Manual Jac

B-Class MPV Service Manual Engine-Contents
Engine
General Information and Maintenance....................... GI-1
GI General Information........................................ GI-1
Precautions..................................................................................... GI-1
How to Use This Manual................................................................. GI-6
Model Identification Information.................................................... GI-7
Lifting Points.................................................................................. GI-12
Tow Truck Towing.......................................................................... GI-13
Tightening Torques of Standard Bolts.............................................. GI-14
Terminology.................................................................................... GI-15
MA Maintenance............................................................... MA-1
Preparation...................................................................................... MA-1
General Maintenance...................................................................... MA-2
Periodic Maintenance...................................................................... MA-3
Recommended Oils and Lubricants................................................. MA-4
Engine Maintenance........................................................................ MA-6
Chassis and Body Maintenance....................................................... MA-11
Engine............................................................................ EM-1
EM Engine Mechanical..................................................... EM-1
Precautions..................................................................................... EM-1
Preparation...................................................................................... EM-3
Engine Structure Overview............................................................. EM-6
Drive Belts...................................................................................... EM-8
Air Cleaner and Air Duct................................................................ EM-10
Intake Manifold.............................................................................. EM-12
Exhaust Manifold and Three Way Catalyst...................................... EM-14
Ignition Coil and Spark Plug........................................................... EM-15
1
Fuel Injector and Fuel Rail.............................................................. EM-17

Timing Belt..................................................................................... EM-21
Camshaft and Rocker Arm.............................................................. EM-24
Oil Seal........................................................................................... EM-27
Cylinder Head and Valves............................................................... EM-30
Cylinder Block and Crankshaft....................................................... EM-37
Oil Pan and Oil Strainer.................................................................. EM-50
Positive Crankcase Ventilation........................................................ EM-52
Engine Assembly Removal and Installation..................................... EM-53
Trouble Diagnosis........................................................................... EM-56
Service Data and Specifications...................................................... EM-59
LU Lubrication System....................................................... LU-1

Precautions..................................................................................... LU-1
Preparation...................................................................................... LU-1
Engine Oil....................................................................................... LU-2
Oil Filter......................................................................................... LU-4
Oil Pump......................................................................................... LU-6
Service Data and Specifications...................................................... LU-8
CO Cooling System............................................................. CO-1

Precautions..................................................................................... CO-1
Preparation...................................................................................... CO-2
Cooling System Circuit................................................................... CO-3
Engine Coolant............................................................................... CO-4
Radiator.......................................................................................... CO-6
Cooling Fan.................................................................................... CO-8
Water Pump.................................................................................... CO-9
Water Inlet and Thermostat Assembly............................................. CO-10
Water Outlet and Water Piping........................................................ CO-12
Trouble Diagnosis........................................................................... CO-13
2
Service Data and Specifications...................................................... CO-15
FL Fuel System.................................................................... FL-1

Precautions..................................................................................... FL-1
Preparation...................................................................................... FL-2
Fuel System Composition............................................................... FL-2
Fuel Injector and Fuel Rail.............................................................. FL-3
Fuel Filter....................................................................................... FL-4
Feed Pipe Assembly and Vapor Pipe Assembly............................... FL-6
Fuel Level and Sensor Unit............................................................. FL-6
Fuel Tank........................................................................................ FL-9
Fuel Pump....................................................................................... FL-9
Fuel Evaporative Emission System................................................. FL-12
Trouble Diagnosis........................................................................... FL-14
Service Data and Specifications...................................................... FL-15
ACC Accelerator Control System....................................... ACC-1

Accelerator Control Unit................................................................. ACC-1
Service Data and Specifications...................................................... ACC-2
EC Engine Control System................................................. EC-1

Precautions..................................................................................... EC-1
Preparation...................................................................................... EC-2
Engine Control System Overview................................................... EC-3
Engine Control System Components............................................... EC-9
On-Board Diagnostic (OBD) System.............................................. EC-25
Trouble Diagnosis........................................................................... EC-29
Service Data and Specifications...................................................... EC-85
3
B-Class MPV Service Manual General Information and Maintenance
General Information and Maintenance

GI General Information
Precautions
Description:
Please read the following precautions to ensure personal safety and proper servicing.
Precautions for supplemental restraint system (SRS) “air bag” and (SB) “seat
belt pre-tensioner”:
The supplemental restraint system (SRS) “air bag” and (SB) “seat belt pre-tensioner”,
used along with a seat belt, help reduce the risk or severity of injury to the driver and
front passenger in the event of a vehicle collision. The information necessary to
service the system safely is included in the SRS section and SB section of this Service
Manual.
Warning:
 To avoid rendering the SRS inoperative, which could increase the risk of personal
injury or death in the event of a collision, all maintenance operations must be
performed by an authorized JAC dealer.
 Improper maintenance, including incorrect removal and installation of the SRS,
can lead to personal injury or death caused by unintentional activation of the
system.
 Do not use electrical test equipment on any circuit related to the SRS unless
instructed to in this manual. SRS wiring harnesses can be identified by yellow
and orange harnesses or harness connectors.
General precautions:
 Do not operate the engine for an GI001

extended period of time without proper
exhaust ventilation. Keep the work
environment well ventilated and away
from any inflammable materials. Special
care should be taken when handling any
inflammable or poisonous materials,
such as gasoline, refrigerant, natural gas,
etc. When working in a pit or other
enclosed room, ensure the working place
is ventilated well before handling any
hazardous materials. Do not smoke while
working on the vehicle.
GI-1
 Before jacking up the vehicle, put wheel GI002

chocks or other tire blocks under the
wheels to prevent the vehicle from
moving. After jacking up the vehicle,
support the vehicle weight with safety
stands at the points designated for proper
lifting before working on the vehicle.
This operation should be done on a level
ground.
 When removing a heavy component such GI003

as the engine or transmission, please do
not waggle it using excessive force in
order to disconnect it. Also, do not allow
them to strike adjacent parts, especially
the brake pipes and master cylinder. Battery
 Before starting repairs which do not GI004

require battery power: Turn off ignition
switch and disconnect the negative
battery terminal.
 If the terminal is disconnected, memory
in the control module will be cleared.
 To prevent scalds: Avoid contact with hot
metal parts. Do not remove the radiator
cap when the engine is hot.
 Dispose of drained oil or the solvent GI005
used for cleaning parts in an appropriate
manner.
 Clean all removed parts in the designated
liquid or solvent prior to inspection and
assembly.
 Replace oil seals, gaskets, packings,
O-rings, locking washers, cotter pins,
self-locking nuts, etc. with new ones.
 Replace inner and outer races of tapered roller bearings and needle bearings as a
set.
 Arrange the removed parts in accordance with their assembled locations and
sequence.
 Please do not touch the ports of electronic components which use
microcomputers (such as ECM). Static electricity may damage internal electronic
GI-2
components.
 After disconnecting vacuum or air tubes, attach a tag to indicate the proper
connection.
 Use only the oils and lubricants recommended in this manual.
 Use approved bonding agents, sealants or their equivalents when needed.
 Use hand tools, power tools (for disassembly only) and special tools correctly for
safe and efficient repairs.
 When the ongoing repairs relate to the fuel, oil, water, vacuum or exhaust system,
check all affected lines for leaks.
 Before repairing the vehicle:

Seat cover
① Protect fenders, upholstery and
carpeting with appropriate covers.
② Be careful not to allow things like keys
and buttons to scratch paintwork.
Fender pad
Warning:
To prevent ECM from storing the diagnostic trouble codes incorrectly, do not
carelessly disconnect the harness connectors which are related to the engine control
system. Operate only according to the work flow of trouble diagnoses in EC section.
Precautions for three way catalyst:
If a large amount of unburned fuel flows into the three way catalyst, the catalyst
temperature will rise sharply. To avoid this, follow the instructions below:
 Use unleaded gasoline only. Leaded gasoline will seriously damage the three way
catalyst.
 When performing spark plug tests or measuring cylinder pressure, do the jobs
quickly and only when necessary.
 Do not run engine when the fuel tank level is low, otherwise the engine may
misfire, causing damage to the three way catalyst.
 Please do not park the vehicle on inflammable materials. Keep inflammable
materials away from the exhaust pipe and the three way catalyst.
Precautions for fuel:
 The 4G93D DL engine uses unleaded gasoline with an octane rating of number
93 or above
 Please do not use leaded gasoline. Using leaded gasoline will damage the three
way catalyst. Using a fuel other than that specified could adversely affect the
emission control equipment and system, and could also affect the warranty
GI-3
coverage validity.
Precautions for multiport fuel injection system or engine control system:
 Before connecting or disconnecting any harness connector for the multiport fuel
injection system or ECM:
① Turn ignition switch to “OFF” position.
② Disconnect negative battery terminal. Otherwise, there may be damage to ECM.
 Before disconnecting pressurized fuel line from fuel pump to injectors, be sure to
release fuel pressure.
 Be careful not to shake components such as ECM and sensors.
Precautions for hoses: GI007 Do not scratch tube

1. Hose removal and installation
 To prevent damage to a rubber hose, do
not pry off it with pointed tool or
screwdriver.
 To fix the rubber hose securely, make GI008 Insert hose to here
sure that hose insertion length is
adequate and clamp position is correct.
(If metal tube is equipped with hose
stopper, insert hose into tube until it
butts up against hose stopper.)
Hose stopper
2. Hose clamp GI009 Trace of clamping

 If old rubber hose is reused, install hose
clamp in its original position (at the Bulge
indentation where the old clamp was). If
there is a trace of metal tube bulging left
on the old rubber hose, align rubber
Hose
hose at that position.
 Discard old clamps; be sure to replace Tube
with new ones.
GI-4
 After installing plate clamps, apply GI010 Depress for better fitting
force to them in the direction of the
arrow in the figure, clamping rubber
hose equally.
Plate clamp
Precautions for engine oil:
Prolonged and repeated contact with used engine oil may cause skin cancer.
Therefore, avoid direct skin contact with used oil. If skin contact is made, wash
thoroughly with soap or cleanser as soon as possible.
Health protection precautions:
 Avoid prolonged and repeated contact with engine oil, particularly used engine
oil.
 Wear protective clothing. Please use impervious gloves where practicable.
 Please do not put oily rags in pockets.
 Please do not contaminate clothes, particularly underwear, with oil.
 Heavily soiled clothing and oil impregnated footwear should not be worn.
Overalls should be cleaned regularly.
 First aid treatment should be obtained immediately for skin cuts and other body
wounds.
 Apply barrier cream to skin before starting each work in order to help the removal
of oil from the skin.
 Wash with soap and water to ensure all oil is removed (skin cleansers and nail
brushes will help). Use lanolin in replace of the natural skin oils which have been
removed.
 Please do not use gasoline, kerosene, diesel oil, gas oil, thinners or solvents for
cleaning skin.
 If skin disorders develop, take medical measures without delay.
 Where practical, degrease components prior to use.
 Where there is a risk of eye contact, goggles or face shields should be worn; in
addition, an eye wash facility should be provided.
Environmental protection precautions:
Dispose of waste oil and oil filters through officially approved waste disposal
contractors to licensed waste disposal sites, or to the waste oil reclamation enterprises.
If you have any question on disposal of waste substances, contact the local authority.
It is illegal to pour used oil on to the ground, down sewers or drain ditches, or into
water sources; the laws and regulations concerning pollution vary between regions.
GI-5
Precautions for air conditioning:

Use an approved refrigerant recovery unit any time the refrigerant in the A/C system
must be discharged. Refer to corresponding items in AC section for specific
instructions.
How to Use This Manual
Description:
This manual explains “Removal, Disassembly, Installation, Inspection and
Adjustment” and “Trouble Diagnoses”.
Terms:
 The captions WARNING and CAUTION warn staffs of steps that must be
followed to prevent personal injury or damage to some parts of the vehicle.
WARNING indicates the possibility of personal injury if instructions are not
followed.
CAUTION indicates the possibility of component damage if instructions are not
followed.
BOLD TYPED STATEMENTS besides WARNING and CAUTION also give you
helpful information.
Standard value: Tolerance at inspection and adjustment.
Limit value: The maximum or minimum limit value that should not be exceeded at
inspection and adjustment.
Units:
 The UNITS of measurement used in this manual are primarily expressed as the
SI UNIT (International System of Unit).
Example: Outer Socket Lock Nut: 59-78 N·m
Contents:
 THE CONTENTS are listed on the first page of each section.
 THE TITLE is indicated on the upper portion of each page and shows the parts
or systems involved in this page.
 THE PAGE NUMBER of each section consists of two or three letters which
designate the particular system and a number (e.g. “GI-6”).
 THE SMALL ILLUSTRATIONS show inspection, use of special tools, knacks
of work and hidden or tricky steps which are not shown in the previous large
illustrations.
Special tools:
 Tools marked with JAC special tool numbers are special tools provided by JAC.
Tools not marked or general-purpose tools are commercially available in the
mark.
GI-6
How to follow trouble diagnoses:

Description:
Trouble diagnoses indicate work procedures required to diagnose problems effectively.
Read the following instructions before diagnosing.
1. Before performing trouble diagnoses, read the “Preliminary Check”, the
“Symptom Chart” or the “Work Flow” first.
2. After repairs, recheck that the problem has been completely eliminated.
3. Refer to Component Parts and Harness Connector Location for the Systems
described in each section for identification/location of components and harness
connectors.
4. Refer to the Circuit Diagram Volume.
If you need to check circuit continuity between harness connectors in more detail,
such as when a sub-harness is used, refer to Wiring Diagram and Harness Layout in
each individual section for identification of harness connectors.
5. When checking circuit continuity, ignition switch should be set to OFF position.
6. Before checking voltage at electrical components, check battery voltage first.
7. After accomplishing the Diagnostic Procedures and Electrical Components
Inspection, make sure that all harness connectors are reconnected as they were.
Model Identification Information
Vehicle type:
Body number Engine model Manual transmission number
B-Class MPV 4G93D DL F5M41-G6
Vehicle identification number (VIN):

1) Vehicle identification number (VIN) location: On name plate or at lower left
corner of windshield.
GI-7
2) Vehicle identification number description
Digit capacity
Geographic region Serial number
Country Vehicle feature code Assembly plant
Maker Check digit Year
A letter or number A number
① The first section: World Manufacturer Identifier (WMI) composed of 3 digits

according to GB16737. This code must be subject to application, approval and
filing. The code for JAC is LJ1 which applies to trucks, non-complete vehicles,
buses, passenger vehicles, tractors and special purpose vehicles manufactured by
our company. See the following table for the world manufacturer identifier
(WMI).
Table World Manufacturer Identifier (WMI)
Code Name of maker Applicable vehicle types
Trucks, non-complete vehicles, buses, passenger

LJ1 Anhui Jianghuai Automobile Co., Ltd.
vehicles, tractors, special purpose vehicles
② The second section: Vehicle Descriptive Section (VDS) code composed of 6

digits according to GB16737. It can reflect basic features of a vehicle type
adequately.
VDS composition:
Digit capacity
Check digit
Engine type/rated power
Wheel base of truck/length of passenger

vehicle, bus and chassis
Maximum total mass
Body type
Vehicle type
GI-8
① Vehicle type: 2 represents passenger vehicle.

F: 3-box 4-door
② Body type
G: 2-box 5-door
③ Maximum total mass: K: >1000~2000
④ Wheel base of truck/length of passenger vehicle, bus and chassis: R>2390~2600

1: Gasoline ≤70Kw
⑤ Engine type/rated power 2: Gasoline >70~90Kw
3: Gasoline >90~110Kw
3) The third section: Vehicle Indicator Section (VIS) composed of 8 digits.
Digit capacity
Production SN
Name of assembly
plant
Year
4: Passenger vehicle manufacturer/car plant/general assembly

shop/assembly plant
Assembly plant
7: Commercial vehicle manufacturer/general assembly shop of
commercial vehicles
8: 2008
Year 9: 2009
A: 2010
GI-9
Engine model:
Location of 4G93D DL engine model is shown in the figure:
Engine model
Engine serial number
Rear view of cylinder block
GI011
Manual transmission model: GI012

Location of F5M41-G6 transmission model is
shown in the figure.
GI-10
Vehicle parameters:
List of Vehicle Parameters
Overall body size
Overall length (mm) 4550
Overall width (mm) 1775
Overall height (mm) 1660
Front tread (mm) 1505
Rear tread (mm) 1495
Wheel base (mm) 2710
Front overhang (mm) 940
Rear overhang (mm) 900
Mass parameters
No. of seats (occupants) 5/7
Vehicle 1450
Kerb mass (kg) Fore axle 850
Back axle 600
Vehicle 1920
Gross mass (kg) Fore axle 920
Back axle 1000
Wheels
Size 16×6 1/2J
Tires
Regular 205/55R16 91V
Spare tire
GI-11
Lifting Points
Service tools:
Tool name Description
Board on attachment
Safety stand attachment
Caution:
 Make sure vehicle is empty when lifting.
 Since the vehicle’s center of gravity changes when removing main parts on the
nose (e.g. engine, transmission, suspension etc.), be sure to support a jack up
point on the rear side garage jack with a transmission jack or equivalent.
 Since the vehicle’s center of gravity changes when removing main parts on the
tail (e.g. rear axle, suspension, etc.), support a jack up point on the front side
garage jack with a transmission jack or equivalent.
 Be careful not to smash any circuit or do anything that would affect the piping.
Garage jack and safety stand:
Warning:
 Park the vehicle on a level road before using the jack. In addition, make sure to
avoid damaging important parts such as pipes etc. under the vehicle.
 Never get under the vehicle while it is supported only by the jack. Use safety
stands to support the vehicle when you have to get under it.
 Place wheel chocks at both front and back of the wheels on the ground.
2-pole lift:
Warning:
 When lifting the vehicle, open the lift arms as wide as possible and ensure that the
front and rear of the vehicle are well balanced.
 When setting the lift arm, do not allow it to contact the brake lines, brake cable,
fuel lines and sill spoiler.
GI-12
Board-on lift:
Caution:
 Make sure vehicle is empty when lifting.
 The board-on lift attachment set at front end of vehicle should be set on the front
of the sill under the front door opening.
 Position attachments at front and rear ends of board-on lift.
Tow Truck Towing
Caution:
 All applicable local laws regarding the
×
towing operation must be obeyed. GI013
 Be sure to use proper towing equipment
to avoid possible damage to the vehicle
during towing operation. For more
details regarding towing, refer to related
instructions on the “Owner’s Manual”.
 Be sure to attach safety chains before
towing.
 When towing, make sure that the transmission, steering system and power train
are in good order. If any unit is damaged, dollies must be used. It is recommended
that the vehicle be towed with the driving (front) wheels off the ground as shown
in the above figure.
Vehicle recovery (freeing a stuck vehicle):
 Pull the cable straight out from the front or rear of the vehicle. Never pull on the
hook at an angle.
 When towing a vehicle forward, remove front spoiler. Otherwise front spoiler
may be damaged by the towing equipment.
 Pulling devices such as ropes or canvas straps are not recommended for use in
vehicle towing or recovery.
 Use towing hook only and not other components of the vehicle. Otherwise, the
vehicle body will be damaged.
 Use towing hook to free a vehicle stuck in sand, snow, mud, etc. only. Please do
not perform long-distance towing using towing hook only.
 When used for freeing a stuck vehicle, the towing hook will be subjected to a
large force.
 Keep away from a stuck vehicle.
GI-13
Tightening Torques of Standard Bolts

Tightening Torque Table
Tightening torque (without lubricant)

Bolt diameter Pitch
Grade Bolt size Hexagon head bolt Hexagon flange bolt
mm mm
N·m N·m
M6 6.0 1.0 5.5 7
1.25 13.5 17
M8 8.0
1.0 13.8 17
1.5 28 35
4T M10 10.0
1.25 28 35
1.75 45 55
M12 12.0
1.25 45 65
M14 14.0 1.5 80 100
M6 6.0 1.0 9 11
1.25 22 28
M8 8.0
1.0 22 28
1.5 45 55
7T M10 10.0
1.25 45 55
1.75 90 100
M12 12.0
1.25 90 100
M14 14.0 1.5 190 170
M6 6.0 1.0 11 13.5
1.25 28 35
M8 8.0
1.0 28 35
1.5 55 80
9T M10 10.0
1.25 55 80
1.75 100 130

M12 12.0
1.25 100 130
M14 14.0 1.5 170 210
*: Nominal diameter
1. Special parts are excluded.
2. This standard is also applicable to bolts having the following marks embossed on the bolt head.
GI-14
Grade Mark
4T ………………… 4 M 6
7T ………………… 7 Nominal diameter of bolt threads (unit: mm)
9T ………………… 9 Metric screw threads
Terminology
See the following chart for notes of the terms that appear in this manual:
Terminology List
DG Speed sensor
TF-W Coolant temperature sensor
ZSK Ignition coil
FPM Accelerator pedal
ECU Electronic control unit (commonly referred to as Computer)
EKP Fuel pump
EMS Engine management system
EV Injector
LSH Heated oxygen sensor
KS Knock sensor
KSZ Fuel rail assembly
KVS Fuel rail
PG Phase sensor
RUV Distributorless ignition system
TEE Fuel pump bracket assembly
TEV Canister control valve
GI-15
MA Maintenance
Preparation
List of Commercial Service Tools
Tool name Description
Radiator cap tester adapter

Connecting radiator cap tester
to radiator cap and radiator
filler port
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm
Oil filter wrench
Removing and installing oil

filter
Radiator cap tester
Checking radiator and radiator

cap
Spark plug wrench
Removing and installing spark

plugs
MA-1
General Maintenance
General maintenance includes those items which should be checked during the normal
day-to-day operation of the vehicle. They are essential if the vehicle is to continue
operating properly. The owners can perform these checks themselves or have their JAC
dealers do them.
Outside the vehicle:
The maintenance items listed here should be performed from time to time, unless
otherwise specified.
Item
Check tire pressure (including spare tire) with a pressure gauge at a service station
Tires regularly. Adjust to the specified pressure if necessary. Check tires carefully for
damage, cracking or excessive wear.
Clean the windshield on a regular basis. Check the windshield at least every six
Windshield
months for cracks or other damage. Please repair or replace as necessary.
Windshield
Check for fracture or wear if they do not wipe properly.
wiper blades
Check that all doors as well as the engine hood and tail gate can be opened and
closed normally. Also make sure that all latches lock securely. Lubricate if
Doors and necessary. Make sure that the secondary latch keeps the hood from opening when
engine hood the primary latch of the engine hood is released.
When always driving in areas using road salt or other corrosive materials, check
lubrication frequently too.
Tire rotation Tires should be rotated every 8,000 km.
Make sure that the headlights, fog lights, stop lights, taillights, turn signal lights,
Lamps and other lighting are all operating properly and fixed securely. Also check
headlight aim.
Inside the vehicle:
Item
Warning lights
Make sure that all warning lights and buzzers are operating properly.
and buzzers
Windshield, Check that the wipers and washer operate properly and that the wipers do not
wipers and washer streak.
Windshield Check that the air comes out of the defroster outlets properly and that air is
defroster sucked in sufficient quantity when operating the heater or air conditioner.
Check that it has the specified free play (<35 mm); check it for hard steering or
Steering wheel
abnormal noise.
MA-2
Check that buckles, anchor bolts, adjusters and retractors of seat belts operate
Seat belts properly and smartly and are installed securely; check seat belts for cracking,
fraying, wear or damage.
Check the pedal for smooth operation and make sure it does not catch or
Accelerator pedal require uneven effort.
Keep the undercover mat away from the pedal.
Check the pedal for smooth operation and make sure it has the proper distance
Brake pedal and
from the undercover when depressed fully. Check the brake booster function.
booster
Keep the undercover mat away from the pedal.
Parking brake Check that the pedal has the proper travel.
Under the hood and vehicle:

The maintenance items listed here should be checked periodically, e.g. each time you
check the engine oil or refuel.
Item
Windshield
Check that there is adequate fluid in the reservoir tank.
washer fluid
Engine coolant
Check the coolant level when the engine is cold.
level
Check the level after parking the vehicle on a level ground with the engine shut
Engine oil level
down.
Make sure that the brake fluid level is between the “MAX” and “MIN” lines on
Brake fluid level
the reservoir.
Battery Check battery terminal condition.
Check under the vehicle for fuel, oil, water or other fluid leaks after the vehicle
has been parked for a while. Water dripping from the air conditioner after use is
Fluid leaks normal.
If you should notice any leaks or gasoline fumes are evident, check for the cause
and repair it immediately.
Periodic Maintenance
The periodic maintenance section lists the minimum maintenance items required to
ensure trouble free operation of the vehicle roughly. Some additional maintenance items
may be required depending on areas and climates. For more detailed information,
please refer to your Warranty Manual.
MA-3
Recommended Oils and Lubricants

Table of Oils and Lubricants
Recommended oils/lubricants
Name
L
With oil filter SAE 5W-30 (winter in northern areas)

3.5
change
Engine oil SAE 15W-40 (year round in southern areas
drain and refill and summer in northern areas), SJ quality
Without oil
3 grade above
filter change
With reservoir
6~6.5 ELQ-L3 long life antifreeze
Cooling tank
system
Reservoir tank 0.8 ELQ-L3 long life antifreeze
2.1 (Top off to Hypoid gear oil SAE 75W~85W

Manual transmission fluid lower edge of
filler) API GL-4 grade above compliant
Power steering fluid 1.1 ATF-III
Brake fluid Just enough DOT4
Multi-purpose grease Just enough No. 2 general purpose lithium base grease
*1: For detailed instructions, please refer to “SAE Viscosity Numbers”.

*2: Please use original engine coolant for JAC B-Class MPV or products of equal quality so as to
avoid aluminum metal corrosion in engine cooling system caused by use of false and inferior engine
coolant.
Please note that the engine cooling system damage caused by use of false and inferior engine
coolant is not covered by the JAC warranty even within warranty period.
SAE viscosity number (gasoline engine):

SJ quality grade above SAE 5W-30 (winter in northern areas) and SAE 15W-40 (year
round in southern areas and summer in northern areas). If 5W-30 is not available, please
select the viscosity suitable for outside temperature range from the table.
Ambient temperature
MA-4
Specific gravity of engine coolant:

The engine cooling system is filled at the factory with a high-quality long life antifreeze
coolant. The coolant contains special corrosion and freeze inhibitors. Therefore,
additional cooling system additives are not necessary.
Caution:
 When adding or replacing coolant, be sure to use only original JAC engine coolant
or products of equal quality with the proper mixture ratio. Refer to the examples in
the following table.
Coolant Composition Table
Outside temperature down to Composition
℃ ℉ Engine coolant (concentrate) Distilled or demineralized water
-15 5 30﹪ 70﹪
-35 -30 50﹪ 50﹪
Use of other types of engine coolant solutions may damage your engine cooling system.
 When checking the engine coolant mixture ratio by the coolant hydrometer, use the
chart below to correct your hydrometer reading (specific gravity) according to
coolant temperature.
Coolant Specific Gravity Comparison Table
Coolant temperature ℃ (℉)

Engine coolant mixture ratio
15 (59) 25 (77) 35 (95) 45 (113)
30﹪ 1.046-1.050 1.042-1.046 1.038-1.042 1.033-1.038
50﹪ 1.076-1.080 1.070-1.076 1.065-1.071 1.059-1.065
Warning:
Never open the radiator cap when the engine is hot. Serious burns could be caused by
high pressure fluid escaping from the radiator. Wait and do not operate until the engine
and radiator cool down.
MA-5
Engine Maintenance
Checking drive belts:
Be sure to perform the following when engine is stopped.
1 Check belts for cracks, wear and oil trace. MA001

If necessary, please replace.
② Check drive belt deflection at a point on
belt midway between pulleys.
 Inspection should be done only when
engine is cold, or over 30 minutes after
engine is stopped.
 When measuring the deflection, apply 98 N at the marked point.

 Adjust if the belt deflection exceeds the limit.
 Specified value of belt deflection: 7~10mm.
Tension adjustment:
Table of Locations for Drive Belts Tension Adjustment
Location Belt tightening method for adjustment
Alternator Adjusting bolt on pulley
Power steering oil pump and A/C compressor belt Adjusting bolt on power steering oil pump
Caution:
 When deflection of a belt being used exceeds “limit value”, please adjust it to the
specified value.
 When checking belt deflection immediately after installation, first adjust it to the
specified value. Then, after turning crankshaft two turns or more, readjust to the
specified value to avoid variation in deflection between pulleys.
 When installing belt, please make sure that it is correctly engaged with pulley
groove.
 Please keep fluids such as engine oil and engine coolant away from belts.
 Please do not wind or bend belt excessively.
1. Alternator
① Loosen idler pulley lock nut, and then adjust tension by turning adjusting bolt.
 Follow the specified belt tension.
② Tighten adjusting nut.
MA-6
③ Tighten lock nut.

2. Power steering oil pump and A/C compressor belt
① Loosen lock bolt.
② Loosen mounting bolt of power steering oil pump.
③ Adjust tension by turning adjusting nut.
 Follow the specified belt tension.
Caution:
 Loosen adjusting bolt by turning it counterclockwise.
④ Tighten lock bolt.
⑤ Tighten mounting bolt of power steering oil pump.
Engine coolant:
The semitransparent coolant expansion tank is installed in the engine compartment.
Keep the coolant level in this expansion tank between the “MIN” and “MAX” lines. Be
sure to check coolant level when engine is cold.
Coolant consumption is very small under MA002

normal conditions. When coolant level drops,
it indicates possible leaks. If this occurs,
immediately drive to a JAC approved service
station for inspection.
If the coolant level drops to below the level of
the “MIN” line on the coolant expansion tank,
please add coolant promptly.
Precautions:
 When coolant of other brand is to be used, be sure to drain original coolant and
clean. Hybrid use of coolants of different brands will cause damage to such
components as engine and radiator.
 Coolants are harmful to human health! The coolant should be kept properly in its
original container and particularly out of reach of children.
 Note that the expansion tank cap can not be opened during operation when engine
is hot. A certain pressure exists in cooling system of a hot engine. Serious burns
will be caused when hot coolant ejects.
 Do not spill fluid when filling coolant. Otherwise wipe up the spillage with a cloth
immediately.
 The coolant contains harmful corrosion inhibitors. Therefore, flush clean with clear
water immediately if the fluid spills on your body inadvertently.
MA-7
 Never open radiator cap before engine cools down completely. Serious burns could
be caused by high-pressure fluid spilling from radiator.
 Wrap a thick cloth around radiator cap. First turn radiator cap 1/4 turn to release
built-up pressure in radiator, and then screw off radiator cap all the way.
1. Changing engine coolant
Hybrid use of coolants of different brands is not allowed. When changing to a different
coolant, you need to drain the original antifreeze coolant in the engine radiator and
engine completely as follows:
① Remove radiator cap.
② Remove radiator drain valve (from lower left part of radiator), and drain coolant in
radiator and engine water jacket.
③ Remove expansion kettle and drain coolant in it.
④ Loosen radiator inlet pipe clamp and pull out the pipe. Clean engine coolant lines
by pouring clear water through radiator inlet until clean water is drained. Then
install radiator inlet pipe and clamp it.
⑤ Tighten radiator drain valve firmly.
⑥ Pour coolant designated by JAC Motors in radiator slowly until it is topped off.
Start engine and then liquid level in radiator should drop. Wait until radiator is
filled with coolant, and then install radiator cap.
⑦ Fill expansion tank with coolant until liquid level reaches line “MAX” (full).
⑧ Install expansion tank cap.
⑨ Start engine and warm it up until thermostat opening.
⑩ After thermostat opening, run engine at full speed for several times and then shut it
down; wait until engine cools down, and then fill expansion tank with engine
coolant until liquid level reaches line “MAX” (full).
2. Coolant
The engine coolant contains corrosion inhibitor-ethylene glycol. The cylinder head and
water pump are aluminum alloy die castings. To prevent these components from
corrosion, be sure to change engine coolant regularly.
The coolant contains corrosion inhibitors, so do not replace it by light water even in
summer.
Content of the required coolant varies with ambient temperature used:
Contrast Table of Coolant Content and Ambient Temperature
Minimum ambient temperature (℃) -10 -20 -35 -45
Ethylene glycol content (%) 25 30 35 40
MA-8
3. In cold seasons
When the air temperature in the location of your vehicle drops to below 0℃, the
coolant in the engine or radiator may have the risk of freezing causing serious damage
to them. To prevent coolant from freezing, add sufficient quantity of coolant in it. The
engine coolant filled at delivery of the vehicle has an antifreeze effect even at a low
temperature of around -35℃. Before start of each cold season, check coolant content
and add coolant to the system in time when necessary.
Flushing cooling system:
① Install reservoir tank and radiator drain plug if removed.
Caution:
 Be sure to clean drain plug and install with new O-ring.
 If water drain plugs on cylinder block are removed, please install and tighten them.
② Remove air duct component.
③ Disconnect heater hose.
 Raise heater hose as high as possible.
④ Fill radiator and reservoir tank with water, and install radiator cap.
 Disconnect when engine coolant overflows heater hose, and then reconnect heater
hose and continue filling engine coolant.
⑤ Install air duct component.
⑥ Run engine and warm it up to normal operating temperature.
⑦ Rev engine 2 or 3 times under no-load.
⑧ Stop engine and wait until it cools down.
⑨ Drain water from the system.
⑩ Repeat steps 1~9 until clear water begins to drain from radiator.
Checking cooling system:
MA-9
1. Checking cooling system hose MA003

Check hose for improper attachment, leaks,
cracks, damage, loose connections, wear or
aging. If necessary, please repair or replace
damaged parts.
2. Checking radiator cap
① Pull out negative-pressure valve to open
it, and make sure that it closes
completely after pressure release.
 Make sure that there is no dirt or damage MA004

on the valve seat of radiator cap
negative-pressure valve.
 Make sure that there are no unusualness
in the opening and closing conditions of
negative-pressure valve.
② Check radiator cap relief pressure.
 When connecting radiator cap to the radiator cap tester (commercial service tool)
and the radiator cap tester adapter, apply engine coolant to the cap sealing surface.
Please replace radiator cap if negative-pressure valve operates abnormally or relief
pressure drops to below the limit.
3. Checking radiator
Check radiator for mud or clogging. If necessary, clean radiator as follows.
 Be careful not to bend or damage radiator fins.
 When radiator is cleaned without removal, please remove all surrounding parts
such as cooling fan, cowl and horns. Then tape harness and electrical connectors to
prevent water from entering.
① Apply water by hose to flush the back side of the radiator core vertically
downward.
② Apply water to flush all radiator core surfaces once per minute.
③ Stop washing if any dirt no longer flows out from radiator.
④ Blow compressed air into the back side of radiator core vertically downward.
 Use compressed air lower than 490 kPa and keep distance more than 30cm.
⑤ Blow compressed air into all the radiator core surfaces once per minute until no
water sprays out.
4. Checking cooling system for leaks
MA-10
 To check for leaks, apply pressure to the MA005

cooling system with the radiator cap tester Hose connector
(commercial service tool) and radiator cap

tester adapter.
Warning!
Do not remove radiator cap when engine is hot.
Otherwise serious burns could be caused by
high-pressure engine coolant escaping from
radiator.
Caution:
Higher test pressure than specified may cause radiator damage. In a case that engine
coolant decreases, replenish radiator with engine coolant.
 Maximum test pressure: 157 kPa.
 If any part is found damaged, repair or replace.
Checking fuel lines
Check fuel lines, filler cap and tank for improper attachment, leaks, cracks, damage,
loose connections, wear or aging. If necessary, please repair or replace damaged parts.
Changing engine oil:
Warning!
 Be careful not to burn yourself, as engine oil may be hot.
 Prolonged and repeated contact with used engine oil may cause skin cancer;
therefore, avoid direct skin contact with used engine oil. If skin contact is made,
wash thoroughly with soap or cleanser as soon as possible.
① Warm up the engine, and check for oil leakage from engine room.
② Stop the engine and wait for 10 minutes.
③ Loosen filler cap, and then remove drain plug.
④ Drain engine oil.
⑤ Install drain plug with new washer.
Caution:
Be sure to clean drain plug and install with new washer.
⑥ Refill with fresh engine oil.
Caution:
 When filling engine oil, do not pull out oil level gauge.
 The refill capacity depends on the engine oil temperature and drain time.
 Always use oil level gauge to check for proper engine oil refill capacity.
MA-11
⑦ Warm up the engine and check area around drain plug and oil filter for engine oil
leakage.
⑧ Stop the engine and wait for 10 minutes.
⑨ Check if the oil level is within the normal range.
Chassis and body maintenance
Checking exhaust system:
Check exhaust pipes, muffler and mounting brackets for improper positions, cracks,
damage, loose connections or wear; if any part is found damaged, please repair or
replace.
Transmission:
Both poor lubricant quality and lubricant excess or lack will affect normal operation
and service life of the manual transmission. Use gear oil SAE 75W~85W as the manual
transmission fluid. Check oil volume as follows:
① Check oil volume after vehicle driving with transmission still hot.
② When checking, be sure to park your vehicle on a flat, level and good ground and
set parking brake. Do not proceed with the next operation until making sure the
vehicle has come to a full stop.
③ Set shift lever to neutral position.
④ Screw off filler plug at left side of transmission and wipe up filler with a clean
cotton cloth. Check that the fluid level is within the range from lower edge of filler
to not lower than 5mm from the lower edge.
⑤ If the fluid is found dilute, gumming or too dirty, change immediately.
Caution:
 Do not spill fluid when filling. Otherwise wipe clean the spillage immediately.
■ Hybrid use of gear oils of different brands will damage transmission. Be sure
to use the designated hypoid gear oil SAE 75W~85W (API GL-4 grade above
compliant).
Brake system:
Check brake fluid level in reservoir tank. The level must be between the “MIN” and
“MAX” lines on the tank. Brake fluid level will slightly drop when brake pad is worn.
If brake fluid level drops significantly in a short period of time, it indicates oil leaks in
brake system. If this occurs, immediately drive to a JAC approved service station to
have your vehicle serviced.
Use DOT 4 brake fluid. Brake fluids are water absorbing liquids. Braking performance
will be reduced if the brake fluid contains excessive moisture. In addition, the brake
fluid cup is provided with a special sealing gland in order to prevent air entry. This
gland can not be removed at will.
Brake fluid level is monitored by a float. When brake fluid level drops to below the
“MIN” line, the brake fluid warning light will come on.
MA-12
1. Changing brake fluid

The brake fluid can absorb moisture, so it will absorb the moisture in the surrounding
air as time elapses. However, excessive water content in the brake fluid could cause
corrosion damage to the brake system. In addition, boiling point of the brake fluid will
drop significantly. Therefore, be sure to change the brake fluid every 2 years.
Caution:
 If the brake fluid has been used for an extended period of time, bubbles will be
produced in the brake system under extremely high braking load, thus impairing
braking efficiency and driving safety seriously.
 Use DOT 4 brake fluid approved by JAC only at brake fluid change. In addition, it
is required that brake lines be cleaned thoroughly. Ensure hybrid use of 2 types of
brake fluid will not occur.
Caution:
 Brake fluids are harmful to human health! Therefore, the coolant should be kept
properly in its original sealed container and particularly out of reach of children. In
addition, take care to prevent brake fluid from corroding automobile finish.
 Pay attention to disposal of brake fluid. It will impair both eyes and skin and
spray-painted surfaces. Flush clean with clear water immediately if the fluid spills
on your body inadvertently.
 Be sure to keep brake fluid cup clean. Its gland must be tightened to prevent dirt
entry.
 When filling brake fluid, wipe clean brake fluid cup gland and filler with a clean
rag first and then refill with designated clean brake fluid.
 If the brake fluid is found deteriorated, drain the fluid in brake system and then
refill with clean designated brake fluid.
2. Checking brake lines and cables
Check brake lines and parking brake cables for improper positions, leaks, wear, chafing
and aging, etc.
3. Checking disc brake MA006

1) Brake disc
Check condition, wear, and damage.
2) Brake caliper
Check for oil leaks.
3) Brake shoe
Check for wear and damage.
(Refer to service data of Chassis section.)
MA-13
Checking steering gear and linkage:

Steering gear:
1) Check gear housing and boots for looseness, damage and grease leakage.
2) Check connection with steering column for looseness.
Steering linkage:
Check ball joint, dust boots and other parts for looseness, wear, damage and grease
leakage.
Checking power steering fluid and lines:

Power steering fluid:
Check power steering fluid level in reservoir tank with engine idling.
Check power steering fluid level in reservoir tank. The level must be between the
“MIN” and “MAX” lines on the tank.
Please use the “recommended oil: PSF-3”. MA007

Caution:
 Please do not overfill.
 It is recommended that the oil designated
by JAC or equivalent be used.
 Check lines for improper attachment,
leaks, cracks, damage, loose connections,
wear or aging.
 Check rack boots for accumulation of MA008
power steering fluid.
Axle and suspension parts:
Check front and rear axle and suspension parts
for excessive play, cracks, wear or other
damage.
 Shake each wheel to check for excessive
play.
 Check wheel bearings for smooth
operation.
 Check axle and suspension nuts and bolts
for looseness.
 Check strut (shock absorber) for oil
leakage or other damage.
 Check suspension ball joint for grease
MA-14
leakage. MA009
 Check ball joint dust cover for cracks or
other damage.
Strut Ball joint
Tires:
For safe driving of your vehicle, type and size of tires must be suitable for the vehicle
model; in addition, tire treads must be in good condition and appropriate tire pressures
must be provided.
The way to service tires and the method for tire replacement are described below.
Warning!
 Use of excessively worn or under inflated tires will cause accidents resulting in
personal injury or death.
 All instruction regarding tire inflation and maintenance in the Operation Manual
must be observed.
Overview of inflation:
Keeping tires properly inflated provides the best combination of steerability, tread life
and driving comfort.
 Underinflation may cause uneven wear of tires and affect steerability and fuel
consumption, and much more likely result in air leaks due to overheating.
 Overinflated tires will make your ride in the vehicle uncomfortable, are more likely
to be damaged by rugged roads, and are subjected to uneven wear.
Measure tire pressure with a tire gauge at least monthly. Even pressure of a tire in good
condition may decrease by 10~20KPa (0.1~0.2kgf/cm2) per month. Also check spare
tire each time all tires are checked.
Measure tire pressure when tires are cold. This means that the measurement should be
made after your vehicle has been parked for at least 3 hours or when travel distance
does not exceed 1.6km. If necessary, inflate or deflate tires until their tire pressures
reach the value recommended for cold tires in the name plate on driver side door frame.
When pressure of a tire is checked when hot (after a travel of several kilometers), the
reading will be 30~40KPa (0.3~0.4kgf/cm2) higher than that when cold, which is
normal. Do not deflate the tire in order to reach the specified cold tire pressure reading,
otherwise tire underpressure will result.
When a tubeless tire is punctured, its self-seal function will be activated. If pressure of
a tire starts to drop, locate air leak carefully.
MA-15
Checking tires:
Also check tires for wounds, punctures by foreign materials and other abrasions at each
tire inflation check.
 Damage and bulge on tread or sidewall. If any is found, replace the tire.
 Scratch, crack or fracture on sidewall. If tire fabric or cord can be seen, replace the
tire.
 Excessive tread wear.
Servicing tires:
In addition to proper inflation, correct wheel alignment also helps reduce tread wear. If
uneven tire wear is found, check wheel alignment.
If some kind of continuous vibration is felt during driving, check tires. Perform tire
balance as long as a tire has ever been removed from its wheel. When installing a new
tire, be sure to perform tire balance. This can increase ride comfort and prolong tire life.
Caution:
 Inappropriate wheel balance weights will damage aluminum alloy wheels.
Therefore, use original wheel balance weights of JAC to keep wheels balanced
only.
Tire rotation:
To prolong service lives of tires and ensure

even tire wear, rotate tires every 8,000km. At MA010 Vehicle front
each rotation, move tires to the positions

shown by the figure at right. The figure at right
indicates how to rotate tires of a vehicle
provided with a standard spare tire.
If directional tires are used, swap tires on front
and rear wheels only at tire rotation. If a (Non-directional (Directional tire
standard spare tire is used at tire rotation, tire and wheel) and wheel)
please refer to the figure at right.
Replacing tires and wheels:

Select radial ply tires of same size, load range, rated speed and maximum cold pressure
(marked on sidewall) for replacement.
Hybrid use of radial ply tires and bias ply tires will reduce braking capacity, driving
force (ground adhesion) and steering precision of your vehicle.
MA-16
Use of tires of different sizes or structures will MA011 Non-directional tire and wheel
result in anti-lock brake system (ABS) failure
Vehicle front
to work normally. ABS works by comparing
speeds of wheels. When replacing a tire, be
sure to use one of same size as original tires of
the vehicle. Size and structure of tires will
affect wheel speed and may result in
uncoordinated movements of the system.
It is preferable that the 4 tires be replaced at
the same time. If impossible or unnecessary,
replace 2 front or rear tires in pairs. Replacing Directional tire and wheel
only one tire will affect steerability of your Vehicle front
vehicle badly.
If a wheel replacement is required, ensure the
new wheel and the original one match in size.
Warning!
Installing with unsuitable tires will affect steering mobility and stability of your vehicle
and may result in accidents, causing casualty.
Always use the tires of the recommended size and type indicated in the tire name plate
affixed to the vehicle.
For size of the tires applicable to this vehicle, please refer to the tire name plate affixed
to driver side door frame or consult a JAC authorized after service shop.
MA-17
B-Class MPV Service Manual EM Engine Mechanical
Engine
EM Engine Mechanical
Precautions
Precautions for drain engine coolant and engine oil:
 Drain engine coolant after the engine is cooled.
Precautions for disconnecting fuel piping:
 Before starting work, make sure no fire or spark producing items are in the work
area.
 Release fuel pressure first before disconnecting and disassembly. Please refer to
“Releasing fuel pressure in fuel piping” in page EM-19 for the way to release fuel
pressure.
 After disconnecting pipes, plug openings to stop fuel leakage.
Precautions for removal and disassembly:
 When instructed to use special service tools, please use them. Always be careful
to work safely, and avoid forceful or uninstructed operations.
 Exercise maximum care to avoid damage to mating or sliding surfaces.
 If necessary, cover openings of engine system with a tape or equivalent to seal out
foreign materials.
 Mark and arrange disassembly parts in an organized way for easy troubleshooting
and reassembly.
 When loosening nuts and bolts, as a basic rule, start with the one furthest outside,
then the one diagonally opposite, and so on. If the order of loosening is specified,
please do exactly as specified.
Precautions for inspection, repair and replacement:
 Before repairing or replacing, thoroughly inspect parts. First inspect new
replacement parts in the same way, and please replace if necessary.
Precautions for assembly and installation:
 When tightening nuts and bolts, as a basic rule, equally tighten in several
different steps starting with the ones in center, then ones on inside and outside
diagonally in this order. If the order of tightening is specified, please do exactly as
specified.
 Gaskets, oil seals or rubber seal rings can be easily damaged during removal. If
necessary, please replace.
 Thoroughly wash, clean, and blow-dry each part. Carefully check engine oil or
engine coolant lines for clogging.
 Release air in pipes when refilling after draining engine coolant.
 After repairing, start the engine and increase engine speed to check engine
coolant, fuel, engine oil, and exhaust gases for leakage.
EM-1
Parts requiring angle tightening:

 Use the angle wrench for the final tightening of the following engine parts:
- Cylinder head bolts
- Main bearing cap bolts
- Connecting rod cap bolts
- Crankshaft pulley bolt (No angle wrench is required as bolt flange is provided
with notches for angle tightening.)
 Please do not use a torque value for final tightening.
 The torque value for these parts are for a preliminary step.
 Ensure thread and seat surfaces are clean and coated with engine oil.
Removal of sealant:
 After removing mounting nuts and bolts, EM001

separate the mating surface using the seal
cutter and remove old sealant. JAC-T1F017
 Be careful not to damage the mating
surfaces.
 Insert the cutter, and then slide it by Slide
Knock
tapping on the side as shown in the
figure.
 In areas where the seal cutter is difficult
to use, please use a plastic hammer to
EM002
lightly tap the parts to remove it.
Scraper
 If for some unavoidable reason tool such
as a screwdriver is used, please be
careful not to damage the mating
surfaces.
Sealant application procedure:
 Using a scraper, remove old sealant
adhering to the application surface and
the mating surface.
EM003
 Remove sealant completely from the
groove of the sealant application surface,
mounting bolts, and bolt holes.
 Wipe the sealant application surface and
the mating surface with unleaded
gasoline to remove adhering moisture,
grease and foreign materials.
 Apply sealant without breaks to the
specified location with the specified
dimensions.
EM-2
 If there is a groove for sealant EM004 Inside
application, apply sealant to the groove.

 As for bolt holes, normally apply sealant
inside them and occasionally outside Groove Bolt hole
them.
 Within 5 minutes of liquid gasket
application, install the mating
component.
Inside
 If the sealant has stains, please clean
them off immediately.
 Please do not retighten bolts or nuts after the installation.

 After 30 minutes or more have passed from the installation, refill engine oil and
engine coolant.
 If there are specific instructions in this manual, please observe them.
Preparation
List of Special Tools
SN Tool Outline drawing Number Description
Fixing camshaft
1 End fork clip
timing gear
JAC-T1D001
Used in
2 Pin conjunction with
end fork clip
Installing and
Piston pin
3 removing piston
positioner set
pins
JAC-T1F005
Used in
conjunction with
4 Guide
piston pin
positioner set
EM-3
Flywheel
5 JAC-T1F011 Fixing flywheel
stopper
Valve spring Compressing

6 JAC-T1F012
compressor valve spring
Removing and
Oxygen
7 JAC-T1F015 installing oxygen
sensor socket
sensor
Oil pan
8 JAC-T1F017 Removing oil pan
remover
Valve oil seal Installing valve

9 JAC-T3F001
installer oil seal
Camshaft oil Installing engine

10 JAC-T3F002
seal installer camshaft oil seal
Guiding during
Crankshaft
installation of
11 front oil seal JAC-T3F003
crankshaft front
guide
oil seal
EM-4
Crankshaft Installing engine

12 front oil seal JAC-T3F004 crankshaft front
installer oil seal
Crankshaft Installing
13 rear oil seal JAC-T3F005 crankshaft rear oil
installer seal
List of Accessory Materials for Engine Assembly
SN Name Application Specification and brand
5W-30 (in winter in northern areas); 15W-40 (in

Engine Engine oil for filling and
1 summer in northern areas or year round in
oil assembly
southern areas); SJ quality grade and above
Silica Oil pump, water pump, oil

2 LT5699 or equivalent
gel pan, crankshaft rear oil seal
Oil pressure switch, water

3 Sealant LT243 or equivalent
drain plug, flywheel bolt
Coolant temperature
4 Sealant sensor, coolant temperature LT648 or equivalent
warning switch
5 Gasoline RON93# and above unleaded gasoline
6 Sealant Stud bolt LT271 or equivalent
List of Accessory Materials for Cylinder Head Assembly
SN Name Available material and type Assembly location
5W-30 (in winter in northern areas); 15W-40 (in Valve head, camshaft, rocker
Engine
1 summer in northern areas or year round in arm, rocker arm shaft,
oil
southern areas); SJ quality grade and above camshaft oil seal
2 Sealant LT271 or equivalent Stud bolt
Spark plug guide, cylinder

3 Sealant LT962T or equivalent block/cylinder head bowl plug,
filler neck
EM-5
Engine Structure Overview

The exterior of the engine is shown in the figure:
Outside View of Engine Assembly

As shown in the figure, this engine assembly is mainly used on B-Class MPV models
manufactured by JAC Motors.
B-Class MPV
EM-6
Structural parameters of the engine:

List of Structural Parameters of the Engine
Model 4G93D-DL
Form L4/16V, DOHC, MPI
Number of cylinders 4
Combustion chamber Ridge type
Total displacement (CC) 1834
Bore mm 81
Stroke mm 89
Compression ratio 10.5
Valve and valve gear DOHC-4VLVE
Cylinder center distance mm 87.5
Cylinder block height mm 263.5
Center distance between connecting rod big and

133.5
small ends
Intake valve 8
Number of valves
Exhaust valve 8
Maximum power 100kW/6500r/min

Output
Maximum torque 165N·m/5000r/min
Octane number of fuel RON93# and above unleaded gasoline
Applicable emission regulations National IV
622mm (length) × 610mm (width) × 650mm

Overall size (without transmission)
(height)
Engine weight (Kg) 135±2 (dry)
Lubrication system Force feed oiling
Fuel supply mode Electric fuel pump without return oil system
Oil pump type Cycloid gear pump
Cooling system Forced circulation, water cooling
Oil pump type Centrifugal, impeller type
EM-7
Engine number location and cylinder block number:

Example:
Engine model Engine serial number
Rear view of cylinder block
Drive belts
Engine Drive Belts Schematic
EM-8
Inspection before removal:

1. Check belts for cracks, wear and oil trace. If any, please replace.
2. Check if belt is located in pulley groove properly.
3. Check drive belt deflection at a point on belt midway between pulleys.
Caution:
 Inspection should be done only when engine is cold, or over 30 minutes after
engine is stopped.
 Check with a belt tension gauge.
 Adjust if the belt deflection exceeds the limit.
Table of Technical Specifications of Belts
Name Used belt New belt
Alternator drive belt tension 392 ±98N 686 ±98N
Power steering pump and A/C compressor belt 8~12mm 7~9mm
Applied push 98N
Table of Methods for Belts Adjustment
Tension adjustment portion Belt tightening method for adjustment
Alternator Adjusting nut on alternator
Power steering pump and A/C compressor belt Adjusting nut on idler pulley
Removal:
1. Unscrew idler pulley lock nut, and then adjust tension by turning adjusting nut to
loosen power steering pump and A/C compressor drive belt.
2. Take off power steering pump and A/C compressor drive belt.
3. Adjust tension by turning alternator adjusting nut to loosen alternator drive belt.
4. Remove alternator drive belt from alternator pulley.
Installation:
1. Install belts to their pulleys in the reverse order of removal.
Caution:
 After a replacement belt is installed, adjust its “new belt” value to pulley groove.
 When installing belt, make sure that it is correctly engaged with pulley groove.
 Please do not splash fluids such as engine oil, power steering fluid and engine
coolant onto belt and each pulley groove.
 Please do not wind or bend belt excessively.
EM-9
2. Adjust belt tension to the specified value first. Then, after turning crankshaft two
turns or more, recheck if the specified value is reached so as to avoid variation in
deflection between pulleys.
3. Tighten bolts and nuts to the specified torques.
4. Make sure that tension of each belt is within the standard range.
Air Cleaner and Air Duct
1
3
Location Plan of Components

1-Intake hose 2-PCV hose 3-Air cleaner assembly
Removal:
1. Loosen intake hose locking clamp and PCV hose clamp.
2. Remove upper cover latch of air cleaner. EM005

3. Remove intake hose, and take off air
cleaner upper cover and intake hose.
4. Remove 3 bolts securing air cleaner
base, and take off the base.
 Tightening torque: 8~12 N·m
EM-10
Inspection after removal:

Check air duct for cracks or wear. If any, please replace.
Installation:
Install in the reverse order of removal.
Caution:
 Install each joint properly. Put back and tighten clamp.
Checking and changing air cleaner element:

Removal:
1. Loosen locking clip of air cleaner upper EM006

cover, and lift the cover.
2. Remove air cleaner element. EM007
Inspection after removal: EM008

 Be sure to clean or replace air cleaner
element regularly at recommended
intervals.
 Blow compressed air into back side of
air cleaner element until clean air is
blown out.
Installation:
 Install in the reverse order of removal.
EM-11
Intake Manifold
Components:
Exploded View of Intake and Exhaust Manifolds

1-Engine assembly 2-Intake manifold support 3-Intake manifold 4-Intake manifold gasket
5-Exhaust manifold support B 6-Exhaust manifold support A 7-Oxygen sensor
8-Exhaust shroud 9-Exhaust manifold 10-Exhaust manifold gasket
Intake manifold removal:
Warning:
 To avoid being scalded, please do not drain engine coolant when the engine is
hot.
1. Drain engine coolant.
2. Release fuel pressure.
3. Remove engine hood.
4. Remove air cleaner assembly.
5. Disconnect harness connectors of the following:
 Intake manifold absolute pressure sensor (MAP sensor)
 Fuel injector
EM-12
 Throttle position sensor (TPS)

 Idle speed stepper motor
 Canister control solenoid valve
6. Disconnect hose connectors of the following:
 Water pipe connector
 PCV tube
 Vacuum hose of intake manifold side brake vacuum booster
 Canister solenoid valve side vacuum hose
 Minor cycle water pipe on throttle body
7. Remove accelerator cable from throttle body.
 Tightening torque: 15~22N·m
8. Fuel injector assembly removal
9. Remove mount securing intake manifold and engine block.
 Tightening torque: M8 15~20 N·m
M10 27~33 N·m
10. Remove mounting bolts and nuts of intake manifold.
11. Take off intake manifold and its gasket.
Check the following. If any problem is found, replace involved parts.
① Check parts for damage or cracks.
② Check vacuum tube outlet and water passage or air passage for clogging.
③ Check cylinder head mounting surface for distortion using straightedge and
feeler gauge.
Standard value: <0.15mm
Limit value: 0.20mm
Installation:
 Install in the reverse order of removal.
Caution:
 Please do not reuse non-reusable parts.
 Please check engine coolant level before starting the engine. If the level is below
required, please fill up to the specified level.
 Recheck engine coolant level after the engine cools down. If necessary, refill up
to the specified level.
 Follow the follow procedure to check for fuel leakage.
EM-13
- Turn ignition switch to “ON” position, and check junctions for fuel leakage.
- Start engine, and recheck junctions for fuel leakage with engine accelerating.
Exhaust Manifold and Three Way Catalyst
Exhaust manifold removal:
Removal procedure:
1. Loosen 4 bolts securing exhaust EM009

manifold cover, and take off the cover.
2. Loosen bolt securing exhaust front tube
to front catalyst, and disconnect the
tube.
3. Disconnect harness connectors of front EM010

and rear oxygen sensors.
4. Loosen bolts securing exhaust EM011

manifold to cylinder block, and take
off exhaust manifold and gasket.
5. Checking exhaust system

Check exhaust pipes, three way catalytic converter, muffler and fixtures for improper
attachment, leakage, cracks, damage or aging. If necessary, please repair or replace
damaged parts.
Installation:
Please note the following and install in the reverse order of removal.
 If bolt securing exhaust front tube has been removed, please install and tighten to
the specified torque.
EM-14
Tightening torque: 45±5 N·m

Caution:
 Replace exhaust pipe gasket at each reassembly.
 Please repair or replace seriously deformed heat insulator and clear it of
accumulation such as mud.
 When installing heat insulators, avoid excessive gaps and interferences between
the insulators and exhaust pipes.
 Clear each joint sealing surface of deposit. Connection must be made firmly to
prevent gas leakage.
 Pretighten exhaust manifold side mounting nuts and bolts, check for interference
between parts, and then tighten to the specified torque.
 When installing a mounting rubber, care should be taken to avoid its distortion or
stretching.
Inspection after installation:
 Check exhaust pipe joints for air leak and abnormal sound with engine running.
 Make sure both fixing bracket and mounting rubber have been installed properly
without overstress. Improper installation may cause excessive noise and
vibration.
Ignition Coil and Spark Plug
Removal:
Caution:
 Make sure ignition switch is in “OFF” EM012

position.
1. Disconnect negative battery terminal.
2. Screw off 4 bolts securing middle cover, EM013

and take off the cover.
EM-15
3. Disconnect wire connector from ignition EM014

coil assembly.
4. Screw off 2 bolts securing ignition coil,
and take out ignition coil.
5. Disconnect secondary cable from
ignition coil.

1) Ignition coil
 Check resistance of primary coil between terminals.
Resistance of primary coil: 0.77~0.95Ω
 Check resistances between high voltage terminals of No. 1 and No. 4 cylinders
and those of No. 2 and No. 3 cylinders.
Resistance of secondary coil: 7.75~10.23KΩ
Caution:
 When measuring coil resistance, be sure to pull off ignition coil harness
connector.
2) Spark plug
Checking spark plug:
 Check spark plug insulator for damage or fracture.
 Check for spark plug fouling. See the following table for causes of fouling.
Analysis Sheet of Causes of Spark Plug Fouling
Symptom Black carbon White carbon
Impurities content in fuel filled Impurities content in fuel filled, or ignition timing
Cause
or mixture too rich incorrect, or spark plug not tightened
 Check spark plug electrode for damage.

 Check spark plug gap.
EM-16
Check spark plug gap with a feeler gauge. EM015

Standard gap: 1.0~1.1mm
If the gap exceeds the standard value, please
replace.
 Check spark plug electrode surface for
fouling. If necessary, please clean with a
spark plug cleaner. Cleaner air pressure
<588kpa; cleaning time <20 seconds
Caution:
 Please do not use a wire brush for cleaning.
 Check spark plug electrode surface for ablation. If necessary, please replace.
3) Ignition cable
 Check ignition cable for damage or fracture.
 Check resistance of ignition cable.
No. 1 cylinder: 5.8KΩ
No. 3 cylinder: 2.9KΩ
If the resistance is out of the standard, please replace.
Installation:
1. Install spark plug with a spark plug socket and tighten to 25N·m.
2. Install ignition coil and tighten its bolt to 10N·m.
3. Connect spark plug secondary cable and ignition coil harness connector, and
secure the cable to its clip.
4. Install spark plug cover and tighten its bolt to 3N·m.
Fuel Injector and Fuel Rail
Removal:
Warning:
 Before handling fuel system, be sure to read “Precautions” in page EM-1.
1) Releasing fuel pressure in fuel piping: EM016

① Turn ignition switch to “OFF” position,
and remove battery negative (-).
② Open fuel tank cap.
③ Put a thick rag or towel on test port of
fuel rail, and depress needle valve to
release pressure.
EM-17
2) Disconnect intake manifold side PCV EM017

hose connector.
3) Disconnect harness connectors of MAP EM018

sensor and fuel injector.
4) Disconnect throttle body side
accelerator cable and cable holder.
5) Disconnect fuel hose connector on fuel rail.

Caution:
 Please get a vessel and rag ready in advance as fuel may leak.
 Avoid open flame and sparks.
 Please keep parts away from any heat source.
 Be sure to keep junctions clean and avoid damage and entry of foreign material.
Please cover them completely with plastic bags or similar objects.
6) Remove 2 bolts securing fuel rail.
7) Take out fuel injector and fuel rail from intake manifold side.
Caution:
 When moving them away, be careful to avoid interference with fuel injector.
 Use a rag to absorb fuel leaking from fuel tube.
8) Follow the procedure below to remove fuel injector from fuel rail.
a. Pry off and remove clip.
b. Pull fuel injector straight out of fuel tube.
Caution:
 Pay attention to leakage of residual fuel in fuel tube.
 Be careful not to damage fuel injector nozzle.
 Never drop it or subject it to impact.
 Please do not disassemble it.
EM-18

1) Fuel injector
 Check upper and lower seal rings of fuel injector for cracks, aging and breakage.
If any, please replace.
 Check fuel injector nozzle opening for EM019

clogging. If any, please use special
apparatuses to clean or replace.
Standard value:
Working pressure: 350 kPa
Fuel injector resistance: 11~16Ω
Working temperature: -40~130℃
2) Fuel rail
 Check fuel test port for damage or seizure. If any, please replace.
 Check inside of fuel rail for residue. If any, please clean.
Installation:
1) When installing new O-rings to fuel injector, please pay attention to the
following:
Caution: EM020
 Upper and lower O-rings are different.
Please do not confuse them.
Fuel tube side: thick
Nozzle side: thin
 Please install O-ring with bare hands.
 Lubricate O-ring with gasoline.
 Please do not clean O-ring with solvent.
 Please make sure that O-ring and its mating part are free of foreign material.
 When installing an O-ring, please be careful not to scratch it with a tool or
fingernails. Also be careful not to twist or stretch O-ring.
 Insert new O-ring straight into fuel injector. Please do not angle or twist it.
2) As shown in the figure, install fuel injector ④ to fuel tube ① with the following
procedure.
③: thick
⑤: thin
a. Insert clip ② into clip mounting groove on fuel injector. Insert clip section D into
EM-19
lug F of fuel injector.

Caution:
 Each time a clip is removed, replace it with a new one.
 Make sure clip does not interfere with O-ring.
b. Insert fuel injector into fuel tube with clip attached.
Caution:
 Insert it while aligning it with axis.
 Insert clip section C into lug B of fuel tube.
 Make sure that fuel tube flange A is securely fixed in flange fixing groove E on
clip.
c. Make sure that installation is complete by checking that fuel injector does not
move or come off.
3) Install fuel rail and injector assembly at inside of intake manifold.
Caution:
 Take care to avoid fuel injector nozzle tip contacting other parts.
4) Install remaining parts in the reverse order of removal.
Check for fuel leakage with the following procedure.
1) Turn ignition switch to “ON” position (do not start engine), and check
connections of fuel piping for leakage.
2) Start engine, and recheck connections of fuel system for fuel leakage by
increasing engine speed.
EM-20
Timing Belt
Components:
Exploded View of Timing Belt

1-Upper time belt cover 2-Lower timing belt cover 3-Engine right support
4-Camshaft timing gear 5-Timing belt 6-Crankshaft timing gear
7-Automatic tensioner arm assembly 8-Idler pulley 9-Tensioner arm assembly
10-Rear timing belt casing 11-Sheave
Removal:
Timing belt and sheave removal: EM021

1. Loosen sheave bolt.
2. Remove sheave.
3. If timing belt is to be reused, draw an
arrow on it with a marker pen to
indicate its direction of rotation before
removal. This can ensure proper
installation of timing belt during reuse.
EM-21
Camshaft timing gear bolt removal: EM022

1. Use the special tool shown in the figure
to lock camshaft timing gear to
corresponding position.
2. Unscrew camshaft timing gear bolt.
Timing belt inspection after removal:

Check timing belt carefully. If any of the following defects is found, replace with a
new belt.
1. Back-side rubber is hardening (smooth without elasticity and hardening so that
no traces will appear when you scratch it with fingernails).
Crack Crack
2. Cracks occur on back-side rubber EM023
surface.
3. Canvas is torn (or separated from
rubber). Separation
Crack side
4. Cracks occur at tooth root.
5. Cracks occur at side face of belt.
6. Abnormal wear occurs on side face of
Cracked tooth root
belt.
Caution: EM024 Edge fillet
 Side face of belt is normal if it is

knife-cut sharp.
Abnormal wear
(core exposed)
7. Tooth is worn abnormally. EM025

Canvas wear causing
Initial stage: rubber exposed
Canvas fibers are slack; rubber structure

disappears; white fade occurs; canvas Toothless
structure is difficult to identify.

Final stage:
Canvas is worn to expose rubber (tooth width
decreases).
8. Tooth has disappeared.
EM-22
Sheave: EM026
Check if pulley rotates smoothly without play
and abnormal noise. If necessary, replace.
1. Align marks (blue dot marks).
2. Align timing mark on crankshaft timing
gear with that on front housing.
3. Install timing belt into crankshaft timing EM027

gear, water pump pulley, idler pulley,
camshaft timing gear and sheave pulley
in turn.
4. Unscrew sheave mounting bolt 1/4~1/2 turn, compress push rod of automatic
tensioner arm to its extreme lower position and insert a pin to lock it, insert a
torque wrench with sheave socket attached into adjusting hole of sheave and turn
sheave until it just clings to timing belt. Then tighten sheave mounting bolt.
Finally pull out lock pin of automatic tensioner arm to allow automatic
tensioning of timing belt.
5. Rotate crankshaft 2 turns in normal direction of rotation (clockwise) and check if
timing marks are aligned correctly.
Caution:
 In this way, tension is applied to timing belt evenly through crankshaft driving
moment. Crankshaft must be turned in above direction. Turning it in reverse
direction is not allowed.
EM-23
Camshaft and Rocker Arm

Components:
Exploded View of Camshaft and Rocker Arm

1-Oil filler cap 2-Rocker arm chamber cover 3-Camshaft cover (RR) 4-Camshaft cover (FR)
5-Camshaft cover 6-Intake camshaft 7-Exhaust camshaft 8-Hydraulic tappet 9-Rocker arm
10-Cylinder head subassembly
Removal:
Remove in numerical order (1~10) shown in the figure above and precedence order of
names of components.
Hydraulic tappet removal:
When removing, keep tappet upright to ensure that light oil in it will not spill and that
dirt adhesion will not occur.
EM-24
Checking camshaft: EM028

1. Measure cam height. If the height
exceeds the specified limit value,
replace camshaft.
2. Service limit value of camshaft height:
Intake: 34.87 mm
Exhaust: 34.41 mm
Installation:
Hydraulic tappet installation:
Before installing, make sure that hydraulic tappet body and mounting hole are clean.
When installing, insert tappet gently into cylinder head with its nose outward while
paying attention to direction. At this time, take care to prevent light oil in it from
spilling. In case of spilling, follow the tips for air bleeding to bleed.
 Tips for air bleeding: Hard wire

Put a single hydraulic tappet in light oil.
Depress the steel ball in the tappet lightly
with a hard wire while pressing ball head of Light oil
the tappet 4~5 times to set the tappet to its
maximum stroke.
Caution:
 The mass of the steel ball is only a few grams, so be careful not to press it hard
with the hard wire.
 Abnormal sound will be made if there is air in the hydraulic tappet after it is
installed onto the engine. Then you need to eliminate the abnormal sound by
following the tips below to bleed it.
Troubleshooting:
Throttle opens slowly
1. Warm up for 1~3 minutes with engine Throttle closed
idling.
2. Operate in the mode (30s per cycle) as Idle edge
shown in the figure at right.
15 15
seconds seconds
1 cycle
Hydraulic tappet exhaust operation mode
EM-25
3. During repeated operation, make sure no abnormal sound is heard in idling mode.
(An abnormal sound generally consists of approx. 10 cycles and will disappear at
about 30 cycles. If the abnormal sound does not differ from its initial conditions
after 30 cycles, the cause must not be air in hydraulic tappet and other causes
should be taken into consideration.)
4. After the abnormal sound is eliminated, operate approx. another 5 cycles to
ensure complete air bleeding.
5. Then run another 1~3 minutes in idling mode to confirm if the abnormal sound
has been completely eliminated.
Rocker arm and camshaft installation:
1. Put rocker arm on tappet and valve lifter in correct direction. Then install
camshaft. Finally install camshaft cover.
2. Tighten camshaft cover bolts to the specified torque. Note that all bolts must be
tightened evenly. Tighten each bolt symmetrically in several steps.
Camshaft cover bolt Rocker arm Camshaft cover
Timing belt side

Hydraulic tappet
Camshaft
Installation Schematic
Camshaft oil seal installation:
Use the special tool shown in the figure to EM031

drive oil seal into cylinder head.
EM-26
Rocker arm chamber cover installation: EM032

Order of tightening: Tighten in the order
 Tightening method: After tightening
them for 2 times in the order shown in
the figure above, retighten the bolts
with SNs 1, 2, 3, and 4.
Oil seal EM033

Crankshaft front oil seal removal:
1. Run engine until timing mark on
camshaft timing gear and that on
cylinder head are aligned.
2. Turn crankshaft clockwise until timing EM034

mark on crankshaft timing gear and
that on front housing are aligned.
3. Unscrew sheave bolt, and remove EM035

timing belt.
4. Using special tool, remove crankshaft
timing gear.
5. Take out front oil seal with a suitable
tool as shown.
EM-27
Installation:
1. Use a debris-free cloth to thoroughly
clean oil seal groove in oil pump and
running surface on crankshaft.
2. Put the special tool shown in the figure
on front end of crankshaft and apply
engine oil to its outer circumference.
3. Apply engine oil to seal lip, and then
push oil seal in along its guide until it
comes into contact with front oil seal
housing.
4. Install crankshaft timing gear.
5. Align timing marks on camshaft and
crankshaft respectively, and install
timing belt.
Crankshaft rear oil seal removal: EM038

1. Using the special tool shown in the
figure, lock flywheel to corresponding
position, and then screw off bolt
securing flywheel and remove
flywheel.
2. Pry off crankshaft rear oil seal from
cylinder block with a flat head
screwdriver gently. In addition, be
careful not to leave any scratches on
crankshaft sealing surface. EM039
Installation:
1. Clean oil seal groove on cylinder block
and working surface on crankshaft.
Ensure that these surfaces are
thoroughly clean without residual
sealant and are dry.
2. Apply a little engine oil to oil seal lip
and dust seal lip of oil seal retainer.
EM-28
3. Apply 1.5mm sealant to new oil seal.

Use the oil seal installer to press the oil Oil seal installation
seal into cylinder block quickly and
stay there for 1 minute. Before turning
crankshaft or topping up engine oil,
allow at least 30 minutes for sealant to
flow into and fill the device.
4. Remove oil seal installer, and install
flywheel.
Camshaft oil seal removal and EM041

installation:
Removal:
1. Run engine until timing mark on
camshaft timing gear and that on
cylinder head are aligned.
2 Turn crankshaft clockwise until timing
mark on crankshaft timing gear and
that on front housing are aligned.
3. Unscrew sheave bolt, and remove EM042

timing belt.
4. Use the special tool shown in the figure

to lock camshaft timing gear to
corresponding position.
5. Screw off nut securing camshaft timing EM043

gear, and remove the gear.
6. Wrap head of flat head screwdriver
with a piece of rag, insert the
screwdriver into notch groove on oil
seal, and pry oil seal to take it off
slowly.
EM-29
Installation:
1. Clean sealing zone of cylinder head Oil seal guide
and camshaft bracket.

Caution:
 Do not perform this with a scraper
because it may damage sealing surface.
Press-fitting tool
2. Apply engine oil to camshaft oil seal lip.

3. Put new oil seal installed on its guide in front of camshaft end.
4. Install camshaft oil seal using the oil seal drift shown in the figure.
5. Install camshaft timing gear.
6. Align timing marks on camshaft and crankshaft respectively, and install timing
belt.
Cylinder Head and Valves
Exploded View of Cylinder Head and Valves

1-Cylinder head bolt 2-Cylinder head bolt washer 3-Cylinder head 4-Valve collet
5-Valve spring retainer 6-Valve spring 7-Exhaust valve 8-Intake valve
9-Cylinder head gasket 10-Cylinder block
EM-30
Removal: EM045
Cylinder head bolts removal:
Unscrew cylinder head bolts using the tool
Collet removal:
Tie labels to remove valves, springs and
other parts to indicate their cylinder numbers
and locations for easier reassembly. Store
these parts securely.
Valve oil seal removal: EM047

Valve oil seal is non-reusable part which can
not be reused after removal.
Inspection after removal: EM048

Cylinder head:
1. Before cleaning cylinder head, check it
for water leak, air leak, cracks, and other
damages.
2. Clear all engine oil, scale, sealant and
carbon deposit. After cleaning oil
passage, blow compressed air into it to
make sure it is not clogged.
3. Using straightedge and feeler gauge, check cylinder head gasket surface for
distortion (follow the procedure shown in the figure). If the distortion exceeds
the specified limit value, grind gasket surface according to its specification.
 Standard value of gasket surface distortion: <0.03mm
 Cylinder head height (when new): 132±0.1mm
EM-31
Caution:
 Total grinding allowance of mating surfaces on cylinder head and cylinder block
is not greater than 0.2mm.
Valves:
1. Check valve face for correct contact. In the case of uneven or poor contact,
regrind valve seat surface.
2. If margin thickness is less than the

specified value, replace valve.
Standard value: Limit value:
Intake valve: 1.5mm Intake valve: 1.0mm Contact (must be
at center of the
Exhaust valve: 1.7mm Exhaust valve: 1.2mm surface) Edge thickness
3. Measure total length of valve. If the measurement is less than the specified value,
replace valve.
Intake valve: 104.19mm Intake valve: 103.69mm
Exhaust valve: 103.87mm Exhaust valve: 103.37mm
Valve spring:
1. Measure free height of valve spring. If Perpendicular

the measurement is less than the alignment
specified value, replace valve spring.

Standard value: 45.0 mm
Limit value: 44.5 mm Free height
2. Measure valve spring squareness. If the

measurement exceeds the specified limit
value, replace valve spring.
Standard value: 2°
Limit value: 4°
Valve guide: EM051
1 Measure valve guide to stem clearance.

2. If the specified limit value is exceeded,
replace either part or both parts. Valve guide
Standard value:
Intake valve guide: 0.020-0.047mm
Outside diameter of valve stem
Exhaust valve guide: 0.035-0.062mm Inside diameter of valve guide
EM-32
Limit value: EM052 End face of valve stem
Intake valve guide: 0.10mm

Exhaust valve guide: 0.15mm Protrusion height of valve
Valve seat:
Install valve, and then measure valve Valve spring retainer face
protrusion height between valve stem end

face and valve spring seat surface. If the
measurement exceeds the specified limit
value, replace valve seat.

Intake valve: 46.69mm Intake valve: 47.04mm
Exhaust valve: 46.67mm Exhaust valve: 47.02mm
Operation tips for valve seat refacing:

1. Before refacing valve seat, check guide
to valve clearance. When necessary,
replace valve guide.
2. Use a suitable special tool or valve seat
grinder to reface valve seat until the
specified seat surface width and angle
are achieved.
3. After refacing valve seat, grind valve and valve seat using abrasive compound.
Then check protrusion height of valve stem. (Refer to the check steps for valve
seat described above.)
Operation tips for valve seat replacement: EM054

1. To reduce wall thickness, cut off the
valve seat to be replaced from its inside
and then remove valve seat.
Cut off
2. Rebore valve seat hole on cylinder head
until it matches the selected valve seat
of increased diameter.
Intake valve seat hole diameter (increased by 0.3mm: 34.300-34.325mm)

Intake valve seat hole diameter (increased by 0.6mm: 34.600-34.625mm)
Exhaust valve seat hole diameter (increased by 0.3mm: 30.800-30.825mm)
Exhaust valve seat hole diameter (increased by 0.6mm: 31.100-31.125mm)
EM-33
3. Before press-fitting, prevent valve seat

cooled by liquid nitrogen from chafing
cylinder head hole.
4. Reface valve seat until the specified Valve height
width and angle. (Refer to operation tips
for valve seat refacing).
Increased hole bore
Operation tips for valve guide EM056

replacement:
1. Drive out valve guide with a press
towards cylinder block side.
2. Rebore valve guide hole on cylinder
head until it matches the oversized valve
Protrusion
guide to be installed. height
Caution:
 Do not install valve guide of same size again.
Valve guide hole diameter:
Increased by 0.05: 11.050-11.068mm
Increased by 0.25: 11.250-11.268mm
Increased by 0.50: 11.500-11.518mm
 Press valve guide in until its protrusion height reaches the specified value.
Standard value: 20.4±0.2mm
Caution:
 Valve guide must be installed in from cylinder head upside.
 Lengths of valve guides at intake and exhaust sides are unequal.
 After press-fitting valve guide, insert new valve and check it for smooth sliding.
EM-34
Installation:
Valve oil seal installation:
1. Install valve spring seat first. EM057

2. Then install new valve oil seal using the
special tool shown in the figure.
Caution:
 Valve oil seal can not be reused.
 Valve oil seal must be installed using
proper special tool. Improper installation
may result in oil leak from valve guide.
Valve spring installation:

Valve spring
When installing valve spring, position its retainer
Painted end
painted end to rocker arm side.
Valve stem oil

seal
Valve spring
retainer
Collet installation:
1. Install valve spring collet using the
special tool shown in the figure.
2. If valve spring is over compressed,
bottom end of collet will contact it,
causing damage to valve stem seal.
Cylinder head bolts installation:

1. Before reusing a cylinder head bolt,
check if its length exceeds the specified
limit value. If the measurement exceeds
the limit value, replace this bolt.
Limit value: 96.4 mm
2. Install washer as shown in the figure.
3. Apply engine oil to washer on threaded
portion of bolt.
EM-35
4. Tighten bolts in the order shown in the

figure until torque of each bolt is Timing belt side
20±2N·m.
5. Tighten each bolt for another 180°
sequentially.
6. Unscrew bolts completely.
7. Retighten bolts in the order shown in the figure until torque of each bolt reaches
20±2N·m.
8. Put paint marks on cylinder head bolt heads and cylinder head (as shown in the
figure).
9. Tighten each bolt for another 90° in the order of tightening.
10. Tighten each bolt for another 90°, and then check if paint marks on bolt heads
and those on cylinder head are aligned.
Caution:
 If tightening angle of bolts is less than 90°, they are impossible to be strong
enough to fasten cylinder head.
 If tightening angle of bolts exceeds 90°, remove them completely and reinstall.
 If used cylinder head bolts are replaced during maintenance, service in the order
of (2) through (10).
 If used cylinder head bolts are not replaced during maintenance, service in the
order of (2), (3), (7), (8), (9), and (10).
EM-36
Cylinder Block and Crankshaft

Components:
Exploded View of Cylinder Block and Crankshaft

1-Adapter plate 2-Flexible flywheel 3-Crankshaft bushing 4-Crankshaft gasket
5-Upper baffle plate 6-Oil seal housing assembly 7-Bearing cap
8-Main bearing shell lower half 9-Crankshaft 10-Main bearing shell upper half
11-Thrust plate 12-Steel ball 13-Cylinder block assembly
Removal:
Please perform removal procedure according to sequence of names of parts described
above.
EM-37
Crankshaft clearance:
Plastigage
Crankshaft clearance can be measured easily
with a plastigage. Follow the procedure
below to measure crankshaft clearance using
plastigage.
1. Wipe off all engine oil from crankshaft
journal and bearing inner surface.
2. Install bearing.
3. Cut plastigage so that its length matches

bearing width. Then put it on journal
Plastigage
along axial direction of journal.
4. Install crankshaft bearing shell cover
gently, and tighten bolts to the specified
torque.
5. Remove bolts, and remove crankshaft
bearing shell cover gently.
6. Measure squeezed part on plastigage at

the widest point using the scale printed
on plastigage bag.
Standard value: 0.015-0.048mm
Limit value: 0.1mm
Caution: Fillet rolling area
 Both connecting rod journal and main

journal of crankshaft are rolled and need
not to be machined to reduced sizes.
Cylinder block
1. Inspect for cracks, rust and corrosion
visually and check cylinder block using
defect inspection agent. Repair defects
as far as possible or replace cylinder
block.
2. Keep top surface free of gasket debris
and other foreign materials. Check for Feeler gauge
cylinder block top surface distortion
using straightedge and feeler gauge.
Standard value: <0.03mm
Limit value: <0.1mm
EM-38
3. Check cylinder wall for cracks and trace

of scuffing of cylinder bore. In the case
of noticeable defects, bore all cylinders
to increased size or replace cylinder
block.
4. Measure each cylinder bore and its
cylindricity with a bore gauge. If any
cylinder is seriously worn, bore all
cylinders to increased size and replace
pistons and piston rings accordingly.
Measuring points are shown in the figure. EM067

Standard value:
Cylinder bore: 81.0mm
Cylindricity: <0.01mm
Boring cylinder bore: Coat seal ring
1. Oversized pistons used should be Outer diameter of

piston
determined by cylinders having
maximum bores.
2. Oversized pistons having the following sizes:

0.25mm, 0.50mm, 0.75mm and 1.00mm. Measure diameters of pistons used. After
boring cylinder bores, ensure that piston to cylinder clearances conform to the
standard value. (Measure piston diameter at the points shown in the figure.)
3. Calculate bore size according to piston diameter: [Bore size] = [outer diameter of
piston] + [piston to cylinder clearance: (0.02~0.04) mm] – [lapping allowance
(0.02mm)]
4. Bore each cylinder to calculated bore size.
Caution:
 To prevent the distortion caused by the heat generated during boring, please bore
cylinder bores in the following order: No. 2 cylinder, No. 4 cylinder, No. 1
cylinder, No. 3 cylinder.
5. Grind cylinder to finish size (outer diameter of piston + piston to cylinder
clearance).
6. Check piston to cylinder clearance.
Installation:
Main bearing shell installation:
1. Select bearing shell according to identification mark or color code of crankshaft.
(Refer to the following table. If they can not be identified, measure crankshaft
diameter and select corresponding bearing to match it.)
EM-39
Crankshaft Identification Marks and Bearing Matching Table

Bore of bearing hole on
Crankshaft journal Bearing shell
cylinder block
Identification Journal Identification
Scope Identification mark
mark diameter mark
0 1
1 1 49.994~50.000 1 2
2 3
0 2
2 2 49.988~49.994 1 3
2 4
0 3
3 3 49.982~49.988 1 4
2 5
No. 5 main journal

Grade mark of crank journal
No. 4 main journal
Grade Mark
No. 3 main journal
No. 2 main journal
No. 1 main journal
Mark sheet of
crankshaft journal
Cylinder block main journal grade
Grade Mark
EM-40
2. Identification mark of bearing shell bore EM068

is stamped at the position as shown.
Be sure to select and install bearings
according to these identification marks.
3. Select bearing shell from above table
based on identification mark check in
steps 1 and 2.
See the following example:
a. If the measured journal is 50.000mm, it

Grooved
corresponds to the first grade in above Grooveless
table.
b. If the identification mark on bearing
shell bore on cylinder block is 1, select a
bearing shell with identification mark 2.
4. All bearing shell upper halves are Main bearing shell lower half (No. 1, No. 2, No. 3, No. 4,
No. 5)
grooved; all bearing shell lower halves are Main bearing shell upper half (No. 1, No. 2, No. 3, No. 4,
grooveless. No. 5)
Bearing cap installation:

1. There is an arrow on one end of bearing cap. The arrow must point to timing belt
side. Tighten bolts in the order shown in the figure.
Engine front
SNs shown in the figure show tightening order of bolts.

Tighten to 25Nm sequentially.
Then tighten another 90° sequentially.
Sequence Diagram of Bolts Tightening
EM-41
2. After installing main bearing shell,

measure axial clearance of crankshaft. If
the measurement exceeds the specified
limit value, replace crankshaft bearing Dial indicator
shell.
Measure axial clearance of crankshaft.
Caution: EM071
Leave this fillet forward
 Also install thrust plate while installing
intermediate main bearing shell. When
installing, please pay attention to Crankshaft gasket
installation direction of thrust plate.
Crankshaft gasket installation: Crankshaft
Install crankshaft gasket with its chamfered

side facing flywheel side (as shown in the
figure).
Piston and connecting rod:
Exploded View of Piston and Connecting Rod

1-Cylinder block assembly 2-Connecting rod nut 3-Connecting rod cap
EM-42
4-Connecting rod bearing shell lower half 5-Connecting rod bearing shell upper half
6-Piston pin 7-Connecting rod 8-Piston 9-Top piston ring 10-Second piston ring
11-Oil ring 12-Piston and connecting rod assembly
Removal:
Please perform removal procedure according to sequence of names of parts described
above.
Connecting rod cap removal:

Cylinder number is stamped on side face of
connecting rod big end for easier
reinstallation. Cylinder number
Piston pin removal: EM073

1. Insert a push rod (special tool) from
the arrow side at front, and then install Push rod
guide D.
Piston pin
2. Install piston and connecting rod
assembly onto piston pin mount set
Mark of front
(special tool) with front mark on piston Mark of
upward. front
3. Drive out piston pin with a press.

Caution: Guide sleeve A
 After piston pin is removed, put piston,

piston pin and connecting rod together.
Base
Do not put pistons, piston pins and
connecting rods of cylinders together
with them mixing up. Guide sleeve B
EM-43

Piston rings:
1. Check piston ring side clearance. If the
clearance exceeds the specified limit
value, replace piston ring or piston or
both.
Standard value:
Feeler gauge
Top ring: 0.03-0.07mm
Second ring: 0.02-0.06mm
Limit value: Push in together with piston
Top ring: 0.1mm

Second ring: 0.1mm
2. Put piston rings in cylinder bore, and
push them down using piston.
Ensure that piston top comes into
contact with piston rings and that rings Piston ring Gap clearance
are perpendicular to cylinder wall.

Then measure the piston ring end gap
with a feeler gauge. If the end gap is
too large, replace piston ring.
Standard value:
Top ring: 0.25-0.40mm
Second ring: 0.40-0.55mm
Oil ring: 0.10-0.35mm
Limit value:
Top ring: 0.8mm
Second ring: 0.8mm
Oil ring: 1.0mm
Connecting rod bearing shell clearance

(plastigage method): Contrast scale
1. Wipe off all engine oil from

connecting rod journal and connecting Plastic ruler
rod bearing shell.
2. Put a plastigage cut to a length equal to
bearing shell width on connecting rod
journal. Plastigage must be placed at
center of connecting rod journal and is
parallel to axis of the journal.
EM-44
3. Place connecting rod cap in position

gently and tighten bolts to the
specified torque.
4. Remove bolts, and remove connecting
rod cap slowly.
5. Measure squeezed part on plastigage at
the widest point using the scale printed
on plastigage bag.
Limit value: 0.1mm
Installation:
Piston pin installation:
1. Measure the following lengths (as
shown in the figure).
① Piston boss to piston boss outside
dimension Connecting rod
② Piston boss to piston boss inside Piston pin

dimension
Piston
③ Piston pin length
④ Connecting rod small end thickness
2 Incorporate measured value into the
following formula:
( A  C)  (B  D)
L
2
3. Insert a push rod (special tool) into
piston pin, and then install guide A
(special tool).
4. When installing piston and connecting
rod, ensure that their front marks are at
the same side.
5. Apply engine oil to external circle of
piston pin.
6. Start with guide A. Press guide A,
piston pin and push rod into front mark Guide B Guide A
side of piston in turn.
EM-45
7. Screw guide B into guide A. The

clearance between the 2 guides is 3mm
plus the L value calculated in step 2. Push rod
8. Install piston and connecting rod onto

piston pin mount set with front mark Piston pin
on piston downward.
Mark of front
Mark of front
9. Install piston pin with a press. If
press-fit load exceeds the specified
value, replace piston pin and piston
assembly and connecting rod or both.
Guide sleeve A
Standard value: 1000±500 kg/cm2
Base
Guide sleeve B
Oil ring installation:

Steel ring
1. Install oil ring spacer into piston ring
groove.
2. Then install top and bottom steel rings.
Space ring
Caution: Top steel ring Bottom steel ring
Installation positions of spacer and steel

Gap of bottom steel ring
Gap of top steel ring
rings are shown in the figure. Top and

bottom steel rings are same.
3. When installing a steel ring, as shown
in the figure, install its one end into the
groove by hand and then press the rest
of it in place. Gap of spacer ring
Space ring
EM-46
4. After steel rings are installed, check if EM082 End face of steel ring
they can move smoothly in both
directions.
Second piston ring/top piston ring

installation:
Using piston ring expander, install second
and top piston rings with their identification
marks upward (on piston top side).
Piston ring expander
Identification mark: Identification mark “manufacturer ID 1”
Top piston ring: Manufacturer ID 1 Size mark

“Manufacturer ID 2”
Second piston ring: Manufacturer ID 2
Top ring
2nd ring
Steel ring Top ring
Piston pin
2nd ring and band Steel ring
EM-47
Piston and connecting rod assembly EM086

installation:
1. Apply engine oil to piston, piston rings
and piston pin. As shown in the figure,
align gaps of gas rings and oil rings
(steel rings and spacers).
2. Press piston and connecting rod
assembly into cylinder with front
arrow on piston top facing timing belt
side.
3. Compress piston rings with a suitable piston ring compressor, and then press
piston and connecting rod into cylinder together.
Caution:
 Do not knock on piston hard, otherwise piston rings may be broken and cracks
may occur on connecting rod journal.
Connecting rod bearing shell installation:
Please confirm identification marks on crankshaft and connecting rod at the positions
shown in the figure and select bearing shell according to the following table.
Bearing Shell Selection Table
Crank diameter grade and Identification mark of connecting Bearing shell grade and
mark rod mark
Ⅰ. (1. Ⅰ. (1.
Ⅱ. (2. Ⅱ. (2.
Ⅲ. (3. Ⅲ. (3.
EM-48
Connecting rod cap installation: EM088

Install with mark “93” forward
1. Install connecting rod bearing cap onto
connecting rod, aligning the marks mad
at disassembly. In the case of a new
connecting rod (without mark), ensure
that bearing shell lock gaps are at the
same side.
EM089
Cylinder number
2. Check if connecting rod big end side

clearance is within specification.
Standard value: 0.10-0.25mm Feeler gauge
EM-49
Connecting rod nut installation: Paint mark

Paint
Caution: mark
 If cylinder head has been installed

before connecting rod nut installation,
spark plugs must be removed first.
Connecting rod bolts and nuts are
Bolt
tightened by means of plastic Nut
deformation tension. When a bolt is to

be reused, be sure to check it for
scratches.
1. To check a bolt for scratches, tighten its nut by hand to get through the entire
length of thread. It indicates that the threaded portion of the screw thread is free
of scratches only when the nut can be screwed through the entire thread smoothly,
otherwise the bolt must be replaced.
2. Before installing a nut, apply engine oil to its threaded portion and seat surface.
3. Install nut onto bolt, and finger tighten them. After that, nuts must be tightened
alternately to ensure proper installation of connecting rod cap.
4. Tightening torque for the nut: 20.0±2.0N·m. As shown in the figure, put a paint
mark on top of each nut.
5. Put a paint mark on corresponding bolt at the point where is 90°~94° in
clockwise direction from the paint mark on the nut.
 Turn the nut until the paint marks on the bolt and nut are aligned.
Caution:
 If angles of rotation of nuts are less than 90°, tightening force of connecting rod
cap may be insufficient.
 If angles of rotation of nuts are greater than 94°, unscrew them completely and
perform the tightening procedure again.
Oil Pan and Oil Strainer
Removal: EM093
1. Remove mounting bolts of oil pan.
2. As shown in the figure, drive the special
tool in between oil pan and cylinder
block.
3. Tap side face of special tool to move the
tool along sealing surface of oil pan and
cylinder block, and then remove oil pan.
EM-50
Installation:
1. Clean mating surfaces of cylinder block and oil pan.
2. Apply 4mm wide edge-curled sealant beads to entire outer circumference of oil
pan flange.
 Designated sealant: LT5699
Install
hexagon
socket bolts at
these 2 points.
Sealant Location Schematic

Drain plug gasket installation:
1. Replace with new drain plug gasket. Install new gasket as shown in the figure.
Caution:
 If the gasket is installed in wrong
direction, oil leak may result. Oil pan side
2. The required torque for drain plug is
33~35N·m. Under torque will result in
loose plug; over torque may cause
damage to oil pan threads.
Oil strainer installation:

1. Clean oil filter mounting surface on oil pump housing.
2. Apply engine oil to O-ring of oil filter.
3. Tighten oil filter until O-ring is seated on mounting surface, and then screw oil
filter for another turn (tightening torque: 12~16N·m).
Caution:
 Oil filter must be tightened with a commercially available filter wrench. Hand
tightening filter will result in oil leak due to insufficient tightening torque.
EM-51
Positive Crankcase Ventilation

Components:
Breather hose
Positive crankcase ventilation valve
Breathing hose
Positive Crankcase Ventilation System Diagram
System description:
 Crankcase evaporative emissions control system is a kind of system that prevents
blowby gas from escaping into the atmosphere from inside of crankcase.
 Fresh air is sent into crankcase from air cleaner through breather hose and mixes
with blowby gas in crankcase. Blowby gas in crankcase is sucked into intake
manifold through positive crankcase ventilation valve.
 Positive crankcase ventilation (PCV) valve can control blowby gas flow
accurately by lifting plunger according to degree of vacuum in intake manifold.
In other words, blowby gas flow is regulated to maintain engine stability when
engine is running at low load and is increased to improve ventilation performance
when engine is running at high load.
Installation positions of components:
They are mounted on PCV valve body.
Positive crankcase ventilation (PCV) EM095

inspection:
Positive crankcase
1. Remove breather hose from PCV valve. ventilation valve
2. Remove PCV valve from cylinder head

cover.
3. Then install PCV valve onto breather
hose.
4. Start engine and run it under idle speed.
EM-52
5. Put your fingers at opening of PCV valve and make sure vacuum can be felt in
intake manifold.
Caution:
 At this time, plunger in PCV valve will move back and forth.
6. If no vacuum is felt, clean PCV valve or replace.
PCV valve inspection:
1. Insert a thin rod into PCV valve from EM096

the side shown in the figure (installation Positive crankcase ventilation valve
side of rocker arm cover), and move this

rod back and forth to make sure the
plunger is moving.
2. If plunger is stationary, it indicates
internal clogging of PCV valve. In such
a case, clean or replace this valve.
Engine Assembly Removal and Installation

Precautions:
 Always be careful to work safely before removal, and avoid forceful or
uninstructed operations.
 Do not start working until exhaust system and engine coolant cool down
completely.
 Place blocks at both front and back of rear wheels to choke your vehicle.
 When removing fore axle, support at fixed positions on the vehicle with lifts.
 When hoisting engine, be careful not to break other spare and accessory parts.
 When lifting engine, install wire ropes onto engine lugs and ensure safety.
 If required items or operations are not included in engine section, please refer to
related sections of this manual.
Removal:
Preparation:
① Release fuel pressure.
② Drain engine coolant in radiator.
③ Drain engine oil, transmission oil, and clutch oil.
④ Reclaim refrigerant in refrigeration piping.
⑤ Drain power steering fluid in reservoir tank.
Caution:
 Do not perform this step until engine cools.
 Please do not spill engine coolant on drive belts.
EM-53
⑥ Remove the following related parts from periphery of engine assembly:

 Engine hood
 Air duct and air cleaner assembly
 Battery and its tray
 Engine coolant expansion tank
 Power steering fluid reservoir tank
 Radiator assembly and radiator fan assembly
 Front wheel and tire
 Front bumper fascia and front bumper
 Front condenser
⑦ Disconnect ECM side engine room harness connectors.
Caution:
 Be sure to keep harness connectors clean and avoid damage and entry of foreign
material. Please cover them completely with plastic bags or similar objects.
⑧ Remove the following hoses and pipes around engine body.
 Heater hose
 Vacuum hose on intake manifold
 Fuel evaporator hose
 Fuel feed hose connector
 Engine side brake booster vacuum hose
 Pressure hose and suction hose on oil tank side power steering oil pump
 High and low pressure pipes on A/C compressor
 Accelerator cable
 Gear select and shift cables (move them aside)
 Exhaust manifold front section
 Engine support beam
⑨ Disconnect sensor harness connectors connected to engine block, and set harness
aside.
⑩ Remove shift cable and clutch hydraulic fluid pipes connected to transmission.
EM-54
Removal work:
① Install hangers onto engine lifting EM097

hooks.
② Lift engine and secure it in position.
③ Use a manual lift table caddy or
equivalent tool to securely support
bottom of engine and transmission
assembly, and simultaneously adjust
hoist tension.
Caution:
 A cushion can be placed on support surface to secure a completely stable
condition.
 To ensure safety, install wire ropes of lifter onto engine lugs before performing
this step.
④ Separate left and right engine front and rear mountings.
⑤ Use a special hoist to lift engine and transmission assembly from under chassis.
⑥ Lower engine and transmission assembly carefully. Please note the following
when performing this step:
 Confirm there is no interference with the vehicle.
 Make sure that all connection points have been disconnected.
 Keep in mind the center of vehicle gravity changes. If necessary, please use jack
(s) to support the vehicle at rear lifting point (s) to prevent it from falling off the
lift.
Separation work:
① Remove power steering pump assembly, A/C compressor assembly and generator
assembly from engine and transmission assembly.
② Remove starter.
③ Lift with transmission jack(s) and separate engine and transmission.
Caution:
 Before and during this lifting, always make sure that any harnesses are left
connected.
 Torque for bolts connecting transmission with engine: 50~55N·m
Installation:
 Please do not damage engine mounting cushion and avoid engine oil getting on it.
 When assembling transmission and engine assembly, use a central spindle as
positioning aid at clutch installation.
EM-55
 Make sure all engine mounting insulators are seated properly, and then tighten
nuts and bolts as required.
① Before starting engine, please check levels of engine coolant and engine oil. If
less than required quantity, please fill to the specified level.
② Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to
fuel piping, check for fuel leakage at connection points.
③ Start engine. With engine speed increased, check again for fuel leakage at
connection points.
④ Run engine to check for unusual noise and vibration.
⑤ Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust
gases, or any other oil/fluid including engine coolant, engine oil and power
steering fluid.
⑥ Shut down engine, and recheck oil/fluid levels including engine oil and engine
coolant after engine cools down. Please refill to the specified level, if necessary.
⑦ See the following table for summary of inspection items:
Table of Leak Check Items
Before starting Engine After engine

Item
engine running stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Transmission oil, brake fluid, power

Level Leakage Level
steering fluid, clutch fluid
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —
Trouble Diagnosis
Hard engine start:
Symptom and cause Troubleshooting
1. Connection point of battery terminal

Tighten or charge.
loose or battery low
Starter does not rotate.
2. Circuit open Check and repair.
3. Starter damaged Repair or replace.
1. Ignition timing incorrect Adjust.

Spark plug does not ignite.
2. Ignition coil damaged Replace.
EM-56
3. Bad grounding Repair.
4. Spark plug gap improper or spark

Adjust or replace.
plug burned out
5. Electronic ignition system

Repair or replace.
malfunction
1. Fuel supply from gasoline pump

Repair or replace.
insufficient
Fuel supply system is
malfunctioning.
2. Gasoline hose and gasoline filter
Clear.
clogged
1. Cylinder fracture Replace.
2. Valve clearance improperly adjusted Adjust, repair or

or valve damaged replace.
Cylinder compression pressure
decreases.
3. Intake manifold loose causing air
Tighten.
inflow
4. Piston, piston ring or cylinder worn Repair or replace.
Underpower during running:
Accelerator pedal and throttle

Adjust.
body improperly adjusted
1. Check valve, spark plug and

Cylinder compression pressure cylinder head gasket for leakage.
decrease
2. Grind cylinder.
Ignition timing inaccurate Adjust.

Underpower occurs
during running. Gasoline supply shortage Adjust or repair.
Air intake shortage Check intake system.
Check exhaust system and clear

Exhaust clogged
carbon deposit.
Spark plug gap improper or

Adjust or replace.
spark plug damaged
EM-57
Piston knock from inside of engine:
Bearing shell, camshaft cam and rocker arm

Replace.
worn
Crankshaft, connecting rod journal and Replace or

piston pin seriously worn repair.
Piston knock from inside of
engine is heard.
Piston ring damaged Replace.
Valve clearance improper Adjust.
Thrust clearance of crankshaft too large Adjust.
Engine overheat:
Ignition timing incorrect Adjust.
Spark plug gap improper or carbon deposit Clear or adjust.
Intake manifold loose or exhaust manifold clogged Tighten or clear.
Fan belt tension insufficient Adjust.

Engine overheat
Coolant shortage or water pipe clogged Refill or clear.
Water pump clearance improper or water pump damaged Repair or replace.
Oil shortage Refill.
Oil circuit clogged or oil pump damaged Clear or replace.
Cylinder head gasket damaged Replace.
Engine overheat Clutch slip Repair or replace.
Radiator clogged by scales Clear or replace.
Excessive oil consumption:
Valve guide oil seal worn or damaged Replace.
Oil consumption is Oil ring worn or damaged Replace.

excessive.
Gaps of piston rings not staggered as
Adjust.
required
EM-58
Cylinder head gasket damaged Replace.
Valve or valve guide worn Replace.
Part of lubricant discharged from vents due

Check related components
to engine overheat and internal pressure
and clear the trouble.
increase
Service Data and Specifications

Engine Service Data Sheet
Item Standard value Limit value
Camshaft
Intake 35.373 34.87

Camshaft height mm
Exhaust 34.908 34.41
Camshaft journal mm Φ26 —
Cylinder head and valves
Cylinder head gasket surface (cylinder head lower plane)

<0.03 0.1
flatness mm
Total height of cylinder head mm 131.9~132.1 —
Intake valve 1.5±0.15 1.0

Valve margin thickness
mm
Exhaust valve 1.7±0.15 1.2
Valve stem diameter mm φ6 —
Intake 0.020~0.047 0.10

Valve stem to guide
clearance mm
Exhaust 0.035~0.062 0.15
Valve taper 45°~45.5° —
Intake valve 46.69 47.04

Valve stem projection
mm
Exhaust valve 46.67 47.02
Camshaft
Intake valve 104.19 103.69

Total length of valve mm
Exhaust valve 103.87 103.37
Free height of valve spring mm 45.0 44.50
Valve spring load/installation height N/mm 257/37.5 —
EM-59
676/27.8 —
Valve spring squareness <2° 4o
Contact width of valve seat mm 0.9~1.3 —
Inner diameter of valve guide mm φ6 —
Valve guide projection mm 19.0 —
Increased by 0.05 φ11.05~11.068 —

Valve guide hole diameter with
Increased by 0.25 φ11.25~11.268 —
oversized cylinder head mm
Increased by 0.50 φ11.50~11.518 —
Increased by 0.3 φ34.3~34.325 —

Intake
Increased by 0.6 φ34.6~34.625 —
Diameter of oversized
valve seat ring hole mm
Increased by 0.3 φ30.8~30.825 —
Exhaust
Increased by 0.6 φ31.1~31.125 —
Oil pump and oil pan
Oil pump gear tip clearance mm 0.06~0.18 —
Oil pump gear backlash mm 0.04~0.095 —
Oil pump gear to body clearance mm 0.10-0.181 0.35
Piston and connecting rod
Basic major diameter of piston mm 81.0 —
Top ring 0.03~0.07 0.1

Piston ring side clearance
mm
Second ring 0.02~0.06 0.1
Top ring 0.25~0.40 0.8
Second ring 0.40~0.55 0.8

Piston ring end gap mm
1.0
Oil ring 0.10~0.35
Piston pin outer diameter mm 19.0 —
Press-in load of piston pin (at room temperature) N 4900~9800 —
EM-60
Crank pin clearance (connecting rod journal clearance) mm 0.015~0.048 0.1
Connecting rod big end side clearance mm 0.10~0.25 0.4
Crankshaft and cylinder block
Crankshaft end play mm 0.05~0.18 0.25
Crankshaft main journal diameter mm 50.0 —
Connecting rod journal diameter mm 48.0 —
Crankshaft main journal clearance mm 0.015~0.048 0.1
Cylinder head gasket surface flatness mm <0.03 0.1
Total height of cylinder block mm 263.5 —
Cylinder block cylindricity mm 0.01 —
Basic minor diameter of cylinder block mm 81.0
Piston to cylinder clearance mm 0.02~0.04 —
Tightening Torque Specification Table
Item Unit (N·m)
Engine assembly
Bolt securing engine right mounting 80±5
Engine right mounting bracket nut 60±5
Bolt connecting engine with

43~55
transmission
Engine cover 8~12
Bolt securing accelerator cable and

15~22
throttle body
Alternator and ignition system
Alternator kingpin bolt 34~54
Oil level gauge guide bolt 12~15
Spark plug 19.6~29.4
EM-61
Item Unit (N·m)
Generator support assembly 45~55 (front) 21~25 (left)
Generator adjusting nut 20~25
Generator adjusting bolt 4~6
Ignition coil mounting bolt 8~12
Camshaft position sensor bolt 7.8~9.8
Camshaft position sensor bracket bolt 10~12
Camshaft position sensor toothed plate

17~26
bolt
Timing belt
Rear timing belt casing 10~12
Tensioner arm 42.2~53.9
Sheave 42.2~53.9
Idler pulley 29.4~41.2
Engine right support assembly 44~54
Outer timing belt casing 10~12
Crankshaft pulley assembly 49±2N·m+

60 04 Outside the plant: 165
Automatic tensioner arm assembly 11.8~14.7
Camshaft timing gear 78.5~98.1
Ignition coil and spark plug
Spark plug cover mounting bolt 2~3
Ignition coil mounting bolt 10~13
Spark plug 21~25
Water pump and water pipe
Water inlet pipe connector 17~20
Water pipe assembly 12~15
Coolant temperature sensor 19.6~39.2
Thermostat housing bolt 22~25
EM-62
Item Unit (N·m)
Water pump bolt 20~26
Water outlet pipe connector 12~15
Drain plug 35~45
Intake manifold and exhaust manifold
Intake manifold stay bolt 27~34
Intake manifold bolt 17~22
Exhaust manifold stay bolt (M10) 27~34
Exhaust manifold stay bolt (M8) 17~22
Exhaust manifold mounting nut 14.7~32.3 (both sides 26.5~32.3)
Exhaust shroud bolt 26.5~32.3
Engine lug 15~22
Engine right lug 15~22
Rocker arm, rocker arm shaft and camshaft
Rocker arm chamber casing mounting

3~4
bolt
Middle cover assembly 2.5~3.5
180 04
①20±2N·m②+ ③ loosen ④20±2
Cylinder head bolt 4
N·m⑤+
90 0 ⑥+ 90 40
Oil pump and oil pan
Oil seal housing 9.8~11.7
Oil pan assembly (M6) 6~12
Oil pan (lower half) (M6) 10~12
Strainer 15~22
Oil filter assembly 12~16
Drain plug 34~44
Connecting rod
Connecting rod nut 20±2.0+90°~94°
EM-63
Item Unit (N·m)
Crankshaft and cylinder block
Upper baffle plate 10~12
Flywheel 30±2+
50 20 Outside the plant: 93~103
EM-64
B-Class MPV Service Manual LU Lubrication System
LU Lubrication System
Precautions
 When draining engine oil, please note that the work can not be performed until
the engine cools down.
 Procedure and precautions for clearing LU001

and application of liquid gasket:
Scraper
Refer to “Removal of sealant” in page EM-2.
 If sealant has stains, please clean them
off immediately.
 Please do not retighten bolts or nuts after
the installation.
 After 30 minutes or more have passed
from the installation, refill engine oil and
engine coolant.
Preparation
Service tools:
List of Service Tools
SN Tool Outline drawing Description
1 Oil pressure gauge Measuring oil pressure
Adapting oil pressure gauge to

2 Hose
cylinder block
Oil pressure switch Removing and installing oil pressure

3
socket switch
LU-1
Essential service material:

Lubricant
Item Recommended lubricant Quantity (including lubricant in oil filter)
Engine oil (API grade) 15W-40 SJ grade or above 3.5L
Engine Oil
Engine oil level: LU002

Note:
Before starting engine, park vehicle
horizontally and firmly and check the engine
oil level. If engine is already started, stop it
and wait 10 minutes before checking.
1. Pull out oil level gauge and wipe off
engine oil on it with a clean rag.
2. Insert oil level gauge fully back to its
tube. Upper limit mark
3. Pull out oil level gauge again to check Lower limit mark
the oil level and make sure the level is
within the range shown in the figure at
top right.
4. If the oil level is below “MIN” scale, refill with designated engine oil.
5. Start engine and stop it after idling it for 5 minutes, and then wait a moment
before checking if the engine oil level is within the specified range.
Engine oil appearance:
 Check engine oil for white turbidity or heavy contamination.
 If engine oil becomes turbid and white, it is highly probable that it is
contaminated with engine coolant. Repair or replace damaged parts.
Engine oil leak check:
Check for engine oil leakage around the following areas:
 Oil pan
 Oil pan drain bolt
 Oil pressure switch
 Oil filter
 Mating surface between cylinder block and cylinder head
 Crankshaft oil seals (front and rear)
LU-2
 Mating surface between cylinder head and rocker arm cover

 Front camshaft oil seal
Oil pressure check:
Caution: LU003
 Be careful not to burn yourself, as engine
oil may be hot.
 Oil pressure check should be done in
“PARK position”.
① Check engine oil level.
② Remove air cleaner assembly.
③ Disconnect harness connector at oil pressure switch, and remove the switch.
Position:
Oil pressure switch is located behind cylinder head and close to underside of camshaft
position sensor.
④ Install oil pressure gauge and hose.
⑤ Start the engine and warm it up to normal operating temperature.
⑥ Record oil pressure readings with engine running at idle speed and 2000r/min.
 Engine oil pressure: 150KPa (at 750r/min); 490~590 KPa (at 2000r/min)
Note:
 When the engine oil temperature is low, the engine oil pressure becomes high. If
difference is extreme, check engine oil passage and oil pump for engine oil leaks.
⑦ After the inspections, install oil pressure switch as follows:
 Remove old sealant adhering to oil pressure switch and engine.
 Apply sealant and tighten pressure switch as required.
 Please use designated sealant: LT5699 or its equivalent.
 Wipe engine oil spill.
Note:
 After oil pressure switch is installed, do not start the engine within 1 hour.
⑧ After warming up engine, make sure there is no leakage of engine oil with
running engine.
LU-3
Changing engine oil:

Warning:
 Be careful not to burn yourself, as engine oil may be hot.
 Avoid prolonged direct skin contact with used engine oil. If skin contact is made,
wash thoroughly with soap or cleanser as soon as possible.
1. Start engine and warm it up until coolant temperature reaches 80~90℃.
2. Remove oil filler cap.

3. Remove drain plug, and drain engine
Drain plug gasket
oil. Oil pan side
4. After draining engine oil, install drain

plug.
 When installing drain plug gasket, leave
it facing the direction shown in the
figure.
5. Refill with new engine oil.
 Designated engine oil: 15W-40 (API grade)

Service refill capacity of engine oil of SJ grade or above: 3.5L (including engine oil in
oil filter)
6. Warm up the engine and check area around drain plug and oil filter for engine oil
leakage.
7. Stop the engine and wait for 10 minutes.
8. Check the engine oil level.
Oil Filter
Removal:
1. Remove engine oil filler cap, then remove drain plug and drain engine oil.
2. Using oil filter wrench, remove oil filter.
LU-4
Caution: LU005
 When replacing oil filter, use the oil
filter provided for original JAC cars
or equivalent.
 Be careful not to get burned when
engine and engine oil may be hot.
 When removing, prepare a shop cloth to absorb any engine oil leakage or
spillage.
 Please do not allow engine oil to adhere to drive belts.
 Completely wipe off any engine oil that spills onto engine and vehicle.
Installation:
1. Remove foreign materials adhering to oil filter installation surface.
2. Apply a layer of just enough engine oil to the oil seal surface of new oil filter.
3. Tighten oil filter manually until its LU006

O-ring touches the installation surface,
then tighten it by another 2/3 turn or
tighten to the specification.
4. Fill with engine oil.
5. Idle engine for 2~3 minutes, and then
check installation position of oil filter
for engine oil leakage. O-ring

2. Start the engine, and check there is no
leak of engine oil. 2/3 turn

4. Check the engine oil level, and fill with
engine oil.
LU-5
Oil Pump
Components:
Exploded View of Cylinder Block

1-Cylinder block subassembly 2-Oil pan assembly (lower half) 3-Oil pan assembly 4-Cover
5-Strainer 6-Strainer gasket 7-Oil pressure sensor 8-Oil pump assembly 9-O-ring 10-Oil filter
Removal:
1. Remove eccentric tensioner, and take off LU008

drive belt.
2. Turn engine until No. 1 cylinder piston
is at its top dead center (TDC), and
remove camshaft timing belt.
3. Open engine oil filler cap, and loosen
drain bolt on oil pan to drain engine oil.
4. Remove oil pan and oil strainer.
5. Remove mounting bolts on oil pump
assembly, and take out the assembly.
LU-6
Disassembly: LU009
1. Remove mounting bolts on oil pump
housing, and remove oil pump cover.
2. Remove oil pump drive gear and driven gear
from oil pump body.
Inspection after disassembly: LU010

1. Check all oil holes on oil pump housing
for clogging. When necessary, clean
them.
2. Check oil pump housing for cracks and
other damage. If any, replace.
3. Check oil seal for wear, damage or
aging. If any, replace.
4. Install oil pump gear in oil pump and
turn the gear in close fit condition to see LU011
if it rotates smartly. Check the junction
surface between oil pump body and gear
surface on oil pump cover for wear
groove.
5. Install oil pump drive gear and driven
gear in oil pump housing, and measure
gear tip clearance between drive and
driven gears.
Standard value: 0.06~0.18mm LU012
6. Measure clearance between oil pump
driven gear and oil pump housing with a
feeler gauge.
Standard value: 0.100~0.181mm
Limit value: 0.35mm
7. Using straightedge and feeler gauge, check side clearances between oil pump
drive and driven gears and oil pump housing. The measurements must conform
to the standard value.
LU-7
Installation:
Please install in the reverse order of removal.
2. Start the engine, and check there is no leak of engine oil.
4. Check the engine oil level, and fill with engine oil.
Specification Table of Lubrication System
Engine oil
Grade 15W-40 (API grade) SJ or above engine oil
Without oil filter change 3.0L

Capacity
With oil filter change 3.5L
Oil pump
Oil pump body to driven gear clearance 0.100-0.181mm 0.35mm
Drive gear to driven gear tip clearance 0.06-0.18mm
Oil pump body to drive gear and driven gear side clearances 0.04-0.095mm
Oil pressure
Oil pressure at idle speed (750r/min): 150 KPa
Oil pressure at medium speed (2000r/min): 490~590 KPa
LU-8
B-Class MPV Service Manual CO Cooling System
CO Cooling System
Precautions
Precautions for drain engine coolant and engine oil:
Drain engine coolant after the engine is cooled.
Precautions for liquid gasket:
Removal of liquid gasket:
1. After removing mounting nuts and bolts, separate the mating surface using the
seal cutter and remove old liquid gasket.
Caution:
 Be careful not to damage the mating surfaces.
2. In areas where the seal cutter is difficult to use, please use a plastic hammer to
lightly tap the parts to remove it.
Caution:
 If for some unavoidable reason tool such as a flat screwdriver is used, please be
careful not to damage the mating surfaces.
Liquid gasket application procedure:
Refer to “Removal of sealant” in page EM-2. CO001

Caution: Scraper
 If there is a groove for liquid gasket
application, apply sealant to the groove.
 Within 5 minutes of liquid gasket
application, install the mating
component.
 If liquid gasket has stains, please clean them immediately.

 Please do not retighten bolts or nuts after the installation.
 As for bolt holes, normally apply sealant inside them and occasionally outside
them.
 After 30 minutes or more have passed from the installation, fill engine coolant.
CO-1
Preparation
Service tools:
List of Service Tools
Tool Name Purpose
Radiator cap tester Checking radiator cap and radiator
Essential service material:

Coolant:
Item Quantity Concentration %
High quality ethylene glycol antifreeze coolant 6~6.5L 25~50
Sealant:
Item Designated sealant Remark
Water bypass pipe joint LT648 or equivalent Semi-dry sealant
CO-2
Cooling System Circuit

1. Cooling circuit diagram
Radiator water outlet pipe
Thermostat
Water pump
This loop is closed during
major cycle
Radiator
Heat exchanger
Fan
Engine water jacket

of heater unit
The water temperature control

thermostat here starts to open at
82℃ to enter major cycle and
closes below this temperature to
enter minor cycle.
Rubber Minor cycle
coolant hose
Expansion tank
Radiator water inlet pipe
Cooling System Circuit Diagram
2. Cooling diagram
Radiator
Expansion
tank
Thermostat
Thermostat
housing
Heat exchanger of
Throttle body
heater
Water pump
Cylinder block
Thermostat open
Thermostat close
Cylinder head
Cooling Diagram
CO-3
Engine Coolant
Inspection:
1. Level check: CO002

 Check if the reservoir tank engine
coolant level is within the “MIN” to
“MAX” after the engine cools down.
 Adjust the engine coolant level as
necessary.
2. Leak check: CO003

To check for leaks, apply pressure to the
cooling system with the radiator cap tester.
Warning:
 Please do not remove radiator cap when
engine is hot. Otherwise serious burns
could occur from high-pressure engine
coolant escaping from radiator.
Caution:
 Higher test pressure than specified may cause radiator damage.
 In a case that engine coolant decreases, replenish radiator with engine coolant.
 If any part is found damaged, repair or replace.
Changing coolant:
Caution:
 To avoid being scalded, please do not CO004

change engine coolant when the engine
is hot.
 Wrap a thick cloth around radiator cap
and carefully remove the cap. First, turn
radiator cap a quarter of a turn to release
built-up pressure in radiator. Then turn
radiator cap all the way.
 Hybrid use of coolants of different
brands is not allowed.
 Be careful not to spill engine coolant on
drive belts.
CO-4
Draining engine coolant:

1) Remove radiator cap.
2) Remove radiator drain valve (from lower left part of radiator), and drain coolant
in radiator and engine water jacket.
3) Remove expansion tank and drain CO005

coolant in it completely.
4) Check drained engine coolant for
contaminants such as rust, corrosion or
discoloration. If contaminated, please
flush the engine cooling system.
Flushing cooling system:

① Install reservoir tank and radiator drain plug if removed.
Caution:
 Be sure to clean drain plug and install with new O-ring.
 If water drain plugs on cylinder block are removed, please install and tighten
them.
② Remove air duct component.
③ Disconnect heater hose.
 Raise heater hose as high as possible.
④ Fill radiator and reservoir tank with water, and install radiator cap.
 Disconnect when engine coolant overflows heater hose, and then reconnect heater
hose and continue filling engine coolant.
⑤ Install air duct component.
⑥ Run engine and warm it up to normal operating temperature.
⑦ Rev engine 2 or 3 times under no-load.
⑧ Stop engine and wait until it cools down.
⑨ Drain water from the system.
⑩ Repeat steps 1~9 until clear water begins to drain from radiator.
Refilling with new engine coolant:
1) Tighten radiator drain valve firmly.
2) Fill radiator with new coolant slowly until full. Wait until radiator is filled with
CO-5
coolant, and then install radiator cap.

 Recommended coolant:
High quality ethylene glycol antifreeze coolant (quantity: 6~6.5L).
3) Fill expansion tank with new coolant until liquid level reaches line “MAX”
(full).
4) Install expansion tank cap.
5) Start engine and warm it up to thermostat opening temperature.
6) After thermostat opening, run engine at high speed for several times and then
stop.
7) Wait until engine cools, and then fill expansion tank with engine coolant until
“MAX” line.
Caution:
 When changing with new coolant, air lock may occur due to incomplete air
bleeding of the cooling system, resulting in engine overheating caused by poor
cooling cycle. (This can be judged by checking if temperatures of water inlet and
outlet pipes of radiator rise at bottom of engine.) The way to eliminate air lock:
Run the engine at 3000r/min for 5~10 minutes until air in lines are bled.
 Loosen water drain plug on engine block. When a thorough antifreeze change is
required, drain coolant and flush.
Radiator
Precautions:
 Please do not remove radiator cap when engine is hot. Otherwise burns could
occur from engine coolant.
 Wrap a thick cloth around radiator cap and slowly turn this cap to release air
pressure inside. Wait until pressure is completely released, then screw off radiator
cap and take it off carefully.
 Do not perform this step until engine CO006

cools.
 Please do not spill engine coolant on
drive belts.
 Be careful when removing. Please do not
damage or scratch radiator core.
Removal:
1. Remove radiator cap.
CO-6
2. Loosen radiator drain valve (from lower CO007

left part of radiator), and drain coolant
in radiator and engine water jacket.
3. Move clamp away, and disconnect water
inlet and outlet pipes of radiator and
hose of expansion tank.
4. Remove cooling fan connector.

5. Remove bolts securing radiator to cross member.
6. Remove bolts securing A/C condenser to radiator assembly.
7. Take off radiator and radiator cooling fan component.
Caution:
 When removing, please do not damage or scratch condenser core and radiator
core.
8. Separate cooling fan from the component, and take out radiator.
Checking radiator cap:
1. Check radiator cap for damage, cracking and aging.
2. Check opening pressure of radiator cap valve.
1) Using radiator cap tester adapter, connect radiator cap to radiator cap tester.
Caution:
 Before testing, make sure radiator cap is

clean. Rust and other outside materials at
sealing part of radiator cap will result in
incorrect indication.
2) Check radiator cap relief pressure. Weaken
Increase pressure until pressure gauge
pointer stops moving.
Standard value: 74~102Kpa Weaken
Limit value: 64Kpa
CO-7
 Connect radiator cap to the radiator cap CO009

tester, and please apply engine coolant to
the cap seal surface.
 If the reading can not stabilize for
approx. 10 seconds, replace radiator cap.
Checking radiator:
Check radiator for mud or clogging. If necessary, clean radiator surface as follows.
 Be careful not to bend or damage radiator core.
 Tape harness and electrical connectors to prevent water from entering.
1) Apply water by hose to flush the back side of the radiator core vertically
downward.
2) Apply water to flush all radiator core surfaces once per minute.
3) Stop washing if any dirt no longer flows out from radiator.
4) Blow compressed air into the back side of radiator core vertically downward.
 Use compressed air lower than 490 kPa and keep distance more than 30cm.
5) Blow compressed air into all the radiator core surfaces once per minute until no
water sprays out.
Installation:
Installation is the reverse order of removal.
Cooling Fan
Removal:
1. Drain engine coolant from radiator.
Caution:
 Do not perform this step until engine CO010

cools.
drive belts.
2. Disconnect radiator side radiator hose
(upper).
CO-8
3. Disconnect harness connector from fan motor, and move harness aside.
4. Remove 4 bolts securing radiator cooling fan cowl. Remove cooling fan
component from radiator assembly.
Caution:
 When disassembling, please do not damage or scratch radiator core.
 Dynamic balance settings have been made to fan assembly. Never remove motor
or fan separately without permission during maintenance. It is recommended that
fan and motor be replaced together.
1) Check cooling fan for cracks or unusual bend. If anything is found, please
replace cooling fan.
2) Power on motor terminals, and check fan motor rotation.
3) Check for abnormal noise with motor running.
Installation:
Install in the reverse order of removal.
Water Pump
Caution:
 When removing water pump, be careful not to get engine coolant on drive belts.
 Water pump cannot be disassembled and should be replaced as a unit.
 After installing water pump, connect hose and secure with clamp, then check for
leaks using the radiator cap tester
Removal: CO011
1) Drain coolant from radiator and engine

block.
2) Unscrew tensioner nut, and take out
power steering pump and compressor
drive belt and generator belt.
3) Remove components such as power
steering pump, A/C compressor,
generator, tensioner, and engine right
support in turn.
4) Remove timing belt cover.
CO-9
5) Unscrew timing belt automatic tensioner

nut, and take out timing belt.
Camshaft
6) Remove bolts securing water pump, and timing gear
take out water pump pulley and water
pump. Sheave
Idler
Automatic
tensioner arm
Water pump
pulley
Crankshaft
timing gear
Inspection after removal: CO013

1. Check water pump assembly for rust.
2. Check water pump for damages such as
cracks and wear. If necessary, replace
water pump.
3. Check for excessive play which will
result in malfunction.
4. Check water pump bearing for seizure or damage and such symptoms as
abnormal sound and slow rotation. When necessary, replace.
5. Check sealing surface for damages such as scratches. When necessary, replace.
6. Check for engine coolant leakage. If any, replace water pump.
Installation:
Water Inlet and Thermostat Assembly
CO-10
Removal: CO014
1. Drain engine coolant from drain plug at
the bottom of radiator.
Caution:
 Do not perform this step until engine
cools.
drive belts.
2. Loosen clamp, and remove thermostat

housing side radiator water inlet and Water inlet and thermostat
outlet pipes and minor cycle water pipe. assembly
3. Disconnect harness connectors of

coolant temperature sensor and coolant
temperature warning switch and bolts
securing mounts of harness connectors
of front and rear oxygen sensors, and
move them away.
4. Remove bolts securing water inlet and
thermostat housing, and take off the
housing.
Caution:
 Please do not disassemble water inlet and thermostat assembly. Please replace
them as a unit, if necessary.
5. Remove bolt securing thermostat upper cover, and take out thermostat.
Inspection after removal: CO016

1. As shown in the figure at right, immerse
thermostat in water, and heat water
while stirring.
Check opening and full open temperatures of
thermostat valve.
CO-11
Thermostat Opening Specification Table
Thermostat Standard value
Valve opening temperature 82℃
Valve full open temperature 95℃
Valve lift 8.5mm above
2. Measure valve height at full close and

then that at full open, thus determining
lift.
 Replace thermostat even if it only opens
a little at normal temperature.
 If any serious deflection, visible damage
or crack is found, replace thermostat. Valve lift
 If rust stain or dirt is found, clear.
Installation:
Caution:
 Be careful not to spill engine coolant
over engine. Use rag to absorb engine Thermostat
coolant. Puppet valve
 Never apply engine oil to thermostat

rubber ring.
Rubber band
 Install thermostat with puppet valve
upward. In addition, be careful not to
fold or damage rubber band.

1. Check for leaks of engine coolant using the radiator cap tester.
2. Start and warm up the engine to operating temperature. Visually check for engine
coolant leakage.
Water Outlet and Water Piping
Removal:
1. Drain engine coolant from drain plug at the bottom of radiator.
CO-12
Caution: CO019
Do not perform this step until engine cools.
drive belts.
2. Loosen clamp, and remove water inlet
and outlet hoses of radiator.
3. Remove radiator to reservoir tank
cooling water hose.
4. Remove joints of water outlet, heater Water outlet connector
pipe and water pipe.
Check cooling water hose for cracks, damage 30mm
or aging. When necessary, replace.
Installation:
Please note the following and install in the
reverse order of removal.
 Securely insert each hose, and install clamp at a position other than water pipe
bulge.
Trouble Diagnosis
Cooing System Troubleshooting Chart
System Symptom Check item
Water pump
Worn or too loose drive belt
malfunction
Thermostat stuck
Replacement
closed
Poor heat
transfer Dust or clogging
Damaged fins
Mechanical damage
Cooling system
parts malfunction
Excess foreign material (erosion,
Clogged radiator
dirt, sand, etc.)
Cooling fan does

not operate.
Reduced air
Fan assembly
flow Too high
resistance to fan
rotation
CO-13
Damaged fan
blades
Damaged
— —
shroud
Improper
coolant mixture — —
ratio
Poor engine
— Engine coolant density
coolant quality
Loose clamp
Coolant hose
Cracked hose
Water Pump Poor sealing
Loose
Radiator cap
Poor sealing
Engine coolant O-ring for

leaks damage, aging or
improper fitting
Insufficient
engine coolant Radiator Cracked
expansion tank
Cracked radiator
core
Broken reservoir
Reservoir tank
tank
Cylinder head
Exhaust gas aging
Overflowing
leaks into
reservoir tank
cooling system. Cylinder head
gasket aging
High engine rpm

Except cooling under no load
Engine Overload on
system parts Abusive driving
overheating engine
malfunction Driving for
extended time
CO-14
Driving at
extremely high
speed
Powertrain system malfunction
Installed wheels and tires of

improper sizes
Other
Dragging brakes
Improper ignition timing
Blocked bumper Mud contamination or paper

vent clogging
Installed car brassiere

Blocked air Blocked radiator
flow grille Mud contamination or paper
clogging
Blocked
Blocked air flow
condenser

Service Data and Specification Table
Engine coolant capacities
Engine coolant capacity (with reservoir tank at “MAX” level) 6~6.5L
Reservoir tank engine coolant capacity (at “MAX” level) 0.8L
Radiator
Standard 74~102KPa
Radiator cap relief pressure
Limit 64 KPa
Thermostat
Valve opening temperature 82℃
Valve full open temperature 95℃
Valve lift 8.0mm above
CO-15
B-Class MPV Service Manual FL Fuel System
FL Fuel System
Precautions
Warning:
 When replacing or removing fuel system parts, be sure to observe the following.
 Put a “NO BURNING” sign in the operation position.
 Be sure to work in a well ventilated area and furnish operation position with CO2
fire extinguishers.
 Be sure to put drained fuel in a container and put the lid on securely. Keep the
container in safe area.
 When removing fuel line parts, please perform the following procedures:
- Release fuel pressure from the fuel lines.
- Disconnect the battery cable from the negative terminal.
 Please do not twist fuel tubes when they are being installed.
 Please operate at a level place.
 After connecting fuel tube connectors, make sure they are secure. Ensure that
connector and resin tube do not contact any adjacent parts.
 Please do not tighten hose clamps excessively to avoid damaging hoses.
 After installing fuel tubes, please make sure there is no fuel leakage at
connections in the following steps.
- Apply fuel pressure to fuel lines with turning ignition switch “ON” (with engine
stopped). Then check for fuel leaks at connections.
- Start engine and rev it up and check for fuel leaks at connections.
 Please get a vessel and rag ready in advance as fuel may leak.
 Avoid open flame and sparks.
 Please keep removed parts away from any fire source.
 Be sure to keep junctions clean and avoid damage and entry of foreign material.
Please cover them completely with plastic bags or similar articles.
 Use only genuine fuel system spare parts provided by JAC.
FL-1
Preparation
Special tools:
Fuel pressure
1 JAC-T1F018 Measuring fuel pressure
gauge
Lock nut Removing and installing

2 JAC-T1F019
retainer oil pump lock nut
Fuel System Composition
Fuel System Composition Diagram

1-Injector and fuel rail 2-Fuel filter 3-Feed pipe assembly 4-Fuel evaporative emission system
5-Fuel tank 6-Fuel level and sensor unit
Fuel Injector and Fuel Rail

Removal:
FL-2
1) Release fuel pressure from the fuel lines. FL001

① Turn ignition switch to “OFF” position,
and remove battery negative (-).
② Open fuel tank cap.
③ Put a thick rag or towel on test port of
fuel rail, and depress needle valve to
release pressure.
2) Disconnect PCV hose connector on
intake manifold. FL002
3) Disconnect harness connectors of MAP
sensor and fuel injector.
4) Disconnect throttle body side
accelerator cable and cable holder.
5) Disconnect fuel hose connector on fuel
rail.
 When taking out, use a rag to absorb fuel
leaking from fuel tube.
FL003
6) Remove 2 bolts securing fuel rail.
7) Take out fuel injector and fuel rail from
intake manifold side.
1) Fuel injector:
 Check upper and lower seal rings of fuel
injector for cracks, aging and breakage.
If any, please replace.
FL004
 Check fuel injector nozzle opening for
clogging. If any, please use special
equipment to clean or replace.
2) Fuel rail:
 Check fuel test port for damage or seizure. If any, please replace.
 Check interior of fuel rail for residue. If any, please clean.
 Check fuel rail for cracks and deformation.
Installation:
FL-3
1) When installing new O-rings to fuel injector, please pay attention to the
following:
 Upper and lower O-rings are different. Please do not confuse them.
 Lubricate O-ring with gasoline.
 Please do not clean or lubricate O-ring with other solvent.
 When installing an O-ring, please be careful not to scratch it with a tool or
fingernails. Also be careful not to twist or stretch O-ring.
2) Insert fuel injector into fuel rail, and FL005

install clip.
3) Install fuel rail and injector assembly at
inside of intake manifold.
4) Install remaining parts in the reverse
order of removal.

After finishing installation, check for fuel leakage as follows:
1) Turn ignition switch to “ON” position (do not start engine), and check
connections of fuel piping for leakage.
2) Start engine, and recheck connections of fuel system for fuel leakage by
increasing engine speed.
Fuel Filter
Removal:
Caution:
 Fuel filter should be replaced FL006

periodically according to the
maintenance guide in the “Warranty and
Maintenance Manual”.
1) Release fuel pressure from the fuel lines.
Refer to “Releasing fuel pressure in fuel
piping” in page EM-19.
2) Open fuel filler cap to release pressure
in fuel tank.
Caution:
 Wrap fuel filter with a towel or similar article to avoid ejection caused by residual
FL-4
fuel pressure.
3) Hold the sides of connector, push in its tabs and pull out fuel tube.
4) If connector sticks to resin tube, push and pull connector several times until they
start to move. Then pull out connector.
5) Loosen screws securing filter to its fixing bracket.
6) Take off filter assembly from filter fixing bracket.
 Check filter assembly surface for scratch or serious distortion.
 Check screw securing filter for thread FL007

damage.
Installation:
1) Fuel filter
 Pay attention to installation direction of
fuel filter.
2) Connecting connector FL008
Connect fuel feed hose connector as follows:
① Check the connection for foreign
materials or damage.
② Align the connector with resin tube, and then insert the connector straight into
the tube until a click sound is heard.
③ After connecting, make sure that the connection is secure by following method.
 Make sure that 2 tabs are connected to the connector.
After finishing installation, use the following procedure to check for fuel leaks.
1) Turn ignition switch “ON” (with engine stopped) after jacking up the vehicle to a
certain height, and then check fuel filter line connections for leakage.
2) Start engine and run it at idle speed and high speed, and make sure again there
are no fuel leaks at the fuel filter connections.
Fuel Gauge and Sensor Unit
FL-5
Fuel Gauge and Sensor Unit Schematic

1. Fuel level sensor unit 2. Fuel gauge
Removal:
Follow the same way as that for fuel pump removal to take out fuel level sensor unit.
Fuel gauge sensor component inspection:
1) Resistance check:
① Check that the resistance between terminals of fuel gauge sensor is within the
standard value range when float of fuel gauge sensor component is at F (Highest)
and E (Lowest) positions.
Contrast Table of Fuel Gauge Sensor Resistance and Gauge Reading
Graduation line Reference resistance (Ω)
E 244±6
1/8 (RED) 154±5
1/4 124±5
3/8 104±5
1/2 85±4
5/8 71±4
FL-6
Graduation line Reference resistance (Ω)
3/4 58±3
7/8 49±3
F 40±2
② Check that resistance changes smoothly FL009

when the float moves slowly between F Stopper
(Highest) and E (Lowest) positions.
Position F
2) Heights of float of fuel gauge sensor (highest)
component: Move the float, and
measure F (Highest) and E (Lowest) Position E
(lowest)
positions as well as heights A and B Stopper
when the float rod comes into contact

with the stopper.
 Standard values:
A: 2.75mm
B: 158.8mm
Disassembly: FL010
1. Disconnect harness connector.
 Hold connector by fingers and pull it out,
because there is no stopper release tab. Wire color: white
Wire color: black

Harness connector
2. Remove fuel level sensor unit as FL011 Fuel level sensor unit
follows:
① Using suitable tool, pull up tabs points
as shown in the figure to release the
lock.
Caution:
 Be careful not to damage it. Pull up projecting part
Suitable tool
 An example of using Allen wrench
[2.0mm (0.08 in)] is as shown.
FL-7
② After fixing tabs are disengaged, slide FL012

fuel level sensor unit out in direction
shown by the arrow. Pull
Fuel level
sensor unit
Assembly: FL013
1. Check for damage of fuel level sensor
unit installation position on the side of
fuel filter and fuel pump assembly. Wire color: white
2. Slide fuel level sensor unit until it aligns

to installation groove, and then insert it Wire color: black
until it stops. Harness connector
 Insert until a “click” sound is heard and

engagement is felt.
 After inserting, apply force in reverse direction (removal direction) to ensure it

cannot be pulled out.
3. Connect harness connector.
 Connect harness connector as shown in the figure.
 Securely insert harness connector until it stops.
Installation:
Install in the same way as that for fuel pump installation.
FL-8
Fuel Tank
Components:
The fuel tank system consists of such important components as fuel filler tube, fuel
tank, canister, and fuel pump.
Fuel Tank System Schematic

1-Fuel filler port 2-Fuel tank assembly 3-Fuel tank bracket 1 4-Fuel tank bracket 2
5-Fuel pump assembly 6-Fuel filler tube 7-Fuel filler tube support 8-Canister bracket
9-Canister assembly 10-Fuel filler cap 11-Bracket bolt hoe 12-Fuel feed pipe
Fuel Pump
Fuel Pump Assembly Drawing
Removal:
1) Check fuel level on fuel gauge. If fuel gauge indicates a “FULL” or close to
“FULL” position, drain fuel from fuel tank until the level indicated by fuel gauge
is below “E”.
2) Release fuel pressure from the fuel lines.
3) Open fuel filler cap to release pressure in fuel tank.
FL-9
4) Remove rear seat cushion. FL0141
5) Remove fuel tank service lid.
6) Pry off with a flat screwdriver directly.
7) Disconnect harness connector and fuel

tube connector of fuel pump component.
 Harness connector of fuel pump FL015 Pull
component.
Depress projecting part
 Hold the sides of connector, push in its

tabs and pull out fuel tube.
 If connector sticks to resin tube, push
and pull connector several times until
they start to move. Then pull out
connector.
 Be sure to keep junctions clean and
avoid damage and entry of foreign FL016
material. Please cover them completely
with plastic bags or similar articles.
9) Using special tool, loosen lock nut and
take it off.
10) Remove Y-ring.
FL017
FL-10
11) Take out fuel pump. FL018

Caution:
 When taking it out, tilt fuel pump to
avoid damage to fuel level sensor.
 To avoid contamination with residual
fuel, draw it straight out after wrapping it
with a cloth.

1. Fuel pump:
 Check for breakage and impurities in fuel. If any, please replace or clean.
 Resistance check. Measure resistance between 2 terminals of fuel pump. Its value
should be approx. 2~30Ω.
 Fuel feed pressure check. Connect a 12V power supply and test run in gasoline.
Observe if fuel is output from delivery pipe of fuel pump and check if fuel feed
pressure can be built up.
 Please do not run it for extended time so as to avoid damage to pump core.
2. Y-ring
 Check for starving and breakage.
3. Lock nut
 Check for deformation, cracks, starving, breakage, and mounting thread damage.
4. Fuel level sensor
 Check fuel float for interference and its surface for oxidation.
Installation:
Check for fuel leakage. Refer to “Fuel leak check procedure” in page FL-4.
FL-11
Fuel Evaporative Emission System
Air cleaner
Fuel vapor
Air
Fuel Evaporative System Schematic Diagram

1-Fuel tank 2-EVAP canister 3-EVAP canister solenoid valve 4-Intake manifold
System description:
① The fuel evaporative system is used to reduce hydrocarbons emitted into the
atmosphere from the fuel system. This reduction of hydrocarbons is
accomplished effectively by activated charcoals in the canister.
② The vapor evaporated in the fuel tank is stored temporarily in the canister
through the fuel tank vapor control valve and vapor pipe/hose.
③ The fuel vapor evaporated from the sealed fuel tank is led into the canister which
contains activated carbon and the vapor is stored there when the engine is not
operating or when refueling to the fuel tank.
④ The fuel vapor in the canister is routed into the intake manifold through purge
line when the engine is operating. Canister purge volume control solenoid valve
is controlled by ECM. When the engine operates, the flow rate of vapor
controlled by canister purge volume control solenoid valve is proportionally
regulated as the air flow increases.
⑤ Canister purge volume control solenoid valve also shuts off the vapor purge line
during decelerating and idling.
⑥ Riveted on fuel tank, fuel vapor control valve can prevent excess fuel vapor
emission into canister.
FL-12
Fuel evaporative emission line drawing:
Fuel Evaporative System Line Drawing

1-Canister assembly 2-Hard tube connecting canister with solenoid valve
3-Canister solenoid valve 4-Engine fuel inlet tube
Caution:
 Please do not use soapy water or any type of cleanser while installing vacuum
hose or purge lines.
Component inspection:
1) Canister: FL019
① Canister location:
- The canister is installed on left rear
wheel side member and in front of rear
bumper of the vehicle.
② Canister removal:
Remove 2 bolts securing protective casing of
canister, and take out canister.
③ Vacuum hose removal:

Using thinnose pliers, loosen clamps connecting canister to fuel tank and canister
solenoid valve, and pull off vacuum hose.
2) Canister solenoid valve:
Opening changes of vapor bypass line in canister solenoid valve controls air flow rate.
Canister solenoid valve repeats ON/OFF operations according to signals sent by ECM
and the opening of the valve changes in order to achieve best engine control. The
optimal values stored in ECM depend on different engine conditions. When engine
is running, air flow rate of fuel vapor from canister is regulated with changes of air
draught.
FL-13
① Component description: FL020

Canister solenoid valve uses ON/OFF duty
cycle to control flow rate of fuel vapor
flowing out of canister. Canister solenoid
valve is actuated by ON/OFF duty cycle
signals sent from ECM. The longer the ON
pulse width, the more the fuel vapor that will
flow through the valve.
② Removal:
a. Disconnect canister solenoid valve FL021
vacuum hose.
b. Disconnect canister solenoid valve
harness connector.
c. Take off canister solenoid valve from its
holder.
3) Fuel filler cap:

The fuel filler cap is provided with a vacuum relief valve. When pressure in fuel tank
is high (much fuel vapor), the vacuum relief valve will close to prevent fuel vapor
from emitting into the atmosphere. When pressure in fuel tank is low (negative
pressure), the vacuum relief valve will open to allow outside air to enter fuel tank.
Discharge port vacuum check:
① Disconnect vacuum hose (black stripes) from discharge vacuum tube connector
of throttle body, and connect a hand-operated vacuum pump to the pipe union.
② Start engine, and check that discharge FL022
port vacuum increases with engine Degree of vacuum
speed rise after idling and revving up
engine.
Caution:
 If vacuum changes incorrectly, throttle
body discharge port may be clogged.
Then, clean. Engine speed (r/min)
Trouble Diagnosis
This EFI system does not perform trouble diagnoses to fuel injectors, but does these to
injector drivers. When an injector driver is shorted to battery voltage or overloaded, or
shorted to ground or open, the system will record diagnostic trouble codes (DTCs). At
this time, oxygen sensor closed-loop control and its self-learning precontrol will be
disabled and the last self-learning data will be become valid. After troubleshooting,
DTCs should be cleared.
FL-14
Working pressure: 350 KPa

Fuel injector resistance: 11-16Ω
Operating temperature: -40 ~130℃
The other wires of 4 fuel injectors are connected together. Fuel injector grounding is
controlled by power supply ECU of engine main relay.
Troubleshooting:
 Generally, restricted injection and poor atomization of injector may result due to
long life cycle of engine. Fuel injectors can be cleaned regularly.
 Fuel injector internal coil short or open will also result in injection system
malfunction.
 System circuit short or open.
 Fuel bonding at fuel injector nozzle due to prolonged use of nonconforming fuel
can easily lead to rough idle.
Specification Table of Fuel System
Item Description
Fuel tank capacity 55L
Fuel pump
Working voltage 7~15 V
Rated working voltage 12 V
System pressure 350 KPa
30~200 L/h (Serial products. Select according to maximum

Flow
fuel consumption of engine.)
Range of permissible operating

-30℃~+70℃
temperature
Radio disturbance characteristic Level 2 limit (GB18655-2002)
Fuel injector
Working pressure 350 KPa
Injector resistance 11-16Ω
Operating temperature -40~130℃
FL-15
B-Class MPV Service Manual ACC Accelerator Control System
ACC Accelerator Control System

Accelerator Control Unit
Exploded View of Accelerator Control Unit

1-Accelerator cable 2-Accelerator cable bracket 3-Accelerator pedal
4-Accelerator mounting bolt 5-Accelerator adjusting nut
Removal: ACC001
① Raise accelerator pedal, and disconnect
pedal from cable.
② Remove bolts securing accelerator ACC002

pedal, and take out the pedal from
inside of vehicle.
ACC-1
B-Class MPV Service Manual ACC Accelerator Control System
③ Disconnect accelerator cable from ACC003

throttle body, and loosen cable to adjust
lock nut.
④ Remove bolt securing cable, and
disconnect cable mounting.
⑤ Take off accelerator cable.
Inspection after removal: ACC004

① Accelerator pedal
Check pedal for cracks and movable joint for
good mobility.
② Accelerator cable
Check cable for smooth movement. If not,
please fill with just enough lubricant.
Installation:
 When installing accelerator cable, observe if it is routed without obstruction.
 Check adjusting nut of cable at idle to ensure a pedal free play of 1~2mm.
 Check for unobstructed accelerator pedal operation.

Specification Table of Accelerator Control Unit
Name Technical parameter
Pedal stroke 1~2mm
ACC-2
B-Class MPV Service Manual EC Engine Control System
EC Engine Control System

Precautions
 Be sure to always use a 12V battery as power source.
 Do not attempt to disconnect battery terminals while engine is running.
 Before connecting or disconnecting engine ECU harness connector, be sure to
turn ignition switch OFF and disconnect battery ground terminal.
 Before removing parts, turn ignition switch OFF and then disconnect battery
ground terminal.
 Please do not disassemble engine ECU.
 When checking the EFI system, only use of digital multimeter is allowed.
 During maintenance operation, please use genuine parts. Otherwise normal
operation of the EFI system can not be ensured.
 When performing maintenance operation, please observe the standard service and
diagnostic flows.
 During maintenance, it is forbidden to disassemble and remove EFI system parts.
 During maintenance, it is forbidden to drop electronic components (electronic
control unit, sensor, etc.) to the ground.
 Establish a sense of environmental protection and effectively dispose of the
wastes produced during maintenance.
 Do not remove any component (or its connector) of the EFI system from its
installation position at will so as to avoid accidental damage or entry of such
foreign materials as moisture and oil stain into the connector to affect normal
operation of the EFI system.
 When performing simulation of thermal conditions of a malfunction or other
maintenance operation that may make temperature rise, be careful not to allow
temperature of the electronic control unit (ECU) to exceed 80℃.
 When servicing the fuel system, release pressure in fuel lines as follows before
removing oil pipes: Remove fuel pump relay, and start engine and idle it until it
shuts down automatically. Removal of oil pipes and replacement of fuel filter
should be performed by professional maintenance personnel at a well-ventilated
place.
 Do not energize the fuel pump when removing the electric fuel pump from the
fuel tank so as to avoid producing electric sparks which will cause fire.
 Operation test of the fuel pump is not allowed with the pump dry or in water,
otherwise service life of the pump will be reduced. In addition, never connect
positive (+) and negative (-) of the fuel pump inversely.
 When checking the ignition system, perform spark test only when necessary and
for a duration as short as possible. During inspection, do not open the throttle;
otherwise a large amount of unburned gasoline will enter the exhaust pipe causing
damage to the three way catalyst.
EC-1
 Idle speed adjustment is completely accomplished by the electronic control

system, so no manual regulation is required. The throttle limit adjustment screw
of the throttle body has been adjusted properly by the manufacturer at factory.
Users shall not change its initial position at will.
 When connecting the battery, do not misconnect its positive (+) and negative (-)
so as to avoid damage to electronic components. This system uses negative
ground (minus earth).
 Before on-vehicle welding operation, be sure to remove battery positive and
negative cables and the ECU.
 Do not detect input and output electric signals of parts by piercing wire skins.
Preparation
Service tools:
Tool Number Name Function
Reading/clearing electronic
EFI system control system DTCs,
JAC-T1Z001
diagnostic tester observing data stream, testing
movements of parts, etc.
Ignition timing Checking engine ignition

Purchased
light timing, etc.
Checking characteristic
parameters of EFI system,
Purchased Digital multimeter
such as voltage, current, and
resistance
Checking pressure in intake

Purchased vacuum gauge
manifold
EC-2
Tool Number Name Function
Cylinder pressure Checking pressure in each

Purchased
gauge cylinder
Checking pressure in fuel

system, and judging
Fuel pressure
Purchased operation of fuel pump and
gauge
fuel pressure regulator in the
system
Fuel injector
Cleaning and analyzing fuel
Purchased cleaner and
injectors
analyzer
Engine Control System Overview

System overview:
The engine uses a ME7.9.7-Motronic engine control system.
Generally, an engine control system mainly consists of sensor, microcomputer (ECU)
and actuator. It controls suction air quantity, fuel injection quantity and ignition
advance angle when engine is working. Its basic structure is shown in the figure
below.
Diagnose Diagnose
Sensor ECU Actuator
Engine
Composition of Engine Control System
In the engine control system, as the input part, sensors are used to measure various
physical signals (temperature, pressure, etc.) and then convert these signals into
EC-3
corresponding electric signals. The function of the ECU is to receive the input signals
from sensors, perform computing and processing according to the set procedure, and
then generate corresponding control signals that will be output to the power drive
circuit which drives each actuator to execute different actions to enables the engine to
run in accordance with the set control strategy. At the same time, the fault diagnostic
system of the ECU monitors all components and control functions of the system.
Once a fault is detected and recognized, a DTC will be saved and the “limp home”
function will be called. When the trouble is detected to have been removed, use of
normal value will be resumed.
The most important feature of the ME7.9.7 engine control system is use of the
torque-based control strategy. The purpose of taking torque as main control strategy
is to link large numbers of different control objectives. This is the only way to flexibly
select and integrate various functions into different variants of the ECU according to
models of engines and vehicles.
Structural diagram:
Engine Control System Diagram

1-Canister 2-Canister solenoid valve 3-Throttle body assembly 4-Throttle position sensor
5-Stepper motor 6-Intake air pressure/temperature sensor 7-Fuel injector
8-Camshaft position sensor 9-Ignition coil 10-Front oxygen sensor
EC-4
11-Three way catalytic converter 12-Rear oxygen sensor 13-Engine coolant temperature sensor
14-Crankshaft position sensor 15-Fuel filter 16-Electric fuel pump 17-Fuel tank
18-Diagnostic interface 19-Engine control module
Basic components of the engine electronic control system:
List of Control System Components
Electronic controller (ECU) Throttle
Intake air temperature/pressure sensor Fuel injector
Engine coolant temperature sensor Electronic fuel pump
Throttle position sensor Fuel rail
Camshaft position (phase) sensor Canister control valve
Crankshaft position (speed) sensor Ignition coil
Knock sensor Other
Oxygen sensor
The ME7.9.7 engine control system is an electronically controlled gasoline engine

control system. It provides many control features related to operators and vehicles.
The system provides various control signals for engine running by means of a
combination of open loop and closed loop feedback controls.
Main functions of the system:
1) Basic management functions of an engine using physical model:

 Torque-based system structure
 Cylinder load determined by intake air pressure sensor
 Improved mixture control function in both static and dynamic conditions
 closed loop control
 Cylinder-by-cylinder sequential fuel injection
EC-5
 Ignition timing, including cylinder-by-cylinder knock control

 Emission control functions, including three way catalytic converter (catalyst)
heating, canister control, etc.
 Idle speed control
 Limp home function (fail-safe mode)
2) Additional functions:
 Burglar alarm function
 Connections between torque and external system (e.g. gear train or vehicle
dynamic control)
 Provision of interfaces between matching, programming tools and service tools
3) Online diagnostics (EOBD):
 Fulfillment of a series of EOBD, including three way catalytic converter (TWC)
protection and fire monitoring functions
 Engine condition diagnosis
Control schematic of the engine ECU:
EC-6
Power supply
Ignition Injector 1
5V output 1 Injector 2
5V output 1 Injector 3
Main relay Injector 4
Self-diagnostic K-line Malfunction indication signal
Fuel pump relay

Crankshaft sensor + A/C relay
Crankshaft sensor - Fan 1
Knock sensor A Stepper motor A

Knock sensor B Stepper motor B
Stepper motor C
Stepper motor D
Intake air pressure sensor
Upstream oxygen sensor
Throttle position Oxygen sensor heating
Coolant temperature sensor Oxygen sensor heating
Intake air temperature sensor Canister control valve
Downstream oxygen sensor EGR control valve
A/C pressure/temperature
Acceleration transducer
EGR position
Reserved input Fuel consumption output
Reserved input Speed output
Battery
Fan 2
Camshaft signal Reserved
Vehicle speed Reserved
Electronic load 1 Reserved
A/C switch Reserved
ABS
Electronic load 2
Security code Ignition control 1
Ignition control 2
Oxygen sensor heating
Oxygen sensor heating
Installation position of engine ECU:
Position description:
EC-7
- On left side and under steering wheel EC001
Clutch pedal
Descriptions of Engine ECU pins:
Pin Function Code Pin Function Code
1 NC Q1 33 NC D2
2 Front oxygen sensor heating P1 34 NC C2
3 Ignition coil 1 Q2 35 Stepper motor terminal C B2
4 Rear oxygen sensor heating P2 36 Stepper motor terminal D A2
5 Ignition ground Q3 37 Canister solenoid valve O3
6 NC P3 38 NC N3
7 Ignition coil 2 Q4 39 Sensor ground 1 M3
8 Non-sustainable power source P4 40 Sensor ground 2 L3
9 Engine speed output O1 41 Engine coolant temperature K3
10 A/C pressure switch N1 42 Camshaft position (phase) sensor J3
11 NC M1 43 Electronic ground 1 H3
12 Headlight switch L1 44 A/C switch G3
EC-8
13 NC K1 45 Front oxygen sensor F3
Engine speed (crankshaft position)

14 NC J1 46 E3
sensor terminal B
Engine speed (crankshaft position)

15 Diagnostic K-line H1 47 D3
sensor terminal A
16 UPS G1 48 Power ground 1 C3
17 Ignition switch F1 49 Fuel injector, No. 3 cylinder B3
18 5V power supply 2 E1 50 Fuel injector, No. 1 cylinder A3
19 5V power supply 1 D1 51 Non-sustainable power source O4
Malfunction indicator light

20 C1 52 High-speed fan relay N4
MIL
21 Stepper motor terminal B B1 53 NC M4
22 Stepper motor terminal A A1 54 NC L4
“Service Vehicle Soon”

23 O2 55 NC K4
indicator light SVS
24 Blower switch N2 56 NC J4
25 Intake air temperature sensor M2 57 Vehicle speed signal sensor H4
26 Throttle position sensor L2 58 NC G4
27 NC K2 59 Intake air pressure sensor F4
28 NC J2 60 Fuel pump relay E4
29 Rear oxygen sensor H2 61 A/C compressor relay D4
30 Knock sensor terminal A G2 62 Low-speed fan relay C4
31 Knock sensor terminal B F2 63 Fuel injector, No. 2 cylinder B4
32 Main relay E2 64 Fuel injector, No. 4 cylinder A4
* Specific pin numbers are subject to harnesses schematic. (Null definition means “NC”.)
Engine Control System Components

Intake air pressure/temperature sensor:
EC-9
1) Component position description: EC002

It is mounted on intake manifold as shown in
the figure at right.
2) Component description:
① The sensor is a combination of an intake
manifold absolute pressure (MAP)
sensor and an intake air temperature
(IAT) sensor.
② The MAP sensor is a pressure-sensitive variable resistor. It measures pressure

variations in intake manifold that result in engine load and speed changes and
converts the variations into voltages for output. The MAP sensor is also used to
measure barometric pressure at starting and, under certain conditions, allows
automatic regulation by the ECM at different altitudes. The ECM provides the
MAP sensor with a 5V voltage and receives voltages through signal wire. The
sensor provides a line ground through its variable resistor. Input signals of the
MAP sensor affect the ECM’s control over fuel output and ignition timing.
③ The intake air temperature sensing unit is a negative temperature coefficient
(NTC) thermistor of which the resistance decreases with intake air temperature
rise. This sensor sends a voltage indicating intake air temperature changes to the
controller.
3) Descriptions of component pins: EC003

Pin 1: 40#-ground, sensor
Pin 2: 25#-output, temperature signal
Pin 3: 19#-5V power supply from ECU
Pin 4: 59#-output, intake air pressure signal
4) Symptoms and inspection methods:

 Symptoms: Engine misses, poor idle, etc.
 General sources of trouble: 1. Abnormal high pressure or reverse heavy current
during use; 2. vacuum unit damaged during maintenance.
 Maintenance precautions: During maintenance, it is forbidden to impact vacuum
unit with high pressure gas; when replacing the sensor after a malfunction is
detected, check for normal generator output voltage and current carefully.
 Inspection methods:
① Disconnect harness connector, and check resistance between pins 1 and 2 of the
component.
EC-10
 Rated resistance at 20℃: 2.5kΩ±5%

② Check voltage on pin 4 of the component.
 Approx. 1.3V (at idle)
 At idle, open throttle slowly, the voltage changes little; open throttle rapidly, the
voltage rises to about 4.0V in an instant; close throttle rapidly, the voltage drops
to about 0.8V; finally, the voltage changes to about 1.3V.
 If the voltage is out of range, please check the system for air leaks and clogging.
When necessary, replace the sensor.
5) Removal and installation:
Removal:
① Disconnect intake air pressure/temperature sensor harness connector.
Caution:
 Make sure ignition switch is in OFF position.
② Remove bolt securing intake air pressure/temperature sensor, and take off the
sensor.
 During removal, pay attention to position of seal ring and do not damage or lose
the ring.
Installation:
 Apply a little engine oil to sensor seal ring for easier installation.
 Make sure sensor and intake manifold have fitted perfectly.
 Make sure harness connector is installed securely.
Coolant temperature sensor:
1) Installation position description: EC004

It is mounted on back of engine cylinder
head.
The engine coolant temperature (ECT) sensor is used to detect the engine coolant
temperature. The sensor modifies a voltage signal from the ECU. The modified signal
EC-11
returns to the ECU as the engine coolant temperature measurement input signal. The
sensor uses a NTC thermistor of which the resistance decreases as temperature
increases.

Pin 1: 40#-ground, sensor
Pin 2: 41#-output, temperature signal to ECU
 Symptoms: Hard starting, etc.
 General source of trouble: Human
initiated failure.
 Inspection method:
(With harness connector disconnected), set digital multimeter to OHMs range and
then connect two meter pens to 1# and 2# pins of the sensor respectively. At 20℃, the
rated resistance should be 2.5kΩ±5%. The measurement also can be made by means
of simulation. For example, put work area of the sensor in boiled water (ensure
adequate soak time), and observe resistance changes of the sensor. At this time, the
resistance should drop to 300Ω-400Ω (the specific value depends on temperature of
boiled water).
Removal:
① Remove ECT sensor. Please refer to “Changing engine coolant”.
 Tightening torque: 20N·m
Installation:
Knock sensor:
1) Installation position description: EC006

The knock sensor (KS) is mounted on the
cylinder block portion between No. 2 and No.
3 cylinders of the engine. (See the figure at
right.)
The KS is a kind of vibration acceleration
sensor. It is mounted on engine cylinder
EC-12
block. The sensing element of the sensor is a

piezoelectric crystal. The vibration of engine
cylinder block is transmitted to the
piezoelectric crystal by a mass block in the
sensor. The piezoelectric crystal generates dB
voltages on its two pole faces when subjected
to the pressure caused by vibration of the
mass block, so that vibration signals are
converted into alternating voltage signals for
output. See the figure above for its frequency Frequency
response characteristic curve. The frequency
of the vibration signals caused by engine
knock is much higher than that of normal
vibration signals of engine, so the ECU can
distinguish knock signals from non knock
signals after processing the signals from the
KS.

Pin 1: Connect to 30# of ECU
Pin 2: Connect to 31# of ECU
Pin 3: 3#-connected to shielded wire
 Symptoms: Poor acceleration, etc.

 General sources of trouble: Corrosion to the sensor caused by prolonged contact
with fluids such as engine oil, coolant, brake fluid, and water.
(With harness connector disconnected), set digital multimeter to OHMs range and
then connect two meter pens to 1#, 2# and 1#, 3# pins of the sensor respectively. At
normal temperature, its resistance should be greater than 1MΩ. Set digital multimeter
to MVs range, and tap in the vicinity of the KS with a hand hammer. Then there
should be voltage signal output.
Removal:
① Disconnect knock sensor harness connector.
② Remove knock sensor lock bolt, and take off the sensor.
Caution:
 Do not drop or damage the sensor.
EC-13
Installation:
Caution:
 Tightening torque: 20N·m
 Be careful not to allow the sensor’s prolonged contact with fluids such as engine
oil, coolant, brake fluid, and water.
 Note that use of washers of any type is not allowed during installation. The
sensor must cling to cylinder block through its metal surface.
 When laying signal cables of the sensor, be careful not to resonate the cables in
order to prevent fracture.
 Avoid applying high voltage between 1# and 2# pins when inspecting the sensor,
otherwise piezoelectric element will be damaged.
Throttle position sensor:

It is mounted on throttle body.
The throttle position sensor (TPS) is a rotary
variable resistor. It rotates around throttle
spindle to sense throttle angle. When
throttle spindle rotates, throttle angle of the
TPS will change. The ECM detects throttle
opening according to output signals from the
TPS. EC010
3) Descriptions of component pins:
Pin 1: 39#-ground, ECU
Pin 3: 26#-output signal to ECU

 Symptoms: Poor acceleration, etc.
① Check resistance between pins 1 and 2.
 Resistance: 2kΩ±20% (at normal temperature)
② Check resistance between pins 1 and 3. When throttle is rotated, the resistance
should change linearly in response to throttle opening.
EC-14
③ Check resistance between pins 2 and 3. This resistance should change on the
contrary.
Note: When observing resistance changes, observe for great resistance jump carefully.
④ Check voltage on pin 2.
Note: At this time, turn ignition switch ON without starting the engine.
 Reference voltage: 5.0V.
⑤ Check voltage on pin 3.
 At closed throttle position (CTP), its voltage is around 0.4V.
 At wide open throttle (WOT), its voltage is around 4.0V.
Removal:
① Disconnect TPS harness connector.
Note: Make sure ignition switch is in OFF position.
② Remove throttle body assembly.
③ Remove bolt securing TPS, and take off the sensor.
Installation:
Please note the following procedure and install in the reverse order of removal.
 Make sure harness connector is installed securely.
 Tightening torque: 1.5~2.5N·m
EC-15
Heated oxygen sensors:

The front (upstream) oxygen sensor is
mounted on the exhaust manifold portion in
front of three way catalytic converter
(catalyst).
The rear (downstream) oxygen sensor is
mounted behind three way catalytic
converter.
The heated oxygen sensor senses EC012
concentration of oxygen in exhaust gas and
then transforms it into a voltage signal and
sends it to the ECU. When air-fuel ratio is
above the theoretical value, the output
voltage of the heated oxygen sensor is
approx. 900mV; when air-fuel ratio is below
the theoretical value (in the case of too high
concentration of oxygen in exhaust gas), the
output voltage of the sensor is approx.
100mV. The ECU controls fuel injection
quantity according to these signals so as to
maintain an appropriate air-fuel ratio.

Front oxygen sensor:
Pin 1: 1#-12V power supply from main relay
Main relay
Pin 2: 2# (ECU)-controlling heating power

supply negative (-)
Rear oxygen sensor Front oxygen sensor
Pin 3: 39#-ground signal back to ECU

Pin 4: 45#-signal feedback to ECU
Rear oxygen sensor:
Pin A: 39#-ground signal back to ECU
Pin B: 29#-signal feedback to ECU
Pin C: C#-12V power supply from main relay
Pin D: 4# (ECU)-controlling heating power supply negative (-)
EC-16

 Symptoms: Poor idle, poor acceleration, excess exhaust gas, excessive fuel
consumption, etc.
 General sources of trouble:
① Probe fracture caused by sudden change in temperature due to moisture vapor
entering inside of sensor
② Lead poisoning of oxygen sensor
 Maintenance precaution: It is forbidden to apply any cleaning solution, oily liquid
or volatile solid to the oxygen sensor during maintenance.
① Check voltage between pin 3 (or pin A) and pin 4 (or pin B).
At idle, wait until the oxygen sensor reaches its normal operating temperature (350°C)
and then check. At this time, the voltage should fluctuate rapidly between 0.1~0.9V.
② Check resistance between pin 1 (or pin C) and pin 2 (or pin D).
Note: When checking, disconnect sensor harness connector.
 Resistance: 2.5~4.5
Removal:
① Disconnect oxygen sensor harness connector.
② Using oxygen sensor special socket, EC014

remove oxygen sensor.
Caution:
 Seal mounting hole of oxygen sensor
with lint-free cotton yarn to prevent
foreign materials or oil/water from
entering exhaust manifold.
 Visually check oxygen sensor
appearance.
Red brown: lead poisoning

Off white: normal
Black: carbon deposit
 Service life:
Service life of oxygen sensor is related to lead content of gasoline. See the following
table.
EC-17
Contrast Table of Service Life of Oxygen Sensor and Lead Content of Gasoline
Lead content of gasoline (g/L) Life (km)
0.6 30000
0.4 50000
0.15 80000
0.005 (unleaded gasoline) 160000
Installation:
 Pay attention to route of oxygen sensor harness.
Crankshaft position sensor:

It is mounted on flywheel plane at the back of
the engine.
The electromagnetic crankshaft position
(engine speed) sensor consists of magnet and
coil. Voltage signals of the crankshaft
position (CKP) sensor are transmitted to the
ECU for determining engine speed and
crankshaft position. EC016
Pin 1: 47#-signal wire A of ECU
Pin 2: 46#-signal wire B of ECU
Pin 3: shielded wire
 Symptoms: Start failure, etc.

 General source of trouble: Human initiated failure.
 Maintenance precaution: During maintenance, install by means of pressing in
instead of hammering.
EC-18
① (With harness connector disconnected), set digital multimeter to OHMs range

and then connect two meter pens to 2# and 3# pins of the sensor respectively. At
20℃, the rated resistance should be 860Ω±10%.
② (With harness connector connected), set digital multimeter to AC VOLTAGE
range, and then connect two meter pens to 2# and 3# pins of the sensor. Start the
engine, and then there should be voltage output. (It is recommended that you
check waveforms with an automotive oscilloscope.)
 Disconnect harness connector, and check resistance between pins 2 and 3.
Resistance: 731~989Ω
 Check CKP sensor to signal plate tooth tip clearance.
Standard clearance: 0.8~1.2mm
 Check CKP sensor signals.
Note: Check using automotive oscilloscope with engine started.
The following is the pattern of test waveforms (AC signals):
CKP sensor Oscillogram
5) Removal and installation: EC017

Removal:
① Disconnect harness connector of the
sensor.
② Remove bolt securing CKP sensor, and
take off the sensor.
Installation: EC018
 Pay attention to mounting clearance of
CKP sensor.
 Press in CKP sensor first, and then
tighten it to the specified torque.
EC-19
Camshaft position sensor: EC019

1) Component position description:
It is mounted on camshaft end cover at rear
end of cylinder head.
The Hall camshaft position (phase) sensor is
used to sense No. 1 cylinder’s top dead center
(TDC) on compression stroke. The ECU
determines sequence of fuel injection
according to signals from CMP sensor.

Pin 1: 39#-ground signal back to ECU
Pin 2: 42#-output, ECU signal
 Symptoms: Excess emissions, fuel
consumption rise, etc.
 General source of trouble: Human
initiated failure.
(With harness connector connected), turn ignition switch ON without starting the
engine, and set digital multimeter to DC VOLTAGE range. See the steps below.
① Check output signals of camshaft position (CMP) sensor.
CMP Sensor Output Signal Chart
Engine condition Idle speed 3000r/min
Output signal 0~B+(5~8Hz) 0~B+ (24~26Hz)
② Using VOLTAGE range of multimeter, check that the voltage between pins 3 and
1 is 5V (reference voltage).
③ Using automotive oscilloscope, check pin 2 for normal signal output
(squarewave signal).
Note: Check with engine started.
Removal:
EC-20
① Disconnect PCV tube and sensor EC021

harness connector.
② Remove bolt securing CMP sensor, and
take off the sensor.
Installation:
 Pay attention to mounting clearance.

Standard value: 0.8~1.2mm
 Tightening torque: 7.8~9.8N·m
Double spark ignition coil:

It is mounted at upper end of valve chamber
cover.
When ignition power transistor is opened by
a signal transmitted from the ECU, the ECU
will transmit the signal to the ignition coil,
then current in primary coil is cut off and a
high voltage is generated in the secondary
coil.
① No. 1 (No. 1 and No. 4 cylinders)
Main relay
ignition coil:
Primary winding pin +: 12V power supply
from main relay
Primary winding pin -: 3# (ECU)-controlling No. 1 and No. 4 cylinders No. 2 and No. 3 cylinders
ignition signals of No. 1 and No. 4 cylinders.
② No. 2 (No. 2 and No. 3 cylinders) ignition coil:

Primary winding pin +: 12V power supply from main relay
Primary winding pin -: 7# (ECU)-controlling ignition signals of No. 2 and No. 3
cylinders.
 Symptoms: Start failure, etc.
EC-21
 General sources of trouble: Burn out caused by excessive current, damage caused
by external force, etc.
 Maintenance precaution: It is forbidden to test ignition function by means of
“short-circuit firing test” during maintenance so as to avoid damage to the ECU.
(With harness connector disconnected), set digital multimeter to OHMs range, and
connect two meter pens to two pins of the primary winding respectively. At 20℃, the
resistance should be 0.42-0.58Ω while that of the secondary winding is 11.2-14.8kΩ.
Refer to “Ignition System” for removal and installation.
Canister control valve:
1) Component position description:
It is mounted on the bracket at inside of intake manifold.
2) Component description: EC024
The canister control valve (solenoid valve) is
used to control flow rate of fuel vapor in
canister. It consists of solenoid, armature,
and valve, etc. A filter screen is set at its inlet.
The air flow flowing through the canister
control valve on one hand is related to the
duty cycle of the electric pulse output to the
canister control valve by the ECU, and on the
other hand is related to the pressure
difference between the inlet and the outlet of
the canister control valve. The canister
control valve will close when no electric
pulses are present.
Main relay
Pin 1: 12V power supply from main relay

Pin 2: 37#-signal from ECU controlling the
valve
 Symptoms: Functional failure, etc.
 General sources of trouble: Rust or poor
sealing, etc. caused by entry of foreign
materials into the valve.
(With harness connector disconnected), set digital multimeter to OHMs range, and
connect two meter pens to two pins of the canister control valve respectively. At 20℃,
check resistance between pins 1 and 2.
EC-22
 Rated resistance: 22~30Ω

Removal:
① Disconnect canister control valve side hose.
② Disconnect canister control valve harness connector.
③ Disconnect canister side hose.
④ Take off canister solenoid valve from its holder.
Installation:
 Please note the following and install in the reverse order of removal.
 When installing, ensure that the air flow direction is within the specification.
 During removal and installation, avoid entry of such fluids as water and oil into
the valve.
 To avoid transmission of solid borne sound, it is recommended that the canister
control valve be installed on the hose with the valve suspended.
 Appropriate measures, such as filtering and purge, must be taken to prevent
foreign materials such as particles from entering the canister control valve from
the canister or hose.
 It is recommended that a corresponding protective filter (mesh size  50  m) be
installed at outlet of the canister.
Fuel injectors:

They are installed on fuel rail.
Each fuel injector determines fuel injection
quantity by opening time of fuel injector
solenoid valve according to injection signals
transmitted from the ECU.
Pin 1: 12V power supply from main relay
Pin 2: 50#, 63#, 49#, and 64#-enabling
control over injection time and action point
of each cylinder by ECU respectively
Main relay

 Symptoms: Poor idle, poor acceleration,
start failure (hard starting), etc. No. 1 No. 2 No. 3 No. 4
cylinder cylinder cylinder cylinder
EC-23
 General source of trouble:

Failure caused by gum accumulation in injector due to lack of maintenance.
 Maintenance precautions: (Refer to “Installation precautions”.)
① Check resistance.
Note: Check after harness connector is disconnected.
 Standard resistance: 11-16Ω
② Using trouble diagnostic tester, check working time of fuel injector.
 Standard working time: 2.0~3.0ms at idle (increased at acceleration).
③ Check operating sound of each fuel injector.
Listen to click sound of fuel injector at idle using stethoscope, or check vibration of
fuel injector with fingers.
If no vibration is perceived, check harness connector, injector, or ECU signal
controlling fuel injector.
Recommendation:
 Please clean and analyze fuel injectors using the special fuel injector cleaner and
analyzer within a certain period.
Please refer to “Fuel System”.
Installation precautions:
 Install fuel injector into its seat in the direction normal to the seat, and then secure
fuel injector to its seat with a clip.
 Fuel injector installation should be made by hand. It is forbidden to knock on any
fuel injector using a tool such as a hammer.
 When removing and reinstalling a fuel injector, be sure to replace its O-ring.
Please refer to “Fuel Injectors” in page FL-4 for replacement method.
 Do not pull supporting washer of O-ring out of any fuel injector. When installing,
avoid damage to fuel feed end, O-ring, support ring, nozzle plate and harness
connector of any fuel injector. If damaged, use is forbidden.
 After installing fuel injectors, inspect leak tightness of fuel rail assembly. Only
those having no leakage are acceptable.
 Failure parts must be removed by hand. Remove fuel injector clip first, and then
pull injector out of its seat. After removing, ensure fuel injector seat is clean and
avoid contamination.
EC-24
Idle stepper motor:

It is mounted on throttle body.
By controlling change frequency of current
direction in coil, the ECU can control moves
of the stepper motor thus adjusting
cross-section area of bypass and flow rate of
air flowing through.

Pin A: connected to 22# pin of ECU
Pin B: connected to 21# pin of ECU
Pin C: connected to 35# pin of ECU
Pin D: connected to 36# pin of ECU
 Symptoms: Too high idle speed, misfire
at idle, etc.
 General sources of trouble:
Abnormal idle adjustment of stepper motor caused by partial blocking of air bypass
due to accumulation of dust and oil gas, etc.
① Check resistance.
Note: Check with harness connector disconnected.
 Rated resistance: 53±5.3Ω
 Self-learning: Turn ignition switch ON without starting the engine immediately.
Wait 5s before starting the engine.
If poor engine idle is detected then, be sure to simply repeat above step.
EC-25
Removal: EC030
① Disconnect harness connector, and
remove lock bolts of stepper motor.
② Take off stepper motor.
Caution:
 Do not attempt to press in or pull out the
shaft by applying an axial force of any
form.
Installation:
Note the following procedure and install in the reverse order of removal.
 Before idle adjuster of stepper motor is installed into throttle body, the shaft of
the motor should be fully retracted.
 Pay attention to air bypass cleaning and maintenance.
 After battery or ECU is removed, carefully perform stepper motor self-learning
promptly.
 Install spring washers used, and bond them with bonding agent.
 The shaft with idle speed actuator of stepper motor should not be installed
horizontally or below that level so as to avoid entry of condensate water.
 Tightening torque: 4.00.4Nm
On-Board Diagnostic (OBD) System

The on-board diagnostic system (for short, OBD system) refers to a diagnostic system
integrated in the engine control system for monitoring faulty parts affecting exhaust
emission and main functions of the engine. It has the functions of identifying, storing
and displaying [through self-diagnosis malfunction indicator light (MIL)] fault
messages.
To ensure good emission controllability and durability during uses of vehicles, the GB
18352.3-2005 Limits and measurement methods for emissions from light-duty vehicles
(III, IV) has specified that all autos must be equipped with an OBD system that can
ensure identification of deteriorations or failures of parts within whole life cycle of
each auto. When servicing the vehicles with OBD system, maintenance personnel can
locate the malfunctioning components rapidly and accurately through diagnostic tester,
so that maintenance efficiency and quality are greatly improved.
OBD technology involves a number of brand new concepts. Now we introduce some
elementary knowledge related to OBD technology first for your better understanding
of the follow-up contents.
EC-26
Fault message records:

The ECU monitors sensors, actuators, related circuits, MIL, battery voltage and so on
and even the ECU itself continuously. Also it inspects credibility of output signals of
sensors as well as driving signals and internal signals of actuators (e.g. closed loop
control, coolant temperature, idle speed control, and battery voltage control, etc.). The
ECU will set a fault message record in the fault memory immediately once a link is
found out of order or a signal value is found incredible. The fault message records
are stored in the form of diagnostic trouble codes (DTCs) and are displayed in the
order of appearance of faults.
Faults can be divided into “steady faults” and “incidental faults” (e.g. those caused by
brief open circuit in harness or poor contact of connector) by frequency of occurrence.
Description and control strategies of malfunction indicator light:

Malfunction indicator (MI): Used for indication of failures of emission-related
components or systems required by laws and regulations. MI is generally an indicator
light that can be displayed on the instrument panel and has a shape conforming to
requirements of laws and regulations and standards.
MIL activation abides by the following principles:
1) When ignition switch is turned ON (without starting the engine), the MIL will
keep lighting up.
2) If there is no fault request requiring MIL lighting up in the fault memory 3
seconds after engine start, the MIL will go out. When there is a fault request
requiring MIL lighting up in the fault memory or a same request outside the ECU,
the MIL will light up.
3) When there is a MIL flashing request outside the ECU, or a misfire cause
requiring MIL flashing, or a fault request requiring MIL flashing in the fault
memory, the MIL will flash at a frequency of 1Hz.
4) SVS (or EPC) light: The SVS light is a malfunction indicator light set by the
vehicle manufacturer for vehicle maintenance services. The EOBD regulations
do not specify its shape and activation principles.
5) Control strategies of SVS light: Turn ignition switch ON with K-line grounded
for more than 2.5 seconds and SVS light in blink code (BC) output mode.
6) Working conditions of the SVS light in different modes include:
① In normal mode with fault memory empty
When ignition switch is turned ON, the ECU will start initialization immediately. The
SVS light will go out after lighting up for 4 seconds since initialization. If the engine
is started within the 4 seconds, the SVS light will go out immediately after engine
speed is detected.
② In normal mode with fault (s) in fault memory
When ignition switch is turned ON, the SVS light will keep lighting up. After the
engine is started, the SVS light will light up in the subsequent driving cycle if there is
EC-27
a fault requiring SVS light to come on in failure mode in the fault memory; the SVS
light will go out after engine speed is detected if the fault in the fault memory does not
require SVS light to come on in failure mode.
③ In blind code mode with fault memory empty
If the ECU detects that the SVS light is in blind code mode, the SVS light will flash
the DTCs corresponding to the faults stored in the fault memory. The SVS will keep
lighting up for 4 seconds after ignition switch is turned ON. Then the SVS light will
flash at a frequency of 2Hz after an interval of 1 second to indicate “OK” until speed
is detected after engine start.
④ In blind code mode with fault (s) in fault memory
If the ECU detects that the SVS light is in blind code mode, the SVS light will flash
the DTCs corresponding to the faults stored in the fault memory. The SVS will keep
lighting up for 4 seconds after ignition switch is turned ON. Then the SVS light will
display DTCs stored in the memory in the form of BC after an interval of 1 second.
If all faults entering the memory have been displayed by the SVS light in the form of
BC, the SVS will go out until exiting blink code mode.
Four fault types:
1) Maximum fault: Signal exceeds upper limit of normal range.
2) Minimum fault: Signal exceeds lower limit of normal range.
3) Signal fault: No signal.
4) Unreasonable fault: Improper signals are present.
Basic service procedure:
For vehicles with OBD functions, their troubleshooting should generally follow the
procedure below:
Service Procedure Chart for OBD Malfunctions
1. Connect diagnostic test equipment to diagnostic interface, and turn

on the equipment.
2. Turn ignition switch ON.
3. Read fault-related information [DTCs, freeze frames (FFs), etc.];

refer to the service manual and recognize faulty components and
fault types; prepare maintenance scheme according to fault-related
information and experience.
EC-28
4. Perform troubleshooting.
5. Clear fault memory; drive your vehicle appropriately with driving

patterns satisfying corresponding trouble diagnostic criteria; read
fault information and make sure the trouble has been cleared.
Diagnostic tester connection:

This system uses a K-line communication protocol and a standard EOBD diagnostic
interface. See the figure below. The standard diagnostic interface is permanently
connected to engine harness. 4#, 7# and 16# pins on the standard diagnostic interface
are used to communicate with the engine control system. 4# pin of the standard
diagnostic connector is connected to on-vehicle ground wire; 7# pin is connected to
15# pin of ECU (i.e. engine data K-line); 16# pin is connected to battery positive (+).
Standard EOBD Diagnostic Connector
Through K-line, ECU can communicate with external diagnostic tester and can
perform the following operations:
1) Engine parameters display:
① Speed, coolant temperature, throttle opening, ignition advance angle, injection
pulse width, intake air pressure, intake air temperature, vehicle speed, system
voltage, injection correction, canister purge rate, idle air control, and oxygen
sensor signal
② Target speed, relative engine load, ambient temperature, closing time of ignition,
evaporator temperature, intake air flow, and fuel consumption
③ Signal voltages of TPS, coolant temperature sensor (CTS), intake air temperature
(IAT) sensor, and intake air pressure (IAP) sensor
2) EFI system status display:
States of anti-theft system, safety, programming, cooling system, steady working
condition, dynamic working condition, emission control, oxygen sensor, idle, MIL,
emergency working condition, and A/C system
3) Actuator tests:
Malfunction light, fuel pump, A/C relay, fan, ignition, and fuel injection (single
EC-29
cylinder fuel-cut)
4) Odometer display:
Kilometrage and running hours
5) Version information display:
Vehicle identification number (VIN), ECU hardware number, and ECU software
number
6) Trouble display:
IAP sensor, IAT sensor, ECT sensor, TPS, oxygen sensor, oxygen sensor heater circuit,
air-fuel ratio correction, fuel injector of each cylinder, fuel pump, speed sensor, CMP
sensor, canister control valve, cooling fan relay, vehicle speed signal, idle speed, idle
adjuster, system voltage, ECU, A/C compressor relay, evaporator temperature sensor,
and malfunction light
System features:
 Sequential multiport fuel injection system
 The variable torque functional architecture of the engine shows best compatibility
with other systems and strong extensibility.
 The new modular software and hardware structures provide strong portability.
 Cylinder identification signals are used (CMP sensor).
 A 60-2 tooth signal plate is used to identify speed signal (speed sensor).
 An air bypass is used for idle speed control (idle adjuster-stepper motor).
 Idle torque closed loop control is enabled.
 Catalytic converter heating and protection functions
 “Limp home” function
 Other functions, etc.
Trouble Diagnosis
Trouble diagnosis introduction:
The ECU controls the major engine systems EC031

undertaking fuel injection, ignition timing, Sensor
and idle speed control (ISC), etc. The ECM
accepts input signals from sensors and Actuator
instantly drives actuators. It is essential that
both input and output signals are proper and
stable. At the same time, it is important that
there are no malfunctions such as vacuum
leaks, spark plug failure, or other
malfunctions with the engine.
EC-30
It is much more difficult to diagnose an EC032

incident that occurs intermittently rather Information
than continuously. Most intermittent Cause
incidents are caused by poor electric
connections or improper wiring. In this
case, careful checking of suspected circuits
may help prevent the replacement of good
parts.
A visual check only may not find the cause EC033

of the incidents. Therefore, it is necessary to
connect a diagnostic tester or voltmeter for
circuit tests. During trouble diagnosis, start
your inspection by looking for conventional
malfunctions first. This will help
troubleshoot driveability malfunctions on an
electronically controlled engine.
Diagnosing and clearing DTCs: Vehicle family selection

1) Connect diagnostic tester to diagnostic
interface.
JAC cars dedicated
(Note: The fault diagnosis interface is
located at lower left part of steering wheel.)
2) Turn ignition switch ON, and operate
the apparatus to enter diagnostic
interface.
3) Select vehicle family and confirm
version number.
Page up Page down
4) Select vehicle model.
Back Help
Start
EC-31
5) Select system. System selection

Engine system
Anti-theft system
Anti-lock brake system
Airbag system
Page up Page down
Homepage
of diagnoses Back Print Help
Start
6) Select engine model. System selection

4g93 engine system (UAES)
K4 engine system (Siemens)
Page up Page down
Homepage
Start
7) Function selection: Diagnostic function

Select “Read DTCs”, and then DTCs will be Read version information
displayed immediately after the selection; if Read DTCs
no DTCs exist in the system, you can see Clear DTCs
that a prompt “No DTCs in the system” is
Read data stream
displayed on the apparatus.
Read status data stream
Motion test
Page up Page down
Homepage
Start
EC-32
8) Clear troubles in turn according to DTCs

DTCs and prompts. P0560 system voltage failure Invalid signal
P0203 cylinder 3-fuel injection No signal

nozzle-circuit
P0571 Cruise control/brake switch (A) Invalid signal
circuit fault
Page up Page down
Homepage
Start
Clearing DTCs: Diagnostic function

Select “Clear DTCs” at function selection Read version information
provided that DTCs have been read. Read DTCs
Note: Clear DTCs

Read data stream
 If faults in the system have not been
Read status data stream
eliminated, DTCs can not be cleared.
Motion test
Page up Page down
Homepage
Start
Clear DTCs by operating according to Clear DTCs

prompts on diagnostic tester.
Do you want to clear a recorded DTC?

(Key in ON position, engine stopped)
Y N
Start
EC-33
Clear DTCs
DTC cleared successfully
OK
Start
System DTCs:
DTCs Chart
SN DTC Description
1 P0030 Front oxygen sensor heater control circuit open
2 P0031 Front oxygen sensor heater control circuit short to ground
3 P0032 Front oxygen sensor heater control circuit short to power
4 P0036 Rear oxygen sensor heater control circuit open
5 P0037 Rear oxygen sensor heater control circuit short to ground
6 P0038 Rear oxygen sensor heater control circuit short to power
7 P0053 Front oxygen sensor heater internal resistance improper
8 P0054 Rear oxygen sensor heater internal resistance improper
9 P0105 IAP sensor signal unchanged (frozen)
10 P0106 IAP sensor improper
11 P0107 IAP sensor short to ground
12 P0108 IAP sensor short to power
13 P0112 IAT sensor signal voltage too low
14 P0113 IAT sensor signal voltage too high
EC-34
SN DTC Description
15 P0116 ECT sensor improper
16 P0117 ECT sensor circuit voltage too low
17 P0118 ECT sensor circuit voltage too high
18 P0122 TPS circuit voltage below lower limit
19 P0123 TPS circuit voltage above upper limit
20 P0130 Front oxygen sensor signal improper
21 P0131 Front oxygen sensor signal circuit voltage too low
22 P0132 Front oxygen sensor signal circuit voltage too high
23 P0133 Front oxygen sensor aging
24 P0134 Front oxygen sensor circuit signal fault
25 P0136 Rear oxygen sensor signal improper
26 P0137 Rear oxygen sensor signal circuit voltage too low
27 P0138 Rear oxygen sensor signal circuit voltage too high
28 P0140 Rear oxygen sensor circuit signal fault
Off-line inspection air-fuel ratio closed loop control self-learning

29 P0170
improper

30 P0171
too rich

31 P0172
too lean
32 P0201 Control circuit of fuel injector in No. 1 cylinder open
36 P0261 Control circuit of fuel injector in No. 1 cylinder short to ground
EC-35
SN DTC Description
40 P0262 Control circuit of fuel injector in No. 1 cylinder short to power
44 P0300 Misfire in several cylinders
45 P0301 Misfire in No. 1 cylinder
49 P0317 Rough road test ABS signal fault
50 P0318 Rough road test sensor signal fault
51 P0321 CKP sensor reference point failure
52 P0322 No CKP sensor pulse signal (open or short)
53 P0327 KS signal circuit voltage too low
54 P0328 KS signal circuit voltage too high
55 P0340 Installation position of CMP sensor improper
56 P0341 Poor contact of CMP sensor
57 P0342 CMP sensor short to ground
58 P0343 CMP sensor short to power
59 P0420 TWC oxygen storage capacity deterioration (excess emission)
60 P0444 Control circuit of canister control valve open
EC-36
SN DTC Description
61 P0458 Control circuit voltage of canister control valve too low
62 P0459 Control circuit voltage of canister control valve too high
63 P0480 Control circuit of cooling fan relay open (LO)
64 P0481 Control circuit of cooling fan relay open (HI)
65 P0691 Control circuit of cooling fan relay short to ground (LO)
66 P0692 Control circuit of cooling fan relay short to power (LO)
67 P0693 Control circuit of cooling fan relay short to ground (HI)
68 P0694 Control circuit of cooling fan relay short to power (HI)
69 P0501 Vehicle speed sensor (VSS) signal improper
70 P0506 Idle control speed below target idle speed
71 P0507 Idle control speed above target idle speed
72 P0508 Drive pin of stepper motor short to ground
73 P0509 Drive pin of stepper motor short to power
74 P0511 Drive pin of stepper motor open
75 P0560 System battery voltage signal improper
76 P0562 System battery voltage too low
77 P0563 System battery voltage too high
78 P0627 Control circuit of fuel pump relay open
79 P0628 Control circuit of fuel pump relay short to ground
80 P0629 Control circuit of fuel pump relay short to power
81 P0645 Control circuit of A/C compressor relay open
82 P0646 Control circuit of A/C compressor relay short to ground
83 P0647 Control circuit of A/C compressor relay short to power
84 P0650 MIL driver circuit short to ground
EC-37
SN DTC Description
85 P0651 SVS (Service Vehicle Soon) light driver circuit fault
Air-fuel ratio closed loop control self-learning value above upper

86 P2177
limit (medium load zone)
Air-fuel ratio closed loop control self-learning value below lower

87 P2178
limit (medium load zone)
88 P2195 Front oxygen sensor aging (lean side)
89 P2196 Front oxygen sensor aging (rich side)
90 P2270 Rear oxygen sensor aging (lean side)
91 P2271 Rear oxygen sensor aging (rich side)
Diagnosing according to DTCs:

Description:
1) Perform the following servicing only when you make sure it is a current steady
fault, otherwise diagnostic errors may result.
2) Where “multimeter” is mentioned hereunder, it refers to a digital multimeter. It is
forbidden to check electronic control system lines with an analog multimeter
3) When servicing a vehicle with anti-theft system, pay attention to ECU
programming after replacement where “Replace ECU” appears in “Next step”
column.
4) If a DTC indicates too low voltage in a circuit, it means that short to ground or
open may exist in the circuit; If a DTC indicates too high voltage in a circuit, it
means that short to power may exist in the circuit; if a DTC indicates a circuit
fault, it means that open or several kinds of improper wiring may exist in the
circuit.
Diagnosis help:
1) A DTC can not be cleared or the fault is a steady one; in the case of an incidental
fault, check harness connector for looseness carefully.
2) Inspection has been made with the above procedure. No abnormality is found.
3) During servicing, do not overlook effects of maintenance condition, cylinder
pressure, and mechanical ignition timing, etc. of the vehicle on the system.
4) Replace ECU and test.
 If the DTC can be cleared then, the fault is located in the ECU; if the DTC still
can not be cleared then, replace with the original ECU and repeat the flow to
perform another servicing.
Descriptions of scanning tools or diagnostic tester modes:
EC-38
The OBD system provides many trouble diagnosis related messages. These messages
are highly informative for servicing of the engine electronic control system.
According to the definition in the international standard ISO/DIS15031-5 for
automobile industry, information related to an OBD system can be obtained through
the diagnostic tools meeting the requirements in ISO/DIS15031-4 in 9 different
services/modes. The main functions in each mode are described below:
- 01 Read current diagnostic data of engine system.
- 02 Read freeze frame data.
- 03 Read emission-related system DTCs.
- 04 Clear and reset emission-related diagnostic information.
- 05 Read monitoring test results of oxygen sensor.
- 06 Read OBD test results of specific monitoring system.
- 07 Read OBD system monitoring DTCs obtained during current or previous
driving cycle.
- 08 Perform component testing (non mandatory).
- 09 Read identification numbers of vehicle and software.
Note: Scanning tools or diagnostic testers may differ during design and use, but the
message read must be one of above modes. The corresponding DTC will be displayed
and output in Mode 3 only after a fault is recognized; all DTCs existing in current
driving cycle or occurred in previous driving cycle will be displayed and output in
Mode 7.
EC-39
Diagnosing DTCs:
 All related ECU pins mentioned hereunder are subject to actual wiring diagrams.
1) DTC P0030: Front oxygen sensor heater control circuit open
Step 1: Read “Mode 3” and “Mode 7” with a diagnostic tester.
Read result 1 Read result 2
In Mode 3 In Mode 7 In Mode 3 In Mode 7
Fault information Fault information not Fault information not Fault information
available available available available
P0030 P0030
Maintenance tips: Maintenance tips:

The fault has been recognized. Its causes The fault has not been finally recognized. It may
may be the following: be an intermittent fault. Check the following:
1) An open circuit exists between the 1) Measure line resistance between ECU
circuit connected to ECU pin and 2# connector pin and 2# pin of front oxygen
pin of front oxygen sensor. sensor. Judge if the measurement is normal.
2) The circuit connecting 1# pin of front 2) Measure resistance between 1# pin of front
oxygen sensor to main relay is open. oxygen sensor and main relay. Judge if the
measurement is normal.
3) An open circuit exists between 1# and
2# pins of front oxygen sensor. 3) Measure resistance between 1# and 2# pins of
front oxygen sensor. Judge if the
measurement is normal.
2) DTC P0031: Front oxygen sensor heater control circuit short to ground
Fault information Fault information Fault information not Fault information

available not available available available
P0031 P0031
Maintenance tip: Maintenance tip:

The fault has been recognized. Its cause The fault has not been finally recognized. It may be an
may be the following: intermittent fault. Check the following:
1) Short to ground exists in the circuit 1) Measure resistance to ground of ECU pin and
connected to ECU pin. check that it is normal.
EC-40
3) DTC P0032: Front oxygen sensor heater circuit short to power
P0032 P0032

The fault has been recognized. Its causes may be The fault has not been finally recognized. It
the following: may be an intermittent fault. Check the
following:
1) A short circuit exists between the circuit
connected to ECU pin and 1# pin circuit of 1) Measure ECU voltage and check that it
front oxygen sensor. is normal.
2) A short circuit exists between the circuit 2) Measure resistance between ECU pin
connected to ECU pin and other power and 1# pin circuit of front oxygen sensor.
circuit.
4) DTC P0036: Rear oxygen sensor heater circuit open
P0036 P0036

The fault has been recognized. Its causes may be The fault has not been finally recognized. It
following:
1) An open circuit exists between the circuit
connected to ECU pin and 2# pin of rear 1) Measure line resistance between ECU
oxygen sensor. connector and 2# pin of rear oxygen
sensor.
2) The circuit connecting 1# pin of rear
oxygen sensor to main relay is open. 2) Measure resistance between 1# pin of rear
oxygen sensor and main relay.
3) An open circuit exists between 1# and 2#
pins of rear oxygen sensor. 3) Measure resistance between 1# and 2#
pins of rear oxygen sensor.
EC-41
5) DTC P0037: Rear oxygen sensor heater circuit short to ground
P0037 P0037

The fault has been recognized. Its cause may be The fault has not been finally recognized. It
following:
1) Short to ground exists in the circuit
connected to ECU pin. 1) Measure resistance to ground of ECU pin
and check that it is normal.
6) DTC P0038: Rear oxygen sensor heater circuit short to power
P0038 P0038

The fault has been recognized. Its causes may The fault has not been finally recognized. It
be the following: may be an intermittent fault. Check the
following:
connected to ECU pin and 1# pin circuit of 1) Measure voltage on ECU pin and check
rear oxygen sensor. that it is normal.
2) A short circuit exists between the circuit 2) Measure resistance between ECU pin and
connected to ECU pin and other power 1# pin circuit of rear oxygen sensor.
circuit.
7) DTC P0053: Front oxygen sensor heater internal resistance improper

Description of oxygen sensor heater diagnosis: The system identifies if heater output
is correct by measuring sensor heater resistance. In some adverse circumstances,
oxygen sensor will be damaged by condensates, especially at cold start.
EC-42
Front oxygen sensor will be heated directly after engine start. Rear oxygen sensor will
be heated only when theoretical temperature in catalytic converter is above 308℃.
P0053 P0053

The fault has been recognized. Its cause may be The fault has not been finally recognized. Wait
the following: for the system to finish diagnosis.
1) Front oxygen sensor heating function is
disabled. Replace the sensor.
8) DTC P0054: Rear oxygen sensor heater internal resistance improper

Description of oxygen sensor heater diagnosis: The system identifies if heater output
is correct by measuring sensor heater resistance. In some adverse circumstances,
oxygen sensor will be damaged by condensates, especially at cold start.
Front oxygen sensor will be heated directly after engine start. Rear oxygen sensor will
be heated only when theoretical temperature in catalytic converter is above 308℃.
P0054 P0054

1) Rear oxygen sensor heating function is
disabled. Replace the sensor.
EC-43
9) DTC P0105: IAP sensor signal unchanged (frozen)
P0105 P0105
Maintenance tips: Maintenance tip:

The fault has been recognized. Its causes may The fault has not been finally recognized.
be the following: Check the following:
1) IAP sensor vacuum leak or clogging 1) Reinstall after checking or cleaning sensor
vacuum tube. Read after-start pressure
2) IAP sensor serious aging with a diagnostic tester in “Mode 1”.
10) DTC P0106: IAP sensor signal improper
P0106 P0106

following:
1) Air leak from sensing unit in the sensor
1) The sensor is a free voltage sensor, so it
2) Sensor damaged can not be diagnosed by reading pressure
3) Air leak from installation position of the parameters in diagnostic tester. Therefore,
sensor wait for the system to give a final
diagnostic result.
4) Migration characteristics of the sensor
EC-44
11) DTC P0107: IAP sensor short to ground
P0107 P0107

following:
1) ECU detects sensor signal circuit short to
ground. 1) Resistance between ECU pin and ground
12) DTC P0108: IAP sensor short to power
P0108 P0108

following:
1) ECU detects sensor signal circuit short to
power. 1) Voltage on ECU pin
13) DTC P0112: IAT sensor signal voltage too low
EC-45
P0112 P0112

following:
1) Sensor signal circuit connected to ECU pin
short to ground 1) Measure resistance between sensor signal
circuit on ECU pin and ground.
14) DTC P0113: IAT sensor signal voltage too high
P0113 P0113

following:
1) Sensor signal circuit connected to ECU pin
short to power 1) Measure voltage of sensor signal circuit on
ECU pin and check that it is normal.
15) DTC P0116: ECT sensor temperature indication improper
P0116 P0116
EC-46

The fault has been recognized. Its cause The fault has not been finally recognized. Wait for
may be the following: the system to finish diagnosis.
1) CTS is damaged and a replacement is
required.
16) DTC P0117: ECT sensor circuit voltage too low
P0117 P0117

following:
1) The circuit connected to ECU pin short to
ground 1) Measure resistance between the circuit
connected to ECU pin and ground.
17) DTC P0118: ECT sensor circuit voltage too high
P0118 P0118

following:
connected to ECU pin and other power 1) Measure voltage of the circuit connected
circuit. to ECU pin and check that it is normal.
EC-47
18) DTC P0122: TPS circuit voltage below lower limit
P0122 P0122

following:
1) ECU pin short to ground
1) Measure resistance between the circuit
connected to ECU pin and ground.
19) DTC P0123: TPS circuit voltage above upper limit
P0122 P0122

following:
connected to ECU pin and other power 1) Measure voltage of the circuit connected
circuit. to ECU pin and check that it is normal.
20) DTC P0130: “Front oxygen sensor signal improper”

Description of source of trouble: When any of the following occurs on a front oxygen
sensor signal, the system will judge that the signal is improper.
a. Front oxygen sensor signal stays within a low voltage range (0.1~0.4V) long
while rear oxygen sensor signal is always above 0.5V.
b. Front oxygen sensor signal stays within a high voltage range (0.6~1.5V) long
while rear oxygen sensor signal is always below 0.1V.
EC-48
c. Front oxygen sensor signal circuit and heater circuit are coupled.
P0130 P0130

The fault has been recognized. Its causes may The fault has not been finally recognized. Wait
be the following: for ECU to finish final inspection.
1) Check for correct and normal oxygen
sensor connector.
2) Check front oxygen sensor signal circuit
and heater circuit for coupling.
21) DTC P0131: Front oxygen sensor circuit voltage too low
P0131 P0131

following:
1) Short to ground exists in the signal circuit
connected to ECU pin. 1) Measure resistance between the signal
circuit connected to ECU pin and ground.
22) DTC P0132: Front oxygen sensor circuit voltage too high
Description of source of trouble: The ECU will measure front oxygen sensor circuit
voltage after the engine is started. When signal voltage stays above 1.5V long, it is
judged a front oxygen sensor signal circuit short to power.
EC-49
P0132 P0132

following:
1) A short circuit exists between the signal
circuit connected to ECU pin and 1# pin of 1) Measure resistance between the signal
oxygen sensor. circuit connected to ECU pin and 1# pin of
oxygen sensor.
circuit connected to ECU pin and other 2) Measure voltage of the signal circuit
power circuit. connected to ECU pin.
23) DTC P0133: Front oxygen sensor aging

Description of source of trouble: Under normal conditions, air-fuel ratio of mixture
switches between rich and lean and the corresponding oxygen sensor signal shows
continuous beating in amplitude. After aging, oxygen sensor’s sensing sensitivity to
mixture will drop, showing longer period of signal fluctuation. The ECU will
calculate average period of signal according to corresponding algorithm. If the period
is found longer than the preset critical value, you can judge that the sensor has been
aging.
P0133 P0133

the following: for ECU to finish final inspection.
1) The sensor has been aging and a
replacement is required.
EC-50
24) DTC P0134: Front oxygen sensor signal fault

Description of source of trouble: The ECU will measure front oxygen sensor circuit
voltage after the engine is started. When signal voltage always changes within
0.4~0.6V, it is judged a front oxygen sensor signal circuit open by the system.
P0134 P0134

following:
1) Oxygen sensor circuit connected to ECU
pin open 1) Measure resistance between ECU
connector and 4# pin of oxygen sensor.
2) Poor connection of oxygen sensor
connector (pin oxidation)
25) DTC P0136: Rear oxygen sensor signal improper

Description of source of trouble: Front oxygen sensor signal circuit and heater circuit
are coupled.
P0136 P0136

be the following: for ECU to finish final inspection.
1) Check for correct and normal oxygen
sensor connector.
2) Check front oxygen sensor signal circuit
and heater circuit for coupling.
EC-51
26) DTC P0137: Rear oxygen sensor signal circuit voltage too low
P0137 P0137

following:
1) Short to ground exists in the signal circuit
connected to ECU pin. 1) Measure resistance between the signal
circuit connected to ECU pin and ground.
27) DTC P0138: Rear oxygen sensor signal circuit voltage too high
Description of source of trouble: The ECU will measure rear oxygen sensor circuit
voltage after the engine is started. When signal voltage stays above 1.5V long, it is
judged a rear oxygen sensor signal circuit short to power.
P0138 P0138

following:
circuit connected to ECU pin and 1# pin of 1) Measure resistance between the signal
oxygen sensor. circuit connected to ECU pin and 1# pin of
oxygen sensor.
circuit connected to ECU pin and other 2) Measure voltage of the signal circuit
power circuit. connected to ECU pin.
EC-52
28) DTC P0140: Rear oxygen sensor circuit signal fault

Description of source of trouble: The ECU will measure rear oxygen sensor circuit
voltage after the engine is started. When signal voltage always changes within
0.4~0.6V, it is judged a rear oxygen sensor signal circuit open by the system.
P0140 P0140

following:
1) Oxygen sensor circuit connected to ECU
pin open 1) Measure resistance between ECU
connector and 4# pin of oxygen sensor.
2) Poor connection of oxygen sensor
connector (pin oxidation)
29) DTC P0170: Off-line inspection air-fuel ratio closed loop control self-learning
improper
too lean
too rich
Note: The service flow applies to IAP sensor, canister solenoid valve, oxygen sensor,
etc. without concurrent DTCs. If related DTCs coexist, please troubleshoot other
malfunctions first and then inspect for normal oil passages.
32) DTC P0201: Control circuit of fuel injector in No. 1 cylinder open
EC-53
P0201 P0201

following:
1) Fuel injector coil open
1) Fuel injector coil for open
2) Poor connection between fuel injector
connector pin and ECU pin 2) Between fuel injector connector pin and
ECU pin for good connection
3) Poor connection between fuel injector
connector pin and main relay 3) Between fuel injector connector pin and
main relay for good connection
36) DTC P0261: Control circuit of fuel injector in No. 1 cylinder short to ground
P0261 P0261

following:
1) Short to ground exists in the drive circuits
connected to ECU pin. 1) Measure resistance to ground of the circuit
connected to ECU pin.
40) DTC P0262: Control circuit of fuel injector in No. 1 cylinder short to power
EC-54
P0262 P0262

following:
other power 1) Measure voltage of the circuit connected
to ECU pin.
44) DTC P0300: Misfire in several cylinders

45) DTC P0301: Misfire in No. 1 cylinder
Description of source of trouble: Misfire refers to combustion process interruption or
combustion failure in an engine cylinder due to ignition system’s failure to release
ignition energy in the cylinder effectively (ignition failure), deviation in fuel injection
quantity (mixture concentration deviation), compression pressure in cylinder too low
or any other causes. Misfire will result in excess emission or catalytic converter
damage due to overheating. As far as OBD diagnostic tests are concerned, it refers
to occurrence of a misfire judged by the system when misfire frequency exceeds the
set value.
P030x P030x
EC-55
be the following: for system validation.
1) Fuel injector requiring cleaning
2) Intake duct requiring cleaning
3) Valve blowby
4) Ignition system malfunction (Check and
replace spark plugs and ignition cables.)
5) Serious cylinder wear
49) DTC P0317: Rough road test ABS signal fault

Description of source of trouble: Signal abnormality from ABS wheel speed sensor
makes this signal impossible to be used for bumpy road detection.
P0317 P0317

following.
1) Check ABS wheel speed signal.
50) DTC P0318: Rough road test sensor signal fault

Description of source of trouble: A sensor malfunction will be judged if the
acceleration measured by the acceleration sensor is outside of the set reasonable range;
after a period of time (e.g. 10 seconds) after vehicle stop, the acceleration sensor
should not detect a bumpy road. If a bumpy road is detected then, the system will
judge an acceleration sensor malfunction.
EC-56
P0318 P0318

following:
connected to ECU pin. 1) Check resistance to ground of the circuit
connected to ECU pin.
power or open 2) Check voltage of the circuit connected to
ECU pin.
3) Installation position or support of
acceleration sensor loose 3) Check that installation position and
support of acceleration sensor are normal.
4) Acceleration sensor damaged
51) DTC P0321: CKP sensor reference point failure

Description of source of trouble: The system uses a 60-2 tooth speed measuring
system. Mounted on flywheel, the 60-2 induction ring gear will generate magnetic
changes in the sensor when it follows flywheel (with same speed as that of crankshaft)
to rotate, so that an induced AC voltage of which the frequency depends on speed is
generated. The ECU signal circuit converts the input sine waves into square waves.
When ECU finds that the distance between falling edges of 2 square waves is greater
than 2 X pitch, the reference position is then detected. Physically, this reference
pitch corresponds to a specific position of No. 1 cylinder. It is defined in the system
that the second falling edge after the reference pitch be the reference point signal of
the software (BM) and that the crank angle from the signal to TDC of No. 1 cylinder
be a fixed value 108°CA. The system will receive a BM at each crankshaft turn. In
addition, the system keeps pace with crankshaft position according to this BM thus
ensuring correct control over fuel injection, intake and ignition timing.
If any of the following cases is found, you can judge that a BM fault occurs:
① It is frequently found that the measured BM appears at the position ahead of or
behind the expected position;
② Speed signals can be detected but BM can not be detected;
③ BM is missed frequently.
P0321 P0321
EC-57

The fault has been recognized. Its causes may No diagnosis is required before final
be the following: confirmation because the malfunction itself is
caused by intermittent short or open circuit.
1) Intermittent short or open circuit in line Wait for the system to confirm by itself.
connections
2) Installation position deviation of
crankshaft signal wheel
3) Installation position deviation of CKP
sensor
52) DTC P0322: No CKP sensor pulse signal (open or short)

Description of source of trouble: The ECU monitors CKP sensor signals and CMP
sensor signals at the same time after the engine is started. If CMP sensor signals can
be obtained continuously but no CKP sensor signals are received, the system will
judge that CKP sensor signal loss occurs.
P0322 P0322

following:
1) CKP sensor circuit connected to ECU
open 1) Resistance of the CKP sensor circuit
connected to ECU
2) CKP sensor circuit connected to ECU
short 2) Voltage of the CKP sensor circuit
connected to ECU
3) CKP sensor coil open
3) CKP sensor coil resistance
53) DTC P0327: KS signal circuit voltage too low

Description of source of trouble: Mounted on engine body, the KS vibrates at different
frequencies in various engine conditions and generates voltage signals containing
various frequencies. Voltage signals not only can indicate if an engine knock occurs
but also show background noise level (noise of mechanical components) of the engine
objectively. When the engine operates normally with KS functioning, the background
noise level will fluctuate within a specification range. Once the level is below the set
value, the system will deem that the signal circuit of the sensor is malfunctioning.
EC-58
P0327 P0327

The fault has been recognized. Its causes may The fault has not been finally recognized.
be the following: Check the following:
1) The circuit connecting ECU pin to 1# pin 1) Check resistance of the circuit connecting
of KS open or short to ground ECU to 1# pin of KS.
2) The circuit connecting ECU pin to 2# pin 2) Check resistance of the circuit connecting
of KS open or short to ground ECU to 2# pin of KS.
54) DTC P0328: KS signal circuit voltage too high

Description of source of trouble: Mounted on engine body, the KS vibrates at different
frequencies in various engine conditions and generates voltage signals containing
various frequencies. Voltage signals not only can indicate if an engine knock occurs
but also show background noise rating (noise of mechanical components) of the
engine objectively. When the engine operates normally with KS functioning, the
background noise level will fluctuate within a specification range. Once the level is
above the set value, the system will deem that a mechanical component of the engine
is malfunctioning.
P0328 P0328

the following: for the system to finish diagnosis by itself.
1) Some components of the engine are worn
seriously. Check mechanical parts of the
engine (piston rings, piston pins, bearing
shells, parts clearances, etc.).
EC-59
55) DTC P0340: Installation position of CMP sensor improper

56) DTC P0341: Poor contact of CMP sensor
Description of source of trouble: The operating principle of the CMP sensor features
use of a hall element which is used to induce a trigger wheel that follows the camshaft
to rotate for monitoring camshaft position. The phase signals received by the ECU
should change alternately between high level and low level regularly. If the ECU only
detects slow high-low level changes or irregular changes, it will deem that a phase
signal fault occurs.
P0340 P0340

following:
1) Installation position of CMP sensor
improper 1) Installation position of CMP sensor (angle,
clearance to phase trigger wheel)
2) CMP sensor harness connector not
connected properly 2) Connection of CMP sensor harness
connector (pin fastening force, pin
oxidation)
57) DTC P0342: CMP sensor short to ground

should change alternately between high level and low level regularly. If the ECU
detects that the phase signals are at low level continuously, it will deem that a phase
signal line short to ground occurs.
EC-60
P0342 P0342

following:
connected to ECU and 3# pin circuit of 1) Check resistance to ground of the circuit
CMP sensor. connected to ECU pin.
2) Short to ground exists in the circuit 2) Check resistances of the circuit connected
connected to ECU. to ECU pin and 3# pin circuit of CMP
sensor.
58) DTC P0343: CMP sensor short to power

should change alternately between high level and low level regularly. If the ECU
detects that the phase signals are at high level continuously, it will deem that a phase
signal line short to power occurs.
P0343 P0343

following:
connected to ECU and 1# pin circuit of 1) Check ECU pin circuit voltage.
CMP sensor.
2) Check resistances of ECU pin circuit and
2) A short circuit exists between the circuit 1# pin circuit of CMP sensor.
connected to ECU and other power circuit.
59) DTC P0420: TWC oxygen storage capacity deterioration (excess emission)
Description of source of trouble: A corresponding relationship exists between
conversion efficiency and oxygen storage capacity of the TWC. Amplitude of rear
oxygen sensor can show oxygen storage capacity of the TWC indirectly. The larger
the amplitude, the poorer the oxygen storage capacity and its corresponding
conversion ability of the TWC. The main principle of TWC diagnosis is monitoring of
voltage fluctuation amplitude of rear oxygen sensor by the system. If the measured
amplitude exceeds the set limit, the system will make a judgment of TWC failure.
EC-61
P0402 P0402

the following. for system validation.
1) Conversion efficiency of TWC is too low,
which may result in excess emission.
60) DTC P0444: Control circuit of canister solenoid valve open
P0444 P0444

following:
1) An open circuit exists between the circuit
connected to ECU and 2# pin of canister 1) Measure line resistance between ECU
solenoid valve. connector and 2# pin of canister solenoid
valve.
2) The circuit connecting 1# pin of canister
solenoid valve to main relay is open. 2) Resistance between 1# pin of canister
solenoid valve and main relay
3) The solenoid between 1# and 2# pins of
canister solenoid valve is open. 3) Resistance between 1# and 2# pins of
canister solenoid valve
EC-62
61) DTC P0458: Control circuit voltage of canister solenoid valve too low
P0458 P0458

following:
connected to ECU. 1) Measure resistance to ground of the circuit
connected to ECU and check that it is
normal.
62) DTC P0459: Control circuit voltage of canister solenoid valve too high
P0459 P0459

following:
connected to ECU and 1# pin circuit of 1) Measure voltage on ECU pin and check
canister solenoid valve. that it is normal.
2) A short circuit exists between the circuit 2) Measure resistance between ECU pin and
connected to ECU pin and other power 1# pin circuit of canister solenoid valve.
circuit.
63) DTC P0480: Control circuit of cooling fan relay open (LO)
64) DTC P0481: Control circuit of cooling fan relay open (HI)
65) DTC P0691: Control circuit of cooling fan relay short to ground (LO)
EC-63
66) DTC P0692: Control circuit of cooling fan relay short to power (LO)
67) DTC P0693: Control circuit of cooling fan relay short to ground (HI)
68) DTC P0694: Control circuit of cooling fan relay short to power (HI)
Description of source of trouble: The circuit control module in the ECU will detect
fan relay circuit voltage after the engine is started. When voltage or current
conforming to a failure mode occurs, a judgment of relay circuit fault is made.
P0480 P0480

following:
1) An open circuit/short to ground/short to
power exists between the circuit connected 1) Measure line resistance or voltage between
to ECU and fan relay. ECU connector and relay pin.
2) The circuit connecting a relay to main 2) Resistance between the relay and main
relay open relay
3) Solenoid of relay open 3) Resistance between 2 pins of relay
69) DTC P0501: VSS signal improper

Description of source of trouble: During your vehicle’s coasting in gear with
accelerator pedal released, the ECU will monitor engine speed and vehicle speed at
the same time. If the engine maintains at a high speed while vehicle speed indication
is “0” or a value significantly low, the system will make a judgment of vehicle speed
signal fault.
P0501 P0501
EC-64
Maintenance tip: Maintenance tips:

following:
1) ECU signal circuit connected to VSS short
to ground or open 1) Check resistance of the ECU connector
circuit connected to vehicle speed signal
sensor.
2) Check resistance to ground of ECU pin
circuit.
70) DTC P0506: Idle control speed below target idle speed
Description of source of trouble: Engine idle speed is achieved through closed loop
control. If actual engine speed is still lower (certain value) than the target idle speed
when a certain period of time has passed after the ECU enters idle speed control mode,
a judgment of this fault will be made.
P0506 P0506

be the following: may be an intermittent fault.
1) Stepper motor stuck at a small opening
2) Check that throttle adjusting screw,
accelerator cable, and throttle condition
are in good order.
3) Inside of throttle body too dirty
71) DTC P0507: Idle control speed above target idle speed
Description of source of trouble: Engine idle speed is achieved through closed loop
control. If actual engine speed is still higher (certain value) than the target idle speed
when a certain period of time has passed after the ECU enters idle speed control mode,
a judgment of this fault will be made.
EC-65
P0507 P0507

be the following: may be an intermittent fault.
1) Check that throttle adjusting screw,
accelerator cable, and throttle condition
are in good order.
2) Inside of throttle body too dirty
3) Stepper motor stuck at a large opening
4) Check positive crankcase ventilation
(PCV) tube for coming off or air leaks.
72) DTC P0508: Drive pin of stepper motor short to ground

73) DTC P0509: Drive pin of stepper motor short to power
74) DTC P0511: Drive pin of stepper motor open
Description of source of trouble: The circuit control module in the ECU will monitor
voltages of drive circuits of the idle stepper motor continuously after the engine is
started. When any of the 4 circuits is shorted to ground/shorted to power/open, the
system will make a judgment of corresponding fault of stepper motor circuit.
P0508 P0508

following:
1) Any of drive circuits of the stepper motor
connected to ECU short to ground/short to 1) Measure resistance or voltage to ground of
power/open each drive circuit of the stepper motor
connected to ECU.
75) DTC P0560: System battery voltage signal improper

EC-66
76) DTC P0562: System battery voltage too low

77) DTC P0563: System battery voltage too high
P0560 P0560

following:
1) Power generation failure due to generator
damaged or electric leakage from battery 1) Check generation capacity of generator.
(Measure generator voltage after engine
2) Exciting circuit of generator open start.)
3) Generating voltage too high resulting from
failure to control generated energy due to
generator regulator damaged
78) DTC P0627: Control circuit of fuel pump relay open

79) DTC P0628: Control circuit of fuel pump relay short to ground
80) DTC P0629: Control circuit of fuel pump relay short to power
P062X P062X

following:
power exists between the fuel pump relay 1) Measure resistance or voltage of the fuel
control circuit connected to ECU and fuel pump relay control circuit connected to
pump relay. ECU.
EC-67
relay open relay
81) DTC P0645: Control circuit of A/C compressor relay open

82) DTC P0646: Control circuit of A/C compressor relay short to ground
83) DTC P0647: Control circuit of A/C compressor relay short to power
P064X P064X

following:
power exists between the A/C compressor 1) Measure resistance or voltage of the A/C
relay control circuit connected to ECU and compressor relay control circuit connected
relay. to ECU.
relay open relay
84) DTC P0650: MIL driver circuit short to ground
P0650 P0650

following:
EC-68
1) Measure resistance or voltage of the MIL

1) MIL drive circuit connected to ECU drive circuit connected to ECU.
open/short to ground/short to power
2) The circuit connecting MIL to main relay
open
3) MIL burned out
85) DTC P0651: SVS light driver circuit fault
P0651 P0651

following:
1) SVS light drive circuit connected to ECU
open/short to ground/short to power 1) Measure resistance or voltage of the SVS
light drive circuit connected to ECU.
2) The circuit connecting SVS light to main
relay open
3) SVS light burned out
86) DTC P2177: Air-fuel ratio closed loop control self-learning value above upper
limit
87) DTC P2178: Air-fuel ratio closed loop control self-learning value below lower
limit
Descriptions of principle and source of trouble: To obtain best overall conversion
efficiency of catalytic converter to HC, CO and NOx, air-fuel ratio of mixture needs
to be controlled at 14.7:1. When manufacturing deviations of parts, deposits of gum in
gasoline on fuel injectors, intake duct or valve back, air leaks from intake and exhaust
systems occur on the engine, air-fuel ratio deviation from 14.7:1 will result to varying
degrees (on lean side or rich side), causing emission deterioration and engine
performance drop. The engine control system will correct and self-learn fuel
injection quantity according to degrees and characteristics of these air-fuel ratio
deviations. When self-learning value reaches the upper limit set in the system (with
mixture on lean side or rich side, the system corrects fuel injection quantity
continuously until maximum), the system will make a judgment of self-learning value
out of limits.
EC-69
P2177 or P2178 P2177 或 P2178

1) Fuel injector is clogged and a cleaning is
required.
2) Air leaks from intake and exhaust systems
3) Too much gum accumulates in intake duct
or on intake valve back and a cleaning is
required.
4) Engine parts deviations
5) Valve clearance deviation
6) Fuel system pressure deviation
88) DTC P2195: Front oxygen sensor aging (lean side)

Description of source of trouble: Air-fuel ratio deviation will result when front oxygen
sensor signal bias occurs and rear oxygen closed loop adjustment will correct such a
deviation. The system sets a certain range for correction of rear oxygen closed loop.
When correction exceeds upper limit of the range set by the system, the system will
judge that front oxygen sensor characteristic has deviated.
P2195 P2195

EC-70
1) Front oxygen sensor characteristic has

deviated, which may cause excess
emission.
89) DTC P2196: Front oxygen sensor aging (rich side)

Description of source of trouble: Air-fuel ratio deviation will result when front oxygen
sensor signal bias occurs and rear oxygen closed loop adjustment will correct such a
deviation. The system sets a certain range for correction of rear oxygen closed loop.
When correction exceeds lower limit of the range set by the system, the system will
judge that front oxygen sensor characteristic has deviated.
P2196 P2196

1) Front oxygen sensor characteristic has
deviated, which may cause excess
emission.
90) DTC P2270: Rear oxygen sensor aging (lean side)

Description of source of trouble: Under normal conditions, oxygen sensor signal
should fluctuate around the control target value. If it is found that sensor voltage
keeps on lean side within a period of time, the system will enrich mixture. If sensor
voltage signal does not become rich in the expected direction, a judgment of oxygen
sensor aging on lean side will be made.
91) DTC P2271: Rear oxygen sensor aging (rich side)
Description of source of trouble: Under normal conditions, oxygen sensor signal
should fluctuate around the control target value. If it is found that sensor voltage
keeps on rich side within a period of time, the system will enlean mixture. If sensor
voltage signal does not become lean in the expected direction, a judgment of oxygen
sensor aging on rich side will be made.
EC-71
P2270 or P2271 P2270 or P2271

1) Rear oxygen sensor performance degrades,
which may cause excess emission.
The diagnostic flow for servicing according to symptoms:

Before starting the procedure for performing trouble diagnosis according to engine
symptoms, conduct a preliminary check first:
1) Make sure engine MIL is in working order.
2) Use a trouble diagnostic tester to check and make sure no fault message records
exist.
3) Make sure the symptoms in the owner’s complaint really exist and confirm the
conditions that exist when the trouble occurs. Then perform a visual inspection:
① Check fuel lines for leakage.
② Check vacuum lines for fracture, kink and correct connections.
③ Check intake lines for clogging, air leaks, flattening or damage.
④ Check ignition cables in ignition system for fracture, aging and correct firing
order.
⑤ Check for clean and firm harness grounding.
⑥ Check connectors of sensors and actuators for looseness or poor contact.
Important notes:
 If any of above symptoms exists, perform maintenance operation according to the
symptom; otherwise, subsequent trouble diagnosis and maintenance works will be
affected.
Diagnosis help:
1) Make sure no engine trouble records exist.
2) Make sure the symptoms in the complaint really exist.
3) Inspection has been made with the above procedure. No abnormality is found.
4) During servicing, do not overlook effects of maintenance condition, cylinder
pressure, mechanical ignition timing, and fuel condition, etc. of the vehicle on
the system.
EC-72
5) Replace ECU and test.

If the symptoms can be eliminated then, the fault is located in the ECU; if the
symptoms still remain then, replace with the original ECU and repeat the flow to
perform another servicing.
Symptoms and their diagnostic flows:
1. The engine does not rotate or rotates slowly when starting.
General trouble locations:
① Battery; ② starting motor; ③ harness or ignition switch; ④ engine
mechanical parts.
General diagnostic flow:
Inspection Follow-up
SN Work procedure
result procedure
Using multimeter, check if the voltage between 2 Y Next step

1 terminals of battery is about 8-12V when the engine is
started. N Replace battery.
Y Next step
Using multimeter, check if the voltage on positive
2 terminal of starting motor is above 8V with ignition
switch held in START position. Repair or replace
N
harness.
Repair or replace
Remove starting motor and check its working Y
harness.
3 condition. Focus on checking it for open circuit or
getting stuck due to poor lubrication.
N Next step
Change to lubricant
If the trouble occurs only in winter, check if it is Y of appropriate
caused by excessive resistance force of starting motor grade.
4
due to improper selection of engine oil and gear case
oil.
N Next step
Repair internal
Check if excessive mechanical resistance exists inside Y resistance of
5 the engine, which results in starting motor’s failure to engine.
rotate or slow rotation.
N Repeat above step.
2. When starting, engine can be dragged to rotate but can not start successfully.
① No fuel in fuel tank; ② fuel pump; ③ speed sensor; ④ ignition coil; ⑤
engine mechanical parts.
EC-73
Inspection
SN Work procedure Follow-up procedure
result
Connect a fuel pressure gauge with its access Y Next step

point at front end of fuel inlet pipe of fuel rail
assembly, start the engine and check if the fuel
1 pressure is around 260kPa in idling mode; pull
out the vacuum tube on fuel pressure regulator, Service fuel supply
N
and then check if the fuel pressure is around system.
300kPa.
Connect an EFI system diagnostic tester, observe Y Next step

data item “Engine speed”, and then start the
2
engine to observe if speed signal output is
present. N Service speed sensor line.
Pull out ignition cable from one of the cylinders, Y Next step
connect a spark plug with the distance from its
3 electrode to engine body kept at around 5mm, and
then start the engine to check for blue-white N Service ignition system.
high-voltage sparks.
Troubleshoot engine
Y
Check pressure in each engine cylinder, and mechanical parts.
4
observe cylinders for underpressure.
N Next step
Connect an EFI system adapter, turn ignition Y Seek for diagnosis help.
switch ON, and check 12#, 13#, 44#, 45#, and
5 63# pins for normal power supply; check 3#, 51#,
53#, 61#, and 80# pins for normal ground Service corresponding
N
connections. lines.
3. Hard hot starting

① Moisture in fuel; ② fuel pump; ③ CTS; ④ ignition coil.
SN Work procedure
result procedure
Connect a fuel pressure gauge with its access point at Y Next step
front end of fuel inlet pipe of fuel rail assembly, start the
1
engine, and check if the fuel pressure is around 300kPa Service fuel supply
in idling mode. N
system.
connect a spark plug with the distance from its electrode
2
to engine body kept at around 5mm, and then start the Service ignition
engine to check for blue-white high-voltage sparks. N
system.
EC-74
SN Work procedure
result procedure
Pull off CTS connector, start the engine, and observe if Service line or
Y
the engine then starts successfully. (Or connect a 300Ω replace sensor.
3
resistor to CTS connector in series to replace the sensor,
and observe if the engine then starts successfully.) N Next step
Y Service or replace.
Check vacuum tube of fuel pressure regulator for
4
looseness or air leaks.
N Next step
Y Change fuel.
Check fuel condition, and observe if the symptom
5
occurs just after a refueling.
N Next step
Seek for diagnosis

Connect an EFI system adapter, turn ignition switch Y
help.
ON, and check 12#, 13#, 44#, 45#, and 63# pins for
6
normal power supply; check 3#, 51#, 53#, 61#, and 80#
pins for normal ground connections. Repair or replace
N
harness.
4. Hard cold starting

① Moisture in fuel; ② fuel pump; ③ CTS; ④ fuel injector; ⑤ ignition coil; ⑥
throttle body and idle air bypass; ⑦ engine mechanical parts.
Inspection
result
Connect a fuel pressure gauge with its access point Y Next step
at front end of fuel inlet pipe of fuel rail assembly,
1
start the engine, and check if the fuel pressure is Service fuel supply
around 300kPa in idling mode. N
system.
then start the engine to check for blue-white Service ignition
N
high-voltage sparks. system.
Pull off CTS connector, start the engine, and Service line or replace
Y
observe if the engine then starts successfully. (Or sensor.
3 connect a 2,500Ω resistor to CTS connector in
series to replace the sensor, and observe if the
engine then starts successfully.) N Next step
EC-75
Inspection
result
Clean throttle and idle

Y
Depress accelerator pedal gently, and observe if the air passage.
4
engine starts easily.
N Next step
Remove fuel injector, and check it for leakage or Y Replace faulty parts.
5 clogging with a special fuel injector cleaner and
analyzer. N Next step
Y Change fuel.
6
N Next step
Troubleshoot engine
Y
7
N Next step
Seek for diagnosis

Connect an EFI system adapter, turn ignition Y
help.
switch ON, and check 12#, 13#, 44#, 45#, and 63#
8
pins for normal power supply; check 3#, 51#, 53#,
61#, and 80# pins for normal ground connections. Service corresponding
N
lines.
5. Hard starting at any time with speed normal

① Moisture in fuel; ② fuel pump; ③ CTS; ④ fuel injector; ⑤ ignition coil; ⑥
throttle body and idle air bypass; ⑦ intake duct; ⑧ ignition timing; ⑨ spark plug;
⑩ engine mechanical parts.
Inspection
result
Y Check intake system.

Check air cleaner for clogging and intake duct
1
for air leaks.
N Next step

2
assembly, start the engine, and check if the fuel Check fuel supply
pressure is around 300kPa in idling mode. N
system.
EC-76
Inspection
result
Pull out ignition cable from one of the Y Next step

cylinders, connect a spark plug with the
3 distance from its electrode to engine body kept
at around 5mm, and then start the engine to N Check ignition system.
check for blue-white high-voltage sparks.
Y Next step
Check spark plug in each cylinder, and observe
4
if its model and gap are within specifications.
N Adjust or replace.
Service line or replace

Y
Pull off CTS connector, start the engine, and sensor.
5
observe if the engine then starts successfully.
N Next step
Y Change fuel.
Depress accelerator pedal gently, and observe if
6
the engine starts easily.
N Next step
Troubleshoot engine
Remove fuel injector, and check it for leakage Y
mechanical parts.
7 or clogging with a special fuel injector cleaner
and analyzer.
N Next step
Y Seek for diagnosis help.

Check fuel condition, and observe if the
8
symptom occurs just after a refueling. Service corresponding
N
lines.
Troubleshoot engine
Y
9
N Next step
Y Next step
Check if firing order and ignition timing of the
10
engine are within specifications.
N Check ignition timing.
11 63# pins for normal power supply; check 3#,
51#, 53#, 61#, and 80# pins for normal ground Service corresponding
N
connections. lines.
EC-77
6. Normal starting with rough idle at any time

① Moisture in fuel; ② fuel injector; ③ spark plug; ④ throttle body and idle air
bypass; ⑤ intake duct; ⑥ idle adjuster; ⑦ ignition timing; ⑧ spark plug; ⑨
engine mechanical parts.
Inspection
result
Y Check intake system.

1
for air leaks.
N Next step
Y Clean or replace.
2 Check idle adjuster for seizure.
N Next step
Y Next step
Check spark plug in each cylinder, and observe if
3
its model and gap are within specifications.
Y Clean.
Check throttle body and idle air bypass for
4
carbon deposits.
N Next step
Remove fuel injector, and check it for leakage, Y Replace faulty parts.
5 clogging or out-of-tolerance flow with a special
fuel injector cleaner and analyzer. N Next step
Y Change fuel.
6
symptom occurs just after a refueling.
N Next step
Troubleshoot engine
Y
7
observe for great cylinder pressure difference.
N Next step
Y Next step
8
N Repair ignition timing.
N
connections. lines.
EC-78
7. Normal starting with rough idle during warming up

① Moisture in fuel; ② CTS; ③ spark plug; ④ throttle body and idle air bypass;
⑤ intake duct; ⑥ idle adjuster; ⑦ engine mechanical parts.
Inspection
result
Y Service intake system.

Check air cleaner for clogging and intake duct for
1
air leaks.
N Next step
Y Next step
2
Remove idle adjuster, and check throttle body, Y Clean related parts.
3 idle adjuster and idle air bypass for carbon
deposits. N Next step

Pull off CTS connector, start the engine, and Y
sensor.
4 observe if rough idle occurs on the engine during
warming up.
N Next step
Y Change fuel.
6
N Next step
Troubleshoot engine
Y
7
N Next step
Seek for diagnosis

help.
8
N
lines.
EC-79
8. Normal starting with rough idle after warming up

① Moisture in fuel; ② CTS; ③ spark plug; ④ throttle body and idle air bypass;
⑤ intake duct; ⑥ idle adjuster; ⑦ engine mechanical parts.
Inspection
result

1
for air leaks.
N Next step
Y Next step
2

Pull off CTS connector, start the engine, and Y
sensor.
4 observe if rough idle occurs on the engine
during warming up.
N Next step
Y Change fuel.
6
N Next step
Troubleshoot engine
Y
7
N Next step
N
connections. lines.
9. Normal starting with rough idle or engine misses at partial load (e.g. with A/C
ON).
EC-80
① A/C system; ② idle adjuster; ③ fuel injector.

Inspection
result
Y Clean related parts.

Remove idle adjuster, and check throttle body, idle
1
adjuster and idle air bypass for carbon deposits.
N Next step
Observe if engine output increases when A/C is Y Go to step 4.

turned ON, namely, observe changes of ignition
2
advance angle, injection pulse width, and air intake
with an EFI system diagnostic tester. N Next step
Connect an EFI system adapter, disconnect Y Next step

3 connecting wire from 75# pin of ECU, and check
harness end for high level signal with A/C ON. N Service A/C system.
Y Next step
Check for normal A/C system pressure, compressor
4
electromagnetic clutch and A/C compression pump.
N Service A/C system.
5 clogging or out-of-tolerance flow with a special fuel
injector cleaner and analyzer. N Next step
Seek for diagnosis

help.
6
normal power supply; check 3#, 51#, 53#, 61#, and
80# pins for normal ground connections. Service corresponding
N
lines.
10. Normal starting with too high idle speed

① Throttle body and idle air bypass; ② vacuum tube; ③ idle adjuster; ④ CTS;
⑤ ignition timing.
Inspection
result
Y Adjust.
Check accelerator cable for getting stuck or
1
excessive tightness.
N Next step
EC-81
Inspection
result

Check intake system and the vacuum line
2
connected to it for air leaks.
N Next step

3
N Next step

Y
Pull off CTS connector, start the engine, and sensor.
4
observe if engine idle speed then is too high.
N Next step
Y Next step
Check if ignition timing of the engine is within the
5
specification.
6
pins for normal power supply; check 3#, 51#, 53#, Service corresponding
61#, and 80# pins for normal ground connections. N
lines.
11. Speed does not rise or engine misses take place during acceleration.
① Moisture in fuel; ② IAP sensor and TPS; ③ spark plug; ④ throttle body and
idle air bypass; ⑤ intake duct; ⑥ idle adjuster; ⑦ fuel injector; ⑧ ignition
timing; ⑨ exhaust pipe.
Inspection
result

1 Check air cleaner for clogging.
N Next step

2
assembly, start the engine, and check if the fuel
pressure is around 350kPa in idling mode. N Check fuel supply system.
Y Next step
3
EC-82
Inspection
result
Y Next step
Check if IAP sensor and TPS and their lines are
5
normal. Service line or replace
N
sensor.
Y Change fuel.
7
N Next step
Y Next step
8
Y Next step
9 Check exhaust pipe for unobstructed exhaust.
Repair or replace exhaust
N
pipe.
N
connections. lines.
12. Slow response during acceleration

① Moisture in fuel; ② IAP sensor and TPS; ③ spark plug; ④ throttle body and
idle air bypass; ⑤ intake duct; ⑥ idle adjuster; ⑦ fuel injector; ⑧ ignition
timing; ⑨ exhaust pipe.
Inspection
result

N Next step
EC-83
Inspection
result
Connect a fuel pressure gauge with its access point Y Next step
at front end of fuel inlet pipe of fuel rail assembly,
2
start the engine, and check if the fuel pressure is Check fuel supply
around 350kPa in idling mode. N
system.
Y Next step
3

4
N Next step
Y Next step
5
normal. Service line or replace
N
sensor.
Y Change fuel.
7
N Next step
Y Next step
8
Y Next step
Repair or replace
N
exhaust pipe.
Seek for diagnosis

help.
10
N
lines.
EC-84
13. Lack of power and poor performance during acceleration

① Moisture in fuel; ② IAP sensor and TPS; ③ spark plug; ④ ignition coil; ⑤
throttle body and idle air bypass; ⑥ intake duct; ⑦ idle adjuster; ⑧ fuel injector;
⑨ ignition timing; ⑩ exhaust pipe.
Inspection
result
Check for faults such as clutch slipping, low tire Y Repair.

1 pressure, braking drag, incorrect tire size, and
improper wheel alignment. N Next step
Service intake
Y
system.
N Next step
Connect a fuel pressure gauge with its access point at Y Y

front end of fuel inlet pipe of fuel rail assembly, start
3
the engine, and check if the fuel pressure is around Service fuel supply
350kPa in idling mode. N
system.
then start the engine to check for normal high-voltage Service ignition
N
spark intensity. system.
Y Adjust or replace.
Check spark plug in each cylinder, and observe if its
5
model and gap are within specifications.
N Next step
Clean related
Y
Remove idle adjuster, and check throttle body, idle components.
6
N Next step
Y Next step
7
normal. Service line or
N
replace sensor.
EC-85
Inspection
result
Y Change fuel.
9
N Next step
Y Next step
10
engine are within specifications. Check ignition
N
timing.
Seek for diagnosis

Y
help.
Service
N
corresponding lines.
Seek for diagnosis

help.
12
normal power supply; check 3#, 51#, 53#, 61#, and
80# pins for normal ground connections. Service
N
corresponding lines.

Technical parameters of CTS:
Limit Data Sheet
Item Value Unit
Rated voltage Run by ECU only.
Rated resistance at 20℃ 2.55% k
Range of running temperature -30~+130 ℃
Maximum measuring current

1 mA
passing the sensor
Permissible vibration
600 m/s2
acceleration
EC-86
Characteristic Data Sheet
Resistance (k)
Temperature
SN Temperature tolerance 1℃ Temperature tolerance 0℃
(℃)
Minimum Maximum Minimum Maximum
1 8.16 10.74 8.62 10.28 -10
2 2.27 2.73 2.37 2.63 +20
3 0.290 0.354 0.299 0.345 +80
Technical parameters of KS:

Limit Data Sheet
Value
Item Unit
Minimum Typical Maximum
Operating
-40 +130 ℃
temperature
Item Value Unit
Sensitivity of new sensor to 5kHz

268 mV/g
signal
Linearity within 3~15kHz 15% of the value at 5kHz
Linearity at resonance 15~39 mV/g
Lifetime fluctuation -17% maximum
Principal resonant frequency 20 kHz
Resistance 1 M
Capacitance 1200400 pF
Impedance
Including cable
28060 pF/m
capacitance
EC-87
Item Value Unit
Leakage resistance (resistance

4.815% M
between 2 output pins of sensor)
Temperature-induced sensitivity
-0.06 mV/gK
change
Technical parameters of TPS:

Limit Data Sheet
Item Value Unit
Mechanical angle between 2 extreme

95 °
positions
Available electrical angle between 2 extreme

86 °
positions
Permissible slide arm current 18 A
Storage temperature -40/+130 ℃
Permissible vibration acceleration 700 m/s2
Value
Item Unit
Total resistance (pin 1-2) 1.6 2.0 2.4 k
Protective resistance of slide arm (slide arm

710 1380 
at zero position, pin 2-3)
Running temperature -40 130 ℃
Supply voltage 5 V
Voltage ratio at right extreme position 0.04 0.093
Voltage ratio at left extreme position 0.873 0.960
UP/US increment rate with respect to throttle

0.00927 1/
angle
Weight 22 25 28 g
EC-88
Technical parameters of oxygen sensor:

Limit Data Sheet
Value
Item Unit
Storage temperature -40 +100 ℃
Ceramic tube end 200 850 ℃
Hexagon head on
570 ℃
shell
Operating temperature
Cable buckle and
250 ℃
stub cable
Connector plug 120 ℃
Exhaust gas at
930 ℃
Maximum permissible ceramic tube end
temperature with heating
element ON (maximum 10 Hexagon head on
630 ℃
minutes each time with shell
cumulative time not
exceeding 40 hours) Cable buckle and
280 ℃
stub cable
Permissible rate of change of temperature at

100 K/s
ceramic tube end
Permissible temperature of ceramic element with

350 ℃
condensate water at exhaust side
Random vibration
800 m/s2
(peak)
Simple harmonic
vibration
0.3 mm
Permissible vibration of (vibration
shell displacement)
Simple harmonic
vibration
300 m/s2
(vibration
acceleration)
Absolute
Continuous DC current at 350℃ A
value 10
EC-89
Maximum continuous AC current with exhaust

20 A
temperature at 350℃ and frequency of 1Hz
Unleaded gasoline or that with a permissible

Permissible fuel additives
lead content up to 0.15g/L
After a 250-hour bench

Item New
test
Exhaust temperature with

350℃ 850℃ 350℃ 850℃
characteristic data established
Voltage of sensing unit (mV) [=0.97

840±70 710±70 840±80 710±70
(CO=1%)]
Voltage of sensing unit (mV) (=1.10) 20±50 50±30 20±50 40±40
Internal resistance of sensing unit (k) 1.0 0.1 1.5 0.3
Response time (ms) (600mV to

<200 <200 <400 <400
300mV)
Response time (ms) (300mV to

<200 <200 <400 <400
600mV)
Electrical Data Sheet of Sensors
Item Value Unit
Room temperature, heating

≥30 M
Insulation element OFF
resistance between
new sensor heating
Exhaust temperature 350℃ ≥10 M
element and sensor
connector
Exhaust temperature 850℃ ≥100 k
Rated voltage 12 V
Continuous working voltage 12~14 V
Working voltage supporting not

Supply voltage on
more than 1% total life (exhaust 15 V
plug
temperature 850℃)
Working voltage supporting not

more than 75 seconds (exhaust 24 V
temperature 350℃)
EC-90
Test voltage 13 V
Heating power at heat balance with a working voltage

of 13V (exhaust temperature 350℃, exhaust flow rate 12 W
approx. 0.7 m/s)
Heating current at heat balance with a working

voltage of 13V (exhaust temperature 350℃, exhaust 5 A
flow rate approx. 0.7 m/s)
Fuse wire of heater circuit 8 A
Technical parameters of CKP sensor:

Limit Data Sheet
Value
Item Unit
Coil zone -40 +150 ℃
transition zone Mixed Mixed ℃
Wire zone -40 +120 ℃
Ambient temperature in downtime -40 +120 ℃

Withstand
temperature of Long-term ambient temperature in
-40 +120 ℃
PUR wire CKP runtime
sensor
Short-term 150h +150 ℃
ambient
temperature in
runtime 380h +140 ℃
150h +150 ℃
Within whole
service life of 380h +140 ℃
wire zone
1130h +130 ℃
Coil zone -40 +150 ℃

Withstand
temperature of
Transition zone Mixed Mixed ℃
H&S wire CKP
sensor
Wire zone -40 +130 ℃
EC-91
Ambient temperature in downtime -40 +130 ℃
Long-term ambient temperature in

-40 +130 ℃
runtime
Short-term ambient temperature in

+150 ℃
runtime
Within whole 500h +150 ℃

service life of
wire zone 200h +160 ℃
20~71Hz Acceleration40 m/s2

Vibration resistance in
each plane within 168h
71~220Hz Amplitude0.2 mm
Permissible intensity of opposite foreign field 2 kA/m
New 1 M
Insulation resistance (10s,
test voltage 100V)
End of life time 100 k
Withstand voltage (1~3s, 1200V AC) No breakdown
Value
Item Unit
Resistance at room temperature (20℃) 731 860 989 
Inductance 310 370 430 mH
Output voltage at a crankshaft speed of 416rpm 1650 mV
Technical characteristic parameters of CMP sensor:

Limit Data Sheet
Value
Item Unit
Ambient temperature -30 +130 ℃
EC-92
Mounting clearance 0.1 1.8 Mm
Supply voltage 4.5 16 V
Technical characteristic parameters of double spark ignition coil

Limit Data Sheet
Value
Item Unit
Permissible temperature at designated

-40 +120 ℃
test point (see the drawing)
Maximum temperature within 1h +140 ℃
Value
Item Unit
Nominal voltage 14 V
Resistance Primary winding 0.42 0.5 0.58 
(20~25℃) Secondary winding 11.2 13.0 14.8 k
Inductance Primary winding 3.4 4.1 4.8 mH
(20~25℃) Secondary winding 26.5 32.0 37.5 H
Load 50pF 30 kV
Formed voltage
Load 50pF//1M 23 kV
Technical characteristic parameters of canister control valve:

Limit Data Sheet
Value
Item Unit
Working voltage 9 16 V
Overvoltage within 1min 22 V
EC-93
Minimum trigger voltage 7 V
Minimum voltage drop 1.0 V
Permissible operating temperature -30 +120 ℃
Short-term permissible operating temperature +130 ℃
Permissible storage temperature -40 +130 ℃
Tolerable pressure difference between inlet and outlet 800 Mbar
Permissible switching times 108
Permissible vibration acceleration on product 300 m/s2
Leakage rate at a pressure difference of 400mbar 0.002 m3/h
Value
Item Unit
Rated voltage 13.5 V
Resistance at +20℃ 26 
Current under rated voltage 0.5 A
Frequency of control pulse 30 Hz
Typical Type A 7 ms
Pulse width control Type B 6 ms
Flow rate (pressure Type A 2.7 3.0 3.3 m3/h

difference=200mbar;
duty cycle=100%) Type B 1.7 2.0 2.3 m3/h
EC-94
Technical characteristic parameters of fuel injector:

Limit Data Sheet
Value
Item Unit
Storage temperature (in original package) -40 +70 ℃
In-vehicle permissible temperature of fuel

+140 ℃
injector (in downtime)
Continuous -40 +110 ℃

Operating
temperature of In a short period of
fuel injector time after hot start +130 ℃
(approx. 3min)
Permissible Continuous +70 ℃

temperature of
fuel at inlet of In a short period of
fuel injector +100 ℃
time (approx. 3min)
Temperature with fuel flow rate deviation

-40 +45 ℃
corresponding to 20℃ up to 5%
Permissible leakage of O-ring within Fuel wetting is allowed in O-ring area, but dribbling
35~-40℃ is not allowed there.
Maximum permissible vibration

400 m/s2
acceleration (peak)
Service voltage 6 16 V
Insulation resistance 1 M
Tolerable internal fuel pressure 1100 kPa
Tolerable bending stress 6 Nm
Tolerable axial stress 600 N
EC-95
Value
Item Unit
Working pressure (pressure difference) 350 kPa
Fuel injector resistance at 20℃ 11.4 12.6 
Technical parameters of stepper motor of idle speed actuator:

Limit Data Sheet
Value
Item Unit
Operating temperature -40 +125 ℃
Maximum permissible times of contact socket of

2.0106 Times
stepper motor choke plug
Value
Item Unit
Resistance of each coil at 25℃ 47.7 53 58.3 
Resistance of each coil within operating

35 (-40℃) 95 (+125℃) 
temperature range
Inductance of each coil to 1,000Hz at 25℃ 26.8 33.5 40.2 mH
Normal working pressure 7.5 12.0 V
Possible working voltage 3.5 14.0 V
Step length of rotor of stepper motor 15 °
Pressure drop between two ends with

60 kPa
bypass open
Maximum axial force caused by gas

6.28 N
pressure difference
EC-96

Manual Jac

Caricato da

Informazioni sul documento

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Manual Jac

Caricato da

Copyright:

Formati disponibili

B-Class MPV Service Manual Engine-Contents

Fuel Injector and Fuel Rail.............................................................. EM-17

LU Lubrication System....................................................... LU-1

CO Cooling System............................................................. CO-1

Service Data and Specifications...................................................... CO-15

FL Fuel System.................................................................... FL-1

ACC Accelerator Control System....................................... ACC-1

EC Engine Control System................................................. EC-1

General Information and Maintenance

 Do not operate the engine for an GI001

 Before jacking up the vehicle, put wheel GI002

 When removing a heavy component such GI003

 Before starting repairs which do not GI004

 Before repairing the vehicle:

Precautions for hoses: GI007 Do not scratch tube

2. Hose clamp GI009 Trace of clamping

Precautions for air conditioning:

How to follow trouble diagnoses:

Body number Engine model Manual transmission number

B-Class MPV 4G93D DL F5M41-G6

Vehicle identification number (VIN):

2) Vehicle identification number description

Geographic region Serial number

Country Vehicle feature code Assembly plant

Maker Check digit Year

A letter or number A number

① The first section: World Manufacturer Identifier (WMI) composed of 3 digits

Code Name of maker Applicable vehicle types

Trucks, non-complete vehicles, buses, passenger

② The second section: Vehicle Descriptive Section (VDS) code composed of 6

Engine type/rated power

Wheel base of truck/length of passenger

① Vehicle type: 2 represents passenger vehicle.

④ Wheel base of truck/length of passenger vehicle, bus and chassis: R>2390~2600

4: Passenger vehicle manufacturer/car plant/general assembly

Rear view of cylinder block

Manual transmission model: GI012

Overall body size

Overall length (mm) 4550

Overall width (mm) 1775

Overall height (mm) 1660

Front tread (mm) 1505

Rear tread (mm) 1495

Wheel base (mm) 2710

Front overhang (mm) 940

Rear overhang (mm) 900

No. of seats (occupants) 5/7

Kerb mass (kg) Fore axle 850

Back axle 600

Gross mass (kg) Fore axle 920

Back axle 1000

Size 16×6 1/2J

Regular 205/55R16 91V

Tool name Description

Safety stand attachment

 All applicable local laws regarding the

Tightening Torques of Standard Bolts

Tightening torque (without lubricant)

M6 6.0 1.0 5.5 7

M14 14.0 1.5 80 100

M14 14.0 1.5 190 170

M6 6.0 1.0 11 13.5

1.75 100 130