broken engine
Normal
Starter in poor operation Replace starter

Abnormal
assembly
321
No. 230 Idling of starter

Check coil poles of electromagnetic switch for short-circuit, which will result
Malfunction of electromagnetic in idling of starter due to positive pole of power supply connecting to
switch exciting coil of starter; replace electromagnetic switch or starter assembly if
necessary;
Check working, wearing-out and damaging condition of clutch planetary
gear. Hold starter clutch with hand and rotate planetary gear clockwise to
check free rotating of this gear; and try to rotate planetary gear
Malfunction of one-way clutch
counterclockwise; it should not be rotated; replace starter assembly if its
abnormal;
Check starter fastening bolt for loosing, which will result that one-way clutch
Malfunction of starter fastening
Idling of starter cant engage with ring gear of flywheel to drive torque and that the starter is
bolt
idling; bolt should be tightened or replaced;
Check ring gear of flywheel for worn-out or damage and loosing, which will
result that torque cant be driven through starter and that the starter is
idling; flywheel assembly should be replaced;
Check fastening bolt of flywheel for loosing and dropping-off; if its
Malfunction of flywheel abnormal, it should be tightened or flywheel assembly should be replaced;
Check the engaging gears of starter and flywheel for over worn-out or
damaged tooth, which will result that gears cant engage to drive torque and
that the starter is idling; pinion of starter or starter assembly should be
replaced;
Idling of starter
Short-circuit
Short-circuit of internal contacts of electromagnetic Replace electromagnetic switch or
switch for starter starter assembly
Normal
Broken
Slipping or broken tooth of starter one-way clutch Replace one-way clutch
Normal
Loosing
Loosing of starter fastening bolt Tightening
Normal
Abnormal
Damage or loosing of ring gear for starter and flywheel Tighten or replace
flywheel
322
No. 231 Abnormal sound during start-up of starter

Check bearing and pinion of one-way clutch for damage, which may
result in breaking between gear of one-way clutch and ring gear of
flywheel and subsequent abnormal sound during start-up; thus one-way
clutch should be replaced;
Malfunction of one-way clutch
Check if pinion of one-way clutch return well after start-up; if not, the
pinion will contact to ring gear of flywheel after start-up and result in
abnormal sound; one-way clutch should be dismantled for checking and
greasing or replaced;
Check if voltage of battery reaches to 12.5 12.9 V; if the voltage is
over-low, starter will be unable to drive torque to flywheel and
Abnormal sound Malfunction of battery electromagnetic switch of starter will snap-on and generate abnormal
during start-up of sound due to no energy; thus battery should be recharged or replaced;
starter
Check internal bearing bush of starter for wearing condition; if its
Internal malfunction of starter over-worn, stator and rotator of starter will contact and result in abnormal
sound; thus starter assembly should be replaced;
Malfunction of electromagnetic Check coil of electromagnetic switch for short-circuit or poor contact; if its
switch abnormal, electromagnetic switch should be replaced;
Check ring gear of flywheel for over worn-out or damage and loosing,
which may result in bad engaging between one-way gear of starter and
Malfunction of flywheel ring gear of flywheel for driving torque and subsequent abnormal
breaking sound; thus ring gear of flywheel or flywheel assembly should
be replaced;
Abnormal sound during start-up of

starter
Broken
Damage of one-way clutch bearing and pinion Replace one-way clutch
Normal
Over-low
Low voltage of battery Recharge or replace battery
Normal
Over worn-out of internal bearing bush for starter Abnormal Replace starter
Normal
Damage or loosing of ring gear for engine flywheel Abnormal Replace

flywheel
323
No. 232 Over-high or over-low recharging voltage from generator

Check generator belt for tension and wearing condition and if there is 10 mm of
Malfunction of generator
flexibility at middle of belt under 50 N pressure; if the belt is over-loosing or
belt
over worn-out, the generator belt should be adjusted or replaced;
Check fuse of generator (60A) for poor contact; if its broken, the generator
Malfunction of fuse
fuse should be replaced;
Poor contact of harness Check and remove fault of bad wire contact;
Malfunction of generator Check if generator regulator is able to adjust generated voltage; if its
regulator abnormal, regulator or generator assembly should be replaced;
Over-high or 1. Check forward rectifying: Connect one probe of Ohm meter to positive pole
over-low recharging of rectifying diode, and the other probe to every end of rectifiers; changeover
voltage from the polarity of probes and repeat above procedure; the Ohm meter will show
generator conducting for one and cutoff for the other; if the conductivity is different from
above description, the rectifier or generator assembly should be replaced;
rectifier 2. Check backward rectifying: Connect one probe of Ohm meter to negative
pole of rectifying diode, and the other probe to every end of rectifiers;
changeover the polarity of probes and repeat above procedure; the Ohm meter
will show conducting for one and cutoff for the other; if the conductivity is
different from above description, the rectifier or generator assembly should be
replaced.
Check internal plate of battery for sulfurization or short-circuit, which may result
Malfunction of battery in over recharging current and subsequent over recharging energy from
generator, thus the battery should be replaced;
324
Over-high or over-low recharging

voltage from generator
Loosing or over worn-out of generator belt Replace generator

Abnormal belt
Normal
Loosing or bad contact of fuse of generator Change fuse

Abnormal
Normal
Malfunction of generator regulator Replace generator

Abnormal regulator
Normal
Malfunction of generator rectifier Replace generator rectifier or generator

Abnormal assembly
Normal
Sulfurization
Sulfurization or short-circuit of internal battery Replace battery
or
plate
short-circuit
325
No. 233 Generator cant work

Check generator belt for tension and wearing condition and if there is 10 mm of
flexibility in the middle of belt under 50 N pressure; if the belt is over-loosing or over
belt
worn-out, the generator belt should be adjusted or replaced;
Check fuse of generator (60A) for break; if its broken, the generator fuse should be
Malfunction of fuse
replaced;
Malfunction of generator Check if generator regulator is able to adjust generated voltage; if its abnormal,
regulator regulator or generator assembly should be replaced;
1. Check forward rectifying: Connect one probe of Ohm meter to positive pole of
rectifying diode, and the other probe to every end of rectifiers; changeover the
polarity of probes and repeat above procedure; the Ohm meter will show
conducting for one and cutoff for the other; if the conductivity is different from above
Malfunction of generator description, the rectifier or generator assembly should be replaced;
rectifier
2. Check backward rectifying: Connect one probe of Ohm meter to negative pole of
rectifying diode, and the other probe to every end of rectifiers; changeover the
polarity of probes and repeat above procedure; the Ohm meter will show
conducting for one and cutoff for the other; if the conductivity is different from above
Generator cant description, the rectifier or generator assembly should be replaced.
work 1. Place multi-meter to Rx1 grade and connect two probes to any two leads of
armature windings; they should be connected; if the resistance is infinite, it
indicates that the break results in failure of generator, thus the coil or generator
Malfunction of stator coil of assembly should be replaced; 2. Check windings with bond strap: Place
generator multi-meter to Rx1 grade and connect one probe to any lead of armature winding
and the other probe to core of stator; if the resistance is infinite, the insulation of
armature windings is good, otherwise the coil or generator assembly should be
replaced;
1. Check resistance of rotator windings: Place multi-meter to Rx1 grade and
connect two slip rings; the standard resistance should be 2.7 3.1 Ohm; if the
Malfunction of rotator coil
resistance is different from standard, the rotator or generator assembly should be
of generator
replaced; 2. Check flexibility of rotator: The radial swinging standard should be less
than 0.5 mm; if it's abnormal, the generator assembly should be replaced;
The length standard of exposed brush measured by vernier caliper should be 10.5
Malfunction of internal
mm and the minimum length should be 1.5 mm; if the length is smaller than the
brush for engine
minimum length, the brush or generator assembly should be replaced;
Check the harness of generator for short-circuit or poor contact, if it's abnormal, the
generator harness should be checked and repaired;
326
Generator cant
work
Adjust or replace generator belt

Loosing or over worn-out of generator belt
Broken fuse of generator Replace fuse
Loosing or break of wire for connectors of generator

Check and repair
generator loop
Generator rectifier in poor operation Replace rectifier or generator
Generator regulator in poor operation Replace starter

assembly
Open circuit or short-circuit of stator coil of generator Replace generator

assembly
Damage of internal brush or rotator for generator Replace generator

assembly
327
No. 234 Charging indicator of generator is always on or not on

Check generator belt for tension and wearing condition and if there is 10 mm of flexibility
Malfunction of
at middle of belt under 50 N pressure; if the belt is over-loosing or over worn-out, the
generator belt
generator belt should be adjusted or replaced;
Malfunction of Check if generator regulator is able to adjust generated voltage; if its abnormal,
generator regulator regulator or generator assembly should be replaced;
1. Check forward rectifying: Connect one probe of Ohm meter to positive pole of
rectifying diode, and the other probe to every end of rectifiers; changeover the polarity of
probes and repeat above procedure; the Ohm meter will show conducting for one and
Charging cutoff for the other; if the conductivity is different from above description, the rectifier or
indicator of Malfunction of generator assembly should be replaced.
generator is generator rectifier 2. Check backward rectifying: Connect one probe of Ohm meter to negative pole of
always on or not rectifying diode, and the other probe to every end of rectifiers; changeover the polarity of
on probes and repeat above procedure; the Ohm meter will show conducting for one and
cutoff for the other; if the conductivity is different from above description, the rectifier or
generator assembly should be replaced;
Malfunction of Check positive pole fuse of generator for conducting; if its broken, the generator fuse
generator fuse should be replaced;
Malfunction of Check indicating diode of combined instrument for mixed connection or breakdown; if
combined instrument its abnormal, the combined instrument should be replaced;
Malfunction of harness Check charging loop for good contact; if its abnormal, check or repair the loop;
Malfunction of battery Replace battery assembly;
Charging indicator of generator is always on
or not on
Worn-out
belt
Normal
Broken
Broken fuse of generator Change fuse
Normal
Abnormal
Generator regulator
Normalin poor operation
Replace generator
regulator
Normal
Abnormal
Generator rectifier
Normalin poor operation Replace rectifier or generator
assembly
Normal
Abnormal
Short-circuit or open circuit of charging indicator loop of Check or repair charging indicator
generator loop of generator
Normal
Abnormal
Short-circuit or open circuit of internal charging indicator of Replace
combined instrument combined
328
No. 235 Flashing of charging indicator of generator

Check generator belt for tension and wearing condition and if there is 10 mm
of flexibility at middle of belt under 50 N pressure; if the belt is over-loosing or
belt
over worn-out, the generator belt should be adjusted or replaced;
Malfunction of generator Check if the poor contact of fuse for battery positive pole results in insufficient
fuse charging of battery, thus the fuse should be tightened or replaced;
Malfunction of generator Check if generator regulator is able to adjust generated voltage; if its
regulator abnormal, regulator or generator assembly should be replaced.
1. Check forward rectifying: Connect one probe of Ohm meter to positive pole
of rectifying diode, and the other probe to every end of rectifiers; changeover
the polarity of probes and repeat above procedure; the Ohm meter will show
conducting for one and cutoff for the other; if the conductivity is different from
above description, the rectifier or generator assembly should be replaced;
Flashing of
rectifier 2. Check backward rectifying: Connect one probe of Ohm meter to negative
charging indicator
pole of rectifying diode, and the other probe to every end of rectifiers;
of generator
changeover the polarity of probes and repeat above procedure; the Ohm
meter will show conducting for one and cutoff for the other; if the conductivity
is different from above description, the rectifier or generator assembly should
be replaced;
Check magnetic field diode of generator with Ohm grade of multi-meter for
short-circuit or break; if the magnetic field diode is short-circuit or broken, the
Malfunction of magnetic
field voltage will be lower than voltage of charging indicator, and formed
field diode of generator
potential difference will result in lower-than-normal brightness of charging
indicator;
Malfunction of combined Check indicating diode of combined instrument for mixed connection; if its
instrument abnormal, the combined instrument should be replaced;
Check charging loop for good contact; if its abnormal, check or repair the
loop;
329
Flashing of charging indicator of

generator
Abnormal
belt
Normal
Abnormal
Broken fuse of generator Replace fuse
Normal
Abnormal
Generator regulator in poor operation Replace generator
regulator
Normal
Abnormal
Generator rectifier in poor operation Replace rectifier or generator
assembly
Normal
Abnormal
Short-circuit or open circuit of charging indicator loop of Check or repair charging indicator
generator loop of generator
Normal
Short-circuit or open circuit

Short-circuit or open circuit of magnetic Check, repair or replace
field diode generator
Normal
Abnormal
Short-circuit or open circuit of internal charging indicator of Replace
combined instrument combined
330
No. 236 Abnormal sound of generator

Check generator belt for tension and wearing condition and if there is 10
mm of flexibility at middle of belt under 50 N pressure; if the belt is
Abnormal sound of generator belt
over-loosing or over worn-out and results in abnormal sound, the
generator belt should be adjusted or replaced;
Check if the fastening bolts of generator belt pulley are loosing or the
Malfunction of generator belt pulley distortion of pulley results in abnormal frictional sound with other parts;
thus the generator belt pulley or generator assembly should be replaced;
Abnormal sound
of generator Check working condition of generator bearing; if its over-worn or
Malfunction of generator bearing lubricated badly, the generator bearing or generator assembly should be
replaced;
Check working and worn condition of internal brush for generator; if
Malfunction of generator brush uneven worn-out of brush results in abnormal frictional sound with rotator
of generator, the generator assembly should be replaced;
Check if other objects enter to generator internally and result in abnormal
Other faults
bumping sound, thus the generator should be checked and repaired;
Abnormal sound
of generator
Malfunction of Adjust or
generator belt replace
Friction of generator belt

pulley with other object Check, repair or replace
generator
Malfunction of generator Replace generator

brush assembly
Loosing of break of Replace generator

generator bearing bearing or generator
assembly
331
No. 237 Failure of battery storage

Check internal plates of battery for sulfurizing or short-circuit which will
result in automatic discharging of battery, thus the battery should be
replaced;
Check if the battery is undercharged normally and results in subsequent
failure of battery, thus the generator or loop should be checked;
Internal malfunction of battery
Check if the electrolyte level of battery is met to standard; the battery
Failure of should be filled or replaced if the electrolyte level is too low;
battery storage
Check if the density of electrolyte for every battery cell is between 1.25 to
1.29 under 20 degree; if not, the distilled water should be filled or the
battery should be replaced;
Check the battery loop for short-circuit or connecting to bond strap, if it's
abnormal, the loop should be checked and repaired;
Other faults
Check all switches for light for normal working; if there are abnormal, the
switches for light should be replaced;
Fault of battery
storage
Sulfurizing or short-circuit of internal Replace

battery plate battery
Short-circuit or open circuit of battery Check and repair

loop battery loop
Battery is undercharged normally Charge or replace
Insufficient electrolyte or incorrect electrolyte density Filling

for battery
Malfunction of loop Check, or

or switch replace
332
No. 238 Weak running of blower

Check if the voltage of battery reaches to 12.5 12.9V, if the over-low
Malfunction of battery voltage results in weak running of blower, the battery should be charged
or replaced ;
Worn-out or poor contact of
Replace blower assembly
blower carbon brush
Weak running of
blower Check blower coil for short-circuit; check and measure if over-big
Malfunction of blower coil adjusting resistance of blower results in weak running; if its abnormal, the
blower assembly should be replaced;
Malfunction of blower adjusting
Replace blower adjusting resistance;
resistance
Weak running of blower
Over-low
Over-low voltage for blower Charge or replace battery
Normal
Abnormal
Over-big resistance or short-circuit of blower coil Replace blower
motor
Normal
Abnormal
Replace blower
Blocking or unsmooth running of blower blades
assembly
333
No. 239 Blower cant work

Malfunction of fuse Check the fuse of blower for break and replace blower fuse if its broken;
Check #1 and #2 terminal of relay for conducting; if so, check #3 and #4 terminal of
Malfunction of blower
relay for conducting while applying positive voltage to #1 and #2 terminal; if not,
relay
the relay should be replaced;
Malfunction of blower Check every coil of blower adjusting resistance for conducting; if not, the blower
adjusting resistance adjusting resistance should be replaced;
Blower cant Malfunction of blower Check blower coil for short-circuit or conducting; if its not conducted, the blower
work coil motor should be replaced;
Malfunction of blower Check every connector of blower switch for conducting; if there is abnormal
switch connector, the blower switch should be replaced;
Malfunction of Check the harness of blower for short-circuit or break; if it's abnormal, the harness
harness of blower should be checked and repaired;
Malfunction of blower Check blower fan for blocking or other object resulting in blocking, thus the blower
fan should be dismantled and checked;
Blower cant work
Over-low
Low voltage of battery Charg or replace battery
Normal
Break
Broken fuse of blower Replace blower fuse
Normal
Abnormal
Malfunction of blower relay Replace blower relay
Normal
Open circuit
Open circuit of blower speed governing Replace blower speed
resistance governing resistance;
Normal
Short-circuit or open circuit of blower coil Abnormal Replace blower motor
Normal
Abnormal
Normal working of blower switch Replace blower
switch
Normal
Abnormal
Blocking or blocked blower fan Replace blower fan
Normal
Abnormal
Open circuit or poor contact of connector loop for blower Check and repair blower
loop
334
No. 240 Abnormal sound of blower

Check working condition of brush for worn-out and if the friction between
brush and rotator of blower results in abnormal sound; if it's abnormal, the
blower motor or blower assembly should be replaced;
Internal malfunction of blower
Check bearing bush of blower for over-worn; if it's abnormal, the blower
Abnormal sound of motor or blower assembly should be replaced;
blower
Check blower internally for other object; if so, the blower should be
dismantled to take other object out;
Other malfunctions
Check fixing bolt of blower blades and fastening bolt of blower for loosing;
tighten them if its abnormal;
Abnormal sound of blower
Abnormal
Impurity enters into blower
Dismantle
blower
Normal
Abnormal
Loosing of internal blower blades Dismantle
blower
Normal
Abnormal
Internal brush and bearing for blower in poor Replace
operation blower
335
No. 241 Continuous running of cooling fan

Check #1 and #2 terminal of relay for conducting; if so, check #3 and #4 terminal of relay
Malfunction of fan for conducting while applying positive voltage to #1 and #2 terminal; the #3 and #4
relay terminal should be conducted; if the two contacts are still normal-close resulting in
continuous running of fan, the relay should be replaced;
1. Check if the opening temperature of thermostat is 80 84 degree; if not, recirculation
and heat dispersion of cooling water will be bad and the high water temperature will
result in continuous running of fan; then the thermostat should be replaced;
Malfunction of
thermostat 2. Check thermostat valve for lift; when water temperature is about 93 degree, the lift
should bigger than 8 mm; if not, insufficient recirculation and heat dispersion of cooling
water will result in high water temperature and subsequent continuous running of fan;
Continuous
then the thermostat should be replaced;
running of cooling
fan Check if the resistance of coolant temperature sensor varies according to water
Temperature sensor
temperature; check if the resistance of sensor is 2.5 kOhm +/- 5% under 20 degree; if it's
for coolant
abnormal, the temperature sensor for coolant should be replaced;
Check if there is leakage of coolant for radiator and cooling system; if so, it will result in
Other malfunctions insufficient cooling water and high water temperature and subsequent continuous
running of fan, thus the leaking parts should be replaced or treated for sealing;
Malfunction of Check harness of fan motor for short-circuit or mixed connection; if its abnormal, the fan
harness loop should be checked and repaired;
Malfunction of Check internal program of engine ECU for short-circuit or mixed connection; if its
engine ECU abnormal, thus the engine ECU should be replaced;
Continuous
running of cooling
Leakage
Leaking or insufficient coolant Check cooling
system
Normal
Abnormal
No recirculation and heat dispersing Check, repair or
for coolant of radiator replace thermostat
Normal
Abnormal
Fan relay in poor operation Replace fan
relay
Normal
Abnormal
Water temperature sensor in poor Replace water
operation temperature
Normal
Abnormal
Short-circuit or break of fan loop Check and
repair fan loop
Normal
Abnormal
Engine ECU in poor operation Replace engine
336
No. 242 Cooling fan cant work

Malfunction of fan Check fan blades for distortion which may contact with fan guard and prevent fan from
blades rotating; if its abnormal, thus fan blades should be replaced;
Malfunction of fuse Check fuse of cooling fan for conducting; if its broken, the fuse of cooling fan should be
for cooling fan replaced;
Check #1 and #2 terminal of relay for conducting; if so, check #3 and #4 terminal of relay
Malfunction of relay for conducting while applying positive voltage to #1 and #2 terminal; if not, the relay should
be replaced;
Malfunction of Check if the resistance of coolant temperature sensor varies according to water
cooling temperature; check if the resistance of sensor is 2.5 kOhm +/- 5% under 20 degree; if it's
Cooling fan temperature sensor abnormal, the temperature sensor for coolant should be replaced;
cant work
Check internal coil of cooling fan motor for break or short-circuit; disconnect connectors of
fan and connect battery and ammeter to the connectors; check if the current of cooling fan
Malfunction of while running should be 5.7 7.7 A; if its abnormal, the motor assembly of cooling fan
motor for cooling should be replaced;
fan
Check internal brush of cooling fan motor for worn-out; if its abnormal or over-worn, the
motor assembly of fan should be replaced;
Malfunction of Check the harness of cooling fan for short-circuit or break; if it's abnormal, the harness of
harness cooling fan should be checked and repaired;
Check engine ECU internally for fault; if so; detect and clear code with diagnostic
Engine ECU
equipment and then reset it; if it doesnt work, then replace engine ECU;
Cooling fan cant work
Blocked
Replace fan blades
Fan blades blocked due to contacting with fan guard
Normal
Open circuit
Broken fuse of fan Change fuse of fan
Normal
Fan relay in poor operation Abnormal Replace fan relay
Normal
Abnormal
Water temperature sensor in poor operation Replace water
temperature sensor
Normal
Short-circuit or open circuit of cooling fan motor Abnormal Replace fan motor
Normal
Open circuit of cooling fan motor loop Break Check and repair fan motor
loop
Normal
Abnormal
Engine ECU Replace engine ECU
337
No. 243 Weak running of cooling fan

Check if the voltage of battery reaches to 12.5 12.9V, if the over-low voltage
Malfunction of battery
results in weak running of fan, the battery should be charged or replaced ;
Malfunction of cooling fan Check fuse of cooling fan for good contact; if its broken, the cooling fan fuse
fuse should be replaced;
Check if fan relay is well power-on; or check if corrosion of pins will result in
Malfunction of cooling fan
weak running of cooling fan; if its abnormal, the cooling fan relay should be
relay
replaced;
Check if internal bearing bush of cooling fan is over-worn resulting in loosing or
Weak running of blocking of motor rotator and subsequent weak running; thus the motor
cooling fan assembly of cooling fan should be replaced;
Check internal coil of cooling fan motor for break or short-circuit; disconnect
connectors of fan and connect battery and ammeter to the connectors; check if
Internal malfunction of motor the current of cooling fan while running should be 5.7 7.7 A; if its abnormal,
for cooling fan the motor assembly of cooling fan should be replaced;
Check internal brush of cooling fan motor for worn-out; if its over-worn, the
motor assembly of cooling fan should be replaced;
Check if the fastening bolts for cooling fan blades are loosing or loose fitting;
tighten or replace fan blades;
Weak running of cooling fan
Over-low
Low voltage of battery Charge or replace battery
Normal
Abnormal
Poor contact of fan fuse Replace fuse of fan
Normal
Abnormal
Poor power-on of fan relay Replace fan relay
Normal
Abnormal
Short-circuit of fan motor Replace fan motor
338
No. 244 Wiper cant work

Check fuse of wiper for break or short-circuit; if its abnormal, the fuse should be
Malfunction of fuse
replaced or the loop should be checked and repaired;
Malfunction of wiper Check internal contacts of wiper switch for short-circuit or open circuit; if its
switch abnormal, the wiper switch should be replaced;
Malfunction of wiper Check internal coil of wiper motor for short-circuit; if its abnormal, the wiper motor
motor assembly should be replaced;
Malfunction of fuse for Check fuse of centralized controller for conducting; if its broken or short-circuit, the
centralized controller fuse of centralized controller should be replaced;
Wiper cant work Internal malfunction of Check centralized controller for normal working; if its abnormal, the centralized
centralized controller controller assembly should be replaced;
Check wiper loop for break or short-circuit; if its abnormal, the loop should be
checked and repaired;
1. Check if there is dropping-off at connection of wiper link and wiper motor; if so, and
the dropping-off results in malfunction of wiper, the link should be checked for
Mechanical damage; thus the wiper link should be replaced;
malfunction
2. Check connection of wiper link for bad lubrication resulting in blocking and
subsequent malfunction or continuous turning of wiper; thus the link should be
greased or replaced;
Wiper cant work
Broken fuse of wiper Broken Change fuse
Normal
Short-circuit or break of internal Abnormal Replace wiper

contacts of wiper switch switch
Normal
Short-circuit of internal coil of wiper Abnormal Replace wiper motor
Normal
Dropping-off of connection between wiper link and wiper motor Abnormal Check, repair or replace link
Normal
Short-circuit or open circuit of wiper loop Abnormal Check and repair wiper
loop
339
No. 245 Wipe doesnt work at intermitting position

Check if internal contacts of wiper switch are contacted well; if its
Malfunction of wiper switch
short-circuit or poor contact, the wiper switch should be replaced;
Check intermitting relay of wiper for normal working; if its abnormal, then
Malfunction of wiper relay
the intermitting relay of wiper should be replaced;
Malfunction of fuse for centralized Check fuse of centralized controller for conducting; if its broken or
Wipe doesnt controller short-circuit, the fuse of centralized controller should be replaced;
work at
intermitting Check internal coil of wiper motor for short-circuit or break; if its broken,
position Malfunction of wiper motor then check if the wiper works normally at other position; if it doesn't work
too, the motor assembly of wiper should be replaced;
Check wiper harness for break or short-circuit; if its abnormal, the loop
should be checked and repaired;
Malfunction of centralized Check centralized controller for normal working; if its abnormal, the
controller centralized controller assembly should be replaced;
Wipe doesnt work at intermitting position
Internal open circuit of wiper switch Abnormal Replace wiper switch
Normal
Short-circuit or open circuit of wiper motor coil Abnormal Replace wiper motor
Normal
Broken fuse of centralized controller Broken Change fuse
Normal
Open circuit of wiper loop Open circuit Repair the loop
Normal
Centralized controller in poor operation Abnormal Replace centralized

controller
340
No. 246 Electric fuel pump cant work

Over-low voltage of battery
Check the fuse of fuel pump for conducting and replace fuse if its
Malfunction of fuse for fuel pump
broken;
Check relay of electric fuel pump for normal working; if it cant work
Malfunction of fuel pump relay
normally, then the relay of fuel pump should be replaced;
Check if the resistance of pump is 0.20 3.0 Ohm under 20 degree;
Electric fuel pump Internal Malfunction of fuel pump and check internal coil of electric fuel pump for break or short-circuit; if
cant work it's different, the electric fuel pump assembly should be replaced;
Check if harness of electric fuel pump is able to conduct, and if
Malfunction of harness connectors and relay sockets are well contacted; if not, the fuel pump
loop should be checked and repaired;
Check main relay for normal working; if its abnormal, the main relay
Malfunction of main relay
should be replaced;
Check engine ECU for normal working; if its abnormal, the engine ECU
Malfunction of engine ECU
should be replaced;
Electric fuel pump cant work
Broken fuse of fuel pump Broken Change fuse
Normal
Fuel pump relay in poor operation Abnormal Replace fuel pump relay
Normal
Open circuit
Open circuit of fuel pump loop Repair fuel pump loop
Normal
Abnormal
Main relay in poor operation Replace main relay
Normal
Open circuit or short-circuit of internal coil for fuel pump Abnormal Replace electric fuel
pump
Normal
Engine ECU in poor operation Abnormal Replace engine ECU
341
No. 247 Insufficient pressure of electric fuel pump

Malfunction of fuel pipeline Check fuel pipeline for leakage; if so, the fuel pipeline should be replaced;
Malfunction of strainer for fuel Check strainer for fuel pump for blocking; if so, the strainer should be
pump cleaned or replaced;
Internal malfunction of fuel Check electric fuel pump for internal pressure discharging; if so, the
pump electric fuel pump assembly should be replaced;
Insufficient
pressure of electric Check fuel pressure regulator for normal working; if its abnormal, the fuel
Malfunction of fuel regulator
fuel pump pressure regulator should be replaced;
Check fuel filter for blocking; if so, the fuel filter assembly should be
Malfunction of fuel filter
replaced;
Check injector for good sealing; if its leaking, the injector assembly should
Malfunction of fuel injector
be replaced;
Over-quick pressure discharging of

electric fuel pump
Leakage
Distortion or leakage of fuel pipeline Replace or repair
Normal
Abnormal
Malfunction of fuel pressure regulator Replace pressure
regulator
Normal
Abnormal
Internal pressure discharging or bad sealing Replace electric fuel
for electric fuel pump pump
Normal
Abnormal
Bad sealing of injector Replace injector
342
No. 248 Positive pressure of fuel tank too high

Malfunction of Check fuel tank cover and gasket for distortion or damage; if resulting in blocking or
fuel tank cover damage of check valve on the cover, the fuel tank cover should be replaced;
Malfunction of Check if the venting tube for fuel tank is bent, distorted or vented smoothly; if in case
venting tube for of blocking or venting hardly and resulting in over-pressure of fuel tank, then it
fuel tank should be replaced;
Malfunction of
Check if the venting check valve for fuel tank is blocked or unavailable resulting in
venting check
over-pressure of fuel tank, thus the check valve should be replaced.
valve for fuel tank
1. Inspect visually if the canister is cracked or broken; if so, the canister assembly
Positive pressure should be replaced;
of fuel tank too
high Malfunction of 2. Blocking the outlet of canister, blow air (4.71 kPa) into adsorbing entry and check
control canister the air discharged from desorbing outlet; if it doesnt conform to regulation, the
canister should be replaced;
3. Blow the air to adsorbing entry, and check the air should discharge through other
outlet freely; if not, the canister assembly should be replaced;
Malfunction of
Check canister control valve for resistance; the rating resistance under 20 degree
canister control
should be 22- 30 Ohm; if not, the canister control valve should be replaced;
valve
Malfunction of Check engine ECU for pulse signal controlling solenoid of control valve; if it results
engine ECU in malfunction of control valve, the engine ECU should be replaced;
Positive pressure of fuel tank too high
Broken
Malfunction of venting check valve for fuel tank Replace
Normal
Abnormal
Malfunction of venting tube for fuel Replace
tank
Normal
Abnormal
Malfunction of fuel tank cover Replace
Normal
Malfunction of control canister Abnormal Replace
Normal
Abnormal
Malfunction of canister control Replace
valve
Normal
Malfunction of engine ECU Abnormal Check, repair or

replace
343
No. 249 Failure of remote controller

Malfunction of
Are indicators on keys bright or dark while emitter is working? If they are dark, then the
remote controller
battery is low or in poor contact and should be checked, repaired or replaced;
battery
Malfunction of Check if the voltage of battery is enough, if its over-low, the battery should be charged
battery or replaced;
Malfunction of fuse
Check fuse of centralized controller for conducting; if its broken, the fuse of centralized
for centralized
controller should be replaced;
controller
Failure of
remote Mismatch of remote Check remote controller for matching to centralized controller; if not, the remote
controller controller type controller should be coded or replaced for coding process;
Internal Malfunction Check internal electronics of remote controller for short-circuit or break; if its broken, the
of remote controller remote controller should be replaced;
Malfunction of Check centralize controller loop for conducting to every connector; if its conducted, the
harness harness of centralize controller should be checked and repaired;
Internal Malfunction Check if the centralized controller is able to receive signal from remote controller
of centralized normally and control every actuating component; if its abnormal, the centralized
controller controller assembly should be replaced;
344
Failure of remote
controller
Is voltage of remote controller battery too low? Over-low Replace remote controller
battery
Normal
Is voltage of battery too low? Over-low Charge or replace battery
Normal
Broken fuse of centralized controller Broken Change

fuse
Normal
Broken internal part of remote controller Broken

Replace remote
controller
Normal
Mismatch
Is remote controller matched to centralized Coding
controller?
Normal
Short-circuit or break of centralized controller loop Abnormal Check and repair

centralized controller loop
Normal
Centralized controller in poor operation Abnormal Replace centralized

controller
345
No. 250Door lock is not self-locked after driving 30 feet

Malfunction of fuse for Check fuse of centralized controller for conducting; if its broken, the fuse of
centralized controller centralized controller should be replaced;
Internal malfunction of Check centralized controller for normal working; if its abnormal, the
centralized controller centralized controller assembly should be replaced;
Check normal function of speedometer and then check if the signal is
Door lock is not Malfunction of speed sensor transferred to centralized controller; if its not working normally, the speed
self-locked after sensor should be replaced;
driving 30 feet
Locking latch for left-front door
Check, repair or replace locking latch for left-front door;
in poor operation
Failure of speedometer Check why the speedometer indicates abnormally, or replace combined
indication instrument;
Check loop of centralized controller and relative central control locking; if its
Malfunction of harness abnormal, the loop should be checked and repaired;
Door lock is not self-locked after driving 30 feet
Broken fuse of centralized controller Break Change fuse
Normal
Abnormal
Short-circuit or open circui of centralized controller Check and repair
loop centralized controller
loop
Normal
No signal from speed sensor to centralized controller Abnormal Repair speed sensor
Normal
Door locking in poor operation Abnormal Replace door lock

locking
Normal
Abnormal
Speedometer indication in poor operation Replace combined
instrument
Normal
Centralized controller in poor operation Abnormal Replace

centralized
346
No. 251 Failure of central control locking while driving

1. Check if the lockup unit is firm and free of dropping-of; if not, it should
be repaired;
1. Malfunction of lockup unit 2. Check the lockup unit for blocking; it should be moved freely during
normal working; if its blocked, the lockup unit should be replaced;
3. Check motor of lockup unit and measure its resistance for short-circuit
Failure of central control or break; if so, it should be replaced;
either by manual control
4. Check fuse of central control for break; if so, the loop should be
or by remote control
checked for short-circuit, grounding and over-current; if so, the fuse
2. Malfunction of circuit should be replaced after repairing;
5. Check connector for loosing or dropping-off; if so, it should be
repaired;
6. Centralized controller is damaged internally; the centralized controller
3. Centralized controller
Failure of central control locking while driving
Abnormal
Loosing or dropping-off of the lockup unit Repair
Normal
Blocking of lockup unit Abnormal Check, repair or

replace
Normal
Short-circuit or open circuit of lockup unit motor Abnormal Replace
Normal
Poor contact, short-circuit or open circuit of loop Abnormal Check and repair
Normal
Internal malfunction of centralized Abnormal Replace

controller
347
No. 252 Flashing CGQ alarm indicator for speedometer

1. Check if the resistance of sensor is in normal range; replace it if
necessary;
1. Malfunction of speed sensor 2. Lift front wheels and shift the gear; check speed sensor for signal;
replace it if necessary;
Flashing CGQ 3. Check speed sensor for dropping-off or poor contact; repair it if
alarm indicator for necessary;
speedometer during
2. Malfunction of drive assembly Check speedometer for blocking or damage, otherwise replace it if
driving
for speedometer necessary;
4. Check sensor combined instrument loop and all connectors for
2. Malfunction of circuit
short-circuit, open circuit or poor contact; otherwise repair it if necessary;
3. Malfunction of combined Check internal PCB of combined instrument for fault; otherwise replace
instrument it if necessary;
Flashing CGQ alarm indicator for speedometer
Abnormal
Speed sensor Replace
Normal
Abnormal
Drive assembly for speedometer Replace
Normal
Abnormal Check and

Circuit
repair
Normal
Combined instrument Abnormal Replace
348
No. 253 Window lifter cant work

Check if fuse of lifter burnt; if so, check if the circuit connects to earth wire and results
Fuse burnt
in fuse burning because of over-current; replace fuse after repairing.
Circuit Check all connectors of circuit for poor contact, short-circuit or open circuit;
Check switch of lifter for loosing or poor contact; if so, repair it.
Switch of lifter Check if the voltage of power supply for switch of lifter is 12V and there is power
output after pressing switch; if not, replace the switch of lifter.
Dismantle internal decorating plate of door; Check motor of window lifter for normal
working after power-on; if its abnormal, replace it;
Window lifter
Motor of lifter Check if the resistance of glass along the sliding groove is too big and if the sliding
cant work
groove is distorted; if its abnormal, it should be checked and repaired;
Check motor of lifter and measure the resistance between terminals of motor with
Ohm meter; if the resistance is infinite, the lifter should be replaced;
Check fuse and relay of centralized controller harness; if they are abnormal; replace
them;
Centralized controller Check if connector of centralized controller is firm; if it's abnormal, it should be
checked and repaired;
Check centralized controller for normal working with displacement method, otherwise
replace it if necessary;
Window lifter cant work
Malfunction of fuse Abnormal

Checking, repairing or
replacing
Normal
Abnormal
Malfunction of circuit Check and repair
Normal
Abnormal
Malfunction of lifter switch Check, repair or replace
Normal
Abnormal
Malfunction of lifter motor Check, repair or replace
Normal
Abnormal
Malfunction of centralized controller Check, repair or replace
349
No. 254 Blocking Door lock

Rusty internal mechanism of Door lock can't be moved. Clear, lubricate or
Rusty Door lock
replace it on rusty condition.
Check if the lockup unit is firm and free of dropping-of; if not, it should be repaired;
Malfunction of opener Check the lockup unit for blocking; it should be moved freely during normal working;
of Door lock if its blocked, the lockup unit should be replaced;
Check motor of lockup unit and measure its resistance for short-circuit or break; if
so, it should be replaced;
Check if the door is distorted and if there is sign of squeezing or bumping; if its
Door cant be Door abnormal, the door should be calibrated;
opened due to
blocking latch Check if the blocking of internal mechanism of Door lock is because of
Over-abrading Door
over-abrading; if so, it should be replaced;
lock
Dislocation of Door Check Door lock for loosing; if so, adjust or replace it.
lock due to external
force Check Door lock for distortion; if so, replace it.
Dismantle internal decorating plate of door and check supporting bar for knob of
Supporting bar for
Door lock for blocking or distortion; if it's abnormal, it should be calibrated or
knob of Door lock
replaced.
Blocking door latch
Rusting or
blocking
Blocking or rusting of door latch Check, repair or
replace
Normal
Abnormal Check, repair or
Malfunction of door opener
replace
Normal
Distortion or
dislocation
Distortion or dislocation of door Check, repair or
replace
Normal
Worn-out
Over-abrading door latch Replacing
Normal
Blocking or
interference
Blocking or interference of door latch knob Checking and
repairing
350
No. 255 Failure of door lock

1. Check if internal knob is too tight and unable to return; if
so, it should be adjusted or replaced;
1. Internal knob of door is blocked and unable
to return 2. Check if internal knob of door is unable to return
because of distortion or dislocation; if so, it should be
adjusted or replaced;
3. Check if core of door lock is unable to return because of
Door cant be 2. Blocking of core of door lock rusting or over-abrading, so that the Door lock cant be
closed because of sprung back; if so, clear or replace it;
failure of door lock
4. Check internal structure of Door lock body for damage; if
3. Broken body of door lock
so, it should be replaced;
5. Check door for distortion due to external bumping;
4. Distortion of door
If so, it should be adjusted or replaced;
6. Check operating knob of door lock for distortion or
5. Distorted or blocking knob of door lock
interference; otherwise it should be repaired or replaced;
Failure of door lock
Blocking of internal knob of door Yes Repair or replace
No
Yes
Blocking or damage of core of door lock Replace
No
Yes
Broken body of door lock Replace
No
Yes
Distortion of door Check, repair or replace
No
Yes
Distortion of door lock knob Replace
351
No. 256 If four doors of vehicle are not closed, the anti-theft alarm will be activated automatically and
central control will be locked automatically
If four doors of vehicle Is triggering switch of door control Check if the triggering switch of door control is unable to return
are not closed, the broken? or blocked; repair or replace it according to condition;
anti-theft alarm will be
activated automatically Check if there is signal outputted from centralized controller;
Is centralized controller broken?
and central control will repair or replace it according to condition;
be locked Check loops among all doors for break, short-circuit or poor
automatically Malfunction of circuit contact, otherwise repair them;
If four doors of vehicle are not closed, the anti-theft alarm will be activated automatically and
central control will be locked automatically
Blocking or non-return of door control Yes Replace

switch
No
Centralized controller is broken Yes Replace
No
Poor contact, short-circuit or open circuit Yes Check and

repair
352
No. 257 Reversing radar cant work while reversing

Failure of switch for
Replace reversing switch;
reversing light
Failure of sensor of
Check, repair or replace reversing sensor;
reversing radar
2) Check if connection between body harness and controller is reliable;
Poor contact between if the connection is normal, slight vibration should be touched by hand
harness and controller on sensor. If not, check if the voltage of power supply for controller
harness is normal.
No display or 3) Check if connection between body harness and controller is reliable;
alarm of Poor contact between if the connection is normal, all LEDs will be on for about 1s when power
reversing radar harness and display is on. If not, check if the voltage of power supply for controller harness is
while reversing normal.
4) If display works normally when power is on and slight vibration has
Broken connecting been touched on sensor connected to controller when reversing, but no
harness between reversing data are showed on display, the connection between display
controller and display and controller should be checked for correct conducting; the break and
short circuit test may be conducted with multi-meter.
5) After inspections stated above, if there is still fault, it can be
Broken reversing radar
determined that controller or display is broken. External power supply
controller or display
mode can be used to check and determine the parts to be replaced.
Reversing radar cant work
Failure of switch for reversing light Abnormal Check and
Normal
Failure of sensor of reversing radar

Abnormal
Check and
repair
Normal
Poor contact between harness and display

Abnormal Checking and
Normal
Broken connecting harness Abnormal

between controller and display Check and repair
Normal
Broken reversing radar controller or Abnormal Replace

display
353
No. 258 Wrong information from the reversing radar

1) Failed sensor is determined according to direction indicators of display
(When obstacle is detected by two left sensors, left indicator is on; and right
1) Sensor is installed
indicator is on per contra; when obstacle is detected by two middle sensors,
incorrectly;
Figures which dont both left and indicators are on.). Please adjust sensor promptly if inclined
change according installation of sensor is inspected.
to the distance of
obstacle are 2) Broken harness for 2) The connected harness between sensors and controller should be checked
showed on display sensor connecting for short circuit or break with multi-meter.
when reversing. 3) After inspections stated above, if there is still fault, it can be determined that
controller or sensors are broken. Corresponding sensor can be replaced by
3) broken sensor or
good one, if there is still fault, then it can be determined that controller is
controller
broken.
Wrong information from
Abnormal
Abnormal installation for sensor Adjust
Normal
Short-circuit or break f connecting harness Short-circuit or break

between controller and sensor Check, repair or replace
Normal
Broken
Broken sensor or controller Replace
354
No. 259 Sunroof cant move, including malfunction of automatic closing and anti-nip
Broken fuse Check if fuse is burnt-out; if so, replace it;
Poor contact of switch Check switch for poor contact with multi-meter; if so, replace the switch;
Sunroof cant Disordered memory for Check if the sunroof has functions such as automatic shutting and
move, including control module jam-preventing; if not, power-off the sunroof, and power-on again after 30 s to
malfunction of reset;
automatic closing
Malfunction of control
and anti-nip Check control module for burn-out; if so, the control module should be replace;
module
Reverse connection Connect the harness again;
Malfunction of motor Check motor for normal working; if its abnormal, replace the motor;
Sunroof in poor
operation
Burnt
Fuse burnt Change fuse
Normal
Poor contact of switch Broken Replace switch
Normal
Power-off the sunroof, and power-on
Disordered memory for control again after 30 s to reset
module
Normal
Burnt
Control module burnt
Replace control module
Normal
Burnt
Malfunction of motor Replace motor
355
No. 260 Abnormal sound and vibration of sunroof while operating

Obstacle or blocking of sliding Check sliding groove for obstacle; if so, clear it and lubricate the sliding
groove groove;
Abnormal sound
and vibration of Broken moving mechanism Dismantle the glass and slide and check moving mechanism manually for
sunroof while damage; if so, the moving mechanism should be replaced;
operating
Internal malfunction of motor Replace sunroof and motor assembly;
Distorted window frame Replace sunroof and motor assembly;
Abnormal sound and vibration of sunroof

while operating
With impurity
Impurity or blocking of sliding Clearing impurity and lubricating
groove
Normal
Broken or blocking moving Broken Replace moving

mechanism mechanism
Normal
Over-low
Internal malfunction of motor Replace sunroof and
motor assembly
Normal
Distorted
Distorted window frame Replace sunroof and motor

assembly;
356
No. 261 Leaking of sunroof (water on internal decoration of roof)

1) Check if one side of the clearance between glass of sunroof and roof is
1) Uneven clearance around
too big; if so, dismantle left and right decorating bars for sunroof and release
glass of sunroof and opening of
Water on fastening bolt for glass; insert shim to the clearance around glass of sunroof
roof
internal and roof to even the clearance;
decoration of
roof 2) Clog-up of sunroof drain 2) Check drain for clog-up; if so, the drain should be cleaned;
3) Dropping-off of sealant at rear 3) Check sealant at rear drain for dropping-off; if so, the rear drain should be
drain re-installed;
Leaking of sunroof (water in internal decoration

of roof)
One side of the clearance between Too-big Adjust the clearance around
glass of sunroof and roof is too big glass of sunroof and roof evenly
Even
Clog-up of drain Clog-up Clear the drain
Unblocked
Dropping-off of sealant at rear Drooping-off

drain Re-install rear drain
357
No. 262 Air-conditioner cant work

Undercharge of refrigerant Undercharge of refrigerant results in insufficient refrigerating capacity;
Air-conditioner
cant work Undercharge or overdose of refrigerant results in insufficient refrigerating
Overdose of refrigerant
capacity;
Air in system Air in system results in insufficient refrigerating capacity;
Leakage in system Check and remove leakage in system;
Over-loose belt for Over-loose belt for compressor results in over-low rotating speed of
compressor compressor, warm air outlet and abnormal sound; stretch or replace the belt;
Open-circuit of AC pressure
Replace AC pressure switch;
switch
Clog-up of drying filter Replace AC clog-up of drying filter;
Less amount of cooling air for Less amount of cooling air for condenser results in over-pressure at LP and
condenser HP side; check if the rotating speed of fan is normal and if the voltage is low;
The fins of condenser is Blocked fins of condenser by dirt results in over-high HP and bad heat
blocked by dust radiating effect; clean the dust on condenser;
Dirt in system will result in vacuum or very low pressure at LP side, high
pressure at HP side, frost or dew deposited on pipeline near drying reservoir
or heat expansion valve and warm air outlet; if the condition is not improved
Dirt in system
after power-off, then it can be determined that the system is clogged up by
dirt. Then the drying reservoir should be replaced and heat expansion valve
should be cleaned;
After certain working duration, moisture in system will result in obvious lower
and lower pressure at LP side, clog-up of hest expansion valve by ice, frost
Moisture in system deposited on evaporator and warm air outlet; and system will be normal if
power-on again after certain duration of shut-down; but the malfunction of
intermitting cooling will occur repeatedly;
Low rotating speed or failure of blower will result in frost deposited on
Low rotating speed or failure of evaporator, warm air outlet and insufficient refrigerating capacity; check
blower blower speed adjusting switch, relay and speed adjusting resistance for
damage and replace it, or replace blower assembly if necessary;
Slipping of compressor electromagnetic clutch will result in abnormal running
Electromagnetic clutch of
of compressor and insufficient refrigerating capacity; electromagnetic clutch
compressor is slipping
can be replaced separately or compressor will be replaced;
Too much refrigerating oil in system will result in turbid streaking on sight
Too much refrigerating oil in
glass and insufficient refrigerating capacity; discharge exceed refrigerating
system
oil;
Clogging of air inlet duct by other object will decrease air amount and result in
Air inlet duct of AC is clogged
insufficient cooling capacity and increased noise; clear clogging object from
by other object
air duct;
Unclosed fresh air damper of AC will result in higher temperature of air outlet
Fresh air damper of AC is not
and insufficient refrigerating capacity; check the cause of unclosed fresh air
closed tightly
damper and treat it;
Air filter screen of evaporator Blocking of air filter screen of evaporator by dust or other object will result in
is blocked by dust or other decreased air amount and insufficient refrigerating capacity; clean air filter
object screen;
The fins of evaporator is Blocking of fins of evaporator by dust will result in decreased air amount and
blocked by dirt insufficient refrigerating capacity; clean it by compressed air;
Malfunction of evaporator Malfunction of evaporator will resulting in failure of AC;
Bad packing of temperature wrap for heat expansion valve will result in
Bad packing of temperature
loosing of heat isolating layer and insufficient refrigerating capacity; pack it
wrap for heat expansion valve
properly again;
Incorrect adjusting of Incorrect adjusting of temperature controller; replace the temperature
temperature controller controller;
Exceed or less opening of Replace expansion valve assembly, pump for vacuum and fill refrigerant;
358
expansion valve
Malfunction of compressor Malfunction of compressor will resulting in failure of AC;
Short-circuit or break of loop
Check and repair loop and harness;
and harness
Malfunction of engine ECU Replace engine ECU;
359
Air-conditioner cant work
Abnormal
Dirt in system
Repair or clear
Normal
Abnormal
Malfunction of air duct Check, repair or replace
Normal
Abnormal
Undercharge or overdose of Check and
refrigerant repair
Normal
Abnormal Check and
Air or moisture in system
repair
Normal
Abnormal
Check and repair
Too much refrigerating oil or dirt in system
Normal
Abnormal
Malfunction of evaporator Check and repair
Normal
Abnormal
Electromagnetic clutch of compressor is slipping or belt is Check, repair or
loosing replace
Normal
Abnormal
Malfunction of blower Check, repair or
replace
Normal
Abnormal Check, repair or

Malfunction of condenser or
evaporator replace
Normal
Abnormal
Malfunction of temperature controller Check, repair or
or temperature wrap replace
Normal
Abnormal
Malfunction of Check, repair or
compressor replace
Normal
Short-circuit or circuit of circuit Abnormal Check and repair loop
and harness and harness;
Normal
Malfunction of engine ECU Abnormal

Replace engine ECU
360
No. 263 Normal suction pressure and too high exhaust pressure for AC compressor
1) Air in system: Drain refrigerant and vent air out; pump vacuum and fill
Air in system
refrigerant again.
Too much refrigerant 2) Too much refrigerant: Discharge exceeding refrigerant.
Normal suction Condenser blocked 3) Clog-up of condenser: Clean or replace condenser; pump vacuum and fill
pressure and too refrigerant again.
high exhaust 4) Clog-up of drying reservoir: Replace drying reservoir; pump vacuum and
pressure for AC Drying reservoir blocked fill refrigerant again.
compressor while
running of vehicle Pipeline blocked 5) Clog-up of pipeline: Clear clog-up; pump vacuum and fill refrigerant
AC again.
Insufficient air amount of
6) Insufficient air amount of condenser fan: Replace fan.
condenser fan
High temperature of engine
7) High temperature of engine water tank: find the cause and remove it.
water tank
Normal suction pressure and too high exhaust

pressure for AC compressor
Air in system Abnormal Check and repair
Normal
Abnormal
Too much refrigerant Discharge
Normal
Abnormal
Condenser blocked Check, repair or replace
Normal
Abnormal
Drying reservoir blocked Check, repair or replace
Normal
Abnormal
Abnormal
Pipeline blocked Check, repair or replace
Normal
Insufficient air amount of condenser fan Abnormal Check, repair or replace
Normal
Abnormal
High temperature of engine water tank Check, repair or replace
361
No. 264 Too high suction pressure and exhaust pressure for AC compressor
Overdose of refrigerant 1) Overdose of refrigerant: Discharge exceeding refrigerant.
Malfunction of heat expansion
2) Malfunction of heat expansion valve: Replace heat expansion valve.
valve
Broken suction valve segment
3) Broken suction valve segment of compressor: Replace compressor.
of compressor
Too high Over-high temperature of inlet 4) Over-high temperature of inlet air for evaporator: Check if fresh air damper
suction air for evaporator is closed tightly; find the cause and remove it.
pressure and
Air in system 5) Air in system: Vent air in system out; pump vacuum and fill refrigerant again.
exhaust
pressure for Poor heat radiating for 6) Poor heat radiating for condenser: Check if fins of condenser are blocked by
AC compressor condenser dirt and if fins are bent or distorted; clean or replace them.
while running
of vehicle AC 7) Insufficient air amount of condenser fan: Check if fan circuit is in poor
Insufficient air amount of
contact, if the rotating speed of fan is normal and if there is too much dust on
condenser fan
fins of condenser; find out the cause and remove it.
8) Loose fixing of temperature wrap: The temperature wrap contacts badly with
Loose fixing of temperature outlet of evaporator or outer heat isolating part of temperature wrap is broken;
wrap fix the temperature wrap again to ensure good heat isolating and contact of
temperature wrap for heat expansion valve.
Too-high suction pressure and exhaust pressure for AC
compressor
Abnormal
Overdose of refrigerant Check and
repair
Normal
Abnormal
Fault of heat expansion valve Replace
Normal
Broken suction valve segment of Abnormal Check, repair or replace

compressor
Normal
Abnormal
Too-high temperature of inlet air for Check and
evaporator repair
Normal
Air in system Abnormal Check and

repair
Normal
Poor heat radiating for condenser Abnormal Check, repair or replace
Normal
Abnormal
Insufficient air amount of condenser fan Check, repair or replace
Normal
Abnormal
Loose fixing of temperature wrap Check and
repair
362
No. 265 Too high suction pressure and normal exhaust pressure for AC compressor
1) Too high temperature of inlet air for evaporator: Check fresh air
Too high temperature of inlet
damper for leakage; the doors and windows should be closed to keep
air for evaporator
outside warm air away from carriage;
Too high suction
pressure and normal Malfunction of heat expansion 2) Malfunction of heat expansion valve: Replace heat expansion valve;
exhaust pressure for valve
AC compressor
Broken compressor 3) Broken compressor: Replace compressor;
while AC running
Loosing or bad heat isolating
4) Loosing or bad heat isolating of temperature wrap for heat expansion
of temperature wrap for heat
valve: Tighten it to ensure good contact and enhance isolating protection;
expansion valve
Too high suction pressure and normal exhaust

Too high temperature of inlet

air for evaporator Abnormal Check and
repair
Malfunction of heat expansion Check, repair or replace

valve Abnormal
Broken compressor Replace

Abnormal
Loosing or poor heat isolating of

temperature wrap for heat expansion Check and
valve Abnormal repair
363
No. 266 Too low suction pressure and exhaust pressure for AC compressor
Insufficient refrigerant in 1) Insufficient refrigerant in system: Check system for leakage; repair it and
Too low suction system supplement refrigerant again;
pressure and Malfunction of heat
exhaust pressure for 2) Malfunction of heat expansion valve: Replace heat expansion valve;
expansion valve
AC compressor
while running of 3) Moisture in system: Discharge refrigerant, replace drying filter and pump
Moisture in system
vehicle AC vacuum repeatedly (not less than 30 min) and fill refrigerant again;
Broken compressor 4) Broken compressor: Replace compressor;
Too low suction pressure and exhaust

Insufficient
Insufficient refrigerant in system Filling

Normal
Abnormal
Malfunction of heat expansion Checking, repairing or

valve Normal replacing
Abnormal
Moisture in system Checking

Normal and repairing
Abnormal
Broken compressor Checking, repairing or

replacing
364
No. 267 Air conditioning has abnormal sound

t
(1)The driving belt has not been tensioned. It will be prolonged in the process of usage and
The thus cause the abnormal sound; the belt shall be re-tensioned in case of this situation
compressor occurs;
has abnormal
sound during
the operation (2).The pulley and the tensioner bearing break down with rumbling sound during the
operation; a harsh feeling is showed when rotating the pulley by hand: replace the bearing,
check the tensioner and the pulley, replace them in case they are out of service.
(3)The abnormal sound may be caused by the looseness of the mounting bolt between the
engine and the compressor bracket as well as untightening of the bolt when mounting the
compressor bracket; the bolt shall be checked and retightened to ensure its reliable
connection;
The compressor
has abnormal (4).The compressor is oil shortage that causes the piston seizure, the piston scraping and
sound also the abnormal sound: the refrigeration oil shall be added;
(5).Too much or too little refrigerant, which causes the malfunction or the liquid impact of the
compressor; the refrigerant must be refilled;
(6).Failure of compressor electromagnetic clutch; replace the electromagnetic clutch or the

compressor assembly;
(7).Undersupply of the sedan generator battery that causes the insufficiency in the
compressor electromagnetic clutch coil suction resultant; the electromagnetic clutch is in
nearly sucking condition, which may cause the abnormal sound; the generator battery shall
be checked or replaced;
(8).The pulley is un-tightened: tightening the fastening screw;
(1).The abnormal sound is generated owing to the mismatch of the thermo expansion valve
structure with the system; it normally occurred when opening or closing the air conditioning;
here opening of the thermo expansion valve can be lowered (clockwise fasten the set screw
by half turn to 3/4 turn; over low fastening has no effect and over high fastening will influence
the performance); replace the thermo expansion valve if the above method is invalid;
(2)Performance of the thermo expansion valve does not mate with the system. The thermo
The thermo expansion valve will have an abnormal sound under certain operation mode if the capacity of
expansion valve the thermo expansion valve is too large; replace into a thermo expansion valve of suitable
has abnormal capacity.
sound
(3).Resonance of the thermo expansion valve will be caused if the thermo expansion valve
structure does not mate with the system; the thermo expansion valve shall be replaced under
this condition;
(4). It is caused by the quality problem of the thermo expansion valve such as ultra low of the
spring force; the thermo expansion valve shall be replaced;
The air (1) abnormal sound of the blower, imbalance of the blower fan blade, abnormal sound
conditioning has caused by excessive wear of the blower motor: replace the blower;
other abnormal
sound (2) Looseness of the clamp or the knock during the operation: tighten the clamping stirrup,
eliminate the friction or the vibration between the hoses and other parts;
(3) There has chatter in the pressure line caused by overfilling of the refrigerant; surplus
refrigerant shall be discharged;
(4) There has hissing sound at inlet of the thermo expansion valve caused by inadequate
filling of the refrigerant; the refrigerant shall be supplied;
365
Abnormal noise of the auto air conditioning reversing servomotor of generation II Vision and
Leading; replace the servomotor
The air conditioning has abnormal sound
Abnormal
Abnormal noise of the Overhaul or replace
compressor
Normal
Abnormal
Abnormal noise of the thermo Replace
expansion valve
Normal
Abnormal
Other abnormal sounds of the air Overhaul or replace
conditioning
No. 268 The air conditioning has no heating supply or the heating air is not warm

t
Malfunction of the blower switch 1) Malfunction of the blower switch: replace the blower switch;
2). Air leak of the heating radiator shell or the blower shell: tighten the connection
Air leak of the heating radiator screw and replace the sealing gasket;
shell or the blower shell
The cooling fin of the hot-water
pipe inside the heating radiator is 3). Cooling fin of the hot-water pipe inside the heating radiator is squeezed and
squeezed and deformed. deformed, which blocks the wind passing through the heater: straighten the
The air cooling fin with a nipper pliers; it shall be replaced by a new heater in case that
conditioning the cooling fin is unable to be straightened.
has no
heating
supply or Hot air outlet is blocked by the 4). Hot air outlet is blocked by the heater felt gasket: readjust the felt gasket
the heating heating radiator felt gasket position;
air is not
warm
The water valve switch is in

Reopen it in correct position;
wrong open position
Improper adjustment to the mix

5). Improper adjustment to the mix air throttle: re-adjust the air throttle;
air throttle
366
The air conditioning has no heating supply or

the heating air is not warm
Malfunction
The blower switch is out of Overhaul or replace
service
Normal
Air leakage
The heating radiator shell or the
blower shell is air leakage Overhaul or replace
Normal
Deformation
The cooling fin of the hot-water pipe
inside the heating radiator is Overhaul or replace
squeezed and deformed.
Normal
Block
Hot air outlet is blocked by the heating radiator felt Adjust
gasket
Normal
Improper adjustment
The mix air throttle is in improper Adjust
adjustment
367
No. 269 A/C compressor fails to start
Malfunction
Cause Solution
symptom
A/c compressor Fuse, electric appliance relative fuse is blown, the electric appliance element is of poor contact, the relay
assembly fails to element and relay are coil is broken: check the service condition of each electric appliance element and
start when the malfunction replace damaged one;
a/c is in
operation The belt is over loose Readjust or replace the belt
Failure of low voltage Low temperature protection switch takes effect; when the environment
switch temperature is lower than 15oC, the low temperature protection switch will
automatically cut out the circuit controlling the compressor: check if the
environment temperature is lower than 15oC and if the low temperature protection
switch is in normal operation;
Water temperature is too Check and eliminate the failure of ultra high in water temperature;
high
The idle speed is too low Eliminate it per the preclusion method of too low idle speed of engine;
The temperature Performance parameter of the temperature controller is over proofed while the
controller is failure temperature inside the car is ultra high, but the temperature controller is incapable
of being switched on to operate the compressor: replace the temperature
controller;
The thermo sensitive The thermo sensitive resistance is damaged and incapable of sensing the
resistance is damaged temperature correctly: check and replace the thermo sensitive resistance;
High pressure switch The high pressure switch takes the protection effect so that the compressor fails to
start; check if the high pressure is too high and the system is blocked;
The electromagnetic The electromagnetic clutch can not be sucked together and is incapable of being
clutch can not be sucked operated along with the compressor: check if the clearance of the electromagnetic
together clutch is too large, replace the electromagnetic clutch;
The electromagnetic The electromagnetic clutch cant work: check if the electromagnetic clutch coil is
clutch cant work broken, replace the electromagnetic clutch;
The refrigerant is leaking The refrigerant is leaked to the set value of low pressure switch, the low pressure
protection switch takes effect so that the compressor fails to start: check the
system leaking position and eliminate it;
The compressor bearing The compressor bearing is damaged or oil shortage: replace the compressor and
is damaged or oil fill up the refrigeration oil as required;
shortage
Cylinder sticking of Cylinder sticking of compressor; there may have foreign materials inside the
compressor cylinder or the piston position maybe changed after long-term abrasion that causes
the seizure or the oil shortage: remove the compressor for replacement;
Malfunction of ECU Replace the ECU assembly

interior short circuit
control
368
A/C compressor fails to start
Fuse, electric appliance element Abnormal

and relay are in trouble Overhaul or replace
Normal
Abnormal
Malfunction of low pressure Overhaul or replace
switch
Abnormal
Malfunction of temperature Replace
controller
Abnormal
High pressure switch Overhaul or replace
The electromagnetic clutch can not be Unable to suck Overhaul or replace

sucked together
Leaking
The refrigerant is Overhaul
leaking
Damaged
The compressor bearing is damaged or oil Replace
shortage
The electromagnetic Cylinder sticking Replace

clutch cant work
Abnormal
The compressor is of piston Overhaul or replace
seizure
Abnormal
Short circuit of ECU Replace the ECU
assembly
369
No. 270 The A/C control mechanism is hard to operate
Malfunction
Cause Solution
symptom
Manipulating key of the control 1).Manipulating key of the control mechanism and rocker on the shell
mechanism and rocker on the shell body are heavy: spread lubrication oil at the sliding part of each
The A/C control body are heavy revolving member.
mechanism is
hard to operate
The air throttle is ineffective in
2).The air throttle is ineffective in rotation: repair the air throttle.
rotation
The A/C control mechanism is hard to

operate
Manipulating key of the control mechanism Heavy

Overhaul
and rocker on the shell body are heavy
Normal
Blocked
The air throttle is ineffective in Overhaul
rotation
No. 271 The A/C evaporator is frosting
Malfunction symptom Cause Solution
The thermo expansion 1).The thermo expansion valve is in abnormal operation: replace the
valve cant work thermo expansion valve;
.Thermo sensitive
resistance of the 3). Thermo sensitive resistance of the temperature controller is
temperature controller is mounted in incorrect position, so it is incapable of sensing the surface
mounted in incorrect temperature of the evaporator. Install the resistance in correct position;
position
The A/C evaporator is 4). Thermo sensitive resistance of the temperature controller fails so
frosting during the operation Malfunction of thermo that the compressor can not stop; uninterrupted refrigeration will lower
sensitive resistance of down the surface temperature of the evaporator. when the temperature
the temperature is below 0 degree, water vapor in the air flowing through the evaporator
controller will be frosting on external surface of the evaporator: replace the
thermo sensitive resistance;
Temperature of the
5).Temperature of the temperature controller thermo sensitive
temperature controller
resistance is set so low, causing surface temperature of the evaporator
thermo sensitive
below 0 degree to frost: replace the thermo sensitive resistance;
resistance is set too low
370
The a/c evaporator is frosting
Abnormal
The thermo expansion valve is in
abnormal operation Replace
Normal
Deficient
The evaporator is deficiency in draught Overhaul
Normal
Incorrect
Thermo sensitive resistance of the
temperature controller is in incorrect Re-mount
mounting position
Correct
Abnormal
Thermostat of the temperature controller is out of Replace
service
Normal
Abnormal
Design temperature of the temperature
controller thermostat is over low Replace
371
No. 272 Constant malfunction and solution of A/C components
Spare parts name Constant malfunction Preclusion method
A/C relay 1).The contact is superficial charring; 1).Connection check: bridge a wire at the suction position
2).The relay coil is burnt out; of the relay. If the compressor or the fan is in normal
3).The spring leaf is damaged and incapable of operation after the bridging, it means there is failure in the
sucking; relay;
2) Displacement method check: replace into a new relay
of the same type and specification to make the judgment
of the original relay. When replacing the damaged relay, it
shall adopt the relay of the same model and specification
and the relay position shall not be changed randomly;
Compressor 1).Cylinder sticking and cylinder scoring of Replace into a new compressor of the same model;
compressor; the link rod is breakout; the pulley
does not rotate or is hard to rotate; there has
abnormal sound;
2).Valve leaf and valve plate of the compressor
is damaged and there has abnormal sound;
3).The compressor sealing gasket is breakdown
that result in coalition between high and low
pressures; high pressure is the same as the low
pressure;
4).The compressor shaft seal is leaked that
causes large leakage of the refrigerant;
5).Pulley bearing is damaged. Ultra large belt Replace the electromagnetic clutch and adjust the belt
tension will generate too much radial bearing tensioning force;
force, and the suction cup will be seized with the
pulley thus damage the bearing;
6).Coil of the electromagnetic clutch is short or Replace the electromagnetic clutch;

broken so that the suction can not be generated;
7).Clearance between the suction cup and the
pulley is too small that causes the sticking or the
seizure between the suction cup and the belt
surface, or even the pulley charring;
8).Fuse of the electromagnetic clutch is blown
out;
9). The electromagnetic clutch is slipping; Reason of insufficient suction and its preclusion method:
suction between the pulley and the suction cup (1).The electromagnetic clutch is insufficient in the power
is inadequate that causes the slippage; supply voltage: recharge the battery;
(2).A/C relay is in poor contact: check the relay and
replace it if anything wrong with it.
(3).There has too much refrigerant or the compressor is
of piston seizure that causes excessive load; discharge
the surplus refrigerant or replace the compressor;
(4).The electromagnetic clutch has slipping sound caused
by the belt slippage; re-tension the belt;
Evaporator 1).The evaporator is leaking that causes the Replace the evaporator assembly or the evaporator.
shortage of refrigerant or no refrigerant; the
result is that the evaporator is insufficient in the
cooling volume or does not refrigerate.
372
Frosting on the sedan A/C evaporator can be treated according to

the following aspects:
1).The thermo expansion valve is in abnormal operation: replace the
thermo expansion valve;
2).The evaporator is deficiency in draught: find out the reason and
eliminate it;
3). Thermo sensitive resistance of the temperature controller is in
incorrect mounting position, so it is incapable of sensing the surface
temperature of the surface temperature. Install the thermo sensitive
2).The evaporator is frosting; resistance per correct position;
4). Thermo sensitive resistance of the temperature controller is out
of service so that the compressor can not stop; uninterrupted
refrigeration will lower down the surface temperature of the
evaporator. When the temperature is below 0, water vapor in the
air flowing through the evaporator will be frosted on external surface
of the evaporator: replace the thermo sensitive resistance;
5).Design temperature of the temperature controller thermostat is
over low that causes surface temperature of the evaporator below
0 to frost: replace the thermostat;
3) The ice block is caused by the moisture in the system and the
dirty block is caused by the impurities such as the aluminium chips in
3)The evaporator assembly is the system; result of the ice block is that the evaporator is not cool
blocked sometimes, while the result of the dirty block is that the evaporator is
not cool or is inadequate in the cooling volume: eliminate the
moisture or the impurities.
4).Constant malfunction of the thermo expansion valve: power head

(gas phase head) of the thermo expansion valve is leaked that
4)The thermo expansion valve
causes inadequate opening or incapable of being opened of the
is blocked or leaked;
thermo expansion valve, thus the evaporator is not cool or is
inadequate in cooling volume: replace the thermo expansion valve.
1).There has dirt on the

condenser flat pipe and the
heat emission fin, which will
Clean out dirt and impurities on the flat pipe and the heat emission
reduce the heat transfer
fin;
capability and increase the high
pressure in the refrigeration
system;
Condenser
2).There is impurity blockage
on the condenser heat Purge them with compressed air;
emission fin;
3).The condenser heat

Calibrate it with the nipper pliers and replace the condenser if it is
emission fin is of flexural
severe;
deformation;
4).The condenser is leaking; Replace the condenser
The block reason is the pulverizing of the drier as well as too many
impurities in the system; the phenomena is that the high pressure is
1)Dry reservoir assembly is
increased and there has apparent temperature difference between
blocked;
inlet and outlet of the dry reservoir assembly: replace the dry
Dry reservoir reservoir;
Thermo expansion valve maybe blocked so that the a/c will not
2)Filter screen inside the dry
refrigerate: replace the dry reservoir and check the thermo
reservoir assembly is damaged;
expansion valve;
373
1).The hose is aging damaged; Replace damaged hose assembly;
2).The connection is loose; Retighten the connection or replace the hose assembly;
Pipeline assembly
3).The connection thread is
Replace the hose assembly;
damaged;
Replace O seal ring. The above failures will cause the refrigerant
4).O seal ring is damaged;
leaking;
1).Wire of the blower or the fan

Reconnect the fan wire;
is broke off;
2).Motor of the fan or the

Replace the blower or the fan;
blower is damaged
3). Fuse of the blower or the fan

is blown out or the switch is in Check and replace the fuse, eliminate the switch bad contact;
Blower and condenser bad contact;
fan
4).Governing resistance of the

Replace the governing resistance;
blower is damaged;
Replace the condenser fan (the above failure will cause deficiency in
fan draught or no draught of the fan so that the high pressure will be
5).The fan blade is battered abnormally high; deficiency in the blower draught or no draught of
the blower will cause the evaporator to frost, deficiency in heating air
or no heating air);
374
Diagnoses flow of air-conditioning system constant malfunction
375
Solution to auto a/c Constant malfunction: Auto air-conditioning system of Vision and Leading
models are provided with failure self-diagnostic function. Some basic failures can be checked by
the self checking function. In addition, we have enumerated some familiar failure symptoms and
treatment processes, according to which you can find out the failure reasons and help your
clients to solve the problems.
No.273 Vehicle temperature sensor is in poor condition
(code display 01)
Yes
Power on and test if the voltage between B3 and B2 is0.5VVi4.8V
Pull out B plug behind the control panel The a/c controller is in poor condition
Test the ohmic value between B3 and B2 of B plug at the harness end with the meter
Vehicle interior temperature sensor
Yes
Is the ohmic value between 500 and
100K?
B2 B3 No
1. Harness or metal plug-in connected with B3 and b2 is in B3 and B2 metal plug-in card inside B plug are in
poor condition; poor contact with the controller socket;
2. The vehicle temperature sensor is in poor condition.
No.274 The vehicle exterior temperature sensor is in poor condition;

(code display 02)
Yes
Power on and test if the voltage between A12 and A11 is 0.5VVi4.8V
No
Pull out A plug Aehind the control panel The a/c controller is in poor condition
Vehicle exterior temperature sensor Test the ohmic value between A12 and A11 of A plug at the harness end with the
meter
Yes
Is the ohmic value between 500K and
100K?
A11 A12 No
1. Harness or metal plug-in unit connected with A12 and A11 is A12 and A11 metal plug-in card inside A plug are in
in poorcondition; poor contact with the controller socket;
2. The vehicle exterior temperature sensor is in poor
condition.
A/C controller
376
No.275 The evaporator temperature sensor is in poor condition.

(code display 03)
Yes
Power on and test if the voltage between B4 and B1 is 0.5VVi4.8V
No
Pull out B plug behind the control panel The A/C controller is in bad condition
Test the ohmic value between B4 and B1 of B plug at the harness end with the meter
Vehicle exterior temperature sensor
Yes
Is the ohmic value between 500 and
100K?
B3 No
B2 B3
1. Harness or metal plug-in unit connected with B4 and B1 is B4 and B1 metal plug-in card inside B plug are in
in bad condition; poor contact with the controller socket;
2. The evaporator temperature sensor is in bad condition.
A/C controller
No.276 The temperature adjustment performer is in poor condition;
(code display 04)
1. Turn the ignition switch to "ON";

2. Remain the environment temperature at about 25 (or unplug the temperature sensor
inside and outside the vehicle);
2. Test the voltage between B9 and B2 (ground lead) pins with a meter;
3. Adjust the TEMP+ or the TEMP- key on the control panel.
Does the voltage between B9 and B2 continuously changed

between 1.1V and 4.0V when the design temperature varies
continuously between HI and LO?
No
Yes
Yes
Does the voltage value
The A/C controller is in bad
A/C controller remain constant?
condition
No
1. The temperature adjustment 1. B10, B9 and B13 wires inside B plug are in poor
performer is in bad condition; contact with the performer or broken;
2.The A/C controller is in poor condition 2. The temperature adjustment performer is in bad
condition or the mechanism is seized;
3. The A/C controller is in bad condition.
377
No.277 The sun sensor is in poor condition.(code display 05)
Yes
Power on and test if the voltage between B2 and B5
is0.7VVi4.85V
No
1. Pull out B plug behind the control panel; let the light sensitive
head fully exposed under the sun;
1.Pull out B plug behind the control panel; 2. Connect B5 pin at the harness end B plug with the digital
2.Cover the light sensitive head of the sun sensor
multimeter red pen and connect B2 (ground lead) with the black
with a light-tight object.
A/C controller pen.
Yes
Test the ohmic value between B2 and B5 of B plug at Test if the ohmic value between B5 and B2 is
the harness end with the meter reduced apparently?
No
Yes
Is the ohmic value less than 100K? The sun sensor is
in poor condition.
No
1. Harness or metal plug-in unit connected with B2

and B3 is in poor condition;
The a/c controller is
2. The sun sensor is in poor condition.
in poor condition
6-
No.278 The fan governing module is in poor condition;
(code display 06)
40A 800 power line (2)
GAUSE meter
3BW
Fan relay
1.Turn the ignition switch to "ON";

2.Adjust the "air volume plus" key on the control panel. There has no air or abnormal
Blue air volume variation from gear 1 to gear 5; the air volume is in normal condition at the
M Max. gear 6.
High speed realy
Blower
speed regulation module
Test the voltage between B7 and B2 with a meter from gear 1 to gear 5. The normal
voltage shall be as follow: 3.9V at gear 1; 4.0V at gear 2 and 4.3V at gear 3; 4.5V at
gear 4; 4.8V at gear 5.
black
E
blue/brown
grey/brown
Yes
blue/black
Fan ground lead Is the voltage value in normal

condition?
No
A/c controller 1.The harness connected with 1The governing module is in poor
B7 and the plug-in unit are in condition;
poor condition; 2.The plug-in unit at DS end of the
2.The a/c controller is in poor governing module is in poor contact.
condition.
378
No.279 The high speed relay is in poor condition; (code display 07)
1. Turn the ignition switch to gear "ON";

GAUSE meter 2. Adjust the "air volume plus" key on the control panel. There has no
air or abincreaseunsharpness air volume variation from gear 1 to gear
5, the air volume does not increase apparently at the Max. gear 6.
Fan relay
Blue
M
Blower Test the voltage value between B6 and B2 with a

meter. The normal value shall be 13V at gears
excepet gear 6 and no more than 1V at gear 6.
speed regulation module
Yes
Is voltage value at gear 5 or gear 6 close to 0V?
black No
E
1.The GAUSE meter wire is in bad condition;
grey/brown
blue/black
blue/brown
Fan ground lead Yes 2. The high-speed relay socket is in bad

Is the voltage value at gear 6 1V?
contact;
No 3. The high-speed relay is in bad condition.
A/c controller
1. The controller card connected with B6 1. The high-speed relay socket is in bad
is in bad contact; contact; A/c controller

2. The high-speed relay is in bad
2. The a/c controller is in bad condition; condition.
No.280 The rear defrosting function is invalid
800 powe line (2)
1. Turn the ignition switch to gear "ON";

2. Operate the "rear defrosting" key on the control panel; the defrosting
2# lamp will light up after pressing the key once and will go out after
30A pressing it again.
Test the voltage value between A3 and the ground with a

meter. The normal value shall be 13V at light off and 1V
Rear defrosting control
at light on.
Is the voltage value at light on or ligh off close to 0V?

Green/White
1. The GAUSE meter wire is broken;
2. The rear defrosting relay socket is in bad contact;

Is the voltage value no more than 1V
when the light is on? 3. The rear defrosting relay is in bad condition;
A3
A/C controller
1. The A3 plug-in unit is in bad contact with the 1. The rear defrosting relay socket is in bad
controller socket; contact;
2. The a/c controller is in bad condition;
2. The rear defrosting relay is in bad condition;
3. The rear defrosting heater and concerned
harness problem.
379
No.281 The display screen has no display
No.282 The internal and external circulation regulation is invalid
380
No.283 The wind direction adjustment is abnormal
No.284 The blower is in poor operation
381
No.285 Vehicle interior air conditioning is in poor condition
382
No.286 Vehicle interior central heating is in poor condition
No.287 Night light regulation function of the a/c controller is invalid
383
No.288 The compressor is out of service
No.289 Effect of the air conditioning is in poor condition (check it per

the content in the following table)
Phenomena and state Analysis of causes Solution
1. There is too much air mixed in the system. Vacuumize again and refill the refrigerant.
2. Too much refrigerant filled. Discharge the surplus refrigerant.
Check or replace, discharge the surplus

Both high pressure and 3. Too much lubrication oil.
lubrication oil.
low pressure are too high
Clean the dirt on the condenser surface or
4. The heat emission effect of condenser is poor.
replace with a new condenser.
5. The cooling fan common used by the condenser and

Check it or replace with a new cooling fan.
the water tank is abnormal.
1. There is insufficient refrigerant filled. Add the filling volume of the refrigerant.
Both high pressure and Make the leak check and replace the
low pressure are too low 2. The refrigerant is leaking.
leaked spare.
3. The O-ring is damaged. Replace the O-ring.
1. The expansion valve is in over size opening or is Adjust the opening of the expansion valve
damaged. or replace with a new expansion valve.
The high pressure is
normal and the low
pressure is too high 2. Too much refrigerant filled. Discharge the surplus refrigerant.
3. Something wrong with the compressor. Replace the compressor.
1. Insufficient refrigerant filled. Add the filling volume of the refrigerant.

The high pressure is
2. The expansion valve is ice blocked. Replace with a new liquid storage drying
normal and the low
bottle.
pressure is too low
3. Dirt on the evaporator surface or has clogging inside Clean the evaporator surface or replace
the evaporator. with a new evaporator.
384
Check it or replace with a new

1. The compressor efficiency is decreased.
compressor.
The high pressure is low
yet the the low pressure is
high Adjust the opening of the expansion
2. Opening of the expansion valve is too big. valve or replace with a new expansion
valve.
1. The low pressure increase fast after the power off- the Replace with a new liquid storage
The high pressure is low system is ice blocked. drying bottle.
yet the the low pressure is
of negative pressure
2. The low pressure increase slowly after the power off -
Clean the system.
the system is blocked.
Replace with a new inlet air filter

1. The inlet air filter is blocked.
cartridge.
2. The air duct is blocked. Clear the air duct.

The
voltage is
normal 3. There is dirt on the evaporator surface. Clean the evaporator surface.
The air
volume is
Check or replace with a new blasting
insufficient 4. The blasting motor is in sluggish operation.
motor.
The 1. Supply voltage of the entire car is unsteady.

voltage is Check .
inadequate
2. The power ground is out of order.
The high pressure can only

1. The clutch or the belt is slippery. Check or replace the clutch or the belt.
reach a certain value.
1. The evaporator temperature sensor is in poor Replace the sensing head or check if its
condition. position is correct.
2. Harness and plug-in unit of the evaporator

Check
temperature sensor are in poor condition.
The evaporator is frozen

3. Too much refrigerant Discharge a portion of the refrigerant
4. Air capacity passing through the evaporator is Inspect if the fan rotation speed is
inadequate. normal.
5. Failure expansion valve Replace it
385
No.290 Installation and Commissioning of the Air Conditioning

Commissioning
Inspect the Leak detection by

leaking point nitrogen positive
pressure
No felling back occurs when the filling pressure is 3.0Mpa
Vacuumizing
Leak Remain it for at least 72 hours after the vacuum degree is 745mmHg
detection
Close the manifold pressure gauge and watch for 5 minutes without felling back
being occurred
Fill in the refrigerant The liquid refrigerant can be filled from the high pressure side per the regulation
before the system start-up; gaseous refrigerant must be filled from the low
pressure side after the system start-up.
Watch the window until the filling volume

is appropriate
386
Cautions for installation safety

Installation staffs of air conditioning must wear protective glasses.
During the operation and the commissioning of the air conditioning unit, hands of the loading staffs shall be
kept away from various fans and water tank fans.
The high pressure and low pressure pipes shall be checked carefully before charging the cooling medium to
avoid the explosion.
Open flame is strictly prohibited to touch the refrigerant to avoid the choking caused by the toxic gas
generated by the burning.
The radiator fin shall be taken care not to scuff the hand skin when the radiator is operated.
Metal ornament is strictly prohibited when the air conditioning is installed to avoid the injury caused by the
short circuit.
Treatment to the installation accident
If the refrigerant touches the eyes, a great deal cold water shall be used to flush the eye not less than 10
minutes.
If a great deal of refrigerant is leaked and the skin is frostbite, the frostbite location must be warmed up and
then the injury shall be sent to the hospital.
Installation notice
Usage of the compressor oil.
Usage of the seal.
Installation of the pipeline:
The pipeline installation must be clean and dry; plugging material on the pipeline could be removed only
when the pipe is installed.
R134a pipeline adopted by our company is of the sausage type sealing so the nut shall be tightened only afte
the pipeline connection is ensured to have been inserted totally; the nut must be tightened by hand and then by
two wrenches.
The refrigeration oil must be dripped before the screwed joint is connected to prevent the thread from
stripping and ensure the sealing property.
Sharp transition is not permitted for the pipeline installation especially for the low pressure pipe installation.
Incorrect (the pipeline should

be put naturally)
Correct
387
Special repair kit for air conditioning

The special repair kit for air conditioning is composed of the magnetic thickness gauge, the gas leak tester, the
spare gas bottle, the service valve wrench, the refrigerant filling valve, the filling hose gasket and the service
valve gasket, etc. Above tools are special tools used to repair the vehicle air-conditioning. Tools in the kit shall
be used as much as possible during the repair process to ensure the check quality.
Usage of the refrigerant filling valve
The filling valve is as Fig. 4-6
1). Anti-clockwise rotate the filling valve handle until the valve needle is withdrawn.
2). Install the filling valve on the refrigerant tank and anti-clockwise rotate the sheet nut until it reaches the top
position, then clockwise rotate the refrigerant filling valve until the filling valve is embedded into the refrigerant
sealing plug.
3). Clockwise rotate the sheet nut to the end and fix the intermediate hose of the manifold pressure gauge into
the connection of the filling valve.
4). Tighten the sheet nut.
5). Clockwise rotate the handle until the valve needle pierces into the sealing plug.
6). Provided the refrigerant is to be filled, the handle shall be rotated anti-clockwise to uplift the valve needle
and at the same time the hand valve on the manifold pressure gauge is opened.
7). Provided it is to stop adding the refrigerant, clockwise rotate the handle so that the valve needle will enter
into the sealing plug once again to play the sealing effect, and meanwhile close the hand valve on the manifold
pressure gauge.
Usage of the manifold pressure gauge
The manifold pressure gauge is also called the manifold pressure meter, which is connected with the
refrigeration system to carry out the vacuumizing, filling in the refrigerant and diagnosing the failure of the
refrigeration system. Fig. 4-2 shows the structure of the manifold pressure gauge. It consists of the high
pressure gauge, low-pressure gauge, manual low pressure valve, manual high-pressure valve, valve body,
high pressure connection, low-pressure connector and refrigerant vacuumizing connector. During the
operation, high and low pressure connectors are connected with high and low pressure fill in valves of the
system respectively via the hose and the intermediate connector is connected with the suction pump or the
refrigerant (HR134a) cylinder. The connector connecting the hose and the manifold pressure gauge could only
be tightened by hand instead of by wrench, or else the connection thread may be damaged. Air inside the hose
must be drained away during the usage. Detailed steps are as follows:
1). When the manual low pressure valve is opened and the manual high pressure valve is closed, the low
pressure line is connected with the intermediate pipeline and the low pressure gauge. At that time the
refrigerant can be filled or discharged from the low pressure side, and meanwhile pressures at both the high
pressure side and the low pressure side can be detected.
2). When the manual low pressure valve is closed and the manual high pressure valve is opened, the pressure
line is connected with the intermediate pipeline and the high pressure gauge. At that time the refrigerant can be
filled or discharged from the high pressure side, and meanwhile pressures at both the high pressure side and
the high-tension side can be detected.
3). Detection to pressures at high and low pressure sides can be made when both the manual high pressure
valve and the low pressure valve are closed.
4). Refrigerant filling, vacuumizing and detecting to pressures at both the high pressure and low pressure
sides can be carried out when both the manual high and low pressure valves are opened.
388
Open Open
Fig 4-2 Structure of manifold pressure gauge
1 high pressure gauge 2 low-pressure gauge, 3 manual low pressure valve, 4 manual high-pressure valve, 5
valve body, 6 high pressure connection, 7 refrigerant vacuumizing connector
8 low-pressure connector
Usage of the refrigerant charging valve
A charging valve is installed on the inlet and the exhaust pipes of the sedan air conditioning compressor. Its
operating principle is identical to that of the valve core on the tire. During the usage, tighten the quick joint of
the charging hose into the port of the charging valve so that the needle is pressed open; the air-conditioning
system is connected with the detection used hose with the refrigerant flows into it; the charging valve can be
closed automatically when the detection used hose is removed.
Routine method to check the leakage of air conditioning refrigerant
Leak-detection methods generally used in the vehicle air conditioning refrigeration system are nitrogen
supercharging leak detection, vacuum leak detection, charging leak detection, instrument leak detection and
appearance leak detection.
1). Nitrogen supercharging leak detection: charging the nitrogen into the refrigeration system and apply the
soap water at the leak detection position. The soap bubble will be generated when there is the leakage. The
compressed air is strictly prohibited when the supercharging leak detection is adopted. This is because there is
moisture in the compressed air and will cause the ice block at the thermal expansion valve when the moisture
enters into the system along with the air. The industry nitrogen is non-corrosive, moisture-free and low in price,
yet bottle high pressure nitrogen gas must be provided with a decompression adjuster to adjust the air out
pressure. When the system reaches the specified 1.0 Mpa, apply the soap bath at each joints and welding
points of the system to observe the leakage carefully. There is tiny sound at large leakage area with big foam
and there is discontinuous small foam at small leakage area. The leak detection must be made carefully and
repeated for 3 to 5 times. The leaking position shall be marked and restored in time, then the leak detection
can be made at other joints until the leakage is eliminated totally. The leak-off-test shall be made after the
leakage is restored, i.e. the system is kept the pressure for more than 0.5 hours. The leak-off-test is accepted
when the pressure does not reduce; the leak detection must be made once again if the pressure reduces
greatly until the leaking area is found and restored.
Leak-off-test pressure of the refrigeration system is 1.5 ~ 1.7Mpa. Take care when checking the leak.
2). Vacuum leak detection: it shall be made adopting the vacuum pump. The vacuum pressure shall be lower
than 100Pa and constant. It is acceptable when the vacuum pressure is not increased remarkably during
relatively long time.
3). Filling leak detection: it can be made following the vacuum leak detection. The leak detection is carried out
by the electronic leak detector after little refrigerant is charged. The indicator will light up and give out an alarm
when the refrigerant is leaking.
4). Appearance leak detection: normally there is the refrigeration oil leaked out at the refrigerant leaking
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locations. A clean plain paper can be used to wipe it off or the hand can be used to inspect it directly. It means
the refrigerant leakage when the oil stain keeps on leaking.
Locations where air conditioning refrigerant leakage often occurs
Operating condition of the air conditioning is normally rough. Its refrigeration system keeps on vibrating along
with the vehicle operation, hence the pipeline is easy to be damaged and the joint is loose thus causing the
refrigeration leakage. The general leaking locations are shown as the following table.
Locations where air conditioning refrigerant leakage often occurs
Assembly Leaking parts
Connection of the condenser air inlet pipe and the liquid outlet pipe
Condenser
Welding of the condenser flat pipe and the collector pipe
Connection of the evaporator air inlet pipe and the liquid outlet pipe
Evaporator
Each welding of the evaporator
Thermo expansion valve Gas phase head
Fusible plug
Liquid storage dryer
Connection of the evaporator liquid inlet pipe and the liquid outlet pipe
High and low pressure hoses

Refrigerant line
Connections of high and low pressure hoses
Compressor shaft seal
Connection of inlet and outlet

Compressor
Sealings of front and rear cover
Air intake and exhasut valves of the compressor

How to carry out the vacuumizing, leak detection and refrigerant filling to the vehicle air conditioning
There are three purposes of making the vacuumizing by the vacuum pump: the first, to drain out the air and the
moisture in the air-conditioning system; the second, to inspect the leakage in the system; the third, to dry the
system. The refrigerant can be filled only after the system is vacuumized. The vacuumizing can reduce the
boiling point rather than drain the water out from the refrigeration system directly after the vacuum is realized.
The water is drained out from the refrigeration system only after it is transferred into the water vapor.
Connection of the vacuumizing pipeline is shown in Fig.4-3. Detailed steps are as follows:
1). Connect both high and low pressure hoses of the manifold pressure gauge with high and low pressure
charging valve interface of the system (note: for the sedan air-conditioning system, most high and low pressure
charging valves are on the high and low pressure hoses, while very few hoes are on the compressor); connect
the intermediate hose on the manifold pressure gauge with the vacuum pump.
2). Open the manual high and low pressure valves on the manifold pressure gauge and start the vacuum pump;
vacuumize the systemic pressure to below 100pa and keep constant.
3). Close the manual high and low pressure valves on the manifold pressure gauge and see if the pressure
shown by the gauge indicator is recovered; the pressure recover means the system leakage, then the leak
detection and repair shall be made by this time. Provided the gauge indicator keeps still, the hand valve shall
be opened to startup the vacuum pump and keep on vacuumizing until pointer of the if is constant.
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1 compressor 2 vacuum pump 3 air 4 low pressure gauge

5 high pressure gauge 6 manual low pressure valve opening
7 manual high pressure valve opening
Fig 4-3 Vacuumizing of air conditioning refrigeration system
4). simultaneously close the manual high and low pressure valves after the vacuumizing.
5). Screw down the intermediate hose of the manifold pressure gauge from the vacuum pump joint and switch
over a refrigerant cylinder joint.
6). Unscrew the intermediate hose joint on the manifold pressure gauge and slightly open the refrigerant
cylinder valve to send away the air in the intermediate hose by the refrigerant. It is OK just being opened for
2~3 seconds.
7). Open the manual high and low pressure valves and the refrigerant cylinder valve so that small volume of
the refrigerant can enter into the refrigeration system until the gauge indicator points into 1000pa. Close the
manual high and low pressure valve as well as the refrigerant cylinder valve and remain for several hours.
8). If there is no variation in the systemic pressure, it means the system has no leakage; provided the systemic
pressure is reduced, it means there is leakage in the system, then the leaking location shall be found out and
precluded.
9). Open the refrigerant cylinder valve and the manual high-pressure valve so that the refrigerant can be
entered into from the high pressure side after the system is confirmed having no leakage. By this time the
refrigerant cylinder can be inverted to increase the charging rate, however the air conditioning is not permitted
to startup.
10). The refrigerant can also be filled from the low pressure side. The method is that the manual high-pressure
valve is closed and the refrigerant cylinder is kept upright, then the air conditioning compressor is turned on to
operate. Slowly open the manual low pressure valve so that the refrigerant can enter into the suction
compressor in gaseous state from the low pressure side; when the refrigerant charging volume achieves the
requirement, the manual low pressure valve and the refrigerant cylinder valve are closed.
11). Watch it from the sight glass to ensure there is no bubble or surplus refrigerant inside the system. Then
adjust the engine speed to 2000r/min and turn the cold air machine air volume to the top gear. Provided the air
temperature is between 30 and 35, pressure at low pressure side of the system shall be about 0.15 ~
0.20Mpa and that at high pressure side shall be about 1.3 ~ 1.8Mpa.
12). Stop the engine after the charging is finished. Remove the manifold pressure gauge from the compressor
quickly to prevent surplus refrigerant from being discharged.
Operation and notice of filling or adding the refrigeration oil to the air conditioning, judgment to the
refrigeration oil quality
1) Generally it is not required to fill the refrigeration oil when the air conditioning refrigeration system is
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maintained. However, the refrigeration oil must be added when parts of the refrigeration system are replaced
and severe leakage of the system is precluded. There are two methods to fill the refrigeration oil as follows: (1)
Shut down the air conditioning and fill the refrigeration oil utilizing the filling port on the compressor; screw out
the filling port bolt and pour the required refrigeration lubrication oil into the filling port and then tighten the
filling port bolt.
(2) Detailed operation methods of charging the refrigeration oil when the vacuumizing is made are as follows:
Fig. 4-4 Filling the refrigeration lubrication oil with vacuumizing method
1- the manual low pressure valve is closed 2- the manual high pressure valve is opened
3- exhaust the air 4- vacuum pump 5- refrigeration lubrication oil
a. Select a graduated cylinder to contain the refrigeration oil of the volume more than required.
b. Screw down the hose connected with the low pressure charging valve from the manifold pressure gauge
and insert it into the measuring cylinder containing the refrigeration oil. As shown in Fig.4-4.
c. Startup the vacuum pump and open the manual high pressure valve on the manifold pressure gauge. Added
refrigeration oil will be sucked into the compressor through the suction pipe via the charging valve at the low
pressure side. Stop the suction of the vacuum pump and close the manual high pressure valve when the
refrigeration oil volume has reached the specified volume.
d. After the refrigeration oil is added per the vacuumizing method, the refrigeration system shall be vacuumized
and the refrigerant shall be added.
2) The following notices shall be taken care when the refrigeration oil is used: (1). The refrigeration oil is easy
in water absorption so the lid must be tightened right after the refrigeration oil is used
(2). Deteriorate turbid refrigeration oil is not allowed, or else it will influence the normal operation of the
compressor.
(3). Excess refrigeration oil is not allowed to be added into the system, or else it will influence the refrigerating
capacity of the vehicle air conditioning refrigeration system.
(4) The refrigeration oil must be of the grade specified in the compressor instruction of that model.
3) Correlation method and dripping method can be adopted to judge the quality of the refrigeration oil: (1).
Correlation method: put clean and standard refrigeration oil into a test tube as the standard oil and put the oil to
be checked into another test tube of the same size to make the comparison. Provided the oil to be checked is
of light yellow or of saffron yellow, it can be used, however the turbid solution of rufous color can not be used.
(2). Dripping method: drip one drib of the refrigeration lubrication oil to be checked on a clean plain paper and
watch its color. It means there is no impurity in the oil if its color is light and even; the oil can be used.
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How to inspect the refrigeration oil volume in air conditioning compressor

The vehicle air conditioning compressor is a high-speed operation device. Its normal condition depends on the
sufficiency of the refrigeration oil, however excess refrigeration oil will influence the refrigerating effect. Oil
volume inside the compressor must be checked when the compressor or part of the refrigeration system are
replaced. The inspection methods are as follows:
Fig.4-5 shows the inspection to the refrigeration oil volume. Discharge the oil charge plug 1, watch it via the oil
charge taphole and rotate the clutch foreplate; Wipe clean the oil dipstick with the cotton yarn and insert it into
the compressor until end of the oil dipstick touches inner casing of the compressor; take out the oil dipstick and
observe its immersion depth; oil level inside the compressor shall be between scale 4 and scale 6 if the oil
charging is appropriate. Add it if it is inadequate and drain if it is excessive, then tighten the filling port plug.
Fig. 4-5 inspection to the refrigeration lubrication oil volume of the sedan air conditioning compressor
1- oil filling plug 2- Filling port 3- oil dipstick
Provided there is no oil filling plug hole in the compressor, the oil shall be poured into a measuring cup to
make the comparison with the oil charge volume specified in the instruction to judge if the compressor is
required to add the oil. Generally oil content in the compressor shall not be less than 1/3 oil charging volume
specified in the instruction, or else the oil shall be added. Compressor provided with the oil charging plug hole
can also adopt this method, but the compressor assembly must be removed from the air-conditioning system.
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Fig 4-6 Refrigerant filling valve

1 refrigerant reservoir 2 plate nut 3 upper connector of filling valve
4 rotation lever 5 valve pin
How to add the refrigerant to the vehicle air conditioning

When the pressure in the refrigeration system is abnormal, the bubble will appear in the sight glass. It means
the refrigerant is inadequate and shall be added; The vacuumizing is not required when adding the refrigerant.
The refrigeration system can be added directly with the operational methods as follows:
Connect both high and low pressure hoses of the manifold pressure gauge with interfaces of the high and low
pressure charging valves; connect the intermediate hose of the manifold pressure gauge with the refrigerant
cylinder valve. Carry it out according to the operation method related to 4.8. Close the manual high and low
pressure valves and upright the refrigerant cylinder, then start the engine and turn on the air conditioning
compressor to operate; Slowly open the manual low pressure valve so that the refrigerant can enter into the
suction compressor in gaseous state from the low pressure side; when the refrigerant charging volume
achieves the specified volume, close the manual low pressure valve and the refrigerant cylinder valve.
How to check and eliminate the blocking failure of air-conditioning system
When the refrigeration system is blocked, it shows inadequate refrigerant volume or no refrigerating, and
meanwhile high pressure and low pressure inside the system are abnormal. The block often occurs at the
liquid storage dryer and the expansion valve. Temperature difference of the part before and after the blocking
is apparent. The dirty block failure can be eliminated according to the following method:
1). Drain out the refrigerant inside the refrigeration system.
2). Remove the blocked part of the refrigeration system for the cleaning and the replacement.
3). When there is severe block, the refrigeration system shall be dismantled entirely for subsection cleaning.
Spares after the cleaning shall be blown-dried and oven-dried.
How to check and eliminate the icing failure of vehicle air-conditioning thermo expansion valve
The system is poor in the refrigerating effect and low bias in both high and low pressure after the refrigeration
system is iced; the refrigeration is intermittent. The icing generally occurs at the valve seat of the thermo
expansion valve because excessive water vapor contained in the system is iced at valve base of the thermo
expansion valve. When the thermo expansion valve occurs ice block, the refrigerating capacity will be
reduced that causes the temperature rise to melt down the ice at the valve port so the system recovers normal
operations to increase the refrigerating capacity, at that time excessive moisture will be iced again at the valve
port. Methods of eliminating the icing failure of the refrigeration system are as follows:
1). Drain out the refrigerant inside the system.
2). Replace the dry reservoir in the refrigeration system.
3). Inspect the refrigeration system for any leakage and stop it.
4) Make the vacuumizing with the vacuum pump and remove the water vapor inside the system.
5) Add qualified refrigerant.
How to check and eliminate the air inside the air-conditioning system
Air in the system is stored at upper part of the condenser or the dry reservoir owing that it is incapable of being
condensed and is lighter than the refrigerant. Air in the system will influence the cooling and heat emission
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effect of the condenser thus cause the condensing pressure and temperature over high, simultaneously low
pressure of the system is high that causes the refrigerating capacity of overall system being reduced, so that
air in the system shall be removed timely with the preclusion methods as follows:
1). Drain out the refrigerant inside the system.
2). Inspect the refrigeration system for any leakage and eliminate it.
3). Pump out the air in the system repeatedly with the vacuum pump.
How to dismount the sedan air conditioning compressor
When the air conditioning compressor is breakdown, most failure parts shall be dismounted to carry out the
repair or the replacement except very few failure parts can be maintained on the vehicle instead of
dismounting the compressor. The dismounting steps and requirements are as follows:
Steps of dismounting the compressor from the compressor frame:
(1). Dismount the connecting wire of the electromagnetic clutch.
(2) Drain out the refrigerant from the refrigeration system.
(3) Remove the hoses at intake and exhaust port of the compressor; the hose as well as intake and exhaust
ports of the compressor shall be covered to prevent the dust and the water vapor from being entered into the
system.
(4) Dismount the driving belt of the compressor.
(5) Remove the compressor fastening screw and the compressor from the compressor frame.
(6) Pour out the oil inside the compressor and measure the oil output with the measuring cylinder to judge if it
is required to add the oil and inspect the oil for any discoloration as well as any impurities in the oil.
Inspection to the air conditioning control system
The air conditioning control system can be checked according to the following methods: power ignition
switch fuse cutout relay air conditioning switch ( fan switch, temperature detect switch)temperature
control circuitpressure switch circuitelectromagnetic clutchfanelectric machine. After the ignition
switch is turned on, the current flows into the air conditioning switch through the fuse cutout and is branched.
One branch flows into the evaporator blower motor and the other branch flows into the compressor
electromagnetic clutch through the temperature controller and the pressure switch circuit. When malfunction
is found in the auto security protection, the fuse shall be checked first for any burn-out; If it is in normal
condition, control switch of the blower shall be turned on to inspect if the blower plug is in good contact, the
blower governing resistance is in open circuit and the blower motor is damaged; If the blower is in normal
operation, then finally check the control circuit of the electromagnetic clutch, the high and low pressure switch,
the temperature controller as well as the electromagnetic clutch for any failure; eliminate any failure existed.
How to inspect the vehicle air conditioning thermo expansion valve
Inspection steps of the vehicle air conditioning expansion valve (take F type thermo expansion valve as an
example) are as follows:
1). Eliminate the refrigerant in the system and remove the thermal expansion valve from the refrigeration
system.
2). Supply the nitrogen with certain pressure (e.g. 0.05Mpa) at the high pressure inlet side of the thermal
expansion valve. If there is no gas flowing out from the low pressure outlet side, it means the thermal
expansion valve is out of service.
3). Then immerse the thermo bulb of the thermal expansion valve into warm water and enhance the water
temperature; opening of the thermal expansion valve shall be increased (pressure at the low-pressure side is
increased, i.e. the gas flow rate is increased), or else it means media inside the thermal expansion valve power
head is leaked or the thermal expansion valve is blocked by impurities, then the thermal expansion valve shall
be replaced.
4) The blocked thermal expansion valve shall be disassembled to determine the impurity nature.
Other notices in repairing the vehicle air conditioning
1). Operation environment: cleanness and moistureproof shall be paid attention to when the air conditioning is
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checked. Dirt, dust and moisture shall be prevented from entering into the air-conditioning system. Areas
around the assembling unit and the joint shall be cleaned out and rainy day maintenance shall be avoided.
2). Usage of the refrigerant: the refrigerant shall be stored in places of low temperature and dry when the
refrigerant cylinder is stored and transported. It shall not be brought into locations with open flame such as the
welding, nor exposed under the sunshine. Directly heating to the refrigerant cylinder or putting it into the hot
water over 40 Celsius degree is strictly prohibited. The protective glasses shall be worn when the refrigerant is
filled to avoid the eye frost damage. Please be noted that it shall not be contact with the skin. Provided the
refrigerant is contacted with accidentally, a great deal of fresh water shall be used to rinse the contact area
quickly to prevent the frost damage and ask for medical care as soon as possible. Manual high pressure valve
on the manifold pressure gauge is strictly prohibited to open when the engine is in operation. The refrigerant
will back flow into the refrigerant tank that cause the explosion. When the gaseous state refrigerant is charged
from the low pressure side during the engine running, the refrigerant cylinder is not allowed to upend to avoid
the compressor "cylinder slugging". The manifold pressure gauge shall be used to drain out the refrigerant
inside the system from the low pressure side. The refrigerant shall be exhausted slowly with the time interval
not less than 15 minutes to prevent the refrigeration oil from being drained out along with the refrigerant.
3). Operation to the refrigeration system pipeline: the pipeline or the joint shall be capped after the pipeline is
dismounted to prevent the moisture and the dust from entering into it. The bending radius shall be as large as
possible when the pipe is bent; the pipe orifice shall be remained leveling and clean when the pipe is cut and
scraps inside the pipe shall be cleaned out; The trichloroethylene liquid shall be used to clean the pipeline, and
the pipeline shall be dried sufficiently; The refrigeration oil shall be applied at the joint and the O-ring when the
pipeline is connected; two wrenches shall be used to tighten or unscrew the pipeline joint.
4). Operation to the control wire: the battery ground wire (negative wire) shall be dismounted when the repair
work is made to the air conditioning to prevent the circuit short circuit during the refrigeration system repair.
Replaced wires shall be fixed by the adhesive tape and the original fasteners; wires of original color and
original diameter shall be preferred; the wire is not allowed to close to high temperature objects such as the
engine.
There is several methods of judging the constant malfunction of the vehicle air conditioning as follows:
1). Hand feeling inspection: the failure is judged mostly by feeling the temperature of the parts by hand. High
pressure loop (from the compressor outlet, the condenser and the dry reservoir to the thermal expansion valve
outlet) shall be in a thermal behavior (50~ 70) when it is touched; if certain location is exceptionally hot or
there is apparent temperature difference between the inlet and the outlet, it means there is the blocking. The
low pressure loop (from the thermal expansion valve outlet, the evaporator and the compressor inlet) shall be
cool (0~ 5) when it is touched. Provided there is no apparent temperature difference between the high
pressure side and the low pressure side, it means there is the leakage in the system or the compressor is
broken down.
2). Visual examination: inspect each pipeline joint, compressor shaft seal, condenser and evaporator surface
for any oil stain; the system has the leakage if there is any oil stain.
3). Sight glass inspection: observe and inspect the refrigerant state via the sight glass installed on the dry
reservoir or the pipeline. The refrigerant shall be clear and bubble free, and the evaporator air outlet shall be
cold under normal condition. It means that the refrigerant is highly inadequate when it is clear and bubble free
yet the air outlet is not cold; is means that the refrigerant is inadequate when it is clear and has bubble in it, yet
the air outlet is not cold enough.
4). Leak detection made by the electronic leak detector: electronic leak detector is used to inspect each joint
of the overall system for any leakage.
5). Inspection made by the multi-meter: the multi-meter can be used to check out the air conditioning circuit
breakdown and judge the broken circuit or the short circuit.
6). Manifold pressure meter: connect the manifold pressure meter with the system high and low pressure
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valves to judge the breakdown of the refrigeration system. The inspection shall be made when the air
temperature is between 30 ~35oC and the engine speed is 2000r/min. The fan wind speed is adjusted to the
high gear and the temperature is adjusted to the Max. refrigerating gear. The normal condition is that: the
pressure at the high-pressure side is 1.2Mpa ~ 1.8Mpa and that at the low-pressure side is 0.15 Mpa ~
0.20Mpa; the system may have a failure if it is out of this scope. 7). Other inspection methods
(1) Condenser: the thermometer is used for thermometer under normal operation. When the condenser air-in
temperature is about 35oC, the air-out temperature shall be about 55oC.
(2) Continual reduction of the air volume at the air outlet means the frosting on the evaporator surface.
(3) Dry reservoir: inconsistency of the temperature on upper and lower side of the dry reservoir shell means
there is the block inside the dry reservoir.
Maintenance and diagnoses of electronic power-assisted steering system

No.291 Line inspection of "EPS" indicating lamp (the "EPS" indicator
does not light up when the ignition switch is opened)
1. Battery
2. Main fuse
3. Ignition switch
4. Circuit fuse (15A)
5. Control module
6. EPS lamp
7. Main fuse
8. Control box socket
9. Connector
Step Operation Yes No
Are the main fuse and the line fuse in good condition Go to step 2 The main fuse and the line fuse is
1 or not ? broken
1. Turn on the ignition switch Go to step 3 B/W wire is broken or short circuit
2. Inspect the voltage between the terminal "A6"
2 and the module case earthing
3Is it the battery voltage?
1. Check the voltage between the terminal "A8" and Go to step 4 "B/R" wire is broken or short circuit
the module case earthing
3 2. Is it the battery voltage?
1. Turn off the ignition switch and disconnect the Go to step 5 The bulb is burnt out or the "V/G" wire is
connector 8 from the control module broken
2. Disconnect the body ground terminal "A3" on the
connector "8" body
4 3. Turn on the ignition switch again, is the "EPS"
lamp light up?
1. Is the connection between the connector "8" and Terminal A6A7 Poor connection
the control module firm? " A3 " or " A8 " is in
poor contact; the
5 control module case
is in poor earthing;
"B" wire
+12V is broken
397
No.292 Inspection to "EPS" indicator line ("EPS" indicator does not

light up or keep on lighting up when the cross-line connection is made
between the diagnoses switch terminal and the ground terminal)
1. If terminal "A2" of the connector "9" is perfectly connected to Go to step 2 Poor contact
1 the control module
1. Earth the "A2" terminal by wire under the condition that the 1The maintenance line Recheck it with replaced
connector is connected with the control module is broken control module
2 2. Turn on the ignition switch, is the "EPS" lamp flicking? 2. "B/W" line is broken
or "B" line is in poor earth
No.293 Main line of DTC11 torque sensor (the main line is broken or
short circuit)
1Remove the protective cover of the steering column hole 1. "W" wire is broken Go to step 2
2 Turn on the ignition switch and put the steering wheel 2. Terminal "B5" is in poor
towards the right front direction of the vehicle, and check if connection
the terminal voltage of the torque sensor bar foot center "B5" 3. Recheck it with replaced
1 wire is about 2.5V. control module if the above
conditions are normal
1. Close the master switch and disconnect the torque sensor 1. "W" wire to the battery is The torque sensor has
rod head short circuit or earthed defects
2 2. Check the resistance between terminals "B5" and "B2" of 2. The torque sensor connector
the torque sensor is in poor contact with the line
3. Whether it is about 0.96k
No.294 DTC13 torque sensor (there is big difference between the

auxiliary line outputs of the main line and the torque sensor)
1. Remove the protective cover of the steering column hole 1"W" or "B" lines are in The torque
1 2. Turn off the ignition switch and disconnect the torque sensing unit poor condition sensor is
3 Inspect the resistance between the torque sensor side plug-in unit 2. Terminals "B5" or broken down
terminals according to the following state "B4" are in poor
connection
The steering wheel faces 3. Recheck it with
About 0.96 K
towards right ahead replaced control module
if the above conditions
The steering wheel steers are normal
About 0.48 K entirely
RB right
The steering wheel steers

Left
RW The steering wheel face

About 0.96 K
towards right ahead
398

Right

left
No.295 DTC14 torque sensor (power supply voltage of the torque

sensor is too high or too low)
1 1Remove the protective cover of the steering column hole Recheck it with replaced control Go to step 2
2Turn on the ignition switch and check the voltage between module
"R" wire of the torque sensor connector and the terminal
ground
3Is it about 5V?
2 1Turn off the ignition switch and disconnect the torque 1 Terminal "B2" or "B3" is in The torque sensor
sensor connector poor connection is broken down
2 Check the resistance between "R" wire of the torque 2 Harness of the torque sensor
sensor connector and the terminal ground plug-in unit is in poor contact
3Is it about 1.09 K? 3) "R" or "G" line is disconnected
4 "R" or "G" line is grounded and
the battery are short
No.296 Auxiliary line of DTC15 torque sensor (the auxiliary line is

disconnected or short circuit)
1Remove the protective cover of the steering column hole 1"B" wire is disconnected
2 Turn on the ignition switch and put the steering wheel to 2Terminal "B4" is in poor contact
1 the front moving position of the vehicle; check the voltage of 3Recheck it with replaced control Go to step 2
"B" terminal on the torque sensor connector. module if the above conditions
3Is it about 5V? are normal
1Turn off the ignition switch and disconnect the torque

sensor connector. 1"B" wire is ground or the battery
2Check the resistance between "R" wire and "W" wire or is short The torque sensor
2
between "R" and "B" terminals on the torque sensor 2The torque sensor connector is is broken down
connector in poor contact with the harness
3Is it about 0.96 k?
No.297 DTC22 engine speed signal (no engine signal input)

1 Does the tachometer display the engine speed Go to step 2 1The connector is in poor
signal? connection or the line is
0-1V broken
2 There is no rotation
speed signal output in ECU
399
2 1 Remove the control module and connect the "A4" is in poor connection; "Br" line is broken
control module connector when the ignition switch is replace with a good control
off. module if the connection is
2Check the voltage between "A4" terminal of the normal
control module and the earthing when the ignition
switch is on; check the resistance between "R" line of
the torque sensor connector and the terminal ground
3Is it 8~12V?
400
No.298 Vss line (Vss line is disconnected or short circuit)
DTC21Vss line (the engine runs at 2500 R.P.m or higher for continuous 60 seconds (the rotation speed is
4000 R.P.m or higher when the engine is started) and there is no vehicle high speed signal input)
DTC23Vss line (the engine runs at 2500 R.P.m or higher for continuous 60 seconds (the rotation speed is
4000 R.P.m or higher when the engine is started) and there is no vehicle high speed signal input)
DTC24Vss line (the engine is beyond the standard level for continuous 5 seconds/there is no vehicle speed
input)
DTC14 torque sensor (supply voltage of the torque sensor is too high or too low)
Does the speedometer display the speed 1"A5" is in poor connection with "V" Replace with a good
signal? harness vehicle speed sensor
1 2Replace the control module to recheck if
the connection is all right
No.299 DTC41 motor (the motor voltage is too high or too low)
DTC43 motor (the motor current is too high)

DTC42 motor (current displayed on the control module is of great difference from the current actually flowing
into the motor)
DTC44 motor (there is output signal in the control module, yet the motor doesn't start)
DTC45 motor (current actually flowing into the motor is lower than that outputed by the control module)
DTC14 torque sensor (supply voltage of the torque sensor is too high or too low)
1 Is there DTC? Motor failure Go to step 2
1Dismount the hole cover of the steering column Go to step 3 Motor failure
2Disconnect the motor and the clutch connector
when the ignition switch is OFF
2 3Check the conductivity between terminals of the
motor
4Is it conductive?
3 1) Check the resistance between the motor and 1"R" or "B" line is disconnected Motor failure
the clutch as well as the body ground 2"R" or "B" line is short to
2) Is it infinite? ground
3 The connector is in poor
contact
4Replace with a perfect control
module to recheck provided the
above phenomena are normal
No.300 DTC51 clutch line (the clutch line is disconnected or short)

401
1) Remove the hole cover of the Go to step 2 Clutch failure

steering column
2) Disconnect the motor and the
connector when the ignition switch is
1 OFF
3) Check the conduction between
terminals of the clutch connector
4Is it conductive?
1) Check the resistance between the 1"B/B1" or "B/R" line is disconnected Clutch failure
motor and the clutch connector as well 2"B/B1" or "B/R" to ground is short
as between the motor and the ground 3The motor and the clutch connectors are in poor
2) Is it infinite? contact
2 4"A9" and "A10" terminals are in poor contact
5Replace with a perfect control module to recheck
provided the above phenomena are normal
No.301 Power circuit of DTC54 control module

(low voltage of the battery)
1Remove the control module and connect the control 1"A7" terminal is in poor contact Battery failure
module connector when the ignition switch is off. 2) Replace with a perfect control
2Check the voltage between "A7" terminal of the module to recheck provided the
1 control module and the ground when the ignition switch above phenomena are normal.
is ON.
3Is it 10-14V?
No.302 DTC52 and DTC55 control modules (failure of control module)
Replace with a good control module and recheck; Inspection to the control module and its line: the control
module and its line can be inspected by measuring the voltage and the resistance of the module connector;
The multi-meter is strictly prohibited to measure the control module under the condition of disconnecting the
module connector.
No.303 Voltage inspection
1Remove the control module from the body when the ignition switch is OFF
2Connect the control module connector to the control module
3Inspect each terminal voltage of the connector according to the following table
4Voltage of the battery is confirmed to be 11V or higher when the ignition switch is in ON position
Terminal Line Normal voltage Malfunction symptom
A6 Voltage of the ignition switch control 10-14V Engine operates at idle speed
A5 Vss 0-1V and 4-6V The front left tire rotates greatly under the
condition of ignition switch being ON and the
front wheel being locked
B2 Power supply of the torque sensor About 5V Inspect the voltage between "B2" and B3 when
the ignition switch is ON
B1 Blank
A3 "EPS" failure indicating lamp 0-2V, 10-14V "EPS" lamp lights up or off when the engine
operates at idle speed
402
A9 Clutch plus 10-14 The engine operates at idle speed and the
steering wheel is fixed in straight ahead position
of the vehicle
A4 Engine signal
B3 Torque sensor (GND) 0V
B4 Torque sensor plus About 2.5V The engine operates at idle speed, direct
moving direction, the voltage between "B4" and
"B3" terminals
B5 Torque sensor minus About 2.5V The engine operates at idle speed, direct
moving direction, the voltage between "B4" and
"B3" terminals
A10 Clutch minus 0V
A2 Disconnect to the terminal 5V Ignition switch ON
A11 Motor output plus 5-7V The engine operates at idle speed, the steering
wheel is fixed to direct moving position of the
vehicle
A12 Motor output minus 5-7V The engine operates at idle speed, the steering
wheel is fixed to direct moving position of the
vehicle
A7 Power supply plus 10-14V Engine operates at idle speed
A8 Power supply minus 0V
A1 Blank
No.304 Introduction of mechanical assembly
1The steering column assembly can not be disassembled. Provided any part is found to have defect, the
whole assembly shall be replaced.
2It must be noticed not to cause the impact when the steering column assembly is replaced.
Chart of connector functions
403
SN Line No. Name Load Color Dia.

1 B1 Blank
2 B2 +5V 5~10mA R 0.5mm2
3 B3 GND 5~10mA G 0.5mm2
4 B4 Torque signal 1 <5mA B 0.5mm2
5 B5 Torque signal 2 <5mA W 0.5mm2
6 A1 Blank
7 A2 Diagnosis control <10mA B1/W 0.5mm2
8 A3 Indicating lamp 5~20mA V/G 0.5mm2
9 A4 Engine speed <10mA Br 0.5mm2
10 A5 Speed signal <10mA V 0.5mm2
11 A6 ON switch <10mA B/W 0.75mm2
12 A7 12V power <32A B/R 2.5mm2
13 A8 Power ground <32A B 2.5mm2
14 A9 Clutch plus <1A B/B1 0.75mm2
15 A10 Clutch minus <1A B/r 0.75mm2
16 A11 Motor plus <30A R 2.5mm2
17 A12 Motor minus <30A B1 2.5mm2
404
No.305 Diagnoses to the ABS system failure

Flow chart of ABS malfunction diagnosis
Start
Connect the malfunction diagnosis instrument under

the power off condition
Turn the key switch to "ON"
Enter into the ABS system at the address location
No
Can it communicate?
Carry out the inspection refer to the

malfunction code free malfunction
Yes
Enter into the malfunction inquiry system at the

function location
Incidental malfunction Continuous malfunction
Record the malfunction

Clear the malfunction
code
code
Carry out the maintenance by reference to the malfunction code

malfunction diagnostic gist
Carry out the maintenance by reference to the
incidental trouble diagnostic gist
Clear the malfunction

code
The key switch is power off, dismount the malfunction

diagnosis instrument
Real car driving inspection
Normal
End
405
No.306 Quick index list of malfunction clearance

Index of malfunction code malfunction check list
Diagnostic code Malfunction description Diagnostic content Check list No.
65535 Electronic control unit Damaged
01276 ABS hydraulic pump The motor is out of service 1
00283 Left front wheel sensor
00285 Right front wheel sensor

Electro and mechanical failure 2, 3, 4
00290 Left rear wheel sensor
00287 Right rear wheel sensor
01044 ABS code error 5
00668 Power supply terminal 30 6
01130 Abnormal in ABS operation The signal is unreasonable 7
No.307 Index of malfunction code free malfunction check list
Malfunction status Check list No.
Turn the ignition switch to "ON" (the engine is in stall state) and the ABS alarm lamp does not light up 1
The alarm lamp does not light off when the engine starts up 2
Braking forces at both sides are unequal
The braking force is inadequate
ABS is in operation when the brake pedal is stamped slightly (the vehicle is
ABS is in abnormal in stationary state)
3
operation
ABS is in operation when the brake pedal is stamped slightly (the vehicle is
in driving state)
The brake pedal vibrates violently when the ABS is in operation
The brake pedal stroke is too long 4
Very big force is required to stamp the brake pedal 5
There is no malfunction code output (communication with the malfunction diagnosis instrument is
6
unavailable)
406
No.308 Malfunction check list of malfunction code

1 Malfunction code: 01276 Possible cause
z The power is broken or

[Description] When the speed exceeds 20km/h, the ABS ECU will monitor abnormal earthed
operation of the motor, then a malfunction code will be recorded. z The motor harness is loose
[Prompt] When this malfunction code is displayed, it means the harness between the z The motor is damaged
motor and ECU is loose. Function test of the hydraulic unit of the failure diagnosis
instrument can be used to drive the motor to carry out the test.
Note:
The motor is incapable of being driven if the battery is of excess discharging, so the battery voltage must be
confirmed to be normal before the motor driving test is made. The vehicle must be at the stationary state
when the motor driving test is made.
Unplug the motor harness and connect
the battery power directly to the motor Abnormal
plug, does the motor still operate?
Replace the hydraulic control unit
Normal
Abnormal
Inspect the fuse and the ABS ECU joint Replace the fuse or the harness
Normal
Connect the motor harness

Turn the ignition switch to "ON"
Clear the trouble code
Carry out the hydraulic control unit diagnostic
using the failure diagnosis instrument
No
Yes
Does the failure recur? Replace the electronic control unit
Refer to "gist of incidental trouble

maintenance"
407
No.309 The malfunction codes are 00283, 00285, 00290 and 00287
(mechanical malfunction)
2 Malfunction codes: 00283, 00285, 00290 and 00287 (mechanical Possible cause
malfunction)
[Description] The malfunction code will appear when open circuit of the return z Miss installation of the sensor
can not be checked out and there is no signal output when the speed is above z Short of the sensing coil or the harness
20km/h. z Ultra big of the air gap between the
[Prompt] It may be caused by miss installation of the sensor, short of the sensor sensor and the tooth ring
coil or the harness, ultra large air gap between the sensor and the tooth ring, or the z Miss installation of the tooth ring
damage or the tooth ring. z Malfunction of ABS ECU
No
Is the sensor installation correct? Install it correctly
Yes Inspect if the sensor resistance is normal
Inspect the sensor output voltage at Abnormal Abnormal

the ABS25 core socket Inspect each sensor Replace it
Normal
Normal
Abnormal
Inspect each sensor tooth ring
Replace ABS ECU Replace it
Normal
Inspect the wheel bearing Abnormal

clearance Repair or replace
Normal
Inspect the sensor output voltage at

the ABS25 core socket
408
No.310 Malfunction codes: 00283, 00285, 00290 and 00287

3 The malfunction codes are 00283, 00285, 00290 and 00287 Possible cause
[Description] The malfunction code will appear if the sensor signal is out z Intermittent poor contact or short of the
of tolerance when the speed is larger than 20km/h. sensing coil or the harness
[Prompt] The probability is that the weak sensor signal is cause by the z Ultra big or ultra small of the air gap between
intermittent poor contact or the short of the sensing coil or the harness, the sensor and the tooth ring
damage of the tooth ring teeth and ultra large of the air gap between the z Damage of the tooth ring teeth
tooth rings. z Ultra big of the bearing clearance
z Malfunction of ABS ECU
Incorrect
Is the sensor installation correct? Install it correctly
Correct
Inspect the sensor output voltage at Abnormal Inspect each wheel sensor Abnormal
the ABS25 core socket Replace
Normal
Normal
Abnormal
Inspect the tooth ring of each
Replace ABS ECU wheel sensor Replace
Normal
Inspect the wheel bearing Abnormal

clearance Repair or replace
Normal
Inspect the harness between the

sensor and ABS ECU
409
No.311 Malfunction codes are 00283, 00285, 00290 and 00287

(electric failure)
4 Malfunction code: 00283, 00285, 00290 and 00287 (electric Possible cause
malfunction)
[Description] The malfunction code wil appear when there are failures z Connector or coil of the sensor is of open circuit
such as the recognizable open circuit or short circuit existed in the z The sensing coil is short
sensor. z The sensor plug, the harness, the earth or the
[Prompt] It is likely that the sensor is in poor contact, the coil or the power is short
harness is short, or there is a failure in the sensor signal treatment circuit z Treatment circuit of ABS ECU sensor signal is
in ABS ECU. out of order
Inspect the corresponding sensor

Inspect if the harness is normal and watch if the failure will recur
with failure
Normal Abnormal
Abnormal
Remove the ABS ECU plug Inspect the corresponding
Inspect if the resistence value sensor plug Repair the connector
between the following terminals of
ABS ECU meets the standard
value?
Standard value: 1.0 ~ 1.3 k Normal
Shake the sensor harness and the No Refer to the gist
Does the malfunction recur? of the incidental
joint simultaneously when trouble
measuring the resistance. maintenance
MK20 I:
Yes
Left front: 4 - 11
Right front: 3 - 18 Inspect the harness between
the sensor and ABS ECU
Left rear: 2 - 10
Right rear: 1 17
MK20 I/E
Left front: 1 - 2
Right front: 19 - 20
Left rear: 5 - 6
Right rear: 22 23
Normal
Replace ABS ECU
410
No.312 Malfunction code: 01044
[Description] The malfunction code will appear when the ECU software z Error of jumper connection in ABS harness
z Error of ABS ECU code
code is different from the hardware jumper connection of ABS harness.
Use the failure diagnosis instrument to check if the

code of ABS ECU software is correct
Correct value: see relative ABS electric wiring Incorrect
diagram Recode it
Correct
Check if the joint of ABS harness slip stitch is

conductive Abnormal
Joint of correct slip: see relative ABS electric wiring Repair the harness
diagram
[Description] The malfunction code will appear when there is no z Fuse of ABS system is blown out
z The battery voltage is over low or over high
voltage or over high voltage on the power supply terminal 30.
z Connector of ABS harness is damaged
z ABS ECU is damaged
411
Inspect 30A fuse of ABS system Abnormal

Replace the fuse
Normal
Abnormal Abnormal
Disconnect the connection between Inspect ABS harness connector Repair the
ABS harness and ECU, turn the
connector
ignition switch to "ON" and measure
the voltage between the following
terminals of ABS harness Normal
Terminals 8 and 9: 9.5 16.5V
Terminals 24 and 25: 9.5 - 16.5V Refer to the incidental trouble No Check the battery
MK20 I: Retry. Does the abnormal voltage
Terminals 8 and 23: 9.5 16.5V condition recur?
MK20 I/E:
Terminals 8 and 4: 9.5 16.5V
Yes
Check battery voltage
Normal
Replace ABS ECU
[Description] The malfunction code will appear when ABS is z High frequency electromagnetic
interfered by the high frequency electromagnetic wave or the interference
microprocessor regards the input speed signal as false. z The sensor or the sensor harness is
damaged
Abnormal
Abnormal
Inspect output voltage of the sensor Inspect the sensor Replace the sensor
Normal
Normal
Inspect the harness

Replace ABS ECU between the sensor and
ECU
412
No.315 Malfunction check list of malfunction free code

1 The ignition switch is in ON position (the engine is in stall state) while Possible cause
the ABS alarm lamp does not light up
[Description] ABS alarm lamp does not light up. It might be caused by the z The fuse is burnt
open circuit of the alarm lamp power return, burnt out of the bulb or damage z Bulb of ABS alarm lamp is
of the alarm lamp controller. burnt
z The power circuit is broken
z ABS alarm lamp controller is
damaged
Abnormal
Check the ABS alarm lamp fuse in
the central electric appliance box
Replace it
Normal
Abnormal
Inspect the fuse socket of the Repair the fuse socket
central electric appliance box
Normal
Remove the ABS ECU joint, and the

ignition switch is ON No Inspect if bulb of ABS alarm Yes
Does the alarm lamp light up? lamp is burnt
Replace it
No
Yes Inspect if the power return Abnormal

and the earth return of the
alarm lamp in ABS harness is Replace the harness
Inspect if the wire connecting ABS open
alarm lamp controller and ECU in
ABS harness is short or earthed
Normal
Abnormal
Yes Inspect the connector of the
alarm lamp power return and Repair the connector
the earth return
Replace the harness
Normal
No
See the maintenance
Does the failure recur? importance of
incidental trouble
Yes
Replace the alarm lamp

controller
413
No.316 The ABS alarm lamp is normally open after the engine starts
2 The ABS alarm lamp is normally open after the engine is started. Possible cause
[Description] The possible cause is that ABS alarm lamp controller is z The alarm lamp controller is damaged
damaged or the ABS alarm lamp return is open. z Return of ABS alarm lamp controller is open
Note: this failure mode confines to the condition of the system being capable of communicating with the failure
diagnosis instrument (power supply of ABS ECU is normal) and no malfunction code appeared.
Inspect if the wire between ECU and ABS alarm Yes

lamp controller is open
Replace the harness
No
Inspect the ABS alarm lamp controller Abnormal

Replace it
Normal
Replace ABS ECU
No.317 ABS is in abnormal operation

3 ABS is in abnormal operation Possible cause
[Description] This problem is closely related to the driving condition z The sensor is of improper installation
and the road surface, therefore the failure diagnosis is difficult to be z There is something wrong with the sensor harness
made. However the following inspections can be made provided there z The sensor is damaged
is no malfunction code memory. z The tooth ring is damaged
z The sensor is stained with foreign materials
z The wheel bearing is damaged
z ABS HCU (hydraulic unit) is damaged
z ABS ECU (electric control unit) is damaged
414
Is the sensor installation correct?

Install it correctly
Yes
Abnormal Abnormal
Inspect each sensor
Inspect output voltage of the sensor Replace it
Normal
Abnormal
Normal
Inspect each sensor tooth ring Replace it
Carry out the hydraulic control unit

diagnostic using the failure diagnosis
instrument Normal
Abnormal
Inspect the wheel bearing Repair or replace it
clearance
Abnormal
Replace ABS HCU

Normal
Abnormal
Inspect ABS ECU socket and
the central connector Repair the joint
Normal
No Refer to the
Does the failure recur? maintenance gist
of incidental
trouble
Yes
Remove ABS ECU and inspect

ABS
Does the resistence value
between the following terminals
of the harness meet the standard
value? Standard value: 1.0 ~
1.3 k; shake the sensor harness
and the connector
simultaneously during the
measurement Abnormal
MK20 I MK20 I/E Repair the harness or the
front left: 4 11 1 2 connector
front right: 3 18 19 20
rear left: 2 10 56
rear right: 1 17 22 23
Normal Replace ABS ECU
Replace ABS ECU
415
No.318 The brake pedal stroke is too long

4 The brake pedal stroke is too long Possible cause
[Description] Visually inspect if there is any exterior z The braking fluid is leaked
leakage or mechanical failure. Check if there is air in the z The normally closed valve is leaked
system by the air exhausting method. Check if the normally z There is air in the system
closed valve is leaked with the function test of failure z The brake disc is of heavy wear
diagnosis hydraulic unit. z The hand braking is improper adjusted
Abnormal
Visually inspect if the hydraulic pipe joint is leaked Tighten the pipe joint as required
Normal
Inspect worn condition of the brake disc

Abnormal
Replace the brake disc
Normal
Inspect the hand braking adjust device Abnormal

Replace the hand braking adjust device
Normal
Abnormal
Air exhaust inspection Carry out the air exhaust again
Normal
Diagnostic and inspect the sealing property of Abnormal

the normally closed valve with the failure Replace HCU (hydraulic control unit)
diagnosis hydraulic control unit
416
No.319 Large force is required to stamp the pedal

5 Large force is required to stamp the pedal Possible cause
[Description] Inspect the stroke of the booster and the brake pedal with conventional z There is something wrong with the
method. Failure of the normally open valve can be inspected with the function test of the booster
failure diagnosis hydraulic pressure unit. z There is something wrong with the
normally open valve
Diagnostic and inspect the Abnormal

normally open valve with the Replace HCU (hydraulic control unit)
failure diagnosis hydraulic control
unit
Normal
Inspect the stroke of the booster

and the pedal according to the
conventional method of vehicles
without ABS
No.320 There is no diagnostic code output
6 There is no malfunction code output (communication with the failure Possible cause
diagnosis instrument is unavailable)
[Description] ABS ECU power return or the diagnostic line return is open z The fuse is burnt
z The diagnostic line is broken or the joint is
when the communication with the failure diagnosis instrument is unavailable.
loose
z There is something wrong with the failure
diagnosis instrument
417
Is the failure diagnosis instrument There is something wrong with the failure diagnosis
capable of communicating with MK20 No instrument
ABS ECU on other vehicles Carry out the inspection after the repair
Yes
Abnormal
Inspect ABS power fuse
Replace it
Normal
Does there is display on the screen of

Inspect the power line, earth Repair the
the failure diagnosis instrument
wire, diagnostic wire and its Abnormal diagnostic
No connection of the diagnostic connector or
connector harness
Yes
Remove ABS ECU joint

Inspect if ECU relative terminal in ABS
harness (MK20I is terminal 13,
MK20I/E is terminal 7) and the
diagnostic connector (terminal 7 in the
No
failure diagnosis instrument) are Repair the diagnostic connector or ABS harness
conductive
Conductive
Replace ABS ECU
418
No.321 ABS system inspection
Terminal
Ignition switch
Inspection items Standard value Unit
gear
MK20 I MK20 I/E
Battery voltage (motor) OFF 25 8 10.1 14.5 V
Battery voltage
9 24
(electromagnetic valve) V
Power insulation property 8 23 84 0.00 0.5 V
Earth insulation property 8 24 V
Supply voltage ON 8 23 84 10.0 14.5 V
OFF Alarm lamp off Visual inspection
ECU not connected

ON Alarm lamp on Visual inspection
OFF Alarm lamp off Visual inspection

ABS alarm lamp
ECU connected
The alarm lamp lights
up, and lights off after Visual inspection
ON
1.7 seconds
Function of brake lamp

switch
ON 8 12 8 18 0.0 0.5 V
Pedal not stampped down
Function of brake lamp

switch
ON 8 12 8 18 10.0 14.5 V
Pedal stampped down
Diagnostic joint K Diagnostic joint

Diagnostic joint
OFF and 13 K and 7 0.0 0.5
Resistance value of left

front wheel speed sensor OFF 11 4 12 1.0 1.3 k
419
Resistance value of right

OFF 18 3 19 20 1.0 1.3 k
front wheel speed sensor
Resistance value of left

OFF 2 10 56 1.0 1.3 k
rear wheel speed sensor
Resistance value of right

OFF 1 17 22 - 23 1.0 1.3 k
rear wheel speed sensor
Output voltage of left front

OFF 11 4 12 3.4 14.8 mV/ Hz
wheel sensor
Output voltage of right

OFF 18 3 19 20 3.4 14.8 mV/ Hz
front wheel sensor
Output voltage of left rear

OFF 2 10 56 >12.2 mV/ Hz
wheel sensor
Output voltage of right

OFF 1 17 22 - 23 >12.2 mV/ Hz
rear wheel sensor
Output voltage ratio of

Max. peak voltage Min. peak voltage 2
sensor
For example: 15 21 (Jetta 5V)

6 22(Santana 2000) The detail
Model identification OFF 0.0 1.0
refer to relative ABS electric wiring
diagram
420
Inspection items Key switch gear Operation Standard value Remark
Note: there must have the vacuum acting on the vacuum booster when the following inspections are made.
The pedal does not go down

Inspection to the normally
ON Pedal when the left front wheel is closed valve
Tightness of left front incapable of rotating
wheel normally open
valve and normally ON
closed valve (two valves and the Inspection to normally
Pedal when the left front wheel is
pump power on open valve
capable of rotating freely
simultaneously)

ON Pedal when the right front wheel is closed valve
Tightness of normally incapable of rotating
open valve and
normally closed valve of ON
front right wheel The pedal does not go down
(two valves and the Inspection to normally
Pedal when the right front wheel is
simultaneously)

ON Pedal when the left rear wheel is closed valve
Tightness of normally incapable of rotating
open valve and
normally closed valve of
ON
rear left wheel The pedal does not go down
(two valves and the Inspection to normally
Pedal when the left rear wheel is
simultaneously)

ON Pedal when the rear right wheel is closed valve
Tightness of rear right
incapable of rotating
wheel normally open
valve and normally ON
closed valve (two valves and the Inspection to normally
Pedal when the rear right wheel is
simultaneously)
421
No.322 ECU code

When replacing HECU or ECU, code new ECU, otherwise ABS warning lamp will flash and the system can not
operate normally.
Code ECU with diagnosis scanner as following procedures:
Connect diagnosis scanner and diagnosis socket
Enter controller code at address (Addresswort eingeben)
Input 01 and press F1 at function select (Funktion anwhlen)
Input relevant vehicle code at code input (see ABS elementary diagram MK20,
No.01901, and MK60, No.0004097)
Display input number, press
Input 01 at function select (Funktion anwhlen), press F1
End
422
No.323 Fluid filling and air exhaust

Wet HCU
When equipped with wet HCU, implement fluid filling and air exhaust according to the requirements of normal
brake system after HCU replaced.
Dry HECU
When equipped with dry HECU, after replacing HECU, not only implement fluid filling and air exhaust
according the requirements of normal brake system, but also implement air exhaust to 2nd circuit of HECU. The
procedures when operating with diagnosis scanner are as follows:
Implement fluid filling and air exhaust, until there is no bubble in transparent
pipe.
Connect diagnosis scanner and diagnosis socket
At address (Addresswort ein-geben) basic setting, press F1
Ehnter 01 at function select (Funktion anwhlen), press F1
Enter 01 at group number input (Anzeigegruppen-nummer eingeben), press F1
Turn to next page
423
Continued from previous page
Pedal bettigung und halten

Press brake pedal and hold, hydraulic pump operates, pedal rebound
Pedal lsen, VR/ VL, Entlfter-schraube, auf <>

Loose brake pedal, and air drain screws on left and right brake caliper
press
Pedal 10bettigung, Ent-lfterschraube,zu <>
Press brake pedal 10 times and tighten the air drain screws on left and right
brake caliper, press
Repeat step I, II, and III for 7 times.
Teilentlftung beendet
Screen display, air exhaust finished, press and return to function select
menu.
Enter 02 at function select (Funktion anwhlen), press F1
End
424
GEELY INTERNATIONAL CORPORATION
Address: No.87 Qianyang Road, Shanghai, P.R.China
Webside: www.geely-globe.com

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Common Malfunction Diagnosis Flow of

GEELY INTERNATIONAL CORPORATION

Common Malfunction Diagnosis Flow Content of Geely Automobile

No.031 Non-idle speed............................................................................................................ 54

No.064 Electric fuel pump EKP ............................................................................................. 115

Transmission ..................................................................................................... 176

No.145 Transmission with abnormal sound........................................................................... 195

Chassis ................................................................................................................................. 215

No.179 Braking sideslipping, swerving .................................................................................. 248

No.211 Low loudspeaker volume........................................................................................... 291

No.244 Wiper cant work .......................................................................................................339

No.304 Introduction of mechanical assembly ........................................................................ 403

Engine shuts off abnormally when driving

Improper ignition timing Adjust

Fuel quality problem Replace

Fuel pump relay burnt Replace

Pressure temperature sensor failure Replace

Poor ECU signal Replace

Valve gumming Mainatain

Inssuficient engine cylinder pressure Check engine

No. 002 Engine surging

No. 003 Over idle speed when warm-up

Over idle speed when warm-up

No. 004 Idle speed fluctuation

Idle speed fluctuation

Idle speed AC switch or booster

Idle speed unstable or engine shut-off when

Intake system abnormal Check

Insufficient engine cylinder pressure Check

No. 006 Engine shuts off intermittently

Engine shuts off intermittently

ECU and connecting circuit malfunction Check or replace

No. 007 Poor accelerating performance in cold condition

Poor accelerating performance in cold condition

No. 008 Spark plug non-sparking

Spark plug non-sparking

Low idle speed during engine heating in cold

Improper valve clearance Adjust

Idle speed valve (steeping motor) Clean and replace

No. 010 Canister oil leaking

Canister oil leaking

No. 011 Fuel smells in vehicle

Ignition timing maladjustment Maintain ignition timing, whether it is delayed.

Fuel smelling strong in vehicle

Normal Leak, blocked

Fuel tank inner pressure abnormal Check

Canister controlling valve malfunction Replace

Oxygen sensor Replace

No. 012 Engine vibration when operating

Engine vibration when operating

Injector failure Check

Clutch operates abnormal Check

No. 013 Engine noise over normal level

Engine noise over normal level

Normal Over normal value

Normal Leak or block

No. 014 Water temperature over normal value after AC activated

Water temperature over normal value after AC

Insufficient coolant fluid Add

Normal Over normal value

Normal Not smooth

Engine operates abnormally Check

No. 015 Oil pan leak