BAIC X25 Engine-EN PDF

Maintenance Manual of Senova X25
Engine
BAIC Motor Sales Co., Ltd.

Maintenance Manual
X25 2015
Engine
Version：11.2015
X25 2015
Engine
Contents
10 Engine Assembly ...................................................... 1 6.1 Removal and Installation of Engine Mounting
1 System Overview ........................................................ 1 Cushion ........................................................................ 90
2 Check and Diagnosis .................................................. 2 6. Removal and Installation of Transmission Mounting
2.1 Engine Service Precautions ..................................... 2 Cushion ........................................................................ 92
2.2 Common Fault Checking and Eliminating .............. 4 6.3 Removal and Installation of the Rear Mounting
2.2.1 Engine Starts Abnormally ..................................... 4 Cushion ........................................................................ 96
2.2.2 Engine Idle Speed Abnormal ................................ 5 7 Belt ............................................................................ 97
2.2.3 Poor Engine Acceleration and Power Reduction .. 6 7.1 Overview on Accessory Transmission ................... 97
2.3 Regular Tests ........................................................... 8 7.2 Removal and Installation of the Belt ...................... 98
2.3.1 Oil Pressure Switch............................................... 8 7.3 Check the Belt Tension .......................................... 99
2.3.2 Cylinder Pressure Test ........................................ 11 11 Cylinder Head and Timing Device ........................ 100
2.3.3 Fuel Pressure Test ............................................... 12 1 Overview ................................................................. 100
3 Technical Parameters ................................................ 14 2 Check and Diagnosis ............................................... 101
4 Powertrain Units ....................................................... 16 2.1 Common Fault Checking and Eliminating ........... 101
4.1 Removal and Installation of Powertrain Assembly 2.1.1 Abnormal Noise of Valve Mechanism............... 101
Components ................................................................. 16 2.1.2 Timing Mechanism: Noise ................................ 101
4.2 Removal and Installation of Engine Assembly ...... 35 3 Technical Parameters............................................... 103
4.3 Engine Assembly: Disassembly ............................. 43 4 Cylinder Head Cover............................................... 104
5. Engine Structure ...................................................... 58 4.1 Overview on Cylinder Head Cover ...................... 104
5.1 Cylinder Head Component .................................... 58 4.2 Removal and Installation of Cylinder Head Cover
5.1.1 Overview on Cylinder Head Assembly .............. 58 .................................................................................... 104
5.1.2 Disassembly of the Cylinder Head Component .. 59 5 Removal and Installation of Intake and Exhaust
5.1.3 Cylinder Head Cleaning ..................................... 63 Camshafts ................................................................... 108
5.1.4 Cylinder Head Check.......................................... 64 6. Removal and Installation of the Cylinder Head ..... 111
5.1.5 Check on Cylinder Head Bolt ............................. 65 7. Timing Device ........................................................ 112
5.2 Valve Mechanism................................................... 66 7.1 Overview on Timing Device ................................ 112
5.2.1 Valve Cleaning .................................................... 66 7.2 Removal and Installation of Timing Chain Housing
5.2.3 Check Valve Clearance ....................................... 67 .................................................................................... 114
5.2.4 Check on Valve Seat ........................................... 69 7.3 Removal and Installation of Timing Chain .......... 117
5.2.5 Check on Valve Duct .......................................... 69 7.4 Removal and Installation of Exhaust Camshaft
5.2.6 Check on Valve Spring ....................................... 70 Timing Sprocket ......................................................... 123
5.2.7 Check the Valve Tappet ...................................... 70 7.5 Removal and Installation of V.V.T Sprocket ........ 125
5.2.8 Check on Valve Tightness ................................... 71 8 Chain Tensioner ...................................................... 127
5.3 Check Camshaft Dimensions ................................. 73 8.1 Removal and Installation of Chain Tensioner ...... 127
5.4 Cylinder Block Component ................................... 74 12 Crankshaft, Link Mechanism ................................ 128
5.4.1 Overview on Cylinder Block Component........... 74 1 Overview ................................................................. 128
5.4.2 Cylinder Block Component: Disassembly .......... 75 2 Check and Diagnosis ............................................... 129
5.4.3 Check on Cylinder Block.................................... 78 2.1 Common Fault Checking and Eliminating ........... 129
5.4.4 Cylinder-boring................................................... 79 2.1.1 Crankshaft and Link Mechanism Noise ............ 129
5.4.5 Check Oil Clearance of the Crankshaft Bearing . 80 2.1.2 Cylinder Pressure Too Low ............................... 130
5.4.6 Check Thrust Bearing of the Crankshaft ............ 81 3 Technical Parameters............................................... 132
5.4.7 Check on Crankshaft Pin Oil Film ...................... 81 4 Removal and Installation of Cylinder Block ........... 133
5.4.8 Crankshaft Bearing ............................................. 82 5 Removal and Installation of Piston and Connecting
8.1 Assembly of Crankshaft Upper Bearing ................ 82 Rod Components ........................................................ 137
8.2 Assembly of Crankshaft Lower Bearing ................ 84 6 Removal and Installation of Crankshaft .................. 140
5.5 Piston and Connecting Rod Components .............. 85 13 Air Intake/Exhaust System .................................... 143
5.5.1 Overview on Piston and Connecting Rod 1 Overview ................................................................. 143
Components ................................................................. 85 2 Check and Diagnosis ............................................... 144
5.5.2 Disassembly of Piston Connecting Rod 2.1 Common Fault Checking and Eliminating ........... 144
Components ................................................................. 86 2.1.1 Air Intake Backfire ............................................ 144
5.5.3 Check on Piston Ring ......................................... 88 2.1.2 Exhaust Noise ................................................... 144
5.5.4 Check on Side Clearance at Connecting Rod's 3 Technical Parameters............................................... 146
Bigger End ................................................................... 89 4 Air Intake System .................................................... 147
5.5.5 Check on Connecting Rod Bolt .......................... 89 4.1 Removal and Installation of the Air Filter Assembly
6. Powertrain Mounting Components .......................... 90 .................................................................................... 147
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4.2 Air Intake Manifold ............................................. 148 20 Electronic Control System .................................... 199
4.2.1 Removal and Installation of Intake Manifold ... 148 1 Overview ................................................................. 199
4.2.2 Detection of the Intake Manifold ...................... 150 1.1 System Overview ................................................. 199
5 Air Intake/Exhaust System ..................................... 152 1.2 Electronic Control System I/O Signals ................ 201
5.1 Intake/Exhaust Manifold ..................................... 152 1.3 Introduction to System Functions ........................ 202
5.1.1 Removal and Installation of Exhaust Manifold 152 1.3.1 Starter Control ................................................... 202
5.1.2 Check on Exhaust Manifold ............................. 154 1.3.2 Engine Warming-up and Heating Control of
5.2 Exhaust Pipe ........................................................ 155 Three-way Catalytic Converter .................................. 202
5.2.1 Removal and Installation of Catalytic Converter 1.3.3 Acceleration/deceleration and Fuel Stoppage
Assembly ................................................................... 155 Control for Reverse Towing ....................................... 202
5.2.2 Removal and installation of the auxiliary silencer 1.3.4 Idle Speed Control............................................. 203
................................................................................... 158 1.3.5 λ Closed-loop Control ....................................... 203
5.2.3 Removal and Installation of the Main Silencer 1.3.6 Evaporation Emission Control .......................... 203
Assembly ................................................................... 159 13.7 Knock Control .................................................... 203
5.3 Check and Adjustment of Exhaust System .......... 160 1.3.8 V.V.T Control .................................................... 203
14 Lubrication System ............................................... 161 2 DTC Diagnostic Trouble Code................................ 205
1 Overview ................................................................ 161 2.1 List of Engine DTC Faults ................................... 205
2 Check and Diagnosis .............................................. 162 2.2 P010528 Intake air pressure sensor signal not
2.1 Common Fault Checking and Eliminating .......... 162 fluctuating (freezing) P010600 Signal of intake air
2.1.1 Low Oil Pressure .............................................. 162 pressure sensor unreasonable P010711 Intake air
2.1.2 Exceptional Engine Oil Consumption .............. 163 pressure sensor signal circuit undervoltage P010812
3 Technical Parameters .............................................. 164 Intake air pressure sensor signal circuit overvoltage
4 Removal and Installation of Oil Filter Seat ............ 165 P210612 Power drive level fault of electronic throttle
5.3 Oil Pressure Switch.............................................. 166 (short) P210619 Power drive level fault of electronic
5.1 Removal and Installation of the Oil Pressure Switch throttle (overheat or overcurrent) P210692 Power drive
................................................................................... 166 level fault of electronic throttle (SPI bus or signal)
5.2 Check on Engine Oil Pressure Switch ................. 168 P210613 Power drive level fault of electronic throttle
6 Removal and Installation of Oil Pump ................... 169 (open) P210629 Load monitoring fault ...................... 211
7 Removal and Installation of Oil Pan ....................... 170 2.3 P011216 Signal circuit of intake air temperature
8 Removal and Installation of Oil Strainer ................ 172 sensor undervoltage P011317 Signal circuit of intake
9 Removal and Installation of the Oil Level Gauge air temperature sensor overvoltage P011629 Signal of
Conduit Assembly...................................................... 173 intake air temperature sensor unreasonable ............... 216
10 Removal and Installation of Crankshaft Front Oil 2.4 P011716 Engine coolant temperature sensor circuit
Seal ............................................................................ 174 undervoltage P011817 Engine coolant temperature
11 Removal and Installation of Crankshaft Rear Oil Seal sensor circuit overvoltage .......................................... 220
Cover ......................................................................... 176 2.5 P032716 Knock sensor signal circuit voltage is too
15 Cooling System..................................................... 180 low.............................................................................. 223
1 Overview ................................................................ 180 2.6 P034100 Phase sensor signal is implausible ........ 226
2 Check and Diagnosis .............................................. 181 2.7 P048014 Control circuit fault of cooling fan relay
2.1 Common Fault Checking and Eliminating .......... 181 (low speed) P048114 Control circuit fault of cooling fan
2.1.1 Engine Water Temperature Is High ................... 181 relay (high speed) P069212 Control circuit of cooling
2.1.2 Engine Water Temperature Is Low ................... 181 fan relay short to power supply (low speed) P069311
3 Technical Parameters .............................................. 183 Control circuit of cooling fan relay short to ground (high
4 Cooling System Piping Diagram ............................ 184 speed) P069412 Control circuit of cooling fan relay
5 Thermostat .............................................................. 185 short to power supply (high speed) ............................ 230
5.1 How it works ....................................................... 185 2.8 P032200 Vehicle speed sensor signal fault........... 234
5.2 Removal and Installation of Thermostat .............. 186 2.9 P070400 Fault of clutch pedal switch voltage...... 237
5.3 Check on Thermostat ........................................... 187 2.10 P000A26 Operating fault of intake VVT (delay)
6 Radiator .................................................................. 189 P000A29 Operating fault of intake VVT (jamming)
6.1 Removal and Installation of the Radiator ............ 189 P001013 Fault of VVT intake control valve circuit
6.2 Cleaning and Checking Radiator ......................... 191 P001200 Intake VVT not at the default position at start
7 Removal and Installation of Auxiliary Radiator ..... 192 P208811 VVT intake control valve circuit undervoltage
8 Water Pump ............................................................ 194 P208912 VVT intake control valve circuit overvoltage
8.1 Removal and Installation of Water Pump ............ 194 P210612 Power drive level fault of electronic throttle
8.2 Check the Water Pump ........................................ 196 (short) ......................................................................... 240
9 Removal and Installation of Electronic Fan Assembly 2.11 P001621 Deviation of relative position between
................................................................................... 197 crankshaft and intake camshaft lower than the minimum
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limit P001622 Deviation of relative position between position self-learning fault P156400 System voltage
crankshaft and intake camshaft higher than the hardly meets self-learning conditions of electronic
maximum limit P001629 Signal of relative position throttle P156500 Initialization self-learning fault of
deviation between crankshaft and intake camshaft electronic throttle lower limit position P156800
unreasonable .............................................................. 244 Excessive return resistance of electronic throttle
2.12 P066013 Variable intake manifold solenoid valve P157900 Electronic throttle self-learning conditions
circuit open P066111 Variable intake manifold solenoid unsatisfied P133600 Torque limit function of electronic
valve circuit short to ground P066212 Variable intake throttle security monitoring ........................................ 253
manifold solenoid valve circuit short to power supply 2.15 P212216 Electronic accelerator pedal position
................................................................................... 246 sensor 1 signal undervoltage P212317 Electronic
2.13 P05711C Brake signal unreasonable P057129 accelerator pedal position sensor 1 signal overvoltage
Brake signal unreasonable ......................................... 248 P212716 Electronic accelerator pedal position sensor 2
2.14 P012129 Electronic throttle position sensor 1 signal signal undervoltage P212817 Electronic accelerator
unreasonable PP012216 Electronic throttle position pedal position sensor 2 signal overvoltage P213800
sensor 1 signal circuit undervoltage P012317 Electronic Electronic accelerator pedal position sensor signal
throttle position sensor 1 signal circuit overvoltage unreasonable P213829 Electronic accelerator pedal
P022129 Electronic throttle position sensor 2 signal position sensor signal unreasonable ........................... 264
unreasonable P022216 Electronic throttle position 2.16 P044413 Control circuit fault of carbon canister
sensor 2 signal circuit undervoltage P022317 Electronic control valve P045816 Control circuit of carbon canister
throttle position sensor 2 signal circuit overvoltage control valve undervoltage P045917 Control circuit of
P060100 Fault of electronic throttle security monitoring carbon canister control valve overvoltage .................. 270
function (ECU EEPROM fault) P060600 Fault of 2.17 P003013 Heating control circuit fault of upstream
electronic throttle security monitoring function (security oxygen sensor P003111 Heating control circuit of
monitoring fuel cutoff fault) P06061C Fault of upstream oxygen sensor undervoltage P003212 Heating
electronic throttle security monitoring function (throttle control circuit of upstream oxygen sensor overvoltage
body signal, wiring harness or ECU fault) P060647 P00531E Heating internal resistance of upstream
Fault of electronic throttle security monitoring function oxygen sensor unreasonable ....................................... 273
(monitoring model feedback fault) P060648 Fault of 2018 P003613 Heating control circuit fault of
electronic throttle security monitoring function downstream oxygen sensor P003711 Heating control
(monitoring erroneous response fault) P060649 Fault of circuit of downstream oxygen sensor undervoltage
electronic throttle security monitoring function P003812 Heating control circuit of downstream oxygen
(monitoring model inquiry fault) P060655 Fault of sensor overvoltage P00541E Heating internal resistance
electronic throttle security monitoring function of downstream oxygen sensor unreasonable .............. 278
(deformation code monitoring fault) P060661 Fault of 2.19 P013000 Upstream oxygen sensor signal
electronic throttle security monitoring function (ignition unreasonable P013116 Upstream oxygen sensor signal
angle signal, wiring harness or ECU fault) P060662 undervoltage P013217 Upstream oxygen sensor signal
Fault of electronic throttle security monitoring function circuit overvoltage P013300 Upstream oxygen sensor
(reasonableness fault of second layer accelerator pedal aging P013400 Signal circuit fault of upstream oxygen
signal) P060663 Fault of electronic throttle security sensor P219500 Upstream oxygen sensor aging-signal
monitoring function (reasonableness fault of second constantly thick P219600 Upstream oxygen sensor
layer accelerator pedal signal) P060664 Fault of aging-signal constantly thin ....................................... 282
electronic throttle security monitoring function (load 2.20 P013600 Downstream oxygen sensor signal
signal, wiring harness or ECU fault) P060667 Fault of unreasonable P013716 Downstream oxygen sensor
electronic throttle security monitoring function (ECU signal undervoltage P013817 Downstream oxygen
erroneous response monitoring fault) P060675 Fault of sensor signal circuit overvoltage P014000 Fault of
electronic throttle security monitoring function (path test downstream oxygen sensor circuit signal P227000
off fault) P060692 Fault of electronic throttle security Downstream oxygen sensor aging-signal constantly thin
monitoring function (second layer engine speed P227100 Downstream oxygen sensor aging-signal
monitoring fault) P060694 Fault of electronic throttle constantly thick .......................................................... 288
security monitoring function (second layer torque 2.21 P020113 Control circuit fault of first cylinder fuel
monitoring fault) P060696 Fault of electronic throttle injector P026111 Control circuit of first cylinder fuel
security monitoring function (AD converter monitoring injector undervoltage P026212 Control circuit of first
fault) P154521 Throttle body DLR adjustment lower cylinder fuel injector overvoltage .............................. 292
than the minimum limit value P154522 Throttle body 2.22 P020213 Control circuit fault of second cylinder
DLR adjustment higher than the minimum limit value fuel injector P026411 Control circuit of second cylinder
P155900 Second self-learning fault of throttle lower fuel injector undervoltage P026512 Control circuit of
mechanical dead center P155929 Throttle limp second cylinder fuel injector overvoltage .................. 296
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2.23 P020313 Control circuit fault of third cylinder fuel self-learning value higher than the upper limit
injector P026711 Control circuit of third cylinder fuel (intermediate load zone) P217800 Air-fuel ratio
injector undervoltage P026812 Control circuit of third closed-loop control self-learning value lower than the
cylinder fuel injector overvoltage .............................. 300 lower limit (intermediate load zone) P218700 Air-fuel
2.24 P020413 Control circuit fault of fourth cylinder ratio closed-loop control self-learning value higher than
fuel injector P027011 Control circuit of fourth cylinder the upper limit (low load zone) P218800 Air-fuel ratio
fuel injector undervoltage P027112 Control circuit of closed-loop control self-learning value lower than the
fourth cylinder fuel injector overvoltage ................... 304 lower limit (low load zone) ........................................ 333
2.25 P030021 Occurrence of several cylinder fire 2.33 P210612 Power drive level fault of electronic
leading to ultra-limit emission P030022 Occurrence of throttle (short) P210619 Power drive level fault of
several cylinder fire leading to catalytic converter electronic throttle (overheat or overcurrent) P210692
damage P030029 Occurrence of several cylinder fire in Power drive level fault of electronic throttle (SPI bus or
the first statistic cycle of fire detection ...................... 308 signal) P210613 Power drive level fault of electronic
2.26 P030121 Occurrence of first cylinder fire leading to throttle (open) P2106 29 Load monitoring fault ........ 336
ultra-limit emission P030122 Occurrence of first 2.34 P305400 Engine stalling or starter and flywheel not
cylinder fire leading to catalytic converter damage meshing fault P305500 Feedback voltage signal line
P030129 Occurrence of first cylinder fire in the first (KL50r) of key starting switch (KL50r) short to ground
statistic cycle of fire detection P030221 Occurrence of fault P305600 Feedback voltage signal line (KL50r) of
second cylinder fire leading to ultra-limit emission key starting switch (KL50r) short to power supply fault
P030222 Occurrence of second cylinder fire leading to P308800 Starter damaged or starter power supply circuit
catalytic converter damage P030229 Occurrence of interrupted .................................................................. 338
second cylinder fire in the first statistic cycle of fire 2.35 P061513 Starter control relay open P061611 Starter
detection P030321 Occurrence of third cylinder fire control relay undervoltage P061712 Starter control relay
leading to ultra-limit emission P030322 Occurrence of overvoltage ................................................................. 343
third cylinder fire leading to catalytic converter damage 2.36 U012287 Loss of communication with brake
P030329 Occurrence of third cylinder fire in the first control unit ABS/ESP U000188 CAN communication
statistic cycle of fire detection P030421 Occurrence of related diagnosis U014087 Loss of communication with
fourth cylinder fire leading to ultra-limit emission body control module BCM......................................... 346
P030422 Occurrence of fourth cylinder fire leading to 2.37 P161000 ECM not learning SecretKey P161100
catalytic converter damage P030429 Occurrence of PIN code input error P161200 ECM not receiving
fourth cylinder fire in the first statistic cycle of fire IMMO P161300 The last IMMO certification is
detection .................................................................... 311 responded Busy .......................................................... 349
2.27 P021900 Engine speed higher than the maximum 2.38 P042000 Three way catalytic converter capacity
speed limit P050600 Idle control speed lower than target aging (drain over limit) .............................................. 351
idle speed P050700 Idle control speed higher than target 2.39 P060443 Electronic control unit RAM fault
idle speed ................................................................... 316 P060543 Electronic control unit ROM fault .............. 352
2.28 P056000 System battery voltage signal 2.40 P168300 Airbag signal unreasonable P152381
unreasonable P056216 System battery undervoltage Airbag exploded ......................................................... 353
P056317 System battery overvoltage P062211 3 System: Basic Control Logic .................................. 355
Generator load feedback signal undervoltage P062212 3.1 Ignition Switch: Control Logic ............................ 355
Generator load feedback signal overvoltage .............. 318 3.2 Fuel Supply System: Control Logic ..................... 356
2.29 P062713 Control circuit fault of oil pump relay 3.3 Ignition: Control Logic ........................................ 358
P062811 Oil pump relay control circuit short to ground 3.4 Idling: Control Logic............................................ 360
or open P062912 Oil pump relay control circuit 3.5 Knock: Control Logic .......................................... 361
overvoltage ................................................................ 320 3.6 Air-conditioning: Control Logic........................... 362
2.30 P068800 Main relay output voltage unreasonable 3.7 Canister Solenoid Valve: Control Logic ............... 362
P068816 Fault of main relay output voltage signal ... 325 3.8 Three-way Catalytic Converter Protection: Control
2.31 P064513 Control circuit fault of A/C compressor Logic .......................................................................... 363
relay P064611 Control circuit of A/C compressor relay 3.9 Electronic Fan : Control Logic ............................. 363
short to ground P064712 Control circuit of A/C 3.10 Mileage Count: Logic ........................................ 363
compressor relay overvoltage .................................... 328 4 Parts & Components ............................................... 364
2.32 P017000 Air-fuel ratio closed-loop control 4.1 Engine Control Module (ECM) ........................... 364
self-learning in off-line detection unreasonable P017100 4.1.1 Overview ........................................................... 364
Air-fuel ratio closed-loop control self-learning in 4.1.2 Removal and Installation of Engine Control
off-line detection too thin P017200 Air-fuel ratio Module (ECM) ........................................................... 364
closed-loop control self-learning in off-line detection 4.2 Crankshaft Position Sensor .................................. 366
too thick P217700 Air-fuel ratio closed-loop control 4.2.1 Overview ........................................................... 366
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4.2.2 Removal and Installation of the Crankshaft 2 Check and Diagnosis ............................................... 406
Position Sensor .......................................................... 366 2.1 Common Fault Checking and Eliminating ........... 406
4.2.3 Check the Crankshaft Position Sensor .............. 368 2.1.1 Fuel Pressure Is Too Low .................................. 406
4.3 Intake Manifold Absolute Pressure Sensor .......... 369 2.1.2 Excessive Fuel Consumption ............................ 406
4.3.1 Overview ................................................... 369 3 Technical Parameters............................................... 408
4.3.2 Removal and Installation of the Intake Manifold 4 Fuel Pressure Release.............................................. 409
Pressure and Temperature Sensor .............................. 370 5 Removal and Installation of Filler Pipe Assembly .. 410
4.5.3 Check on Air Intake Temperature Pressure Sensor 6 Fuel Tank ................................................................. 412
................................................................................... 371 6.1 Draining of fuel tank ............................................ 412
4.4 Camshaft position sensor .................................. 372 6.2 Removal and Installation of Fuel Tank ................ 413
4.4.1 Overview .......................................................... 372 7 Removal and Installation of the Fuel Pump Assembly
4.4.2 Removal and Installation of the Camshaft Position .................................................................................... 417
Sensor ........................................................................ 373 8 Removal and Installation of Fuel Filter................... 419
4.4.3 Check the Camshaft Position Sensor ................ 374 9 Overview of the Fuel Pipeline................................. 420
4.5 Coolant Temperature Sensor ................................ 375 10 Fuel Rail and Injector Assembly ........................... 421
4.5.1 Overview .......................................................... 375 10.1 Overview ............................................................ 421
4.5.2 Removal and Installation of Coolant Temperature 10.2 Removal and Installation of Fuel Distribution Pipe
Sensor ........................................................................ 376 and Fuel Injector Assembly ........................................ 422
4.5.3 Check on Coolant Temperature Sensor............. 376 10.3 Disassembly of Fuel Distribution Pipe and Fuel
4.6 Knock Sensor ....................................................... 378 Injector Assembly ...................................................... 424
4.6.1 Overview .......................................................... 378 10.4 Check on Fuel Injector ....................................... 425
4.6.2 Removal and Installation of Knock Sensor ...... 378 23 Charging, Starting and Ignition System ................ 426
4.6.3 Check on Knock Sensor.................................... 379 1 Overview ................................................................. 426
4.7 Oxygen Sensor ..................................................... 381 2 Check and Diagnosis ............................................... 427
4.7.1 Overview .......................................................... 381 2.1 Common Fault Checking and Eliminating ........... 427
4.7.2 Removal and Installation of Front Oxygen Sensor 2.1.1 Generator Output Fault ..................................... 427
................................................................................... 383 2.1.2 Abnormal Operation of Starter .......................... 427
4.7.3 Removal and Installation of Rear Oxygen Sensor 2.1.3 Spark Plug: Spark Failure ................................. 428
................................................................................... 385 3 Technical Parameters............................................... 430
4.7.4 Check on Oxygen Sensor.................................. 386 4 Charging System ..................................................... 431
4.8 Engine Oil Control Valve..................................... 388 4.1 Removal and Installation of Engine Assembly .... 431
4.8.1 Overview .......................................................... 388 4.2 Check on Generator.............................................. 433
4.8.2 Removal and Installation of V.V.T Valve .......... 388 5 Starter System ......................................................... 434
4.9 Throttle Control System....................................... 390 5.1 Removal and Installation of Starter Assembly ..... 434
4.9.1 Overview .......................................................... 390 5.2 Check on Starter Assembly .................................. 434
4.9.2 Removal and Installation of Electronic Throttle 6 Ignition System ....................................................... 436
Body Assembly .......................................................... 391 6.1 Ignition Coil ......................................................... 436
4.10 Removal and Installation of Electronic Accelerator 6.1.1 Overview ........................................................... 436
Pedal Assembly.......................................................... 393 6.1.2 Removal and Installation of Ignition Coil ......... 436
5 Emission Control System ....................................... 394 6.1.3 Check on Ignition Coil ...................................... 437
5.1 Overview ............................................................. 394 6.2 Spark Plug ............................................................ 439
5.2 Crankcase Ventilating Oil-gas Separating System395 6.2.1 Removal and Installation of Spark Plug ............ 439
5.2.1 Overview on Crankcase Ventilating Oil-gas 6.2.2 Check on Spark Plug ......................................... 439
Separating System ..................................................... 395
5.2.2 Removal and Installation of PCV Valve ........... 395
5.2.3 Check on PCV Valve ........................................ 397
5.3 Fuel Evaporation Control System ........................ 398
5.3.1 Overview .......................................................... 398
5.3.2 Overview on Fuel Evaporation Pipeline ........... 399
5.3.3 Removal and Installation of Carbon Canister ... 400
5.3.4 Removal and Installation of Canister Solenoid
Valve .......................................................................... 400
5.3.5 Check on Canister Solenoid Valve.................... 401
21 Fuel Supply System .............................................. 403
1 Overview ................................................................ 403
1.1 Instructions for Safe Operation ............................ 403
1.2 Cleaning Basics ................................................... 405
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10 Engine Assembly
1 System Overview
The powertrain of this model adopts the A131, A151 engines, which are the 1.3L/1.5L, 4-cylinder, 16 valves and
DOHC gasoline engine.
1 Technical Features
a. Light and Compact
It uses cast aluminum cylinder blocks, resin intake manifold, and a resin cylinder head cover, which remarkably
reduce the engine weight and make for a light and compact design.
b. High Performance
It uses the new continuous variable valve timing mechanism, and vortex shaped intake manifold with long air duct and
stainless steel exhaust manifold with long air duct, realizing a strong power output.
c. High Compression Ratio
The combustion chamber shape of A131, A151 engine is of roof type, and the spark plug is on the center of
combustion chamber. The compression ratio of the engine is 10.5, and the high compression ratio offers good
dynamics to the engine.
d. High Inflation Efficiency
A131, A151 engines have 16 valves totally, with 8 intake valves and 8 exhaust valves; thanks to the continuous
variable valve timing mechanism, the inflation efficiency is enhanced significantly. Meanwhile, since it uses the
longer heat-insulating intake manifold, the torque for low and medium speed is improved; the smoothness in the
interior surface of the air duct is improved, which can significantly improve the power for the high speed range,
therefore, the inflation efficiency in the whole speed range is high.
e. High Rotation Rate
The maximum rotation rate of A131, A151 can reach 6500～6800rpm, and the rotation rate in the maximum power
point is 6000rpm. Since it uses the dual overhead camshaft, the camshaft directly drive the opening of intake and
exhaust valves through cup-type tappet, so as to reduce the inertial-mass of valve system and improve the rigidness of
the valves, and ensure that the engine runs at high rotation rate.
f. Low Fuel Consumption
The main moving system has low friction and low-bottom water jacket design, and uses a low-tension piston ring as
well as small and high knock-resistance combustion chamber, so the fuel consumption of A131, A151 is very low.
g. Higher Liability
A131 and A151 engines have undergone strict endurance test over 800h, together with resonance fatigue test, and high
water temperature cooling and thermal circulation test in the course of design and development to ensure they have
reliable superb quality.
h. Good Emission
A131, A151 starting
Repair Group 10 - Engine Assembly 1

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Engine
2 Check and Diagnosis

2.1 Engine Service Precautions
Precondition
The precondition for using the Maintenance Manual is able to use the maintenance tools correctly so as to ensure
safety and working efficiency of the engine maintainers.
Safety Warning
Carefully read and follow the cautions and warnings included in this manual, to avoid potential injury. In addition,
improper service may also lead to engine damage.
Basic Operations
 Safety assurance: Start the engine when equipment and people are at a safe distance away from the engine.
 Preparation of tools and measuring devices: Prepare all necessary tools and measuring devices before work.
 Dedicated (specialized) tools: Use dedicated tools if necessary.
 Removal of parts: when eliminating a fault, decide the fault reason as far as possible and understand parts and
sub-assemblies to be removed and disassembled before start of work for the sake of easy replacement and repair.
 Disassembly: If the disassembly process is complicated, disassemble some of the parts. The disassembly should
not affect the performance, appearance and identification of the parts. In this way, reassembly can be performed
effectively.
− Part inspection: Carefully check all disassembled parts for failure, deformation, damage or other problems.
− Part organization: Carefully organize all disassembled parts for reassembly. Separate the parts to be replaced
from those to be reused, or mark them otherwise.
− Clean the parts to be reused: It is necessary to clean all the parts which will be reused.
 Reassembly: Measure all the parts which will be reused, based on relevant standards. Replace the oil seal, washer,
O-ring and other similar parts after disassembly.
 Requirements on Specific Parts
− It is necessary to apply sealant to the washer.
− Apply lubricant to the moving parts of the components.
− Apply the specified lubricant or grease to the specified positions (oil seal, etc.) before assembly.
 Adjustment: Adjust them according to standard values using a gauge and measuring devices.
 Rubber parts and rubber hoses: Prevent rubber parts and hoses from coming in contact with gasoline or lubricant.
 Electrical System
− Ensure that the battery wire and the negative post are not in contact. When removing the connector, don't
pull the wire. When connecting the connectors, make sure you hear the click. Be careful when removing and
installing sensors and relays. Don't let them fall or collide with other parts.
− Only check the electronic injection system with a digital multimeter.
− Don't remove any part or connector of the electronic injection system from its original position without
proper instruction, to prevent unexpected damage as well as preventing water, oil or impurities from
entering the connector and affecting the normal operation of the system.
− Please use genuine parts and components for repair work. Otherwise, the normal operation of the electronic
injection system cannot be guaranteed.
− Use unleaded gasoline only in the process of maintenance.
− Please execute the repair work in compliance with the specified repair and diagnosis processes.
− During repair, don't disassemble or remove the parts and components of the electronic injection system.
− During repair, be careful when handling electronic components (ECU, sensors) and avoid dropping.
2 Repair Group 10 - Engine Assembly

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− When executing the simulation of thermal working conditions or any other repair work that may increase
the temperature, the temperature of the ECU shall not exceed 80℃.
− Don't test the input and output electrical signals of the parts by piercing the wire coating.
− When checking the ignition system, only execute a sparking test as necessary, and do the test as quickly as
possible. During the test, don't open the valve. Otherwise, a lot of unburned gasoline will enter the exhaust
pipe and damage the three-way catalytic converter.
− Be aware of environmental protection and be sure to properly dispose of the waste generated during the
repair process.

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2.2 Common Fault Checking and Eliminating

2.2.1 Engine Starts Abnormally
No. Inspection steps Check results Fault elimination
0 Preliminary Inspection Normal There's a fault Operation methods
Check whether the anti-theft Release its anti-theft
Proceed to Step 1. Anti-theft system working
system is available effect
1 Check the starter Normal There's a fault Operation methods
Listen carefully the sound of Further check and
Starter cannot operate or
starter operation while the Proceed to Step 2. repair the starter =>
operate abnormally
engine is starting. Refer to Page 427
2 Check spark plug ignition Normal There's a fault Operation methods
Further check and
Check status of spark plug Spark plug not arcing or repair the ignition
Proceed to Step 3.
ignition arcing weakly system => Refer to
Page 428
3 Check the air intake system Normal There's a fault Operation methods
Replace the damaged
Check air intake system
Air leakage of air intake part or repair the
parts and connection Proceed to Step 4.
system connection with air
between parts
leakage
Check pressure of fuel
4 Normal There's a fault Operation methods
system
Connect an external fuel Further check and
pressure gauge to check fuel Proceed to Step 5. Fuel pressure is too low repair the fuel system
pressure => Refer to Page 406
Check control signal of the
fuel injector
Check fuse, circuit,
Check connector bonding
No fuel injection control connector and engine
and power supply of the fuel Proceed to Step 6.
signal control unit (ECM) and
injector
eliminate relevant faults
6 Check the fuel injector Normal There's a fault Operation methods
Abnormal fuel injection of
the fuel injector, blocking
Check fuel injection
and oil dripping of the fuel
conditions of the fuel Proceed to Step 7. Replace the injector
injector or poor
injector
atomization of fuel
particles
Check coolant temperature
sensor
Check relevant parameters The coolant temperature
Replace coolant
of the coolant temperature Proceed to Step 8. sensor open or resistance
temperature sensor
sensor abnormal
8 Check the ignition timing Normal There's a fault Operation methods
Check the ignition advance Ignition advance angle
Proceed to Step 9. Replace the ECM
angle abnormal
9 Check the cylinder pressure Normal There's a fault Operation methods
Further check and
Check compression pressure The compression pressure eliminate cylinder
Proceed to Step 10.
of all cylinders of the cylinder is too low underpressure fault =>
Refer to Page 130

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No. Inspection steps Check results Fault elimination

Operate the front electric
Find the cause from
10 windows and check whether End of diagnosis Faults still exist
other symptoms
fault occurs after repairs
2.2.2 Engine Idle Speed Abnormal

No. Inspection steps Check results
Engine mounting cushion Replace the mounting
Check engine mounting
Proceed to Step 1. aging and damaged and cushion or tighten the
cushion and bracket
mounting bracket loose loose mounting bracket
1 Check the spark plug Normal There's a fault Operation methods
Clean carbon deposit
on the spark plug or
Check dirtiness conditions Excessive carbon deposit
further check and
on the surface of the spark on the spark plug or some
Proceed to Step 2. eliminate no arcing or
plug and its arcing cylinders not arcing or
weak arcing fault of the
conditions arcing weakly
spark plug => Refer to
Page 428
2 Check the air intake system Normal There's a fault Operation methods
Replace the damaged
Check air intake system
Air leakage of air intake part or repair the
parts and connection Proceed to Step 3.
system connection with air
between parts
leakage
3 Check the throttle Normal There's a fault Operation methods
Check dirtiness conditions
Proceed to Step 4. Throttle too dirty Clean the throttle
of the throttle
system
Abnormal fuel injection of
the fuel injector, blocking
and oil dripping of the fuel
injector or poor
injector
atomization of fuel
particles
6 Check various sensors Normal There's a fault Operation methods
Check for fault codes of
such sensors as coolant
Replace the faulty
temperature sensor, pressure
Relevant sensor or circuit sensor or troubleshoot
and temperature sensor, Proceed to Step 7.
connector faulty the relevant circuit
throttle position sensor,
connector
crankshaft position sensor,
oxygen sensor, etc.
Check the canister solenoid
valve
Check whether the carbon Carbon canister solenoid
Replace the canister
canister solenoid valve is Proceed to Step 8. valve normally open and
solenoid valve
normally open cannot be closed
8 Check the cylinder pressure Normal There's a fault Operation methods

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Further check and
Excessive compression eliminate abnormal
Check compression pressure
Proceed to Step 9. pressure difference pressure fault of the
of all cylinders
among cylinders cylinder => Refer to
Page 130
Find the cause from
other symptoms
2.2.3 Poor Engine Acceleration and Power Reduction

Air filter element dirty Clear the blockage and
Check whether the air intake
Proceed to Step 1. and blocked by foreign replace the air filter
system is blocked
matters element
system
Abnormal fuel injection
of the fuel injector,
blocking and oil dripping
of the fuel injector or
injector
poor atomization of fuel
particles
Clean carbon deposit or
Excessive carbon deposit
Check dirtiness conditions further check and
on the spark plug and no
on the surface of the spark eliminate no arcing or
Proceed to Step 4. arcing or weak arcing of
plug and its arcing weak arcing fault of the
the spark plug when the
conditions spark plug => Refer to
engine is operating
Page 428
4 Check knock sensor Normal There's a fault Operation methods
Disconnect connector of the
The knock sensor is
knock sensor, bond its
faulty that causes lag of Replace the knock
wiring harness connector Proceed to Step 5.
the ignition advance sensor
and check whether engine
angle
power is improved
5 Check the exhaust system Normal There's a fault Operation methods
The exhaust system is
blocked by foreign Clear the foreign
Check whether the exhaust
matters or the catalytic matters and replace the
system is blocked, especially Proceed to Step 6.
converter is blocked, blocked catalytic
the catalytic converter
featuring unsmooth converter assembly
exhaust
Check for fault codes of
such sensors as pressure and Replace the faulty
temperature sensor, throttle Relevant sensor or circuit sensor or troubleshoot
Proceed to Step 7.
position sensor, crankshaft connector faulty the relevant circuit
position sensor, oxygen connector
sensor, etc.

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Check the ignition advance Ignition advance angle
angle abnormal
Check the cylinder
pressure
Low compression Further check and
Check compression pressure of the cylinder eliminate cylinder
Proceed to Step 9.
pressure of all cylinders and reduction in engine underpressure fault =>
power Refer to Page 130
windows and check Find the cause from
9 Normal Faults still exist
whether fault occurs after other symptoms
repairs

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2.3 Regular Tests

2.3.1 Oil Pressure Switch
Tips
Test oil pressure in case of following conditions to judge whether the fault is caused by abnormal oil pressure:
 Difficulty in starting the engine, unstable idling, weak acceleration.
 Excessive wear and tear, burns, or noise in the engine crankshaft bearing bush.
 Noise in the camshaft.
 Excessive vibration when the engine is running.
Special Tools and Maintenance Equipment Required:
T21451401-Oil pressure measuring
Prerequisites
 The engine has reached normal working temperature (above 80℃).
 The level of engine oil is normal.
Test procedure
1. Turn off the ignition and all electrical equipment.
2. Disconnect the battery negative cable=>Electrical Equipment: Repair Group: 60; Power Distribution; Battery:
Battery Cables: Disconnection and Connection of Battery Negative Cable.

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3. Disconnect the connecting plug -Arrow A- of the starter, lift up the

guard -Arrow C- of the starter terminal and unscrew the fixing nut
-Arrow B- of the starter terminal.
Nuts - Arrow B - Specifications：M8×1.25
Nut -Arrow B- tightening torque: 10 - 12 Nm
Nut -Arrow B- tool: 13mm hexagon sleeve
4. Put aside the starter wiring harness -1-.
5. Unscrew fixing bolts - arrows – for the starter assembly, and remove
the starter assembly-1-.
Bolt -Arrow- specification: M8×1.25×50
Bolt -Arrow - tightening torque: 20 - 28 Nm
Bolt -Arrow- tool: 12mm hexagon sleeve
6. Disengage the connecting plug -Arrow- of the oil pressure sensor.
7. Unscrew the fixing screw -Arrow- of the oil pressure sensor insert
and remove the oil pressure sensor insert-1-.
Screw -Arrow - tightening torque: 0.5 - 1.5 Nm
8. Unscrew the oil pressure sensor -2-.
Tightening torque of oil pressure sensor -2-: 9～11 Nm
Tool of oil pressure sensor -2-: 24mm hexagonal sleeve

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Note
 Before installing the engine oil pressure switch, clean the threads and the threaded hole of the engine oil
pressure switch.
 When installing the engine oil pressure switch, apply some sealant to the threads of the engine oil pressure
switch.
9. Install the engine oil pressure test tool onto the threaded hole of the
engine oil pressure switch.
10. Install the starter assembly -1- and tighten its fixing bolt -Arrow-.
11. Connect the connecting plug -Arrow A- of the starter, lift up the
guard -Arrow C- of the starter terminal and tighten the fixing nut -Arrow
B- of the starter terminal.
12. Connect the battery negative cable=>Electrical Equipment: Repair Group: 60; Power Distribution; Battery:
Battery Cables: Disconnection and Connection of Battery Negative Cable.
13. Start the engine and increase the RPM slowly, when the speed reaches 2000r/m and engine oil temperature reaches
80℃ or higher, the engine oil pressure should be at least 130kpa.
For even higher engine RPM, the engine oil pressure should not exceed 590kpa.

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Tips
 If the oil pressure is lower than the standard value, then:
− Check the screen of the engine oil strainer for blockage.
− If there is no blockage in the strainer screen or duct for engine oil, it indicates failure in the engine oil pump.
Replace the engine oil pump.
 If the oil pressure is higher than the standard value, then:
− Check the engine oil duct, in particular the return duct, for blockage. If the blockage is present, clean the
duct.
2.3.2 Cylinder Pressure Test
Tips
It is required to test the cylinder pressure in case of following conditions to judge whether the fault is caused by
abnormal cylinder pressure:
 Difficulty in starting the engine, unstable idling, weak acceleration.
 Excessive emission of HC.
 Excessive wear and tear of the piston(s) or piston ring(s), which leads to improper piston sealing.
 Throttle valve not airtight.
 Cylinder gasket leakage or blow-by.
Prerequisites
 Engine arrives at the normal working temperature.
 The level of engine oil is normal.
Test procedure
2. Remove driver foot space trim panel assembly =>Body and painting: Repair group: 82: Instrument panel; Removal
and installation of instrument panel left lower trim panel assembly.
3. Extract the fuel pump fuse -1- numbered FB31 (10A).
Note
Don't remove the fuel pump fuse -1- when the engine is still running.
Otherwise, it may damage the fuel pump and the ECU.
4. Remove all the spark plugs=>Refer to Page 439.

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5. Screw the cylinder pressure gauge into the threaded installation hole
of the spark plug in one of the cylinders.
Tips
Keep the connection sealed.
6. Have one technician set the transmission to N and fully press the
accelerator pedal (throttle fully open).
7. Start the engine (at this time, the engine can only be driven by the
starter, but not started).Observe the cylinder pressure gauge, until it
shows no further pressure increase.
Tips
 It must be performed with the battery fully charged.
 Every cylinder must be tested for not less than twice, and the maximum pressure is recorded.
8. Test the rest 3 cylinders by steps 4-7, measure pressure of all cylinders and calculate their pressure difference.
Engine Model A151 A131
Standard value for compression
pressure in the cylinder (engine 1270 kPa 1123 kPa
RPM:300r/min):
Limit value for compression pressure
in the cylinder (engine 1100 kPa 1100 kPa
RPM:300r/min):
Limit value for cylinder pressure
98 kPa
difference
If the compression pressure of the cylinders is lower than the standard value, or the pressure difference between the
cylinders is too high, put some clean engine oil into the spark plug mounting hole and perform the cylinder pressure
test again. If the result is substantially improved, it means the the piston or piston ring aren’t properly sealed, thus
requiring overhaul.If the result isn't obviously improved, it means the valve isn't properly sealed or there is leakage or
blow-by in the cylinder gasket.For improper sealing of the valve, overhaul the valve clearance, valve, and valve
base.For leakage or blow-by, replace the cylinder gasket.
2.3.3 Fuel Pressure Test
Tips
Test fuel pressure in case of following conditions to judge whether the fault is caused by abnormal fuel pressure:
 The engine is unable to start.
 Difficulty is found in starting the engine, unstable idling.
 Weak acceleration or misfire during acceleration is detected.
 High emission of hydrocarbon (HC) or normal emission of CO is detected.
Prerequisites

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 Make sure there is adequate fuel.

 No blockage exists in the fuel filter or the fuel pump screen.
Test procedure
2. Remove driver foot space trim panel assembly =>Body and painting: Repair group: 82: Instrument panel; Removal
and installation of instrument panel left lower trim panel assembly.

4. Start the engine, wait until the engine operates to automatic shutdown
and then turn off the ignition.
5. Install the fuel pump fuse -1- numbered FB31 (10A).
Note
Otherwise, it may damage the fuel pump and the ECM.
6. Connect the fuel pressure gauge to the three-way adapter, and connect
one end of the adapter to the fuel inlet hose -2- of the fuel rail, and the
other end to the fuel rail -1-.
7. Switch on the ignition switch, run the engine at the idle speed and
read the fuel pressure.
Standard value of fuel pressure at idling: 400 kPa
Tips
 Put a towel or a cotton cushion under the oil pipe connector while removing the oil pipe for fear that fuel leaks
into the engine compartment or onto the ground.
 If there is substantial variance between the result and the standard, solve the problem accordingly=> Refer to
Page 406.

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3 Technical Parameters
Torque
Name Specification Grade Tools
Nm
Fixing bolt of battery tray M8×1.25×16 8.8 14～16 10mm Hexagon Sleeve
Fixing nut of the engine wiring terminal M8×1.25 — 6～10 13mm Hexagon Sleeve
Fixing nut of the engine wiring terminal M5×0.8 — 4～6 8mm Hexagon Sleeve
Fixing bolt of brake pump vacuum hose bracket M8×1.25×16 8.8 21～25 12mm Hexagon Sleeve
Fixing bolt of engine wiring harness bonding M6×1.0×16 8.8 4～6 10mm Hexagon Sleeve
Transmission control unit bracket fixing nut M8×1.25 8 21～25 13mm Hexagon Sleeve
Fixing bolt of the gearshift cable assembly
M8×1.25×16 8.8 10～14 13mm Hexagon Sleeve
bracket
Fixing bolt of engine wiring harness bonding M8×1.25×20 8.8 14～16 13mm Hexagon Sleeve
Hinge bolt for cooling oil pipe assembly of
— — 40 20mm Hexagon Sleeve
automatic transmission
Fixing bolt for cooling oil pipe bracket of
automatic transmission
Fixing bolt of the rear mounting cushion M12×1.5×55 10.9 80～95 18mm Hexagon Sleeve
Fixing bolt for rear mounting bracket M12×1.25×60 10.9 75～85 15mm Hexagon Sleeve
Fixing bolt for rear mounting bracket M12×1.25×20 10.9 75～85 15mm Hexagon Sleeve
Fixing bolt for engine mounting bracket M10×1.25×65 12.9 50～60 13mm Hexagon Sleeve
Fixing nut for engine mounting bracket M10×1.25 10 50～60 15mm Hexagon Sleeve
Fixing bolt of the engine mounting cushion M10×1.25×30 10.9 60～70 13mm Hexagon Sleeve
Fixing nut of the engine mounting cushion M10×1.25 10 60～70 15mm Hexagon Sleeve
Fixing bolt for bond strap of the engine mounting
bracket
Fixing bolt of the automatic transmission
mounting cushion
Fixing nut of the automatic transmission
M10×1.25 10 50～60 15mm Hexagon Sleeve
mounting cushion
Fixing bolt of the automatic transmission
mounting cushion (to the body)
Fixing bolt of the manual transmission mounting
cushion
Fixing nut of the manual transmission mounting
M12×1.25 10 75～85 18mm Hexagon Sleeve
cushion
Fixing bolt of the manual transmission mounting
cushion (to the body)
Connecting bolts for hydraulic torque converter M8×1.25×10 10.9 24～28 10mm Hexagon Sleeve
Fixing bolt of the automatic transmission M10×1.25×40 8.8 20～28 10mm Hexagon Sleeve
Fixing bolt of the automatic transmission M10×1.25×50 8.8 20～28 10mm Hexagon Sleeve
Fixing bolt of the manual transmission M10×1.25×40 8.8 20～28 10mm Hexagon Sleeve
Fixing bolt of the flywheel M11×1.0×25 — 90～105 17mm Hexagon Sleeve
Inlet pipe assembly fixing bolt M6×1.0×20 8.8 8～10 10mm Hexagon Sleeve
Inlet pipe assembly fixing bolt M6×1.0×12 8.8 7～9 10mm Hexagon Sleeve
Fixing bolts of knock sensor M8×1.25×30 8.8 15～25 12mm Hexagon Sleeve

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Torque
Nm
Fixing bolts of crankshaft position sensor M6×1.0×16 8.8 8～12 10mm Hexagon Sleeve
Camshaft position sensor fixing bolt M6×1.0×16 8.8 8～12 10mm Hexagon Sleeve
Fixing bolt of the engine lifting lug M8×1.25×20 8.8 18～22 12mm Hexagon Sleeve

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4 Powertrain Units
4.1 Removal and Installation of Powertrain Assembly Components
Required special tools and service equipment
T51131001-Engine balance hanger T51271002-Engine balancing stand cross rod component
Removal
Note
 Before removing and installing the powertrain assembly components, disconnect all power supply harnesses,
drain the engine coolant, and disconnect the harnesses, pipes and other connections between the powertrain
assembly components and the body.
 Once a pipeline connector is disconnected, seal up the opening to prevent foreign objects from entering.
 Mark before disconnection of any wiring harness and pipeline for fear of incorrect connection or omission of
wiring harness and pipeline in installation.
 All drained coolant must be collected and handled as required. Keep the site clean and neat.
 Ensure that the tools and parts are orderly organized at the site and the workspace is well ventilated.
1. Release fuel pressure => Refer to Page 409.

2. Remove the battery => Electrical equipment; Repair Group: 60: Power distribution; Battery; Removal and
installation of battery.
3. Remove the air filter => Refer to Page 147.
4. Removal of the air chamber cover=>Body and painting; Repair group:83; Exterior equipment;Removal and
installation of the air chamber cover.
5. Remove the engine drive belt => Refer to Page 98.

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6. Remove the rubber blockage -arrow A- on the battery tray on, and pry
up the harness clip - Arrow B-.
7. Unscrew fixing bolts -arrows- for the battery tray and remove the
battery tray-1-.
8. Unscrew the fixing nut -Arrow A- of the starter wiring terminal and
the fixing nut -Arrow B- of the engine wiring terminal and disengage the
wiring harness clip -Arrow C-.
Nut -Arrow A- specification：M8×1.25
Nut -Arrow A- tightening torque: 6 - 10 Nm
Nut -Arrow A- tool: 13mm hexagon sleeve
9. Disconnect the joint plug -Arrow D- connecting the engine harness
and the starter harness.

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10. Press the locking clip -Arrow- and remove the cover -1- of the
engine compartment electrical box.
11. Unscrew the fixing nut -Arrow A- of the engine harness terminal,
disengage the fixing clip -Arrow B- of the front compartment electrical
box and remove the front compartment electrical box -1-.
Nut -Arrow A- specification：M8×1.25
12. Disconnect the connecting plug -Arrow C- of the front compartment
electrical box.
Tips
Install the connector of the front compartment electrical box to the
original position and lid the electrical box cover to protect the front
compartment electrical box against pollution by impurities.
13. Remove the fixing clamp -Arrow- of the fuel pipeline and disengage
the fuel pipeline -1-.
Tips
 Place a cloth at the connections before releasing the hoses, and
then pull out the hoses carefully.
 Do not reuse the fixing clamp but replace with a new one.

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14. Loosen the fixing clamp -Arrow- of the brake vacuum hose and
disengage the brake vacuum hose -1-.
15. Unscrew the fixing bolt -Arrow A- of brake pump vacuum hose
bracket and put aside the brake pump vacuum hose bracket -1-.
Bolt -Arrow A- specification:M8×1.25×16
Bolt -Arrow A- tool: 12mm hexagon sleeve
16. Disconnect the connecting plug -Arrow B- of the carbon canister
solenoid valve and disengage the connection between the carbon
canister solenoid valve -2- and the hose -3-. Disengage the carbon
canister solenoid valve -2- and put the carbon canister solenoid valve -2-
(with hose) aside.
Note
Wrap and seal the disconnected pipeline connector for fear of internal pollution.
Applicable to F15 manual transmission

17. Disengage the connection of the gearshift cable -1- and the gearshift
rocker arm assembly -2- with the cable bracket -3-.

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18. Disengage the connection of the selector cable -1- and the gearshift
rocker arm assembly -2- with the cable bracket -3-.
19. Unscrew the fixing bolt -Arrow- of the manual transmission bond
strap and put aside the bond strap -1-.
Bolt - Arrow - Specifications：M6×1.0×12
Applicable to the manual transmission MF513A

20. Pry out selector cable and gearshift cable along -Arrow A-,-Arrow
B-.

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21. Pry out selector cable and gearshift cable along -Arrow A-,-Arrow
B- from cable bracket.
Applicable to the automatic transmission

22. Disengage the connection between the shift cable assembly -1- and
the shift arm -2-.
23. Press the unlocking part -Arrow-, and disengage the connection
between the gearshift cable assembly -1- and the fixing bracket -3-.
24. Unscrew the fixing bolt -Arrow- of the gearshift cable assembly
bracket and put aside the gearshift cable assembly with bracket -1-.
Bolt -Arrow- tool: 13m hexagon sleeve

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25. Unscrew the fixing bolt -Arrow- of the engine wiring harness
bonding and put aside the engine bond strap -1-.
26. Unscrew the fixing nut -Arrow- of the transmission control unit
bracket and remove the transmission control unit with bracket -1-.
Nut - Arrow- specification：M8×1.25
Nut -Arrow - tightening torque: 21 - 25 Nm
Nut -Arrow- tool: 13mm hexagon socket
27. Disconnect the connecting plug -Arrow A- and -Arrow B- of the

transmission control unit.
Applicable to all models

28. Remove A-pillar lower trim panel =>Body and painting: Repair group: 84: Interior equipment: Removal and
installation of A-pillar lower trim panel.

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29. Disconnect the connecting plug -Arrow A- and -Arrow B- of the

engine control unit and engine wiring harness connector -Arrow-C, and
pry up the connector fixing clip -Arrow D- and the wiring harness fixing
clip -Arrow E-.
30. Unscrew the fixing bolt -Arrow- of the engine wiring harness
grounding.
31. Unscrew the fixing clip -Arrow A- for right front cover plate of the
auxiliary instrument panel and remove the right front cover plate -1- of
the auxiliary instrument panel along the direction -Arrow B-.

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32. Lift up the carpet -1-, pry up the fixing clip -Arrow- of the front
passenger foot rest and remove the front passenger foot rest -2-.
33. Disengage the clip -Arrow- of the front oxygen sensor connector.
34. Turn the steering wheel to the straight driving direction.

35. Make the assembly mark - arrow A with a marking pen on the
steering column assembly -1- and electric power-assist steering
assembly -2-.
36. Unscrew the fixing bolts - arrow B-, disengage the connection
between the steering column assembly -1- and electric power-assist
steering assembly -2-.
Bolt - Arrow B - Specifications：M8×1.25×30
Bolt -Arrow B- tightening torque: 20 - 26 Nm
Bolt -Arrow B- tool: 13mm hexagon sleeve

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37. Disconnect the wiring harness connector -Arrow A- and disengage

the wiring harness fixing clip -Arrow B- and -Arrow C-.
38. Disengage the wiring harness rubber cover -1- and pull out the
engine wiring harness -2-.
Tips
While pulling out the wiring harness, take out the wiring harness
connector separately for fear that the connector is clamped at the outlet
and thus damages the wiring harness.
39. Drain the coolant=>Overview; Repair Group:01: General Information; Service and Maintenance: Work
Description: Coolant: Replace.

40. Drain the automatic transmission lubricant => General; Repair group: 01: General information; Maintenance:
Work description: Automatic transmission oil: Replace.
41. Unscrew the hinge bolt -Arrow A- for cooling oil pipe assembly of
the automatic transmission and the fixing bolt -Arrow B- of the oil pipe
bracket and disengage the cooling oil pipe assembly -1- of the automatic
transmission.
Bolt -Arrow A- tightening torque:40 Nm
Bolt -Arrow B- tightening torque: 6±12 Nm
Tips
 Use a proper container to collect the automatic transmission oil while the automatic transmission oil pipe is
disconnected.
 Sealing gasket of the automatic transmission oil pipe shall be replaced.
 Wrap and seal the disconnected connector of the automatic transmission oil pipe.
Applicable to the manual transmission

42. Drain the manual transmission oil => General; Repair group: 01: General information; Maintenance: Work
description: Manual transmission lubricant: Replace.

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43. Unscrew the fixing bolt -Arrow- of the clutch slave cylinder and put
aside the clutch slave cylinder -1-.
Tips
Don't depress clutch pedal assembly after disengaging.

44. Loosen the fixing clamp -Arrow- of the engine drain pipe and
disengage the engine drain pipe -1-.
45. Disconnect the connecting plug -Arrow- of the A/C compressor

clutch.

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46. Unscrew the fixing bolt -Arrow- on the A/C compressor, and
suspend it on the body with a sturdy rope or wire.
47. Loosen the fixing clamp -Arrow A- of the engine feed pipe and
disengage the engine feed pipe -1-.
48. Loosen the fixing clamp -Arrow B- for water inlet pipe of the
heating water tank and disengage the water inlet pipe -2- of the heating
water tank.
49. Loosen the fixing clamp -Arrow C- for water outlet pipe of the
heating water tank and disengage the water outlet pipe -3- of the heating
water tank.
Tips
Collect the overflown fluid with a proper container when disconnecting
the cooling pipe.
50. Install the engine balance bracket with the tool number -T51131001-
and the engine balance bracket crossbar component with the tool
number -T51271002- and fix the engine assembly -1-.
51. Remove the steering knuckle component at both sides => Chassis; Repair group: 41: Front suspension; Drive shaft
assembly: Removal and installation of the drive shaft assembly.

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52. Unscrew the fixing nut - arrow -, and disengage the connection
between the front stabilizer bar right link -1- and front stabilizer bar -2-.
Nut -Arrow - tool:18mm combination wrench
53. Unscrew the fixing nut - arrow -, and disengage the connection
between the front stabilizer bar left link -3- and front stabilizer bar -2-.
Nut -Arrow - tool:18mm combination wrench
54. Pry out the right drive shaft -1- with its removal tool -T61454001-.
Tips
Take out the drive shaft straight for fear of damage to the oil seal.
55. Refer to the description regarding removal of the right drive shaft to
remove the left drive shaft assembly with the same method.
56. Disengage the dustproof rubber cover -1- of the front oxygen sensor.

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57. Disconnect the connecting plug -Arrow- of the front oxygen sensor
-1-.
Tightening torque of the front oxygen sensor -1-: 40～60 Nm
58. Pry up the connection between the wiring harness clip -Arrow- and
the body and disengage the dustproof rubber cover -1- of the rear
oxygen sensor.
59. Disconnect the connecting plug -Arrow- of the rear oxygen sensor.
Tightening torque of the rear oxygen sensor -1-: 40～60 Nm
60. Unscrew the fixing bolt -Arrow- of the catalytic converter assembly
and the exhaust manifold assembly and disengage the hook washer -1-.

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Tips
 Apply a small amount of engine oil inside the installation hole of the lug gasket to facilitate its removal or
installation.
 Please ask another technician to hold the auxiliary silencer assembly for fear that it falls from high.
 61. Unscrew the fixing nut -Arrow- of the catalytic converter

assembly and the auxiliary silencer, disengage the connection
between the catalytic converter-1- and the auxiliary silencer -2-
and remove the catalytic converter assembly -1-.
 Nut - Arrow- specification：M10×1.25
 Nut -Arrow - tightening torque: 49 - 69 Nm
 Nut -Arrow- tool: 16mm hexagon socket
Note
The catalytic converter is expensive and fragile. Handle it carefully during its removal or installation. Otherwise,
damage may occur, causing the converter to malfunction.
62. Unscrew the fixing bolts - arrow A-, bolt - arrow B-, bolt - arrows
C-, and remove the rear suspension cushion assembly -1- and rear
suspension bracket assembly -2-.
Bolt - Arrow A - Specifications：M12×1.25×60
Bolt - Arrow C - Specifications：M12×1.5×55
Bolt -Arrow C- tool: 18mm hexagon sleeve

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63. Disconnect electric power-assist steering assembly connector - arrow

A- and - arrow B-.
64. Place front subframe component -1- with the engine and transmission lifting device.
65. Remove the fixing bolt - arrow A - and - arrow B-, and lower the front subframe assembly -1-.

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Tips
It must be carried out with the assistance of another assembly worker.
66. Put the workbench under the power assembly component and
gradually lower the vehicle until the lower planes of the engine
assembly -1- and the transmission assembly -2- just contact the upper
plane of the workbench -3-.
Tips
 Please use the workbench with turning gear for adjustment of
orientation and angle after removal of the power assembly
component.
 Put vibration-absorptive material on the upper plane of the
workbench.
67. Unscrew the fixing bolt -Arrow C- of the engine ground wire.
Bolt -Arrow C- specification:M8×1.25×20
68. Unscrew the fixing bolt -Arrow A- on the engine mounting bracket.
69. Unscrew the fixing nut -Arrow B- on the engine mount bracket -1- and remove the bracket -1-.

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70. Unscrew the fixing bolt -Arrow A- of the automatic transmission

mounting bracket.
71. Unscrew the fixing nut -Arrow B- of the automatic transmission
mounting bracket.

72. Unscrew the fixing bolt -Arrow A- of the manual transmission
mounting bracket.
73. Unscrew the fixing nut -Arrow B- of the manual transmission
mounting bracket.

74. Unscrew the fixing bolt -Arrow A- of the manual transmission
mounting bracket.
75. Unscrew the fixing nut -Arrow B- of the manual transmission
mounting bracket.

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76. Remove the engine balance bracket with the tool number
-T51131001- and the engine balance bracket crossbar component with
the tool number -T51271002-. Fix the power assembly component on
the workbench with the strapping tape, gradually lift the body, and push
out the workbench and the power assembly component.
Danger
Perform safety work of the lifting device before you operate it.
Note
 While a technician operates the lifting device, another one or two technicians keep a close eye over moving
conditions of all parts throughout the lifting process and prevents the power assembly component collides into
the body part or pulls any connections not disconnected by adjusting its orientation and angle.
 Place the removed powertrain assembly securely in a clean place and seal up all the disconnected pipes, to
prevent contamination of the pipes.
Installation
Install in reverse order of removal procedures and please note the following:
Note
 Arrange and install all pipelines by their original status (such as fuel pipeline, steering oil pipeline, air
conditioning pipeline, coolant pipeline, fuel evaporation pipeline and vacuum pipeline), connect wiring
harness connectors, connectors and fasteners.
 Don't miss or incorrectly reconnect any oil and fluid pipes, air pipes or plugs as it may result in poor
operation of the engine or even cause damage.
 Pay attention to that pipelines and wires shall have enough distance from the moving parts or parts likely to
become hot, especially the brake pipeline and the fuel pipeline for fear of damage to pipelines and wires as a
result of improper installation.
 Connect the diagnostic tester to clear the fault memory after all engine oils are filled.
 Start the engine, warm up to exhaust the cooling system, exhaust the clutch cylinder and test run.

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4.2 Removal and Installation of Engine Assembly

Hoisting device
Removal
1. Remove the power assembly component => Refer to Page 16.
2. Disconnect the connecting plug -Arrow A- of the ignition coil and the
connecting plug -Arrow B- of the fuel injector.
3. Disengage the wiring harness fixing clip -Arrow- C.
4. Disengage the wiring harness clip -Arrow A- and disconnect the

connecting plug -Arrow B- of the solenoid valve.

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5. Disconnect connecting plug -Arrow A- of V.V.T solenoid valve.

6. Disconnect the connecting plug -Arrow B- of the generator, lift up the
generator terminal guard -1- and unscrew the terminal nut -Arrow C-.
Nut - Arrow C- specification：M8×1.25
Nut -Arrow C- tightening torque: 18 - 22 Nm
Nut -Arrow C- tool: 13mm hexagon sleeve
7. Unscrew the fixing bolt -Arrow A- and -Arrow B- of A/C compressor

bracket and remove the A/C compressor bracket assembly -1-.
8. Disconnect the connecting plug -Arrow A- of the crankshaft position

sensor and disengage the wiring harness clip -Arrow B-.

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9. Disconnect the connecting plug -Arrow A- of the knock sensor.

10. Disconnect the connecting plug -Arrow B- of the starter, lift up the
starter terminal guard -1- and unscrew the fixing nut -Arrow C- of the
starter terminal.
11. Unscrew fixing bolts - arrows – for the starter assembly, and remove
the starter assembly-1-.
12. Disconnect the connecting plug -Arrow A- of the oil pressure sensor,
disengage the wiring harness clip -Arrow B- of the starter and remove
the starter wiring harness assembly -1-.
13. Disconnect intake air temperature sensor -Arrow A-, camshaft

position sensor -Arrow B-, coolant sensor -Arrow- C, and electronic
throttle sensor -Arrow D- and disengage the wiring harness clip -Arrow
E-.

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14. Disconnect the automatic transmission connector - arrow A-, and

disengage the harness fixing clip - arrow B-.
15. Disconnect the automatic transmission connector - arrow A -, - arrow

B-, and gear switch connector - arrow C-.
16. Unscrew the fixing bolt -Arrow D- of the engine wiring harness
bonding, disengage the wiring harness fixing clip -Arrow E- and -Arrow
F- and remove the engine wiring harness assembly -1-.

17. Disconnect the connecting plug -Arrow A- of the reversing light
switch, disengage the wiring harness fixing clip -Arrow B- and remove
the engine wiring harness assembly -1-.

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18. Unplug the manual transmission plug -Arrow A-.

19. Unscrew the fixing bolt -Arrow B- of the engine wiring harness
installation bracket and remove the engine wiring harness assembly -1-.

20. Unscrew the fixing bolt -Arrow A- and -Arrow B- of the generator
bracket and remove the generator assembly -1-.
21. Lift the powertrain component -1- slightly, using a lifting unit.
Tips
Ensure powertrain -1- is lifted firmly.

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22. Unscrew the fixing bolt -Arrow- of the bell housing -1- and remove
the bell housing -1-.

23. Unscrew connecting bolts - arrows - for the hydraulic torque
converter.
Tips
Rotate the crankshaft pulley -1- clockwise, so that the next connecting
bolt - arrow - of the hydraulic torque converter rotates to lower position
directly to facilitate dismantling, and totally six bolts are unscrewed.
24. Unscrew the connecting bolt -Arrow A- and -Arrow B- of the

engine assembly -1- and the transmission assembly -2- and remove the
engine assembly -1-.

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25. Unscrew the connecting bolt -Arrow- of the engine assembly -1- and
the transmission assembly -2- and remove the engine assembly -1-.

26. Unscrew the connecting bolt -Arrow- of the engine assembly -2- and
the transmission assembly -1- and remove the engine assembly -1-.
Applicable to all manual transmissions

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27. Use the clutch disc positioner - T61133001- to position the clutch
friction lining -1- for fear that the clutch friction lining -1- falls onto the
ground in removal.
28. Unscrew the fixing bolt -Arrow- of the clutch pressure plate.
29. Remove the clutch pressure plate -2- and the clutch friction lining -1-
separately.
Installation
Install in reverse order of removal procedures.

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4.3 Engine Assembly: Disassembly

Disassembly
1. Fasten the flywheel with a flywheel stopper (Tool No.:T61131201).
2. Loosen the fixing bolt -Arrow- of the flywheel but do not unscrew it
(remove the flywheel stopper -T61131201-).
3. Unscrew the flywheel bolts -Arrow-, and remove the flywheel -1-.
(AT) Bolt -Arrow- Size: M11×1.0×17.5
(MT) Bolt -Arrow- Size: M11×1.0×25
Note
Apply a proper amount of LOCTITE 2701 or equivalent product to threads of flywheel bolts while installing the
flywheel bolts.
4. Install the engine assembly -1- onto the rollover stand -2-.

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5. Unscrew the drain bolt -1- and collect engine lubricant with proper
container.
Tightening torque of drain bolt -1-: 38~42 Nm
Drain bolt -1- tool: 17mm hexagon sleeve
6. Unscrew the fixing bolt -Arrow- of the ignition coil and remove the
ignition coil -1-.
7. Unscrew the spark plug-1-.

Bolt -Arrow- tool: 16mm hexagon long sleeve
8. Unscrew the fixing bolt -Arrow- of the fuel rail assembly and remove
the fuel rail -1-.
Bolt -Arrow - tightening torque: 16.4 - 20.4 Nm

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Note
While removing the fuel rail with fuel injector assembly, do not remove one end separately and remove the other
later, but remove both ends slowly and uniformly. Press in two ends uniformly while installing to ensure they are
installed to due positions.
Tips
 Replace sealing rings -1- and -2- at two ends of the fuel injector as
necessary.
 Apply a thin layer of vaseline or similar product to sealing rings
-1- and -2- while installing.
9. Loosen the clamp -Arrow A-, and pull out the water pipe -1-; loosen
the clamp -Arrow B-, and pull out the water pipe -2-.
10. Unscrew the fixing bolt -Arrow C- of the engine lifting lug and
remove the engine lifting lug -3-.
11. Unscrew the fixing bolt -Arrow A- of the electronic throttle

assembly, remove the drain pipe fixture -2-, unscrew the fixing bolt
-Arrow B- of the electronic throttle assembly and remove the electronic
throttle assembly.
Bolt -Arrow A/B- tightening torque:5～7 Nm
Bolt -Arrow A/B- tool: 10mm hexagon sleeve

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12. Disengage the connection between the PCV venting hose -3- and the
cylinder head cover.
13. Unscrew the fixing bolt -Arrow A- of the intake manifold assembly
and remove the intake manifold assembly -1-.
Tips
 Sealing ring of the intake manifold must be replaced.
 While installing sealing ring of the intake manifold, align its bulging part with relevant position of the intake
manifold.
14. Unscrew the fixing bolt -Arrow B- of V.V.T valve and remove the V.V.T valve -2-.
Tips
 The O-ring is a disposable part, which should be replaced after being removed.
 To avoid damaging the V.V.T valve, wind the fuel duct part of the V.V.T with adhesive tape after removing it.
15. Unscrew the fixing bolt -Arrow- on the inlet pipe assembly -1-.
16. Unscrew the coolant sensor -2-.
Tightening torque of the coolant sensor -2-: 10～14 Nm
Tool of the coolant sensor -2-: 19mm dual wrench
Tips
Apply a proper amount of LOCTITE 263 or equivalent product to threads of the coolant sensor before installing.

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17. Unscrew the fixing bolt -Arrow A- on the inlet pipe assembly, and
remove the inlet pipe assembly -1-.
Tips
Sealing gasket of the water inlet pipe component must be replaced.
18. Unscrew the fixing bolt -Arrow B- on the engine oil filter bracket assembly, and remove the bracket assembly-2-.
Tips
Sealing gasket of the oil filter must be replaced.
19. Unscrew the fixing bolt -Arrow C- of the knock sensor and remove the knock sensor -3-.
20. Unscrew the fixing bolt -Arrow D- of the camshaft position sensor and remove the camshaft position sensor -4-.
Bolt - Arrow D - Specifications：M6×1.0×16
Bolt - Arrow D- tightening torque: 8 - 12 Nm
Bolt -Arrow D- tool: 10mm hexagon sleeve
Tips
 Sealing ring of the camshaft position sensor must be replaced.
 It is necessary to apply continuous beaded sealant with diameter of 1.2-2.2 mm to the cylinder head while
installing.

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21. Unscrew the fixing bolt -Arrow A- of thermostat shell and remove
the thermostat shell -1-.
22. Take out the thermostat -2-.
Note
 While installing the thermostat -2-, keep its air outlet -Arrow B-
in the vertical upward direction.
 Once the thermostat is installed, start the engine and check for
coolant leakage.
 Engine may not operate without a thermostat as removal of the
thermostat will cause adverse effect and result in lowered cooling
efficiency. Therefore, the thermostat cannot be removed even in
the event of engine overheat.
23. Unscrew the fixing screw -Arrow- of the oil pressure sensor insert
Screw -Arrow - tightening torque: 0.5 - 1.5 Nm
Note
 Before installing the engine oil pressure switch, clean the threads and the threaded hole of the engine oil
pressure switch.
 When installing the engine oil pressure switch, apply some sealant to the threads of the engine oil pressure
switch.
 Sealant specification: LOCTITE 565 or equal

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25. Unscrew the fixing bolt -Arrow- of the crankshaft position sensor
and remove the crankshaft position sensor -1-.
Note
 Completely clean residual sealant on the crankshaft position

sensor and the cylinder block surface before installing the
crankshaft position sensor.
 As shown in the figure blow, apply continuous beaded sealant
with diameter of 1.2-2.2 mm to position -a- of the cylinder block.
 Sealant specification: LOCTITE 5699 or equal
26. Unscrew the fixing bolt -Arrow- of the oil level gauge conduit
assembly, remove the wiring harness fixing bracket -2- and extract the
oil level gauge conduit assembly -1-.
Tips
Sealing rubber ring of the oil level gauge conduit must be replaced.

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27. Use the fixing tool -T41131501- of the water pump pulley to fix the
water pump pulley -1-, unscrew the fixing bolt -Arrow- and remove the
water pump pulley -1-.
28. Unscrew the fixing bolt -Arrow- on the water pump assembly, and
remove the water pump assembly-1-.
Tips
O-ring of the water pump must be replaced.
29. Fix the crankshaft pulley with its fixing tool -T61131207-, unscrew
its fixing bolt -Arrow- and remove the crankshaft pulley assembly -1-.
Bolt -Arrow- tool: E20 splined sleeve
Tips
Apply a proper amount of engine oil to threads of the fixing bolts while installing the crankshaft pulley.

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30. Unscrew the fixing bolt -Arrow- of the exhaust manifold heat shield
and remove the exhaust manifold heat shield -1-.
31. Unscrew the fixing bolt -Arrow A- of the exhaust manifold bracket.
32. Unscrew fixing nut -Arrow B- of the exhaust manifold, and remove
the exhaust manifold assembly with bracket -1-.
Note
 Gasket of the exhaust manifold must be replaced.

 While installing the exhaust manifold gasket, keep its bulging part facing the direction of engine.
33. Unscrew the fixing bolt -Arrow- of the cylinder head cover -1- in the
order as shown, and remove the cylinder head cover.

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Note
 At the -Arrow- as shown, apply a strip of liquid sealant in

continuous pearl-drops (diameter: 4 mm).
 Cylinder head cover must be installed within 3 minutes after the
sealant is applied, otherwise remove the sealant that is already
applied and apply a new coat.
 Sealant specification:LOCTITE 5699 or equal
34. Unscrew the fixing bolt -Arrow- on the oil pan -1-.
35. Use the oil pan assembler/disassembler -T61131401- to remove the

oil pan -1-.

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Note
 Remove sealant on oil pan and cylinder block surface, clean and
apply sealant as per the illustrated requirement.
 Apply sealant to the joint between cylinder block and front cover
and the joint between cylinder block and rear oil seal to the
diameter of 4mm.
 Avoid applying too much sealant; otherwise the redundant
sealant will get into the oil pan and block the filter screen on the
engine oil pump.
 The oil pan must be installed within 3 minutes after the sealant is
applied, otherwise remove the sealant that is already applied and
apply a new coat.
 Do not refill engine oil till at least one hour after the oil pan has
been installed.
 After re-filling the engine oil, start the engine and keep it at idle
speed, then check for oil leakage and the oil level.
36. Unscrew the fixing bolt -Arrow A- and -Arrow B- of the oil strainer,
and remove the strainer assembly -1-.
Nut -Arrow A- tightening torque: 10.5 - 12.5 Nm
Tips
 The O-ring is a disposable part, which should be replaced after being removed.
 Make sure the O-ring is entirely retained in the recess of the engine oil strainer; avoid any torsion or damage to
the O-ring.

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37. Unscrew the fixing bolts -Arrow A-, -Arrow B-, -Arrow C-, -Arrow
D- and -Arrow E- on the timing chain housing, and remove the housing
carefully.
Bolt - Arrow D- Specifications：M10×1.25×50
Bolt - Arrow D- tightening torque: 35.5 - 53.5 Nm
Bolt - Arrow E- Specifications：M10×1.25×90
Bolt -Arrow E- tightening torque: 35.5 - 53.5 Nm
Bolt -Arrow E- tool: 14mm hexagon sleeve
Tips
 Clean the sealant residue on the timing chain housing, cylinder
block and cylinder head.
 At -Arrow A- on the timing chain housing as shown, apply a strip
of liquid sealant in continuous pearl-drops (diameter:4~5 mm) At
-Arrow B- on the timing chain housing, apply a strip of liquid
sealant in continuous pearl-drops (diameter:3 ~ 4mm).
Sealant specification:LOCTITE 5699 or equal
Note
The timing chain housing must be installed within 3 minutes after the sealant is applied; otherwise remove the
sealant that is already applied and apply a new coat.

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38. Press the tension adjusting bar assembly -1- along the direction
-Arrow B- and fix the chain tensioner with the fixing pin -2- (the fixing
pin is self-provided).
39. Unscrew the fixing bolt -Arrow A- on the chain tensioner -3-, and
remove the tensioner.
40. Unscrew the fixing bolt -Arrow A- on the tension adjustment lever
assembly -1-, and remove the lever assembly.
41. Unscrew the fixing bolt -Arrow B- on the chain guide rail assembly
-2-, and remove the chain guide rail assembly.
42. Use a wrench to fix the hexagon part of the exhaust camshaft,
unscrew the bolt on the exhaust camshaft sprocket, and remove the
camshaft sprocket -1- and timing chain -2-.

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43. Use a wrench to tighten the hexagon part of the camshaft, remove
bolt -Arrow- on the V.V.T sprocket, and remove the V.V.T sprocket.
Tips
Before installing the V.V.T sprocket, apply an appropriate amount of
engine oil at the following locations.
1. The insertion hole in the V.V.T sprocket (inner and outer surface) and
the bearing surface of the bolt
2. Threads of V.V.T wheel bolts and nuts
3. Camshaft end
44. Following the sequence as shown in the picture, first remove the
front bearing cap of the camshaft, then remove the fixing bolts on the Identification mark
Number
bearing caps of the intake and exhaust camshafts sequentially.
Size of the fixing bolt of the camshaft bearing cap: M6×1.0×35
Tightening torque for the fixing bolt of the camshaft bearing cap: 10～
12 Nm
Tool for the fixing bolt of camshaft bearing cap: 10mm hexagonal
sleeve
Size of the fixing bolt for the camshaft front bearing cap: M8×1.25×30
Tightening torque for the fixing bolt of the camshaft front bearing cap:
21～25 Nm
Tool for the fixing bolt of the camshaft front bearing cap: 12mm
hexagonal sleeve
45. Carefully remove the intake camshaft and the exhaust camshaft.

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Tips
 No. 2 and No. 5 bearing caps of intake and exhaust camshafts are the same in shape that shall be installed by
relevant identification marks. The directions of marks on the bearing caps shall be the same as the directions
before removal.
 Identification mark (printed on No. 2 and No. 5 bearing caps).
I：Air intake
E：Exhaust
46. Unscrew the fixing bolts of the cylinder head in the order from 1 to
10 and remove the cylinder head assembly -1-.
Tightening torque of cylinder cover bolt:
1. Step 2: 22.5～26.5 Nm
2. Step 2: turn from 90°to 92°
3. Step 3: turn from 90°to 92°
Tool for bolts of the cylinder head: T50 spline screwdriver sleeve
47. Remove the cylinder gasket -1-.
Tips
 The cylinder gasket is a disposable part, which should be replaced
after being removed.
 The cylinder gasket has only one direction of installation and shall
match with two positioning pins -Arrow- on the cylinder block.
Assembling
Assemble according to inverse order.

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5. Engine Structure
5.1 Cylinder Head Component
5.1.1 Overview on Cylinder Head Assembly
1 - Exhaust camshaft cap 2 - Intake camshaft cap

 Check, replace as necessary  Check, replace as necessary
3 - Valve tappet 4 - Valve lock clamp
 Check=>Refer to Page 70  Check, replace as necessary
5 - Valve spring upper seat 6 - Valve spring
 Check, replace as necessary  Check=>Refer to Page 70
7 - Valve spring lower seat 8 - Valve oil seal
 Check, replace as necessary  Replacement
9 - Cylinder head 10 - Air intake valve
 Cleaning=>Refer to Page 63  Check=>Refer to Page 66

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 Check=>Refer to Page 64
11 - Exhaust valve 12 - Cylinder head bolt washer
 Check=>Refer to Page 66  Check, replace as necessary
13 - Cylinder head fixing bolt 14 - Intake camshaft
 Total: 10  Removal and installation=>Refer to Page 108
 Size：M0×1.20×143.5
 Tightening torque：22.5～26.5 Nm→+（180°～
184°）
15 - Exhaust camshaft 16 - Camshaft front bearing cap
 Removal and installation=>Refer to Page 108  Check, replace as necessary
17 - Fixing bolt of the camshaft front bearing cap 18 - Fixing bolt of the camshaft bearing cap
 Total: 3  Total: 16
 Specification：M8×1.25×30  Specification：M6×1.0×35
 Tightening torque：21～25 Nm  Tightening torque：10～12 Nm
5.1.2 Disassembly of the Cylinder Head Component


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Valve spring compressor Removal clamp of the oil seal
Installation tool for the oil seal of the valve
Tips
These instructions are for the removal and installation of one valve but may be used as reference for the removal and
installation of other valves.
Removal
1. Following the sequence as shown in the picture, first remove the front
bearing cap of the camshaft, then remove the fixing bolts on the bearing Identificat
ion Mark
caps of the intake and exhaust camshafts sequentially. Number

12 Nm
sleeve
21～25 Nm
hexagonal sleeve

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Tips
before removal.
I：Air intake
E：Exhaust
3. Remove intake valve tappet -1- and exhaust valve tappet -2-.
Tips
 When removing the camshaft component and the valve tappet, put
them at a clean place in order.
 Completely wash all the removed metal components with volatile
solvent (such as gasoline) and dry them with air gun before
installation.
 Apply clean oil to the surface of valve tappet and the contact
surface of the camshaft with the cylinder head and the camshaft
bearing cap while installing.
4. Compress the valve spring components with the valve spring
compressor.
5. Take out a pair of valve lock clamps -1- with the magnetic rod, and
slowly release the valve spring compressor.
6. Remove the valve spring upper seat -2-.

7. Remove the valve spring -3-.
8. Remove the valve spring lower seat -4-.
9. Draw out the valve -6-.

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10. Pull out the valve oil seal -1- with the oil seal disassembling clamp.
Tips
 The valve oil seal cannot be reused.Replace it.
 To facilitate the re-installation of the valve, place the valve spring and other components in order, and mark
them.
Installation
1. Install the valve -1- into the cylinder head in the direction of -Arrow-.
2. Install the new valve oil seal into the valve oil seal installation tool.
Note
 Replace the valve oil sealing.

 When installing the valve oil seal, ensure the valve oil seal is vertically placed into the valve tappet, and don't
tilt it.

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3. Apply engine oil on the valve oil seal lip, and carefully install it onto
the valve duct.
4. Compress the valve spring with the valve spring compressor, and
install the locking clip -1- of the valve spring.
Note
After the installation of the camshaft, check the valve clearance=>Refer to Page 67.
5.1.3 Cylinder Head Cleaning

In order to ensure normal functioning and installation tightness of the cylinder head, an important working part of the
engine, it is necessary to completely remove residual sealant on its surface and eliminate impurities in its oil way,
water way and threaded hole.
Tips
Clean the surface and channels of the cylinder head with a strong solvent (such as gasoline). Once the cylinder head
has been cleaned with strong solvent, don't wash it with water, as the remaining moisture will corrode the internal
parts of the cylinder head. To dry it up, use compressed air to blow off the solvent residual on the cylinder head.

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1. Carefully and gently clean off the residual sealant or dirt on the
cylinder head installation surface -1-, air intake manifold installation
surface -2- and exhaust manifold installation surface -3- with a draw
knife.
Note
The cylinder head is made of cast aluminum. Don't use excessive force
during cleaning, in order to avoid scratching the installation surfaces
of the cylinder head.
2. Clean the installation surface of the cylinder head with a strong
solvent (such as gasoline).
3. Blow the water channel, oil channel, valve duct and the threaded hole
of the cylinder head with a high-pressure air gun.
5.1.4 Cylinder Head Check

1. Clean the cylinder head=>Refer to Page 63.
2. Visually inspect the installation plane of the cylinder head and cylinder block for serious scratches, and check if
there are cracks, serious deformation, or other damage on the cylinder head body.If any such damage is found, replace
the cylinder head.
3. Measure flatness of the cylinder head along direction a and direction b
separately with precise ruler and feeler gauge and correct or replace the
cylinder head-1- if its flatness exceeds the maximum value.
Standard value: max 0.04 mm
Limit value: 0.2 mm
Limit value for grinding: 0.2 mm
Tips
Height of cylinder head (standard height for new accessory):112.9 - 113.1 mm
Note
If the flatness exceeds the limit value for grinding, replace the cylinder head.

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5.1.5 Check on Cylinder Head Bolt

1. Measure the external diameter at -Arrow A- as shown of the cylinder
head blot.
2. Measure the smaller external diameter at -Arrow B- as shown of the
cylinder head blot.
3. When the difference between external diameters of the two positions
-Arrow A- and -Zone B- exceeds the standard value, replace the
cylinder head bolt.
Standard valve：0～0.15 mm

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5.2 Valve Mechanism

5.2.1 Valve Cleaning
1. Carefully remove all carbon deposit on the valve -1- with a draw
knife, and brush off the dirt with a soft brush.
2. Brush off the dirt on the valve seat -2- with a soft brush.
Note
Don't clean the valve seat -2- with a wire brush or other hard object,
as this may lead to improper sealing of the valve.
5.2.2 Valve Check

Check
1. Measure the total length -A- of the valve, and if the measured value
excesses the limit value, replace the valve.
Standard:
 Intake valve: 89.61 mm
 Exhaust valve: 90.95 mm
Limit value:

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2. Measure the valve edge -a-. If the measured value exceeds the limit,
replace the valve.
Tips
During the measurement, the bottom surface of the valve should be in
parallel with and contacted to each other; if not, trim with tools.
Standard:
Limit value:
5.2.3 Check Valve Clearance

Dial Gauge
Tips
 When the engine is cool, check and adjust the valve clearance.
 Cylinder head has been removed.

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1. Turn the crankshaft clockwise, and align the timing mark - Arrow B-
of intake camshaft with the timing mark -Arrow A- of exhaust camshaft,
as shown in the picture.The cylinder 1 is at the top dead center position
position now.
2. Use a thickness gauge to measure the valve clearance indicated by the

-Arrow-. If the valve clearance doesn't meet the standard, record its
value.
Standard:
a. Intake valve：0.18～0.26 mm
b. Exhaust valve：0.26～0.34 mm
Tips
No.2 is the intake valve side.
No.3 is the exhaust valve side.
3. Turn the crankshaft clockwise by 360°, and place the timing mark
-Arrow- on the exhaust camshaft in the position indicated in the picture.
Now, the cylinder moves to the top dead center position.

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4. Check the valve clearance -Arrow- indicated in the picture.

a. Intake valve：0.18～0.26 mm
b. Exhaust valve：0.26～0.34 mm
Tips
No.2 is the exhaust valve side.
No.3 is the intake valve side.
5.2.4 Check on Valve Seat

Measure the dimension of -a- of the protruding part between the valve
rod end and spring seat surface; if the measured value exceeds the limit
value, replace the cylinder head .
Standard:
Limit value:
5.2.5 Check on Valve Duct

Measure the internal diameter -a- of valve duct and the diameter -b- of
valve rod. If the difference between the measured values of -a- and -b-
exceeds the limit, replace the valve or cylinder head.
Items Intake air Exhaust
Diameter of valve 4.965～4.980mm 4.955～4.970mm
rod
Valve guide inner 5（+0.012,0）mm
diameter
Valve duct 12.7～13.3 mm
installation height
Standard:
 Intake valve：0.020～0.047 mm
 Exhaust valve：0.030～0.057 mm
Limit value:
 • Exhaust valve: 0.15mm

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5.2.6 Check on Valve Spring

1. Measure the free height -B- of valve spring, and if the measured
value excesses the limit value, replace the spring.
− Standard: 43.1 mm
− Limit value: 42.1 mm
2. Measure the squareness -A- of the valve spring, and if the measured
value exceeds the limit value, replace the spring.
− Standard value: smaller than 2°
− Limit value: 4°mm
3. Valve spring load/installation length.
− Load：152 Nm
− Length：33.4 mm
5.2.7 Check the Valve Tappet

1. Remove the camshaft => Refer to Page 108
2. Remove intake valve tappet -1- and exhaust valve tappet -2-
3. Use the external diameter micrometer to measure the thickness -a- of
the removed valve tappet.
4. Calculate the thickness of the newly installed valve tappet using the formula below.
a. The thickness of the newly installed valve tappet
b. The thickness of the removed valve tappet
c. Measured valve clearance
Formula:
1. Intake valve: a=b+(c-0.22mm)
2. Exhaust valve ：a=b+(c-0.30mm)

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Tips
The thickness of valve tappet is within the range of 2.70 - 3.30mm.There are 31 types of valve tappets, each with a
0.02mm difference.More detailed information is shown in the following table
Valve tappet information

Identification Identification Identification
Thickness mm Thickness mm Thickness mm
mark mark mark
2.70 70 2.92 92 3.14 14
2.72 72 2.94 94 3.16 16
2.74 74 2.96 96 3.18 18
2.76 76 2.98 98 3.20 20
2.78 78 3.00 00 3.22 22
2.80 80 3.02 02 3.24 24
2.82 82 3.04 04 3.26 26
2.84 84 3.06 06 3.28 28
2.86 86 3.08 08 3.30 30
2.88 88 3.10 10
8.90 90 3.12 12
5. The valve tappet mark is at the -Arrow- as shown in the picture.
5.2.8 Check on Valve Tightness

1. Clean the valve => Refer to Page 66.

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2. Install all the spark plugs -1-.

3. Install all the intake valves -3- and exhaust valves -4-.
4. Add alcohol into all cylinder head combustion chambers -2-, and
check the intake valves -3- and exhaust valves -4- for leakage.
Tips
 Don't spill or splash the alcohol.
 If the part below the valve rod isn't wet or it is wet but there is no
liquid flowing out, it means the valve is properly sealed.
 If there is liquid flowing out the valve rod, it means the valve isn't
properly sealed and check and grinding of the valve or valve seat
are needed=>Refer to Page 69

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5.3 Check Camshaft Dimensions
Tips
Checking method for the intake camshaft and the exhaust camshaft is the same and therefore checking of the intake
camshaft is taken as the example below.
1. Completely clean the camshaft -1- with volatile solvent (such as
gasoline).
2. Put the camshaft -1- on the V-block.
3. Locate dial indicator and magnetic stand, jack the camshaft flange
with the dial indicator head and zero the dial indicator.
4. Turn the camshaft -1- slowly, observe and record change of the dial
indicator pointer and calculate roundness of the camshaft intermediate
journal.
Tips
Replace the camshaft -1- if roundness of its intermediate journal is
excessive.
5. Measure the cam height with a micrometer and replace the camshaft
if its measurement exceeds the limit value.
(A131) (A151) (A131) (A151)
Camshaft Intake Intake Exhaust Exhaust
camshaft camshaft camshaft camshaft
Standard 44.21mm 44.71mm 43.98mm 44.28mm
Limit
43.71mm 44.21mm 43.48mm 43.78mm
value:

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5.4 Cylinder Block Component

5.4.1 Overview on Cylinder Block Component
1 - Crankshaft rear oil seal fixing bolt 2 - Crankshaft rear oil seal cover
 Quantity: Replace 6  Replacement
 Specification：M6×1.0×20
 Tightening torque：8～10 Nm
3 - Cylinder block 4 - Thrust bearing
5 - Crankshaft upper bearing bush 6 - Crankshaft
 Check, replace as necessary  Removal and installation=>Refer to Page 140
7 - Crankshaft lower bearing bush 8 - Crankshaft bearing cap
9 - Crankshaft bearing cap bolt 10 - Fixing bolt of the connecting rod bearing cap

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 Tightening torque：33～37 Nm+60°to 64°  Tightening torque：13～17 Nm+90°to 94°

11 - Connecting rod bearing cap 12 - Connecting rod lower bearing bush
13 - Upper bearing bush of the connecting rod 14 - Sensor ring
15 - Fixing screwing for sensor gear ring 16 - Piston and connecting rod components
 Total: 3  Check, replace as necessary
5.4.2 Cylinder Block Component: Disassembly

1. Remove the fixing bolt -Arrow- on the crankshaft rear oil seal cover
-1-, and remove the oil seal cover.
2. Unscrew the fixing bolt -Arrow- of the connecting rod bearing cap
and remove the connecting rod bearing cap component (with connecting
rod bearing bush) -1-.
Bolt -Arrow- tightening torque: 13～17→90° to 94°
Bolt -Arrow- tool: 8mm 12 angles sleeve

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3. Push out the piston connecting rod component -1- carefully.
Note
 While pushing out the piston connecting rod component, do not

let the connecting rod scratch the cylinder wall or let sharp object
contact the connecting rod bearing bush and its junction surface.
Tips
 Disassemble all the piston connecting rod components in the same
way.Disassemble the piston connecting rod components of
Cylinder 1 and 4 at the bottom dead center of Cylinder
1.Disassemble the piston connecting rod components of Cylinder 2
and 3 at the bottom dead center of Cylinder 2.
Note
 In order avoid mixing up the installation sequence of the piston

and connecting rod components during cleaning and assembly,
once a piston and connecting rod component are removed,
assemble the piston and connecting rod and mark the component
at the bigger end of the connecting rod with the corresponding
cylinder number.
 Keep the piston and connecting rod components well-organized
and place them in a clean place.
4. Unscrew the fixing bolt -Arrow- of the crankshaft bearing cap and
remove the crankshaft bearing cap component (with crankshaft main
bearing bush) -1-.
Bolt -Arrow - tightening torque: 33～37 Nm+60°to 64°
Tips
 There are marks on the bearing cap, so install parts according to
the marks on the crankshaft bearing cap.
 Remove fixing bolts from outside to inside and tighten them
from inside to outside.

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5. Remove the thrust bearing -Arrow-.

6. Take the crankshaft -1- out of the cylinder block.
Tips
The thrust bearing is located at the fourth bearing, altogether two
pieces, on two back-to-back sides.
7. Remove the master bearing bush -1- of the crankshaft.
Note
Once crankshaft master bearing bush is removed, store it in the

original sequence, to avoid confusion.
Installation
Note
During assembly, lubricate all parts that need lubrication.
1. Thoroughly clean the cylinder block before installing it.

Clean the internal and external dirt off using a volatile solvent and a brush.
Blow all water ways (such as the water way around the cylinder liner), threaded hole ways (such as fixing threaded
hole of the cylinder head) and oil ways (such as crankshaft oil way) on the cylinder block clean with high-pressure air
gun.
Note
Ensure no impurities falls out of any of the holes on the cylinder block.

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2. When installing the piston and connecting rod component, pay

attention to the installation angle of the piston ring
Rotate each piston ring to ensure the opening -2- of the first piston ring
is 180°to the opening -5- of the second piston ring and that the two
openings are not aligned with the axis -3- of the piston pin.
Stagger the opening -1- on the upper blade of the third oil ring from the
opening -4- on the lower blade instead of aligning.
3. Use a piston guide -T61131204- to compress the piton ring, install the
piton and connecting rod assembly to the cylinder block, and ensure the
forward mark on at the top of the piston faces against the camshaft
pulley.
5.4.3 Check on Cylinder Block

1. Check the cylinder block for cracks and the installation surface -1- for
serious scratching.
Note
If there is any cracking, serious deformation or damage on the cylinder

block, replace it.
2. Check the top flatness of the cylinder block using a precision ruler
and feeler along Line a and b.
Standard: 0.05 mm
Limit value: 0.1 mm
Note
If the flatness exceeds the limit, replace the cylinder block.
3. Visual check if the inner wall of the cylinder block has vertical scratches.If there is deep scratches, all the four
cylinders need boring.

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Note
If there is any vertical scratch on the inner wall of the cylinder block, it means scuffing has occurred inside the
engine.The deeper the scratch is, the more serious the scuffing is. Replace the cylinder block if necessary.
4. Measure cylindricity of the cylinder bore with the internal dial

indicator and bore or replace the cylinder block in case of severe wear.
Tips
Measure the internal diameter of the cylinder on three planes, namely
the upper plane A, middle plane B and lower plane C, in anti-thrust and
axial directions.
Standard value for cylinder internal diameter:75(+0.015,0) mm
Standard value for cylindricity of cylinder diameter:0.008 mm Thrust direction
Top
Middle Axial
direction
Bottom
5.4.4 Cylinder-boring
1. The use of oversize pistons depends on the cylinder dimension of the cylinder hole.
Dimensions Dimension mark
0.25mm extra 25
Tips
The dimension is marked at the upper part of the piston.
2. If the 0.25mm oversize piston will be used, the bored hole must pass
through the cylinder block, so as to make sure the clearance meets the
standard value. The standard measuring point for the piston's outer
diameter is shown in the picture.
Standard Measuring Point as Shown: 12mm
3. Calculate the final dimension of the bored hole according to the
piston's outer diameter (O.D.) measured.
Final dimension of bored hole = piston's O.D.+ +0.010 - 0.035mm
(gap between piston's O.D. and cylinder) - 0.02mm (edge of bored
hole)
4. Bore all the cylinders to the final dimension calculated for the bored
holes.

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Note
 To avoid possible deformation caused by temperature rise during the boring process, follow the sequence from
No.2 to No.4 first and then from No.1 to No.3.
 When boring the cylinder, ensure the four cylinders are bored to the same dimension. Do not bore only one
cylinder to a greater dimension.
5. Check the clearance between the piston and the cylinder.

Standard valve：0.010～0.035 mm
5.4.5 Check Oil Clearance of the Crankshaft Bearing

1. Clean the oil films on the crankshaft master journal -1- and the inner
surface of the upper/lower bearing for the crankshaft.
2. Install the crankshaft.
3. Put the plastic gauge -Arrow- onto the crankshaft master journal -1-
along the axial direction.
4. Install the crankshaft master bearing cap -1- and tighten the fixing
bolt -Arrow-.
4. Install the crankshaft master bearing cap -1- and tighten the fixing
bolt -Arrow-.
5. Remove the crankshaft master bearing cap -1-.
Note
Don't rotate the crankshaft when assembling and disassembling the

crankshaft master bearing cap.

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6. Measure the width of the pressed part of the plastic gauge -1- based
on the scale printed on the package.
Limit value: 0.1 mm
Tips
If the oil film clearance of the crankshaft journal doesn't meet the
standard, replace the upper and lower crankshaft bearing, and remove
the crankshaft if necessary.
5.4.6 Check Thrust Bearing of the Crankshaft

1. As shown in the picture: Fix the dial indicator on the bracket, and fix
it at the front end of the engine.
2. Vertically point the probe to the front end of crankshaft and pre-tight
by 1 mm.
3. Adjust the dial indicator.
4. Move the crankshaft along the axle direction and read the measured
value on the dial indicator. If the measured value excesses the limit,
replace the crankshaft thrust bearing.
Limit value: 0.30 mm
5.4.7 Check on Crankshaft Pin Oil Film

Check
1. Throughly clean the oil films on the rod journal, rod bearing and crankshaft pin.
2. Cut the plastic gauge of which the length is the same as the width of
the rod bearing, place it on the crankshaft pin -Arrow-, and keep it
parallel to the pin.
3. Carefully install connecting rod bearing on the plastic gauge, and tighten the bolt with a tightening torque of 13±17
Nm and rotate it by +90°( to 94°).
4. Unscrew the bolts, and remove the rod cap carefully.

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5. Adopt the gauge printed on the plastic gauge, and measure the width
of the widest part of the plastic gauge.
Limit value: 0.1 mm
5.4.8 Crankshaft Bearing

8.1 Assembly of Crankshaft Upper Bearing
1. Identify the crankshaft bearing group according to the color in the
picture -Arrow-.
2. Select upper bearing for the crankshaft according to the mark on the
bottom of the cylinder block as well as the following table.
Cylinder block
Bearing indentification
Identification
Journal diameter mm color
mark
1 50.000～50.005 Blue (761)
2 50.005～50.010 Black（762）
3 50.010～50.015 Red（763）

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3. Install the lubricated crankshaft upper bearing on the cylinder block,

and ensure the bearing is built-in the kerf on the cylinder block -Arrow-.

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8.2 Assembly of Crankshaft Lower Bearing

1. Identify the crankshaft bearing group according to the color in the
picture -Arrow-.
2. Select lower bearing for the crankshaft according to the mark on the
rear flange of the crankshaft as well as the following table. Date of production
Crankshaft Bearing
Identification indentification
Journal diameter: mm
mark color
1 46.019～46.024 Black（757）
2 46.014～46.019 Red（758）
3 46.009～46.014 Green（759）
4 46.004～46.009 Purple（760）
3. Install the lubricated crankshaft upper bearing on the crankshaft

bearing cap, and ensure the bearing is built-in the kerf on the crankshaft
bearing cap -Arrow-.

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5.5 Piston and Connecting Rod Components

5.5.1 Overview on Piston and Connecting Rod Components
1 - 1st piston ring 2 - 2nd piston ring

 Removal and installation=>Refer to Page 86  Removal and installation=>Refer to Page 86
3 - Oil ring 4 - Piston
5 - Piston pin 6 - Piston pin retainer ring
7 - Connecting rod 8 - Upper bearing bush of the connecting rod
9 - Connecting rod lower bearing bush 10 - Bearing cap

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11 - Connecting bolt
 Total: 8
 Tightening torque：13～17 Nm+90°to 94°
5.5.2 Disassembly of Piston Connecting Rod Components

T61131204- Piston guide

cylinder
Removal
1. Remove the piston connecting rod components=>Refer to Page 137.
2. Remove the first piston ring -1- and the second piston ring -2- with
tools.
Note
 It is necessary to remove the piston rings with tools. Otherwise, it

may cause hand injury or damage to the piston ring.
 During the installation, ensure that the sides with mark should
face against the top of the piston.
3. Remove the upper blade -3-, the lower blade -5- and the master oil ring -4- by hand.
Note
Do not use any ring expander while installing the blade as it may damage the blade.

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4 .Fix the piston and connecting rod components on the base, and ensure
the piston forward mark -Arrow B- faces upwards.
5. Press the push rod -1- with pressure tooling along -Arrow A-, and
remove the piston pin.
Tips
Place the removed piston, piston pin and connecting rod in sequence.
Installation
1. Apply engine oil on the surrounding of piston pin.
2. Fix the piston and connecting rod on the base, and insert the end of
the piston pin duct to the pin base.
3. Press the push rod -1- with pressure tooling along -Arrow- to
completely press the piston pin to the limit position.
Tips
 Confirm forward marks -Arrow A- on the piston and the connecting
rod are aligning before installing with pressure tool.
 Standard pressure value: 5000 - 11000 N.
 If the value is smaller than the standard value, replace the piston
or both.
 Keep the forward mark -Arrow B- on the piston upward while
installing.

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5.5.3 Check on Piston Ring

Feeler gauge
Use a feeler gauge to check the clearance between the piston ring and
the ring-shaped slot, and replace the piston ring or replace the piston and
the piston ring if the measured value excesses the limit value.
Standard:
 The first piston ring: 0.03 - 0.07 mm
 The second piston ring: 0.02 - 0.06 mm
Limit value: 0.1 mm
2. Clean the cylinder hole. Install the piston ring and press it downwards
with the piston, ensuring that the piston ring and the cylinder wall are at
right angle. Use a feeler gauge to check the gap clearance, and replace
the piston ring if the gap clearance excesses the limit value.
Standard:
 The first piston ring: 0.15 - 0.30 mm
 The second piston ring: 0.30 - 0.50 mm
 Oil ring：0.10～0.60 mm
Limit value:
 The first piston ring: 0.8 mm
 The second piston ring: 0.8 mm
 Oil ring：1.0 mm

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5.5.4 Check on Side Clearance at Connecting Rod's Bigger End

Feeler gauge
 Use a feeler gauge to measure the side clearance at the bigger end
of connecting rod as shown in the picture.
Limit value: 0.4 mm
5.5.5 Check on Connecting Rod Bolt
Tips
The connecting rod bearing cap bolt must be checked before using; if it is found to be extended or the thread
compressed, the bolt must be replaced.
Check
1. Measure the outer diameter at A and B on the front end of connecting
rod bolt in the picture.
Position A: 15mm
Position B: 30 mm
2. If the difference between measured values of A and B excesses
standard value, the connecting rod bolt must be replaced.
Standard valve：0～0.1 mm

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6. Powertrain Mounting Components

6.1 Removal and Installation of Engine Mounting Cushion
T51131001-Engine balance hanger T51271002-Engine balancing stand cross rod component
Removal
2. Remove the engine trim cover assembly -1-.
and the engine balance bracket crossbar component with the tool
number -T51271002- and fix the engine assembly -1-.

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7. Unscrew fixing bolt -Arrow A- and fixing nut -Arrow B- of the

engine mounting cushion and remove the engine mounting cushion-1-.
Installation

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6. Removal and Installation of Transmission Mounting Cushion

Removal
2. Remove the battery => Electrical equipment; Repair Group: 60: Power distribution; Battery; Removal and
installation of battery.
6. Remove the rubber blockage -arrow A- on the battery tray on, and pry
up the harness clip - Arrow B-.
7. Unscrew fixing bolts -arrows- for the battery tray and remove the
battery tray-1-.

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and the engine balance bracket crossbar component with the tool number
-T51271002- and fix the engine assembly -1-.
9. Remove the rear mounting cushion => Refer to Page 96

10. Unscrew fixing bolt -Arrow B- and fixing nut -Arrow C- of the
transmission mounting cushion.
11. Unscrew the fixing bolt -Arrow C- of the transmission mounting
cushion and remove the transmission mounting cushion-1-.
Tips
Adjust engine orientation to remove the transmission suspension.

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13. Unscrew the fixing bolt -Arrow C- of the transmission mounting cushion and remove the transmission mounting
cushion-1-.
Tips
Applicable to the manual transmission MF513
19. Unscrew the fixing bolt -Arrow A- of the transmission mounting
cushion and remove the transmission mounting cushion -1-.

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Bolt -Arrow A- tool:13mm combination wrench
Tips
Installation

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6.3 Removal and Installation of the Rear Mounting Cushion

Removal
1. Lift the vehicle to a proper height
2. Unscrew the fixing bolts - arrow A-, bolt - arrow B-, bolt - arrows C-,
and remove the rear suspension cushion assembly -1- and rear
suspension bracket assembly -2-.
Installation

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7 Belt
7.1 Overview on Accessory Transmission
1 - A/C compressor belt 2 - Water pump pulley

3 - Generator pulley 4 - Belt
5 - Crankshaft pulley
 Check, replace as necessary

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7.2 Removal and Installation of the Belt

Removal
1. Loosen the fixing bolt -Arrow B- and -Arrow C- of the generator.
2. Turn the adjusting bolt -Arrow A- of the generator assembly
counterclockwise and remove the drive belt -1-.
Installation
1. After the belt is installed, check carefully whether it well installed over every pulley.
Note
The belt is likely to rupture in case of installation deviation that endangers running safety.

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7.3 Check the Belt Tension

1. After installation, apply a force of 100 N to the belt in the position of
-Arrow-.Measure to check whether the belt deformation is within the
standard deviation range .
Items Adjustment Replacement
Vibration frequency
148～164 198～221
(Hz)
Tension（N） 441～539 784～980
Deformation (mm) 11.9～14.6 6.3～7.6

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11 Cylinder Head and Timing Device

1 Overview
The cylinder head in this engine model is made entirely of aluminum, and thus features good heat radiation, light
weight and easy processing. The cylinder head is designed to close the cylinder, form the combustion chamber, install
air intake and exhaust valves, and support air intake and exhaust camshaft components.The air intake valve inlet and
the exhaust valve outlet are connected to air intake manifold and exhaust manifold, respectively. The structure of the
cylinder head is complicated, consisting of the cooling channel, the fuel channel, the intake valve and exhaust valve
channels, the valve components and camshaft assembly.
The timing drive is based on dual overhead camshafts and a single chain, with precise distribution timing and reliable
drive.
The main components of the timing mechanism include:

 Camshaft sprocket
 V.V.T sprocket component
 Timing chain
 Chain guide rail assembly
 Tension adjustment lever assembly
 Chain Tensioner
100 Repair Group 11 - Cylinder Head and Timing Device

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2.1.1 Abnormal Noise of Valve Mechanism
Camshaft journal and
bearing seat is worn,
Replace the camshaft or
Check the camshaft Proceed to Step 1. loose, bent, deformed
cylinder head
or has excessive thrust
clearance
1 Check the valve tappet Normal There's a fault Operation methods
If some valve tappets
Remove the camshaft and may be easily pressed Replace the valve
Proceed to Step 2.
press the valve tappet down, this indicates tappet
failure
2 Check the valve spring Normal There's a fault Operation methods
Valve spring has
Check whether the valve Replace the valve
Proceed to Step 3. insufficient tension or
spring is normal spring
even breakage
3 Check the valve Normal There's a fault Operation methods
Broken valve tappet or Replace the valve or
Check the valve and the excessive wear and tear valve duct, and
Proceed to Step 4.
valve duct in the valve rod and overhaul the valve
guide can be found clearance
4 Check the valve retainer Normal There's a fault Operation methods
Uneven wear or burn Repair the valve
Check the wear and tear of can be found in the retainer and maintain
the valve retainer and Proceed to Step 5. valve head or valve the valve clearance.If
valve head retainer, or the valve necessary, replace the
retainer falls off valve and valve retainer
5 End of diagnosis Faults still exist
repairs
2.1.2 Timing Mechanism: Noise

Loose sprocket bolt,
Replace the damaged
Check the camshaft timing broken sprocket or
Proceed to Step 1. sprocket and tighten the
sprocket sprocket gear can be
bolt
found
1 Check the timing chain Normal There's a fault Operation methods
Check the chain
Check if the timing chain The timing chain is tensioner and replace
Proceed to Step 2.
is normal loose the tensioner or chain if
necessary
2 Check the chain plate Normal There's a fault Operation methods
Repair Group 11 - Cylinder Head and Timing Device 101

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Check whether the chain Chain guide plate loose Replace the damaged
Proceed to Step 3.
guide plate is normal or severely worn part and tighten the bolt
Check the crankshaft
timing sprocket
Check whether the
Sprocket ruptured or Replace the sprocket or
crankshaft timing sprocket Proceed to Step 4.
woodruff key loose the woodruff key
is normal
repairs

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Torque
Nm
10mm Hexagon
Cylinder head cover fixing bolt — 8～10
Sleeve
19mm
Coolant temperature sensor (ECT sensor) — — 10～14 combination
wrenches
M10×1.25×50 14mm Hexagon
Timing sprocket shell fixing bolt (M10) — 35.5～43.5
M10×1.25×90 Sleeve
M6×1.0×25
10mm Hexagon
Timing sprocket shell fixing bolt (M6) M6×1.0×30 — 8～12
Sleeve
M6×1.0×45
14mm Hexagon
Fixing bolt of the V.V.T wheel — — 59～70
Sleeve
17mm Hexagon
Fixing bolt of the camshaft sprocket M12×1.25×30 — 78～98
Sleeve
12mm Hexagon
Fixing bolt of the tension adjusting bar assembly — — 21.5～25.5
Sleeve
10mm Hexagon
Fixing blot for chain guide rail assembly — — 8～10
Sleeve
10mm Hexagon
Fixing bolt of the timing chain tensioner assembly M6×1.0×25 — 8～10
Sleeve
10mm Hexagon
Fixing bolt of the camshaft bearing cap (M6) M6×1.0×35 8.8 10～12
Sleeve
12mm Hexagon
Fixing bolt of the camshaft bearing cap (M8) M8×1.25×30 8.8 21～25
Sleeve

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4 Cylinder Head Cover

4.1 Overview on Cylinder Head Cover
1 - Ignition coil fastening bolt 2 - Ignition coil

Specification：M6×1.0×18 Removal and installation=>Refer to Page 436
Total: 4
Tightening torque：7～12 Nm
3 - Spark plug 4 - Cylinder head cover
Removal and installation=>Refer to Page 439 Removal and installation=>Refer to Page 104
5 - Cylinder head cover cushion
Check, replace as necessary
4.2 Removal and Installation of Cylinder Head Cover

Removal
1. Remove the ignition coil=>Refer to Page 436

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2. Unscrew the fixing clamp -Arrow B- of the air outlet pipe, pry up the
fixing clip -Arrow A- of the air filter upper shell and remove the air
filter upper shell -1-.
Clamp -Arrow - tightening torque: 5 - 7 Nm
3. Remove the crankcase venting pipe -1-.
4. Pull out the vent duct -1- of the PCV valve.
5. Unscrew the PCV valve assembly -1-.

PCV valve -1- tightening torque :4~6 Nm

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6. Disengage engine wiring harness clip -Arrow A- and -Arrow B- and

put aside the engine wiring harness -1-.
7. Unscrew fixing bolts -Arrow- of the cylinder head cover in the

illustrated order (1~10).
8. Remove the cylinder head cover -1-.
Installation
1. Clean the sealant residue on the cylinder head cover gasket, timing chain housing and cylinder head.
Tips
 The cylinder head cover gasket must be replaced.
 Lubricate with clean engine oil to ensure good sealing when installing the new gasket of cylinder head cover.
2. At the -Arrow- as shown, apply a strip of liquid sealant in continuous
pearl-drops (diameter: 4 mm).
Sealant specification: LOCTITE 5699 or equal
Note
Cylinder head cover must be installed within 3 minutes after the

sealant is applied, otherwise remove the sealant that is already applied
and apply a new coat.

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3. Tighten the fixing bolts -Arrow- on the cylinder head cover -1- in
reverse sequence as shown in the picture(10-1).

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5 Removal and Installation of Intake and Exhaust Camshafts

Removal
1. Remove the timing sprocket shell=>Refer to Page 114

Bolt -Arrow B- tightening torque: 8~10 Nm

unscrew the bolt on the camshaft sprocket, and remove the exhaust
camshaft sprocket -1- and timing chain -2-.

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7. Fix the hexagonal part of the intake camshaft with a wrench, unscrew
bolts -Arrow- of V.V.T sprocket assembly and remove the V.V.T
sprocket assembly -1-.

8. Following the sequence as shown in the picture, first remove the front
bearing cap of the camshaft, then remove the fixing bolts on the bearing Identificati
on Mark
Number
caps of the intake and exhaust camshafts sequentially.
12 Nm
sleeve
21～25 Nm
hexagonal sleeve
Installation
Note
Install the intake and exhaust camshafts into their installation positions.
Tips
Make sure the positioning pin -Arrow A- for the exhaust camshaft
sprocket and the positioning pin -Arrow B- for the V.V.T sprocket
assembly of the intake camshaft are installed in the positions as shown.

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1. Tighten fixing bolts of intake and exhaust camshaft bearing caps to the
specified torque in the order reverse to the illustrated order and then Identificat
ion Mark
Number
tighten fixing bolts of the camshaft front bearing cap to the specified
torque.
12 Nm
Tool for the fixing bolt of camshaft bearing cap: 10mm hexagonal sleeve
21～25 Nm
hexagonal sleeve
Tips
before removal.
I：Air intake
E：Exhaust
2. Install the exhaust camshaft sprocket assembly => Refer to Page 123.
3. Install V.V.T sprocket assembly => Refer to Page 125.
4. Check the timing.

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6. Removal and Installation of the Cylinder Head

Removal
Tips
 For removal and installation steps of the cylinder head, please refer to disassembly of the engine assembly
component: => Refer to Page 43.

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7. Timing Device
7.1 Overview on Timing Device
1 - Exhaust camshaft sprocket 2 - V.V.T sprocket

3 - V.V.T sprocket bolt 4 - Chain guide rail assembly
 Total: 1  Removal and installation=>Refer to Page 117
5 - Fixing blot for chain guide rail assembly 6 - Tension adjustment lever assembly
 Total: 2  Check, replace as necessary
7 - Tension adjustment lever assembly bolt 8 - Fixing blot for timing chain tensioner
 Tightening torque：21.5～25.5 Nm  Specification：M8×1.25×25

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9 - Timing chain tensioner 10 - Bolts of camshaft sprocket

 Check, replace as necessary  Total: 1
11 - Timing chain housing. 12 - Timing chain

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7.2 Removal and Installation of Timing Chain Housing

Tips
Mark the rotation direction of the belt before removing the compressor belt.
2. Remove the front wheel cover mudguard=>Body and Paint; Repair Group: 83; Exterior Equipment; Removal and
Installation of Front Wheel Cover Mudguard.
4. Unscrew the fixing bolt -Arrow A- of the generator bracket, loosen
the fixing bolt -Arrow B- at the lower part of the generator and push the
generator component -1- towards the direction of radiator until the limit
position.
Bolt -Arrow A- tool:14mm combination wrench
5. Fix the water pump pulley -1- with its fixing tool -T41131501-,
unscrew its fixing bolt -Arrow- and remove the water pump pulley -1-.

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6. Unscrew the fixing bolt -Arrow- on the water pump assembly, and
remove the water pump assembly-1-.
7. Install the engine balance hanger and engine equalizer bar crossbar
component, and fix the engine assembly -1-.


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assembly and extract the oil level gauge conduit assembly -1-.
Tips
Sealing rubber ring of the oil level gauge conduit must be replaced.
12. Remove the cylinder head cover => Refer to Page 104.
13. Remove the oil strainer => Refer to Page 172.
14. Fix the crankshaft pulley with its fixing tool, unscrew its fixing bolt
and remove the crankshaft pulley assembly -1-.
Tips
Apply a proper amount of engine oil to threads of the fixing bolts while
installing the crankshaft pulley.
15. Unscrew the fixing bolts -Arrow A-, -Arrow B-, -Arrow C-, -Arrow
D- and -Arrow E- on the timing chain housing, and remove the housing
carefully.
Bolt - Arrow D- Specifications：M10×1.25×50

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Bolt - Arrow D- tightening torque: 35.5 - 43.5 Nm

Bolt - Arrow E- Specifications：M10×1.25×90
Bolt -Arrow E- tightening torque: 35.5 - 43.5 Nm
Bolt -Arrow E- tool: 14mm hexagon sleeve
Installation
Install in reverse order of removal procedures and please note the
following:
1. Clean the sealant residue on the timing chain housing, cylinder block
and cylinder head.
2. At -Arrow A- on the timing chain housing as shown, apply a strip of
liquid sealant in continuous pearl-drops (diameter:4~5 mm) At -Arrow
B- on the timing chain housing, apply a strip of liquid sealant in
continuous pearl-drops (diameter:3 ~ 4 mm).
Note
The timing chain housing must be installed within 3 minutes after the
sealant is applied; otherwise remove the sealant that is already applied
and apply a new coat.
3. Replace the crankshaft front oil seal => Refer to Page 174.
4. Replace sealing ring of the cylinder head cover => Refer to Page 104.
5. Tighten fixing bolts of timing chain shell in diagonal manner.
7.3 Removal and Installation of Timing Chain

Removal
1. Turn the crankshaft to the top dead center position of Cylinder 1 in the engine running direction.

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7. Use a wrench to fix the hexagon part of the exhaust camshaft, unscrew
the bolt on the exhaust camshaft sprocket, and remove the camshaft
sprocket -1- and timing chain -2-.
Installation

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1. Check if the positioning pin -Arrow A- for the exhaust camshaft

sprocket and the mark -Arrow B- on the V.V.T sprocket assembly is
facing upwards; if not, rotate the camshaft with a wrench till the
positioning pin and mark faces upwards.
2. Rotate the crankshaft clockwise to align the timing mark -1- on the
crankshaft sprocket and that -2- on the cylinder block.
3. Install the chain guide rail assembly -1-, and tighten the fixing bolt
-Arrow-.
4. Place the timing chain -1- on the V.V.T sprocket assembly -2-, chain
guide rail assembly -4- and crankshaft sprocket -3-.
Tips
 Pay attention to the turning mark on the timing chain -1-.
 Place the timing chain -1- into the guide groove of the chain guide
rail assembly -4-.

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5. Align the mark -Arrow- on the V.V.T sprocket assembly and the blue
joint -1- of the timing chain.
6. Align the blue mark -2- on the timing chain with the timing mark -1-
on the crankshaft sprocket.
7. Align the blue mark on the timing chain -1- with timing mark -Arrow
A- on the exhaust camshaft sprocket -2-.
8. Install the timing chain -1- and the exhaust camshaft sprocket -2-
onto the exhaust camshaft.
9. Screw the fixing bolt -Arrow B- for the exhaust camshaft sprocket.
Tips
For the fixing bolt -Arrow B- for the exhaust camshaft sprocket, it is just
necessary to screw it, but do not tighten it.
10. Screw in the exhaust camshaft with a wrench, and align the groove
on the exhaust camshaft sprocket and the positioning pin -Arrow- of the
camshaft.

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11. Use a wrench to fix the camshaft in the square-shape part, and
tighten the camshaft sprocket bolt -Arrow-.
12. Install the tension adjustment lever assembly -1-, and tighten the
fixing bolt -Arrow-.
13. Before installing the timing chain tensioner, press in the plunger of
the tensioner and lock it with a locking pin.
14. Install the chain tensioner, and tighten the fixing bolt -Arrow- on it.
15. Extract the fixing pin out of the chain tensioner.

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Note
When the installation of tensioner is completed, check the alignment of the timing marks again. If the timing
marks are not aligned, re-install the timing chain following the correct procedures.

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7.4 Removal and Installation of Exhaust Camshaft Timing Sprocket

Removal
1. Turn the crankshaft to the top dead center position of Cylinder 1 in the engine running direction.


unscrew the bolt -Arrow- on the exhaust camshaft sprocket -1-, and
remove the camshaft sprocket.
Installation

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2. Install the timing chain tensioner, and pull out the locking pin.
Note
When the installation of tensioner is completed, check the alignment of the timing marks.If the timing marks are
not aligned, re-install the timing chain following the correct procedures.
Other Installation is in reverse order of removal procedures.

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7.5 Removal and Installation of V.V.T Sprocket

Removal
1. Remove the timing chain=>Refer to Page 117.
2. Use a wrench to tighten the hexagon part of the camshaft, remove bolt
-Arrow- on the V.V.T sprocket, and remove the V.V.T sprocket.
Installation
Tips
Before installing the V.V.T sprocket, apply an appropriate amount of
engine oil at the following locations.
1. The insertion hole in the V.V.T sprocket (inner and outer surface) and
the bearing surface of the bolt
2. Threads of V.V.T wheel bolts and nuts
3. Camshaft end

2. Install the timing chain tensioner, and pull out the locking pin.

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Note
When the installation of tensioner is completed, check the alignment of the timing marks.If the timing marks are
not aligned, re-install the timing chain following the correct procedures.

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8 Chain Tensioner
8.1 Removal and Installation of Chain Tensioner
Removal
1. Remove the timing sprocket shell=>133
Installation

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12 Crankshaft, Link Mechanism

1 Overview
The crankshaft and connecting rod of the engine are designed to change the direction of force, convert the
reciprocating movement of the piston into the revolving movement of the crankshaft, and perform work externally.
The front end of the crankshaft mainly drives such accessory mechanisms as valve mechanism, water pump, oil pump,
A/C compressor, etc. Based on the flange structure, the rear end of the crankshaft is designed to mount the flywheel.
The crankshaft journal and rod journal are the most important sliding parts in the engine, which requires quenching at
the surface transition fillet of the journal and it also undergoes induction quenching and other processes, in order to
improve its fatigue resistance..
The axial positioning of the crankshaft uses the anti-thrust gasket, and the positioning device is installed on the middle
bearing.
The crankshaft undergoes dynamic balance checking before assembly.For unbalanced crankshafts, part of the weight
should be drilled off on the heavier side of the crank, in order to meet the balance requirements. The flywheel is
designed to store energy and stabilize engine operation, and has high rotation inertia. There is a gear ring on the outer
margin of the flywheel, which engages the drive gear of the starter and helps the starter to start the engine. Flywheel
and crankshaft of the multi-cylinder engine shall undergo dynamic balance test together. In order to maintain the
relative assembly position between the flywheel and the crankshaft intact during removal and installation, it is
assembled with positioning pins. Pay attention to this during the installation.
The main components of the crankshaft and the connecting rod mechanisms include the following:
 Crankshaft
 Crankshaft master bushing
 Thrust bearing
 Front and rear crankshaft oil seals
 Piston
 Piston ring
 Piston pin
 Connecting rod
 Bearing bush of the connecting rod
128 Repair Group 12 - Crankshaft and Link Mechanism

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2.1.1 Crankshaft and Link Mechanism Noise
Preliminary
Inspection
Further overhaul the
related parts to confirm
There is impact caused by limited engine
Proceed to Step whether there is
Check engine oil oil, low engine oil pressure or
1. damage.Replace the
insufficient lubrication
engine oil and refill it
to the normal level
Check the piston
pin for noise
When the engine changes from idling to
Change the engine
medium RPM, noticeable noise can be
RPM while
heard, which goes away once the RPM
listening, checking
increases, or deteriorates.Under the same
whether or not there Proceed to Step Replace the piston or
RPM, cut off the cylinders one by one.If
is a sharp and crisp 2. piston pin
the noise obviously drops, it indicates the
sound of metal
noise of the piston pin in the specific
knocking against
cylinder.When the engine temperature
the cylinder wall
increases, the noise becomes worse
Check the piston
for noise
At idling or low speed, the knocking
sound is apparent and clear, and after the
RPM increases, the sound reduces or
Change the engine goes away.The sound is obvious at low
Overhaul the piston and
RPM while engine temperature, and when the
piston ring. If the noise
listening for knock temperature increases, it reduces or goes
is serious, disassemble
against the cylinder Proceed to Step away.Keep the engine at the RPM with
the engine and adjust
wall, which may be 3. noticeable sound, and cut off the
the clearance between
heard at the same cylinders one by one, the sound reduces
the piston and the
frequency as the or disappears. Add some engine oil into
cylinder wall
engine is working the installation hole of spark plug and cut
off the cylinders one by one again.If the
noise reduces, it is the piston knocking in
the specific cylinder.
Check the rod
bearing for noise
Repair Group 12 - Crankshaft and Link Mechanism 129

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Engine sound is clear at intermediate
Change the engine
speed and not clear at high speed; the
RPM while
sound is the largest at the moment of
listening to check Replace the rod
engine cold start and especially clear
whether there is Proceed to Step bearing, and the
during change of engine speed; a clear
hard and short 4. connecting rod if
sound may be heard when the connecting
sound of metal necessary
rod bearing is severely burnt whatever
knocking against
the speed or the load is then.
the oil pan
Check the
4 crankshaft master Normal There's a fault Operation methods
bearing for noise
Change the engine The noise increases as the RPM
RPM while increases, and becomes the loudest when Replace the crankshaft
listening for any Proceed to Step the RPM transitions from medium to master bearing, and
heavy and dull 5. high; the noise increases as the engine overhaul or replace the
noise in the rod load increases, and the engine oil crankshaft if necessary
bearing pressure drops substantially
Operate the front
electric windows
End of Find the cause from
5 and check whether Faults still exist
diagnosis other symptoms
fault occurs after
repairs
2.1.2 Cylinder Pressure Too Low

Clear the blockage and
Proceed to The air filter element is dirty or the
Check air inlet system replace the air filter
Step 1. air inlet is blocked
element
1 Check the cylinder gasket Normal There's a fault Operation methods
The cylinder gasket is broken or
Check to see whether Proceed to Replace the cylinder
leaking, or it is used and not up to
cylinder gasket is normal Step 2. gasket
standard
Check the piston
component and cylinder
If the cylinder pressure becomes
Add some engine oil at the
normal, it means the piston, piston Overhaul or replace the
installation hole of spark Proceed to
ring and cylinder bore are piston, piston ring and
plug and measure the Step 3.
excessively worn, or the matching cylinder
cylinder pressure again
clearance is too large
Check the valve and valve
seat

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Carbon has accumulated on the
valve or valve seat, causing
improper sealing when closed The
valve or valve seat has been Clear off the carbon,
Check the valve and the Proceed to
repaired improperly, causing overhaul or replace the
valve seat Step 4.
improper sealing when closed The defective part
valve seat has fallen off, and there
is leakage between the valve seat
and the cylinder head
4 Check the timing Normal There's a fault Operation methods
Proceed to Adjust the timing based
Check if timing is accurate Errors occur in timing
Step 5. on timing marks
windows and check End of Find the cause from
5 Faults still exist
whether fault occurs after diagnosis other symptoms
repairs

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Torque
Nm
13～
8mm 12 angles
Connecting rod bolt — — 17→90°to
sleeve
94°
Fixing bolt for sensor gear ring — — 8～10 —
33～
E12 splined
Crankshaft bearing cap bolt — — 37→60°to
socket
64°
10mm Hexagon
Bolts of rear oil seal shell M6×1.0×10 — 8～10
Sleeve
Name Standard Limit value:

External diameter of piston (mm) 75 —
Side clearance of piston The first ring 0.03～0.07 0.1
ring (mm) The second ring 0.02～0.06 0.1
The first ring 0.15～0.30 0.8
End clearance of piston
The second ring 0.30～0.50 0.8
ring (mm)
Oil ring 0.10～0.60 1.0
External diameter of piston pin (mm) 18 —
Piston pin press-in load (room temperature) N 5000～11000 —
Connecting rod bearing oil film clearance (mm) 0.014～0.052 0.1
Connecting rod bigger end side clearance 0.10～0.35 0.4
Crankshaft and cylinder block
Crankshaft axial clearance (mm) 0.09～0.297 0.3
Crankshaft journal (mm) 46 —
Crankshaft pin outer diameter (mm) 40 —
Crankshaft pin oil film clearance mm 0.014～0.052 0.1
Main bearing bush clearance 0.014～0.034 0.1
Cylinder block upper surface flatness (mm) 0.05 0.1
Cylinder block upper surface grinding limit (total amount
— 0.2
of grinding of cylinder head and cylinder block) (mm)
Total height of cylinder head (mm) 280 —
Cylinder inner diameter mm 75 —
Cylinder bore cylindricity mm 0.007 max —
Clearance between piston and cylinder (mm) 0.010～0.035 —

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4 Removal and Installation of Cylinder Block

Removal
1. Disassemble the engine assembly => Refer to Page 43.
Bolt -Arrow- tightening torque: 13～17 Nm→90°to 94°
Note

Tips

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Note

cylinder number.
bearing bush) -1-.
Tightening torque of bolts -Arrow-: 33-37 Nm → 60° to 64° and tool of
bolts -Arrow-: E12 spline sleeve
Tips
There are marks on the bearing cap, so install parts according to the
marks on the crankshaft bearing cap.
Tips
Install the thrust bearing on No. 4 bearing of the cylinder block. Apply
engine oil to the thrust bearing for easy installation.
8. Remove the master bearing bush -1- of the crankshaft.
Note
Once crankshaft master bearing bush is removed, store it in the

original sequence, to avoid confusion.

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Installation
Note

1. Thoroughly clean the cylinder block before installing it.
Clean the internal and external dirt off using a volatile solvent and a brush.
Using a high-pressure air gun, blow air on all water channels (such as the water channel around the cylinder sleeve),
threaded holes (such as the fixing threaded hole of the cylinder head) and oil channel (such as crankshaft oil channel), etc.,
dry.
Note
Ensure no impurities falls out of any of the holes on the cylinder block.
2. Install the crankshaft=>Refer to Page 140.
3. Check the crankshaft axle clearance=>Refer to Page 81.
4. Check the oil film clearance of the crankshaft bearing=>Refer to Page 80.
5. Pay attention to the following notices while installing the piston connecting rod component:
 Installation angle of the piston ring:
is 180° to the opening -5- of the second piston ring and that the two
Blade opening shall locate at the illustrated position and check whether it
may move freely in two directions.
Upper
Lower
blade
blade
Opening
Opening
Spring opening

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 Apply engine oil to piston periphery, piston ring and oil ring.
pulley.
7. Check the piston connecting rod component => Refer to Page 85.
8. Check oil clearance of the crankshaft pin => Refer to Page 81
9. Remove sealant on the surface of the cylinder block before installing the crankshaft rear oil seal.
10. Apply little amount of engine oil to all areas surrounding the oil seal.
11. Apply continuous beaded specified sealant to the fitting surface between the crankshaft rear oil seal shell assembly and
the cylinder block.
12. Install the crankshaft rear oil seal shell assembly onto the cylinder block within 3 minutes after application of the
specified sealant and tighten all fixing bolts to the specified torque.
Tips
Do not damage the crankshaft rear oil seal while installing the crankshaft rear oil seal shell assembly.
13. Remove sealant, oil and other attachment on the installation surface of the flywheel assembly, crankshaft bolt hole and
the flywheel bolt.
14. Install the flywheel assembly onto the crankshaft.
15. Fix the flywheel assembly with the flywheel stopper in the manner the same as its removal.
16. Apply little oil to the flywheel bolt surface and the crankshaft bolt hole.
17. Apply the specified sealant to the threads of the flywheel bolts.
18. Tighten the flywheel bolts to the specified torque.

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5 Removal and Installation of Piston and Connecting Rod Components

T61131204- Piston guide
Removal
Note

Tips

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Note

cylinder number.
Installation
1. Check the piston ring=>Refer to Page 88.
2. Pay attention to the following notices while installing the piston connecting rod component:
 Installation angle of the piston ring:
is 180°to the opening -5- of the second piston ring and that the two
Blade opening shall locate at the illustrated position and check whether
it may move freely in two directions.
Upper Lower
blade blade
Opening Opening
Spring opening
 Apply engine oil to piston periphery, piston ring and oil ring.
3. Lubricate the surface of the connecting rod bearing bush with clean engine oil and install the connecting rod bearing bush
onto the connecting rod.
4. Dip the piston crown and piton ring into clean engine oil, and install the piton and connecting rod component onto the
piston guide -T61131204-; ensure the position of the piton ring remains unchanged during this process.

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pulley.
6. Push the piston into the cylinder. Meanwhile, guide the connecting rod to the connecting rod journal.
Note
Don't fiercely knock the piton and connecting rod assembly, otherwise the piton ring will be damaged.
7. Lubricate the surface of the connecting rod bearing bush with engine oil and install the connecting rod bearing cap and
the connecting rod bearing bush.
8. Check oil clearance of the crankshaft pin => Refer to Page 81
Install other parts in reverse order.

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6 Removal and Installation of Crankshaft

Removal
Note
Do not turn the crankshaft as far as possible after complete removal of

the connecting rod bearing cap in order to facilitate installation of the
piston connecting rod component.
Tips
Disassemble all the piston connecting rod components in the same way.
Disassemble the piston connecting rod components of Cylinder 1 and 4
at the bottom dead center of Cylinder 1. Disassemble the piston
connecting rod components of Cylinder 2 and 3 at the bottom dead
center of Cylinder 2.
bearing bush) -1-.
Tips

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Tips
Install the thrust bearing onto the No. 4 bearing of the cylinder block.
Apply engine oil to the thrust bearing for easy installation.
7. Unscrew the fixing screw -Arrow- of the crankshaft position sensor gear ring and remove the crankshaft position sensor
gear ring -1-.
Screw -Arrow - tightening torque: 8 - 10 Nm
Note
Avoid the crankshaft position sensor gear ring -1- being crashed and deforming, so as to prevent crankshaft position
sensor signal error.
Installation
Note
1. Install the fixing bolt -Arrow- on the crankshaft position sensor gear
ring -1-.
Note
To prevent crankshaft position sensor signal error, align the

positioning pin -2- on the crankshaft during the installation of the
crankshaft position sensor gear ring -1-.

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2. Apply some engine oil on the crankshaft thrust bearing, and install the
thrust bearing to the position for the fourth bearing in the cylinder block.
Tips
During the installation, the groove on the thrust bearing should face
agaisnt the crankshaft crank arm.
3. Install the crankshaft bearing cap components -1-, and tighten the
bolts in sequence as shown in the picture.
Tips
Tips
Following installation of the crankshaft bearing cap, install the connecting rod bearing cap while keeping the camshaft not
revolving as far as possible.
4. Check the oil film clearance of the crankshaft bearing=>Refer to Page 80.
5. Check thrust clearance of the crankshaft => Refer to Page 81.
6. Check oil film clearance of the crankshaft pin => Refer to Page 81

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13 Air Intake/Exhaust System

1 Overview
Air Intake System
The air intake system is designed to supply sufficient amounts of clean air and ensure the quality of the combustible gas
mixture. Air enters the air filter assembly in the engine compartment that filters out impurities in the air through its filter
element and keeps on the surface of the filter element intake side. The filtered air will be supercharged in the turbocharger
and cooled in the intercooler and then enter the intake manifold through the electronic throttle or the idle speed bypass, mix
with the atomized gasoline injected out of the fuel injector to form combustible mixture gas and finally enter the cylinder
through the open intake valve.
The main components of the air intake system include the following:
 Air filter intake pipe
 Air filter assembly
 Air filter outlet pipe
 Air intake manifold
Exhaust System
The exhaust system is designed to emit the exhaust produced during the fuel combustion in the cylinder block, and clean the
harmful emissions as much as possible while reducing noises. After the exhaust is converted by the catalytic converter, most
of the harmful gas is transformed into harmless gas, and is emitted into the atmosphere after the noise is reduced by the
silencer. After both conversion in the catalytic converter and silencing are finished, the emissions from the exhaust system
can meet national standards.
The exhaust pipeline consists of exhaust manifold, catalytic converter, auxiliary silencer and main silencer assembly,
connected from the vehicle front to the end: exhaust manifold, catalytic converter, auxiliary silencer assembly and main
reducer assembly.
The main components of the exhaust system include the following:
 Exhaust manifold
 Catalytic converter assembly
 Auxiliary silencer assembly
 Main silencer assembly
Repair Group 13 – Air Intake and Exhaust System 143

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2.1.1 Air Intake Backfire
Does the engine works The engine temperature Avoid extended periods
with a heavy load for an Proceed to Step 1. is too high, causing of heavy-duty operation
extended period of time intake backfire of the engine
The injector is blocked
or stagnated, affecting
Check if the fuel injector is Clean or replace the
Proceed to Step 2. the mixture
normal injector
concentration or the
injection timing
Check if the
Some sensors have
pressure/temperature
faults, which affect the
sensor, throttle position Replace the faulty
Proceed to Step 3. fuel injection quantity
sensor and coolant sensors
and mixture
temperature sensor are
concentration
working normally
3 Check the valve gap Normal There's a fault Operation methods
Grind the valve ejector
Small valve clearance,
Check the valve clearance Proceed to Step 4. rod to the reasonable
improper sealing
clearance range
4 Check the valve Normal There's a fault Operation methods
Excessive carbon on
Clean the carbon off the
the valve, improper
valve, and grind down
Check the carbon on the sealing, causing
Proceed to Step 5. the valve if there is
valve ignition of the gas
frequent and excessive
mixture outside of the
carbon
cylinder
5 Check the timing Normal There's a fault Operation methods
Adjust the timing based
Check if timing is accurate Proceed to Step 6. Errors occur in timing
on timing marks
windows and check
6 End of diagnosis There's a fault Operation methods
whether fault occurs after
repairs
2.1.2 Exhaust Noise

Check for leakage in
Check if the exhaust
exhaust connections Replace the damaged
system is functioning Proceed to Step 1.
and damage in exhaust part(s)
normally
system parts
1 Check the fuel Normal There's a fault Operation methods
144 Repair Group 13 – Air Intake and Exhaust System

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Replace with fuel that
meets all specifications.
The fuel is of poor
If the fuel is mixed with
Check if the fuel is normal Proceed to Step 2. quality or mixed with
water, clean the fuel
water
system and replace the
fuel filter
Clean the cabin
deposition on the spark
The spark plug has no
Check if the spark plug is plug or replace the
Proceed to Step 3. jump spark, or the
normal spark plug, and further
jump spark is weak
check the ignition
system if necessary
The fuel injector jams,
Check if the fuel injector is Clean or replace the
Proceed to Step 4. or injects fuel
normal injector
constantly
Check if the
Some sensors have
pressure/temperature
faults, which affect the
sensor, throttle position Replace the faulty
Proceed to Step 5. fuel injection quantity
sensor and coolant sensors
and mixture
temperature sensor are
concentration
working normally
Check if the ignition Errors occur in ignition
timing is normal timing
6 End of diagnosis There's a fault
whether fault occurs after other symptoms.
repairs

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Air Intake System
Torque
Nm
8mm Hexagon
Air filter intake pipe fixing bolt M6×1.0×12 8.8 4～6
Sleeve
10mm Hexagon
Fixing bolt of the air filter shell assembly M6×1.0×35 8.8 4～6
Sleeve
10mm Hexagon
Electronic throttle valve fixing nut M6×1.0×50 8 5～7
Sleeve
Fixing bolt of intake air pressure and temperature 10mm Hexagon
M6×1.0×16 8 4～6
sensor Sleeve
12mm Hexagon
Fixing bolt of the intake manifold M8×1.25×40 8 18～22
Sleeve
Clamp of air filter exit pipe (connected to the air 8mm Hexagon
— — 5～7
filter assembly) Sleeve
Clamp of air filter exit pipe (connected to the 8mm Hexagon
— — 5～7
electronic throttle) Sleeve
Exhaust System
Torque
Nm
Fixing bolt for the upper heat shield of the exhaust 10mm Hexagon
M6×1.0×16 10 9～11
manifold Sleeve
Fixing bolt for the lower heat shield of the exhaust 10mm Hexagon
M6×1.0×10 10 9～11
manifold Sleeve
Fixing bolt of the catalytic converter assembly 14mm Hexagon
M10×1.25 8.8 40～60
(connected to the exhaust manifold) Sleeve
Fixing bolt of the exhaust manifold bracket 14mm Hexagon
M10×1.25×20 8.8 31～39
(connected to the exhaust manifold) Sleeve
Fixing bolt of the exhaust manifold bracket 12mm Hexagon
M8×1.25×16 8.8 18～22
(connected to the cylinder block) Sleeve
12mm Hexagon
Exhaust manifold fixing nut M8×1.25 — 29～39
Sleeve
Fixing nut of the auxiliary silencer assembly 16mm Hexagon
M10×1.25 10.9 49～69
(connected to the catalytic converter assembly) Sleeve
Fixing nut of the main silencer assembly (connected 16mm Hexagon
M10×1.25 10.9 49～69
to the auxiliary silencer assembly) Sleeve
22mm
Front oxygen sensor — — 40～60 combination
wrenches
22mm
Rear oxygen sensor — — 40～60 combination
wrenches

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4 Air Intake System

4.1 Removal and Installation of the Air Filter Assembly
Removal
1. Unscrew the fixing bolt -Arrow- of the air filter intake pipe and
remove the air filter intake pipe -1-.
2. Unscrew the fixing clamp -Arrow- of the air filter outlet pipe, remove
the venting pipe -1- and remove the air filter outlet pipe -2-.
Clamp -Arrow A- tightening torque: 5 - 7 Nm
3. Unscrew the fixing bolt -Arrow- of the air filter shell assembly and
remove the air filter shell assembly -1-.
Installation

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4.2 Air Intake Manifold

4.2.1 Removal and Installation of Intake Manifold
Removal
2. Disconnect the battery negative cable=>Electrical Equipment: Repair Group: 60; Power Distribution; Battery: Battery
Cables: Disconnection and Connection of Battery Negative Cable.
3. Unscrew the fixing clamp -Arrow- of the air filter outlet pipe, remove
the venting pipe -1- and remove the air filter outlet pipe -2-.
5. Disconnect the connection between the PCV valve venting pipe -1-
and the intake manifold.

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6. Disconnect the connecting plug -Arrow A- of the electronic throttle

and disengage the connection between cooling water pipe -3- and the
bracket.
7. Loosen the retaining clamp -Arrow B-, disconnect the outlet pipe -1-
and the throttle.
8. Loosen the retaining clamp -Arrow C-, disconnect the inlet pipe -2-
and the throttle.
Tips
the cooling pipe.
9. Unscrew the fixing bolt -Arrow A- on the electronic throttle, and
remove the retaining bracket -2- of the water pipe.
10. Unscrew the fixing bolt -Arrow B- on the electronic throttle -1-, and
remove the electronic throttle.
Tips
The throttle gasket must be replaced.
11. Disengage the fixing clip -Arrow A- of the engine wiring harness,
disconnect the connecting plug -Arrow B- of the solenoid valve and put
aside the engine wiring harness -1-.

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12. Loosen the fixing clamp -Arrow- of the vacuum hose and disengage
the connection between the vacuum hose -1- and the venting hose -2- of
the carbon canister solenoid valve with the intake manifold.
13. Disconnect the connecting plug -Arrow B- of the intake air pressure
and temperature sensor, unscrew the fixing bolt -Arrow A- of the intake
air pressure and temperature sensor and remove the intake air
temperature and pressure sensor -1-.
14. Remove the vacuum hose -2- and vacuum hose -3- and remove the
electronic valve -4-.
15. Unscrew the fixing bolt -Arrow- of the intake manifold and remove
the intake manifold assembly -1-.
Tips
The intake manifold gasket must be replaced.
Installation
4.2.2 Detection of the Intake Manifold

Visual Inspection
Check the air intake manifold for the following conditions, and replace it if necessary:
 Structural damage or surface cracks occur on the air intake manifold.

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 Damage of the sealing junction surface of the intake manifold leads to poor sealing.
 Damage of installation hole of the fuel injector leads to untight installation or air leakage of the fuel injector.
Clean the pipeline in case of excessive oil sludge and carbon deposit inside the intake manifold pipeline.

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5 Air Intake/Exhaust System

5.1 Intake/Exhaust Manifold
5.1.1 Removal and Installation of Exhaust Manifold
Removal
Note
As the exhaust system pipeline is quite hot while the engine is operating, it is necessary to shut down the engine and
remove its exhaust manifold when it cools to the room temperature, or otherwise the hot parts is likely to cause personal
injury.
1. Remove the catalytic converter assembly => Refer to Page 155.
3. Unscrew the fixing bolt -Arrow- on the upper heat insulation shield
of the exhaust manifold, and remove the upper heat insulation shield-1-.

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4. Unscrew the fixing bolts -Arrow A- and -Arrow B- on the exhaust

manifold bracket-1-, and remove the intake manifold bracket.
5. Unscrew the fixing bolt -Arrow- of the exhaust manifold lower heat shield and remove the exhaust manifold lower heat
shield -2-.
6. Unscrew the fixing nut -Arrow- of the exhaust manifold and remove
the exhaust manifold assembly -1-.
Note
Gasket of the exhaust manifold must be replaced.

The bulging part of the exhaust manifold gasket must face the direction of engine, or otherwise the installation sealing
part is vulnerable to air leakage.
Installation

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5.1.2 Check on Exhaust Manifold

Visual Inspection
Check the exhaust manifold for the following conditions, and replace it if necessary
 Structural damage or surface cracks occur in the exhaust manifold.
 Damage of sealing junction surface of the exhaust manifold leads to poor sealing.
Clean the pipeline in case of excessive oil sludge and carbon deposit inside the exhaust manifold pipeline.

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5.2 Exhaust Pipe

5.2.1 Removal and Installation of Catalytic Converter Assembly
Removal
Note
injury.

3. Remove A-pillar lower trim panel =>Body and painting: Repair group: 84: Interior equipment: Trim part and trim panel:
A-pillar trim panel: Removal and installation of A-pillar lower trim panel.

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and unscrew the front oxygen sensor -1- with removal and installation
tool -T41132201- for oxygen sensor.
oxygen sensor.

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10. Disconnect the connector -Arrow- of the rear oxygen sensor and
unscrew the rear oxygen sensor -1- with removal and installation tool
-T41132201- for oxygen sensor.
11. Unscrew the fixing bolt -Arrow- of the catalytic converter assembly
and the exhaust manifold assembly and disengage the hook washer -1-.
Tips
 Apply a small amount of engine oil inside the installation hole of
the lug gasket to facilitate its removal or installation.
 Please ask another technician to hold the auxiliary silencer
assembly for fear that it falls from high.
12. Unscrew the fixing nut -Arrow- of the catalytic converter assembly
and the auxiliary silencer, disengage the connection between the
catalytic converter-1- and the auxiliary silencer -2- and remove the
catalytic converter assembly -1-.
Note
The catalytic converter is expensive and fragile.Handle it carefully during its removal or installation.Otherwise, damage
may occur, causing the converter to malfunction.
Installation

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Tips
The sealing gasket is disposable that must be replaced after removal.
5.2.2 Removal and installation of the auxiliary silencer

Removal
Note
As the exhaust system pipeline is quite hot when the engine just stops, it is required to shut down the engine and remove
its auxiliary silencer assembly only after it cools to the room temperature, or otherwise the hot parts is likely to cause
personal injury.
1. Lift the vehicle to the proper position.
2. Unscrew the fixing nut -Arrow- of the auxiliary silencer assembly
and the catalytic converter assembly and disengage the connection
between the catalytic converter-1- and the auxiliary silencer-2-.
Tips
Please ask another technician to hold the auxiliary silencer assembly
for fear that it falls from high.
3. Unscrew the fixing nut -Arrow- of the main silencer assembly and
the auxiliary silencer assembly, disengage the connection between the
auxiliary silencer-1- and the main silencer -2- and remove the auxiliary
silencer assembly-1-.
Installation
Tips
The sealing gasket is disposable that must be replaced after removal.

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5.2.3 Removal and Installation of the Main Silencer Assembly

Removal
Note
injury.
2. Unscrew the fixing nut -Arrow- between the main silencer assembly
and the auxiliary silencer assembly and disengage the connection
between the auxiliary silencer -1- and the main silencer -2-.
3. Disengage the main silencer hook washer -1-.
Tips
 Apply a small amount of engine oil inside the installation hole of
the lug gasket to facilitate its removal or installation.
 Please ask another technician to hold the silencer assembly for
fear that it falls from high.
4. Remove the main silencer assembly -2-.
Installation

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5.3 Check and Adjustment of Exhaust System

Check
 Check the various parts in the exhaust system for cracks, broken welding seams, stripped threads and excessive
corrosion of the connecting bolt and nut.
 Check whether the lifting lugs in the exhaust system are sturdy, and check the lug gaskets for excessive deformation,
aging or other damage.
Tips
Replace the damaged parts if necessary.
Adjustment
If the exhaust system generates resonance and clicks at the same time, generally, it means a part of the exhaust system is not
properly aligned.So, check the parts of the exhaust system for breakage, or loose lug gaskets or insulation plates, and adjust
or replace the parts if necessary.
Perform the following steps when aligning the exhaust system:
1. Ensure that the vehicle is level.
2. Loosen the connections between the parts in the exhaust system.
3. Perform the alignment starting from the front end of the exhaust system.
4. When connecting the exhaust system parts, ensure that the corresponding flanges are properly contacted.
5. After the alignment, tighten all nuts at the connections.

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14 Lubrication System
1 Overview
The medium of the engine lubrication system is the engine oil, which performs the functions of lubrication, cleaning,
cooling, sealing and anti-corrosion for the engine parts. When the lubrication system is working properly, the engine oil
pump sucks the engine oil from the oil pan via the engine oil strainer, and delivers it to all the parts that require lubrication,
through pipes or oil channels inside the unit. When the engine oil is delivered to the moving parts or friction surfaces, it
creates an oil film and reduces friction resistance as well as wear on the parts.As it flows, the engine oil also draws away the
heat of the moving parts and the friction surfaces, as well as the metal dust caused by friction, thus ensuring optimal
mechanical operation. When the engine oil reaches the internal wall of the cylinder, it also performs a sealing function.The
engine oil enters the gaps between the internal wall of the cylinder, the piston and the piston ring, so that it is sealed when
the piston moves back and forth inside the cylinder.
Engine oil is the medium of the lubrication system, the quality of which directly influences the normal operation of the
system. The selection of engine oil must comply with the vehicle's operation requirement.If it is too thick, it cannot easily
flow through the pipes and oil channels, thus increasing the resistance in the parts and friction surfaces, or even leading to
direct friction between the mechanical parts due to inability to form an oil film.If it is too thin, the engine oil is overly fluid
and the oil film it creates will soon be destroyed under high temperatures. If mixed with water, the engine oil will create
emulsion, which can not lubricate the parts and even cause rust and jamming to the parts and friction surfaces. Therefore, it
is necessary to check the level and quality of engine oil on a regular basis.
The main components of the lubrication system include the following:
 Oil strainer
 Engine oil pump
 Engine oil regulating valve
 Oil channel (pipe or oil channel inside the unit)
 Oil filter
 Engine oil pressure switch
 Oil pressure alarm
Repair Group 14 - Lubrication System 161

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2.1.1 Low Oil Pressure
The engine oil used
doesn't meet the Replace it with a
Check whether the engine
Proceed to Step 1. standard, including its different engine oil that
oil used meets the standard
viscosity and other meets the standard
performance parameters
1 Check the engine oil Normal There's a fault Operation methods
Check if the level of engine The level of engine oil is Fill oil to normal oil
Proceed to Step 2.
oil is normal low, insufficient level
2 Check the oil filter Normal There's a fault Operation methods
Check whether the oil filter Oil filter is too dirty or Replace the engine oil
Proceed to Step 3.
is reasonably clean blocked and the oil filter
Check the engine oil
pressure switch
Check if the engine oil Failure is detected in the
Replace engine the oil
pressure switch works Proceed to Step 4. engine oil pressure
pressure switch
properly switch
Check the oil pressure
regulating valve
Replace the oil pressure
Check whether the oil regulating valve
Oil pressure regulating
pressure regulating valve is Proceed to Step 5. plunger and replace the
valve jamming
normal front cover assembly if
necessary
5 Check the engine oil strainer Normal There's a fault Operation methods
The screen of the oil
strainer is blocked by
Clean the screen of the
Check whether the oil excessive impurities, or
Proceed to Step 6. oil strainer, and replace
strainer is normal the sealing gasket of the
the sealing gasket
oil strainer is broken or
has fallen off
6 Check the engine oil pump Normal There's a fault Operation methods
Replace the rotor of the
Check if the rotor clearance The rotor of the engine
engine oil pump or
of the engine oil pump is Proceed to Step 7. oil pump is overly worn,
engine oil pump
normal with large clearance
assembly
Check the crankshaft
bearing
Replace the master
Check whether the
Proceed to Step 8. Large play bushing, and the
crankshaft bearing is normal
crankshaft if necessary
Find the cause from
other symptoms
162 Repair Group 14 - Lubrication System

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2.1.2 Exceptional Engine Oil Consumption

There is a broken oil
pan or leakage at the
Check the engine assembly Replace the damaged
connection of the
for possible leakage of Proceed to Step 1. part and top off the
engine oil pipe; an oil
engine oil engine oil
mark can often be
found
Check the cylinder
pressure
The compression
Check if the compression Overhaul the piston
pressure of the cylinder
pressure of the cylinder is Proceed to Step 2. component and the
is obviously lower than
normal cylinder wall
the normal value
repairs

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Engine
Torque
Nm
12mm Hexagon
Bolts of the oil filter seat M8×1.25×30 8.8 18～22
Sleeve
10mm Hexagon
Oil pan bolt M6×1.0×10 8.8 7～9
Sleeve
10mm Hexagon
Oil dipstick assembly bolt M6×1.0×12 8.8 8～10
Sleeve
10mm Hexagon
Bell housing bolt M6×1.0×16 8.8 8～10
Sleeve
10mm Hexagon
Oil strainer bolt (M6) M6×1.0×20 8.8 8～12
Sleeve
12mm Hexagon
Oil strainer bolt (M8) M8×1.25×20 8.8 10.5～12.5
Sleeve

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4 Removal and Installation of Oil Filter Seat

Removal
1. Remove the oil filter => General; Repair group: 01: General information; Maintenance: Work description: Engine oil and
oil filter: Replace.
2. Unscrew the fixing bolt -Arrow- of the oil filter bracket -1-, and
remove the filter bracket.
Tips
Check the oil filter bracket pad, and replace it as necessary.
Installation
Tips
 Clean the installation plane between the oil filter bracket and the cylinder block.
 After the installation and refilling, start the engine and keep it at idle speed, then check for oil leakage.

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5.3 Oil Pressure Switch

5.1 Removal and Installation of the Oil Pressure Switch
T41131401-Oil pressure switch sleeve T21451401-Oil pressure measuring tool
Removal
3. Remove the starter assembly => Refer to Page 434
4. Disengage the connecting plug -Arrow- of the oil pressure sensor.

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5. Unscrew the fixing screw -Arrow A- of the oil pressure sensor insert
Note
 Before installing the engine oil pressure switch, clean the threads
and the threaded hole of the engine oil pressure switch.
 When installing the engine oil pressure switch, apply some
sealant to the threads of the engine oil pressure switch.
Installation
1. Remove any sealant remaining on threaded holes of the oil pressure
switch and cylinder block.
2. Apply a layer of sealant evenly on the thread part -Arrow- of the oil
pressure switch.
Tips
Be careful when applying sealant; avoid the sealant at the end of the
thread part being squeezed out.

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5.2 Check on Engine Oil Pressure Switch
Tips
A simple test of the engine oil pressure switch is outlined below.If specialized tools are available, the test should follow the
manufacturer instructions.
1. Set the multimeter to ohm mode, and connect the probes of the
multimeter to the housing and connector terminal of the engine oil
pressure switch -1-.If the multimeter shows anything other than zero, it
means the engine oil pressure switch has proper conduction. However, if
no value or zero is shown, it indicates failure exists in the engine oil
pressure switch.Then replace the engine oil pressure switch.
2. Connect the manual air pump (with barometer), connectors, ducts and
engine oil pressure switch -1- respectively.
3. Set the multimeter to ohm position and connect its probes to the shell
of the oil pressure switch -1- and the connector terminal respectively.
4. Pump a pressure into the engine oil pressure switch with the manual
air pump.If the multimeter shows infinite pressure, it means the switch
is open circuited.Otherwise, it indicates failure exists in the engine oil
pressure switch.
Tips
 If the results of both tests above are normal it means the engine oil
pressure switch is up to standards.Otherwise, it indicates failure
and replacement is required. If specific alarming pressure value is
needed, test with specialized tools.
 Standard alarming pressure value of the engine oil pressure switch
is 15 - 30Kpa.

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6 Removal and Installation of Oil Pump
Tips
No accessory is provided for the oil pump for the present; if damaged, replace the timing sprocket shell assembly=>Refer to
Page 114.

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7 Removal and Installation of Oil Pan

Special Tools and Maintenance Equipment Required
Torque wrench T61131401- Removal tool of the oil pan
Removal
1. Drain the engine oil=>General Description; Repair Group 01; General Information; Engine Oil Draining and Filling.
3. Unscrew the fixing bolt -Arrow- of the oil pan.


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4. Use the oil pan assembler/disassembler -T61131401- to remove the oil

pan -1-.
Installation
Note
 Clean the installation surfaces on the oil pan and the cylinder
block with a strong solvent (such as gasoline).
 Pay attention to the expiry date on the sealant.
 Remove sealant on oil pan and cylinder block surface, clean and
apply sealant as per the illustrated requirement.
 Apply sealant to the joint between cylinder block and front cover
and the joint between cylinder block and rear oil seal to the
diameter of 4mm.
 Avoid applying too much sealant; otherwise the redundant
sealant will get into the oil pan and block the filter screen on the
engine oil pump.
 The oil pan must be installed within 3 minutes after the sealant is
applied, otherwise remove the sealant that is already applied and
apply a new coat.
 Do not refill engine oil till at least one hour after the oil pan has
been installed.
 After re-filling the engine oil, start the engine and keep it at idle
speed, then check for oil leakage and the oil level.
 While installing the oil drain plug, replace its washer.

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8 Removal and Installation of Oil Strainer

Removal
1. Remove the oil pan=>Refer to Page 170.
2. Unscrew the fixing bolts -Arrow A- and -Arrow B- on the oil strainer
-1- and remove the oil strainer.
Installation
Tips
 The O-ring is a disposable part, which should be replaced after O ring
being removed.
 Make sure the O-ring is entirely retained in the recess of the engine
Oil filter
oil strainer; avoid any torsion or damage to the O-ring.
Notch

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9 Removal and Installation of the Oil Level Gauge Conduit Assembly

Removal
assembly and extract the oil level gauge conduit assembly -1-.
Tips
The sealing ring -2- under the oil level gauge conduit assembly -1- must
be replaced.
Installation

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10 Removal and Installation of Crankshaft Front Oil Seal

Torque wrench
T61131203-Crankshaft front oil seal conduit
T61131202-Crankshaft front oil seal installer T61131207-Tool for fixing crankshaft pulley
Removal
1. Remove the drive belt => Refer to Page 98
2. Remove the right front wheel cover fender =>Body and painting; Repair group: 83: Exterior equipment; Front wheel
cover fender: Removal and installation of the front wheel cover fender.
3. Fix the crankshaft pulley with its fixing tool -T61131207-, unscrew its
fixing bolt -Arrow- and remove the crankshaft pulley assembly -1-.
Tips
Apply a proper amount of engine oil to threads of the fixing bolts while
installing the crankshaft pulley.

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4. Carefully pry out the crankshaft front oil seal -1- with a screwdriver.
Note
Cover the head of the screwdriver with tape or flexible cloth to avoid
damaging the timing sprocket shell.
Note
Replace the crankshaft front oil seal once removed.
Installation
1. Install the crankshaft front oil seal onto the crankshaft front oil seal
duct -T61131203-, and install the assembled crankshaft front oil seal
duct assembly onto the crankshaft journal.
Tips
Apply little oil to the entire inner ring of the oil seal flange before
installation.
2. Use the crankshaft front oil seal installer -T61131202- to press the
crankshaft front oil seal onto the timing sprocket shell, and use a
hammer to evenly knock it into installing position.
Tips
Ensure that the outer surface of the crankshaft front oil seal is level to
its surrounding edge.

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11 Removal and Installation of Crankshaft Rear Oil Seal Cover
Tips
No accessory is provided separately for the rear oil seal of the crankshaft for the present; if damaged, replace the rear oil
seal of the crankshaft.
Removal
1. Remove the clutch => Manual transmission; Repair group: 30: Clutch; Removal and installation of the clutch.
2. Remove the power assembly => Refer to Page 16
3. Disconnect the automatic transmission connector - arrow A-, and
disengage the harness fixing clip - arrow B-.
4. Disconnect the automatic transmission connector - arrow A -, - arrow

B-, and gear switch connector - arrow C-.
5. Unscrew the fixing bolt -Arrow D- of the engine wiring harness
bonding, disengage fixing clip -Arrow E- and -Arrow F- of the wiring
harness and put aside the engine wiring harness assembly -1-.

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7. Unscrew connecting bolts - arrows - for the hydraulic torque

converter.
Tips
Rotate the crankshaft pulley -1- clockwise, so that the next connecting
bolt - arrow - of the hydraulic torque converter rotates to lower position
directly to facilitate dismantling, and totally six bolts are unscrewed.
6. Unscrew the connecting bolt -Arrow A- and -Arrow B- of the engine

assembly -1- and the automatic transmission assembly -2- and remove
the automatic transmission assembly -1-.

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9. Fasten the flywheel with a flywheel stopper (Tool No.:T61131201).
10. Loosen the fixing bolt -Arrow- of the flywheel but do not unscrew it,
remove the flywheel stopper -T61131201-, unscrew flywheel fixing bolt
-Arrow- and remove the flywheel -1-.
(AT) Bolt -Arrow- Size: M11×1.0×17.5
(MT) Bolt -Arrow- Size: M11×1.0×25
Note
Apply a proper amount of LOCTITE 2701 or equivalent product to threads of the flywheel bolts while installing.
11. Unscrew the fixing bolt -Arrow- of the oil pan.

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Installation
1. Clean sealant residual on the installation surface of the cylinder block.
2. Apply a small amount of engine oil onto the sealing lip of the crankshaft rear oil seal.
3. As shown in the figure, apply a strip of liquid sealant in continuous
pearl-drops on the crankshaft rear oil seal installation surface of the
cylinder block.
Tips
The oil seal cover oil must be installed within 3 minutes after the sealant is applied.
Tips
Check for oil leakage.

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15 Cooling System
1 Overview
The internal combustion engine generates large amounts of heat.At present, the heat conversion efficiency of gasoline
engines is around 28%, and up to 72% of the energy is radiated into the atmosphere as heat. If the heat isn't radiated timely,
the engine will suffer from ineffective lubrication, piston scuffing, burnt crankshaft bushings and other serious damage due
to overheating. If the engine radiation is uneven, it will also lead to overheating in some parts, thus causing damage.
Therefore, the engine needs a good cooling system to eliminate extra heat.
If the cooling system undergoes excessive heat radiation, the working temperature of the engine will get too low so that the
engine oil becomes too thick to lubricate the moving parts of the engine.If the parts that need lubrication are not properly
lubricated, the operating resistance of the engine will increase. Meanwhile, the excessive heat consumption will diminish
the engine fuel economy.
If the radiation of the cooling system is inefficient, the working temperature of the engine will get too high so that the
engine oil becomes excessively hot and affects the formation of oil film over the surface of the moving parts, which
prevents the lubrication of the moving parts.If the heat isn't radiated promptly, some parts will expand excessively, causing
stagnation and leading to piston scuffing and burnt bushing.
A good cooling system can properly adjust and control the engine working temperature, thus achieving ideal power output
and excellent fuel economy.
The main components of the cooling system include the following:
 Radiator
 Electronic fan
 Thermostat
 Inlet/outlet pipes
 Water pump
 Auxiliary radiator
 Coolant temperature sensor (ECT sensor)
180 Repair Group 15 - Cooling System

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2.1.1 Engine Water Temperature Is High
Check the level of coolant Proceed to Step 1. Insufficient coolant Top off the coolant
1 Check the radiator Normal There's a fault Operation methods
Excessive dust is found
Check the radiator on the surface of the
Proceed to Step 2. Clear the impurities
appearance radiator, impurities in
seams
sensor
Check whether the coolant Failure in the coolant Overhaul the circuit or
temperature sensor is Proceed to Step 3. temperature sensor or replace the defective
normal circuit sensor
3 Check the thermostat Normal There's a fault Operation methods
The thermostat cannot
Check whether the
Proceed to Step 4. get started within the Replace the thermostat
thermostat is normal
set temperature range
4 Check the electronic fan Normal There's a fault Operation methods
The electronic fan
Check whether the doesn't work when the Check the electronic
Proceed to Step 5.
electronic fan is normal engine is running at fan supply harness
high temperatures
5 Check the water pump Normal There's a fault Operation methods
Leakage in water
Check operating
pump, loose or fallen Replace the water
conditions of the water Proceed to Step 6.
impeller or unsmooth pump
pump
operation are detected
repairs
2.1.2 Engine Water Temperature Is Low

Check whether the coolant Failure in the coolant Overhaul the circuit or
temperature sensor is Proceed to Step 1. temperature sensor or replace the defective
normal circuit sensor
1 Check the electronic fan Normal There's a fault Operation methods
Repair Group 15 - Cooling System 181

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Check the circuit, fuse,
solenoid valve and fan
motor; replace the
Check whether the The electronic fan turns defective parts. Check
Proceed to Step 2.
electronic fan is normal constantly whether the air
conditioning system is
faulty and eliminate the
fault
2 Check the thermostat Normal There's a fault Operation methods
Failure is detected in
Check whether the the thermostat: the
Proceed to Step 3. Replace the thermostat
thermostat is normal valve is constantly
open
repairs

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Torque
Nm
10mm Hexagon
Fixing bolt of the thermostat shell M6×1.0×22 8.8 8～10
Sleeve
10mm Hexagon
Condenser fixing bolt M6×1.0×16 8.8 9～12
Sleeve
Fixing screw of the auxiliary radiator — — 9～11 —
Fixing screw of the electronic fan — — 9～11 —
10mm Hexagon
Fixing bolt of the water pump driving wheel M6×1.0×10 8.8 7～9
Sleeve
10mm Hexagon
Fixing bolt of the water pump M6×1.0×45 8.8 8～10
Sleeve

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4 Cooling System Piping Diagram
1 - Water pump assembly 2 - Engine assembly

3 - Heater core 4 - Throttle assembly
 Removal and installation =>Electrical equipment;  Removal and installation=>Refer to Page 391
Repair group: 73: Air conditioning system; Electric
digital display air conditioner; Removal and
installation of the heater core
5 - Radiator reservoir 6- Radiator assembly
7 - Thermostat
 Removal and installation=>Refer to Page 186

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5 Thermostat
5.1 How it works
The thermostat is the valve controlling coolant path and flow that is generally installed at the engine water inlet (connected
with water outlet hose of the radiator). It is a kind of wax thermostat that is able to adjust automatically coolant path and
flow by water temperature to form large and small circulations of the cooling system.
The paraffin inside the wax-type thermostat expands with heat and contracts with cold. When the coolant temperature is
lower than the set value (the set value is decided at the time of design and production), the delicate wax inside the
thermostat temperature sensor turns to solid state with reduced volume so that it will not push open the valve through the
pushrod. In this case, the thermostat valve closes the passage between engine and radiator under the return effect of the
spring and coolant returns back to the engine through the water pump to carry out small engine circulation; when the coolant
temperature arrives at the set value, the wax melts and turns to liquid state, when its volume increases gradually and forces
the rubber hose to contract. While the rubber hose is contracting, it exerts upward thrust to the pushrod and the pushrod
generates downward reaction thrust to the valve to make the valve open. The coolant flows back to the engine through
radiator and thermostat valve to perform the large engine circulation.

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5.2 Removal and Installation of Thermostat

Removal
1. Drain the coolant=>Overview; Repair Group:01: General Information; Service and Maintenance: Work Description:
Coolant: Replace.
2. Loosen the fixing clamp -Arrow A- of the radiator drain pipe and
disengage the connection between the drain pipe -1- and the thermostat
shell -2-.
3. Disconnect the fixing clip -Arrow B- of the wiring harness.
4. Unscrew the fixing bolt -Arrow- of thermostat shell and remove the
thermostat shell -1-.
5. Take out the thermostat -1-.
Note
 When installing the thermostat -1-, set the air outlet -Arrow- to
the very top end.
 Once the thermostat is installed, start the engine and check for
coolant leakage.
 Engine may not operate without a thermostat as removal of the
thermostat will cause adverse effect and result in lowered cooling
efficiency. Therefore, the thermostat cannot be removed even in
the event of engine overheat.

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6. Take out the thermostat sealing ring -1-.
Installation
5.3 Check on Thermostat

1. Immerse the thermostat and a thermometer into water and slowly heat
the water.
2. During heating the water, observe the temperature shown on the
thermometer when the thermostat valve is open.
Opening temperature of thermostat valve:81.5～83.5℃
Tips
If the opening temperature of the thermostat doesn't meet the standard,
replace the thermostat.
3. Gradually heat water to 95℃, check whether the valve opens to the
maximum opening a and replace the thermostat if valve opening is
inconsistent with the requirement.
Max. valve openness "a":≥ 8 mm
Tips
a：Max. valve openness
b: Greatest openness
b: Remaining closed
Max. valve openness a=c-b
4. Cool down the water to 80~84℃ or below, and check whether the
valve is fully closed.If not, replace the thermostat.

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Tips
If the openness "a" or closing of the thermostat doesn't meet the standard, replace the thermostat.

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6 Radiator
6.1 Removal and Installation of the Radiator
Note
 To avoid damaging the pipeline and the pipe connectors, don't excessively stretch or bend the pipes.
 Once disconnected, seal the pipe connectors in order to prevent impurities from entering the pipes.
Removal
1. Remove the front bumper assembly =>Body and painting; Repair group: 83: Exterior equipment; Front bumper: Removal
and installation of the front bumper assembly.
2. Remove the water tank upper beam=>Vehicle Body and painting; Repair group: 83; Exterior equipment; Removal and
installation of water tank upper beam.
Coolant: Replace.
4. Remove the auxiliary radiator => Refer to Page 192.
5. Remove the electronic fan => Refer to Page 197.
6. Loosen the fixing clamp -Arrow- of the radiator feed hose and
disengage the radiator feed hose -1-.

7. Loosen the fixing clamp -Arrow A- of oil outlet hose and oil inlet hose
-Arrow B- of the transmission oil cooler and disengage the connection
between transmission oil inlet hose -1- and oil outlet hose -2- with the
radiator -4-.
8. Loosen the fixing clamp -Arrow C- of the radiator drain pipe and
disengage the connection between radiator drain pipe -3- and radiator
-4-.

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9. Loosen the fixing clamp -Arrow- of the radiator drain pipe and
disengage the radiator drain pipe -1-.
Tips
 Collect the spilt automatic transmission oil with a proper
container.
 Wrap and seal the pipeline after disconnection of the oil pipe for
fear of entry of impurities into the pipeline.
 After installing oil tube of the transmission oil cooler, check the
automatic transmission oil level and fill the automatic transmission
oil if necessary.
10. Unscrew the fixing bolt -Arrow- of the condenser.
11. Lift up the condenser -2-, disengage its connection with the radiator
-1- and take out the radiator assembly -1- carefully.
Tips
 It is not necessary to disconnect pipeline of the A/C condenser -2-.
Installation
Tips
Add coolants to the standard level, and check the tightness of the coolant pipeline.

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6.2 Cleaning and Checking Radiator

Cleaning
In normal driving, as the radiator is located at the front of the vehicle
and the air inflow is great, significant amounts of dirt and impurities
tend to build up on the surface of the radiator. A clean radiator surface
ensures good radiation performance. If impurities start to build up on the
surface of radiator, blow compressed air on the rear part of the radiator,
from rear to front, after the engine has cooled down.
Tips
Don't wash the radiator with a pressure washer, because this can deform
the radiation fins.
Check
1. Check the surface of the radiator for cracks, rust, and other damage, paying particular attention to the bending and
connecting parts, and replace it if necessary.
2. Check the fins of the radiator for bending or other damage, and replace them if necessary.
3. Check whether the radiator core bends and whether any joint has rust and leakage and replace if necessary.

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7 Removal and Installation of Auxiliary Radiator

Removal
Note
 Once disconnected, seal the pipe connectors in order to prevent impurities from entering the pipes.
1. Unscrew the fixing bolt -Arrow- of the air filter intake pipe and
remove the air filter intake pipe -1-.
2. Disengage the wiring harness clip -Arrow A- and unscrew the upper
fixing screw -Arrow B- of the auxiliary radiator assembly.
Screw -Arrow B- tightening torque: 9 - 11 Nm
3. Loosen the fixing clamp -Arrow A- of the auxiliary radiator hose and
disengage the connection between the auxiliary radiator hose -2- and the
auxiliary radiator assembly -1-.

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4. Loosen the lower fixing screw -Arrow- of the auxiliary radiator

assembly and remove the auxiliary radiator assembly -1-.
Installation
 After the installation of auxiliary radiator is completed, add coolants to the standard level, and check the tightness of
the coolant pipeline.

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8 Water Pump
8.1 Removal and Installation of Water Pump
Special Tools and Maintenance Equipment Required
T41131501-Fixing tool of the water
Removal
Coolant: Replace.
2. Remove the right front wheel cover fender =>Body and painting; Repair group: 83: Exterior equipment; Front wheel
cover fender: Removal and installation of the front wheel cover fender.
4. Use the water pump fixing tooling -T41131501- to fix the water pump
pulley-1–，and unscrew the fixing bolts -Arrow-.
5. Remove the water pump pulley -1-.

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6. Unscrew the fixing bolt -Arrow- on the water pump assembly -1-, and
remove the water pump assembly.
Installation
Tips
 The O-ring is a disposable part, which should be replaced after
being removed.
 Make sure the O-ring is entirely retained in the recess of the water
pump; avoid any torsion or damage to the O-ring.

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8.2 Check the Water Pump

1. Check whether appearance and shell of the water pump -1- have such
damages as crack, collision, unevenness, etc.
2. Check whether there is any trace of coolant leakage at the position
-Arrow- of the water pump bearing.
Tips
 Replace the water pump -1- if its appearance and shell are
damaged.
 Replace the water pump in case of the trace of coolant leakage at
the position -Arrow- of the water pump bearing.
3. Check whether the water pump pulley -1- turns smoothly.
Tips
Replace the water pump if water pump pulley -1- and impeller -2- are
unsmooth in turning or loose.

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9 Removal and Installation of Electronic Fan Assembly

Removal
Danger
The electronic fan may engage at any time. So, don't touch it before disconnecting its power supply.
3. Remove the auxiliary radiator => Refer to Page 192
4. Pry up the wiring harness clip -Arrow B- and disconnect the power
supply connector -Arrow A- of the electronic fan.
5. Unscrew the left fixing screw -Arrow- of the electronic fan.

6. Unscrew the right fixing screw -Arrow- of the electronic fan.


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7. Disengage the transmission oil cooler hose -1-.

8. Disengage the auxiliary radiator hose -1- and carefully remove the
electronic fan assembly -2-.
Installation

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20 Electronic Control System

1 Overview
1.1 System Overview
Diagnosis Diagnosis
Sensor Actuators
Engine
The Engine Electronic Control System is comprised primarily of the sensor, microprocessor (ECU), and the actuator, which
controls the air quantity, oil quantity and ignition advance angle.
In the engine electronic control system, the sensor is as an input part, used to measure various physical signals (temperature,
pressure, etc.), and converts them into an electric signal; ECU receives the sensor's input signal, and calculates & processes
them based on a specific program, then generates the corresponding control signal, outputs them to the power driving circuit,
which takes different actions by actuating various actuators, and enables the engine to run according to the specific control
strategy; the fault diagnosis system of ECU monitors all parts or controlling functions, and once it detects a fault and gets
confirmation, it will store the fault code and invoke the function of "limp home"; as soon as it detects that the fault has been
cleared out, it will restore the normal value and return to service again.
The main character of the electronic control system equipped for this model is its control strategy based on the torque. The
main purpose to take the torque as a major control strategy is to connect all control targets together.
The basic components of the engine electronic control system include:
 Electronic Control Unit (ECU)
Repair Group 20 - Electronic Control System 199

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 Electronic accelerator pedal

 Injector
 Air intake temperature/pressure sensor
 Electronic fuel pump
 Fuel pressure regulator
 Electronic throttle body
 Camshaft position sensor
 Crankshaft position sensor
 Carbon canister control valve
 Knock sensor
 Ignition coil
 Engine oil control valve
 Oxygen sensor
The Engine Electronic Control System of this model is an electronically-controlled gasoline engine management system,
which possesses a number of controlling features in relation to the operator and the vehicle, as well as to the equipment.
With the combination of open-loop and closed-loop (feedback) control, it provides a variety of control signals to the engine.
The main functions of the system include:
 Torque-based system architecture
 Determining cylinder load based on inlet pressure/air flow sensor
 Improved mixture control functionality in both static and dynamic conditions
 λ closed-loop control
 Sequential fuel injection by the cylinder
 Ignition timing, including cylinder-by-cylinder knock control
 Exhaust control function
 Heating of the catalytic converter
 Canister control
 Idle-speed control
 Limp home
 Sensing speed via incremental system
 V.V.T control
200 Repair Group 20 - Electronic Control System

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1.2 Electronic Control System I/O Signals

Electronic Control System I/O Signals
The main sensor input signals of ECU include:
 Intake pressure signal
 Accelerator pedal signal
 Intake temperature signal
 Throttle angle signal
 Coolant temperature signal
 Engine RPM signal
 Phase signal
 Knock sensor signal
 Oxygen sensor signal
 Wheel speed signal
 A/C pressure signal
 Braking signal
Once the input signals of various sensors enters the ECU, they are processed and generate the required actuator control
signals, which are amplified in the output drive circuit and transferred to the specific actuators. These control signals include
the following:
 Opening degree of the electronic throttle
 Injection timing and injection duration
 Fuel pump relay
 Opening degree of the canister control valve
 Ignition coil cam angle and ignition advance angle
 Air conditioner compressor relay
 Cooling fan relay
 Starter relay
 V.V.T angle

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1.3 Introduction to System Functions

1.3.1 Starter Control
During the starting process, special calculations are adopted to control the volume of charged gas, fuel injection and ignition
timing. The air in the intake manifold is stationery at the beginning of the process and the internal pressure displayed in the
intake manifold is the pressure of ambient atmosphere. When the valve is closed, the idling adapter will adjust to the preset
parameter designated according to the starting temperature.
The fuel injection volume changes with the engine temperature, so as to form an oil film on the intake manifold and the
cylinder wall. Therefore, fill in mixture before the engine speed reaches a certain RMP level.
Once the engine has started to operate, the system will start to reduce start thickening immediately, and cancel it completely
till the starting process is completed at 600-700r/min.
During the starting process, the ignition angle gets adjusted all the time. It changes with the engine temperature, intake air
temperature and the RMP.
1.3.2 Engine Warming-up and Heating Control of Three-way Catalytic Converter

The charging efficiency of air cylinder, the fuel injection and the electronic ignition are all adjusted to compensate the
higher torque requirements of engine after the engine starts at low temperature. This process continues until the temperature
rises to the proper threshold value.
The most important thing during this process is the quick heating-up of the three-way catalytic converter, as it would greatly
reduce the emission when its starting process takes place rapidly.
During this process, retard the ignition advance angle moderately to "heat up the three-way catalytic converter" with the
exhaust gas.
1.3.3 Acceleration/deceleration and Fuel Stoppage Control for Reverse Towing

Part of the fuel injected into the intake manifold cannot arrive at the cylinder to participating in the subsequent combustion
process. Conversely, it forms a layer of oil film on the wall of intake manifold. With the increasing of the load and the
prolonging of the fuel injection duration, the fuel stored in the oil film would increase sharply.
As the opening degree of the electronic throttle increases, the injected fuel is absorbed to the oil film. Therefore, the injected
fuel should be filled up accordingly so as to compensate for this and prevent the mixture from being thinned during the
acceleration. Once the load coefficient gets smaller, the additional fuel contained in the oil film on the wall of the intake
manifold will be released. Thus, during the deceleration, the injection duration should be lowered accordingly.
Reverse towing or traction refers to the condition in which the power at the flywheel provided by the engine has a negative
value. Under this condition, the fraction and pumping loss of the engine can be used to decelerate the vehicle. When the
engine is going through a reverse towing or traction, the fuel injection is cut off to reduce the fuel consumption and
emission, but most importantly, it protects the three-way catalytic converter.
Once the RMP has been lowered to the specific RMP (above idle speed) for fuel supply recovery, the fuel injection system
will start to supply fuel again. In fact, there exists a RMP recovery range in the ECU procedure. The range varies with the
dynamic parameters (such as engine temperature, the engine RMP, etc.) and prevents the engine RMP from decreasing
below the specified minimum threshold value.
Once the injection system supplies fuel again, the system starts to make use of the initial injection pulse to supply fuel and
rebuild the oil film on the wall of the intake manifold. When the fuel injection has been recovered, the torque-based control
system helps to increase the engine torque slowly and stably (a smooth transition).

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1.3.4 Idle Speed Control

During the idling, the engine provides no torque to the flywheel. To guarantee a stable operation of the engine at a
most-possibly low idling speed, the closed-loop idle control system must keep balance between the torque generated and the
"power consumed" by the engine. A certain level of power should be generated to meet the various load requirements. The
requirements come from the crankshaft, valve mechanism of the engine as well as the auxiliary mechanisms, such as the
inner fraction of the water pump.
The ME17.8.8 system adopts the torque-based control strategy, which guarantees the engine output torque meets the
requirement of the idling speed under any conditions via the closed-loop idle control system. The output torque increases as
the engine RMP decreases, and vice versa. The system responses new "interfere elements" by requiring for higher torque,
such as the ON/Off of the A/C compressor or the gear shifting of the automatic transmission. When the engine temperature
is relatively low, it is necessary to increase the torque so as to compensate the inner fraction loss and/or to maintain a higher
idle speed. The sum required by all the output torque will be transferred to the torque coordinator, which can dispose and
calculate to get relevant charging density, gas mixture composition and ignition timing.
1.3.5 λ Closed-loop Control

Exhaust after-treatment through the three-way catalytic converter is an effective way to reduce the concentration of harmful
substance in the exhausted gas. The three-way catalytic converter can reduce hydrocarbons, carbon monoxide and nitrogen
oxides as much as 98% or higher, converting them into water, carbon dioxide and nitrogen. Yet such a high conversion rate
can only be reached within a very narrow range around λ=1 in the engine (λ stands for the excessive air coefficient); the
goal of the λ closed-loop control is to maintain the concentration of mixture within this range.
The λ closed-loop control system only works when it is equipped with the oxygen sensor. The oxygen sensor monitors the
concentration of oxygen in the exhausted gas at the three-way catalytic converter side. Thin mixture generates about a
sensor voltage of 100mV and thick mixture about 900mV. At λ=1, the sensor voltage will go through a zag. When the λ
closed-loop control system responses to the input signals and modifies the variables, the modifying factor is generated to
amend the fuel injection duration as a multiplier.
1.3.6 Evaporation Emission Control

Due to the transmission of external radiant heat and return oil heat, the fuel in the fuel tank gets heated, thus forming fuel
vapors. Limited by the evaporation emission regulations, those highly hydrocarbon-contained vapors are not allowed to be
released to the air. The fuel steam in the system is collected in the activated carbon canister and it may get into the engine
for the combustion process through flushing at the proper time. The washing of the vapor flow is achieved through ECU
controlling the canister control valve.
The control only works when the λ closed-loop control system has been closed and activated.
13.7 Knock Control

The system monitors the characteristic vibration produced in the knock by the knock sensor properly installed on the engine
and converts it into electronic signal so that it can be transmitted to the ECU and processed there. ECU detects whether
there is knock in the combustion circulation of each cylinder. Once knock is detected, the knock closed-loop control system
will be triggered. As soon as the danger of knock has been eliminated, the ignition of the affected cylinder will be gradually
advanced back to the preset ignition advance angle.
The threshold value of the knock control system has a good adaptability to fuels of different marks under different working
conditions.
1.3.8 V.V.T Control

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The system achieves phase control through inlet/exhaust camshaft, which effectively reduces the low-speed emission of the
engine and improves the high-speed torque of the engine. The ECU works out the target phase of the inlet/exhaust camshaft
according to the working conditions of the vehicle as well as the driving instructions of the driver; meanwhile, it derives the
phase information from the phase sensor. In this way, the system realizes a closed-loop control of the camshaft phases.
Compared to engines with no V.V.T control systems, the V.V.T system can help engine that has one to reduce fuel
consumption, reduce emission and improve the maximum power.

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2 DTC Diagnostic Trouble Code

2.1 List of Engine DTC Faults
Fault Code Definition
P000A26 Operating fault of intake VVT (delay)
P000A29 Operating fault of intake VVT (jamming)
P001013 Fault of VVT intake control valve circuit
P001200 The Intake VVT Is not in the Default Position at Starting
Deviation of relative position between crankshaft and intake camshaft lower than the
P001621
minimum limit
Deviation of relative position between crankshaft and intake camshaft higher than the
P001622
maximum limit
Relative position deviation signal between crankshaft and intake camshaft
P001629
unreasonable
P003013 Upstream oxygen sensor heating control circuit fault
P003111 Upstream oxygen sensor heating control circuit voltage too low
P003212 Upstream oxygen sensor heating control circuit voltage too high
P003613 Downstream oxygen sensor heating control circuit fault
P003711 Downstream oxygen sensor heating control circuit voltage too low
P003812 Downstream oxygen sensor heating control circuit voltage too high
P00531E Upstream oxygen sensor heating resistance not reasonable
P00541E Downstream oxygen sensor heating resistance not reasonable
P010528 Intake pressure sensor signal is not fluctuating (frozen)
P010600 Signal of intake air pressure sensor unreasonable
P010711 Air intake pressure sensor signal circuit voltage is too low
P010812 Air intake pressure sensor signal circuit voltage is too high
P011129 Air intake pressure sensor signal circuit voltage is too high
P011216 Intake air temperature sensor signal circuit voltage is too low
P011317 Intake air temperature sensor signal circuit voltage too high
P011629 Signal of intake air temperature sensor unreasonable
P011716 The engine coolant temperature sensor circuit voltage is too low
P011817 The engine coolant temperature sensor circuit voltage is too high
P012129 Signal of Electronic Throttle Position Sensor 1 is implausible
P012216 Signal circuit voltage of Electronic Throttle Position Sensor 1 is too low
P012317 Signal circuit voltage of Electronic Throttle Position Sensor 1 is too high
P013000 Upstream oxygen sensor signal not reasonable
P013116 Upstream oxygen sensor signal low voltage

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P013217 Upstream oxygen sensor signal circuit voltage too high
P013300 Upstream oxygen sensor aging
P013400 Upstream oxygen sensor circuit signal circuit fault
P013600 Downstream oxygen sensor signal not reasonable
P013716 Downstream oxygen sensor signal low voltage
P013817 Downstream oxygen sensor signal circuit voltage too high
P014000 Downstream oxygen sensor circuit signal fault
P017000 Air/fuel ratio closed-loop control: offline test shows self-learning is implausible
P017100 Air/fuel ratio closed-loop control: offline test shows thin mixture after self-learning
P017200 Air/fuel ratio closed-loop control: offline test shows thick mixture after self-learning
P020113 Control circuit fault of first cylinder fuel injector
P020213 Control circuit fault of second cylinder fuel injector
P020313 Control circuit fault of third cylinder fuel injector
P020413 Control circuit fault of fourth cylinder fuel injector
P021900 Engine speed higher than the maximum speed limit
P022129 Signal of Electronic Throttle Position Sensor 2 is implausible
P022216 Signal circuit voltage of Electronic Throttle Position Sensor 2 is too low
P022317 Signal circuit voltage of Electronic Throttle Position Sensor 2 is too high
P026111 Control circuit of first cylinder fuel injector undervoltage
P026212 Control circuit of first cylinder fuel injector overvoltage
P026411 Control circuit of second cylinder fuel injector undervoltage
P026512 Control circuit of second cylinder fuel injector overvoltage
P026711 Control circuit of third cylinder fuel injector undervoltage
P026812 Control circuit of third cylinder fuel injector overvoltage
P027011 Control circuit of fourth cylinder fuel injector undervoltage
P027112 Control circuit of fourth cylinder fuel injector overvoltage
P030021 Occurrence of several cylinder fire leading to ultra-limit emission
P030022 Occurrence of several cylinder fire leading to catalytic converter damage
P030029 Occurrence of several cylinder fire in the first statistic cycle of fire detection
P030121 Occurrence of first cylinder fire leading to ultra-limit emission
P030122 Occurrence of first cylinder fire leading to catalytic converter damage
P030129 Occurrence of first cylinder fire in the first statistic cycle of fire detection
P030221 Occurrence of second cylinder fire leading to ultra-limit emission
P030222 Occurrence of second cylinder fire leading to catalytic converter damage

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P030229 Occurrence of second cylinder fire in the first statistic cycle of fire detection
P030321 Occurrence of third cylinder fire leading to ultra-limit emission
P030322 Occurrence of third cylinder fire leading to catalytic converter damage
P030329 Occurrence of third cylinder fire in the first statistic cycle of fire detection
P030421 Occurrence of fourth cylinder fire leading to ultra-limit emission
P030422 Occurrence of fourth cylinder fire leading to catalytic converter damage
P030429 Occurrence of fourth cylinder fire in the first statistic cycle of fire detection
P032200 Vehicle speed sensor signal fault
P032716 Knock sensor signal circuit voltage is too low
P034100 Phase sensor signal is implausible
P042000 Three way catalytic converter capacity aging (drain over limit)
P044413 Control circuit fault of carbon canister control valve
P045816 Carbon canister control valve control circuit voltage too low
P045917 Carbon canister control valve control circuit voltage too high
P048014 Cooling Fan Relay Control Circuit Fault (Low Speed)
P048114 Cooling fan relay control circuit fault (high speed)
P050029 Vehicle speed signal fault
P050600 Controlled idling speed is lower than the target idling speed
P050700 Controlled idling speed is higher than the target idling speed
P056000 System battery voltage signal is implausible
P056216 System battery voltage is too low
P056317 System battery voltage is too high
P05711C Brake signal unreasonable
P057129 Brake signal unreasonable
P060100 Fault of electronic throttle security monitoring function (ECU EEPROM fault)
P060443 Electronic control unit RAM fault
P060543 Electronic control unit ROM fault
P060600 Fault of electronic throttle security monitoring function (security monitoring fuel
cutoff fault)
P06061C Fault of electronic throttle security monitoring function (throttle body signal, wiring
harness or ECU fault)
P060647 Fault of electronic throttle security monitoring function (monitoring model feedback
fault)
P060648 Fault of electronic throttle security monitoring function (monitoring erroneous
response fault)
P060649 Fault of electronic throttle security monitoring function (monitoring model inquiry
fault)
P060655 Fault of electronic throttle security monitoring function (deformation code
monitoring fault)

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Fault of electronic throttle security monitoring function (ignition angle signal, wiring
P060661
harness or ECU fault)
Fault of electronic throttle security monitoring function (reasonableness fault of
P060662
second layer accelerator pedal signal)
Fault of electronic throttle security monitoring function (reasonableness fault of
P060663
second layer accelerator pedal signal)
Fault of electronic throttle security monitoring function (load signal, wiring harness
P060664
or ECU fault)
Fault of electronic throttle security monitoring function (ECU erroneous response
P060667
monitoring fault)
P060675 Fault of electronic throttle security monitoring function (path test off fault)
Fault of electronic throttle security monitoring function (second layer engine speed
P060692
monitoring fault)
Fault of electronic throttle security monitoring function (second layer torque
P060694
monitoring fault)
Fault of electronic throttle security monitoring function (AD converter monitoring
P060696
fault)
P061513 Starter control relay open
P061611 Starter control relay undervoltage
P061712 Starter control relay overvoltage
P062211 Generator load feedback signal undervoltage
P062212 Generator load feedback signal overvoltage
P062713 Fuel pump relay control circuit fault
P062811 Oil pump relay control circuit short to ground or open
P062912 Fuel pump relay control circuit voltage too high
P064513 Control circuit fault of compressor relay
P064611 Compressor replay control circuit short to ground
P064712 Compressor Relay Circuit Voltage Is too High
P066013 Variable intake manifold solenoid valve circuit open
P066111 Variable intake manifold solenoid valve circuit short to ground
P066212 Variable intake manifold solenoid valve circuit short to power supply
P068800 The main relay output voltage is implausible
P068816 Fault of main relay output voltage signal
P069111 Cooling fan relay control circuit short to ground(low speed speed)
P069212 Cooling fan relay control circuit short to power supply (low speed)
P069311 Cooling fan relay control circuit short to ground (high speed)
P069412 Cooling fan relay control circuit short to power supply (high speed)

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P070400 Fault of clutch pedal switch voltage
P133600 Safety monitor torque of electronic throttle limits the function
P154500 DVE position deviation fault
P154521 Throttle body DLR adjustment lower than the minimum limit value
P154522 Throttle body DLR adjustment higher than the minimum limit value
P155900 Second self-learning fault of throttle lower mechanical dead center
P155900 Second self-learning fault of throttle lower mechanical dead center
P156400 System pressure cannot meet the requirements for electronic throttle self-learning
P156500 Initialization self-learning of electronic throttle lower limit position has fault
P156800 Return resistance of the electronic throttle is too great
Electronic throttle self-learning requirement is not met
P161000 ECM not learning Secret Key
P161100 PIN code input error
P161200 ECM not receiving IMMO
P161300 The last IMMO certification is responded Busy
P168300 Airbag signal unreasonable
P152381 Airbag exploded
P208811 VVT intake control valve circuit undervoltage
P208912 VVT intake control valve circuit overvoltage
P210612 Power drive level fault of electronic throttle (short)
P210619 Power drive level fault of electronic throttle (overheat or overcurrent)
P210692 Power drive level fault of electronic throttle (SPI bus or signal)
P210613 Power drive level fault of electronic throttle (open)
P210629 Load monitoring fault
P212216 Electronic accelerator pedal position sensor 1 signal undervoltage
P212317 Electronic accelerator pedal position sensor 1 signal overvoltage
P212716 Electronic accelerator pedal position sensor 2 signal undervoltage
P212817 Electronic accelerator pedal position sensor 2 signal overvoltage
P213800 Electronic accelerator pedal position sensor signal unreasonable
P213829 Electronic accelerator pedal position sensor signal unreasonable
The air-fuel ratio closed-loop control self-learning value is beyond the upper limit
P217700
(middle load area)
The air-fuel ratio closed-loop control self-learning value is beyond the lower limit
P217800
(middle load area)
The air-fuel ratio closed-loop control self-learning value is beyond the upper limit
P218700
(low load area)
The air fuel ratio close loop control self-learning value is beyond the lower limit (low
P218800
load area)

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P219500 Upstream oxygen sensor aging-signal constantly thick
P219600 Upstream oxygen sensor aging-signal constantly thin
P227000 Downstream oxygen sensor aging- signal constantly thin
P227100 Downstream oxygen sensor aging- signal constantly thick
P305400 Engine stalling or starter and flywheel not meshing fault
Feedback voltage signal line (KL50r) of key starting switch (KL50r) short to ground
P305500
fault
Feedback voltage signal line (KL50r) of key starting switch (KL50r) short to power
P305600
supply fault
P308800 Starter damaged or starter power supply circuit interrupted
U000188 CAN communication related diagnosis
U012287 Loss of communication with brake control unit ABS/ESP
U014087 Loss of communication with body control module BCM
Note
Activation rule for fault indicator

Activation rules for fault indicator MIL related to emission and for fault indicator SVS irrelevant to emission are as below
separately:
 Activation rule for fault indicator MIL:
− Type A: MIL indicator is lighted up and the fault code is recorded once the fault happens
− Type B: Occurring once in each two consecutive strokes, MIL lamp will be lit and DTCs will be recorded.
− Type E: Occurring once in each three consecutive strokes, MIL lamp will be lit and aDTCs will be recorded.
Tips
A stroke means a driving cycle during which all OBD tests can be carried out. The testing procedure for National Ⅳ
emission (part I + part II) can be taken as criterion.
 Activation rule for fault indicator SVS:
− Type C: the fault code is recorded and SVS indicator is lighted up when the fault happens but MIL indicator is not
lighted up.
 Fault Z: the fault diagnostic system makes no diagnosis of type Z fault.

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2.2 P010528 Intake air pressure sensor signal not fluctuating (freezing) P010600
Signal of intake air pressure sensor unreasonable P010711 Intake air pressure
sensor signal circuit undervoltage P010812 Intake air pressure sensor signal circuit
overvoltage P210612 Power drive level fault of electronic throttle (short) P210619
Power drive level fault of electronic throttle (overheat or overcurrent) P210692
Power drive level fault of electronic throttle (SPI bus or signal) P210613 Power
drive level fault of electronic throttle (open) P210629 Load monitoring fault
DTC trigger
DTC DTC Definition DTC testing conditions Possible causes
conditions
 Wiring harness or
plug fault
 Engine speed more No pressure drop after
Intake pressure sensor  Intake manifold
than 800rmp. start
P010528 signal is not fluctuating absolute
 Throttle opening Pressure drop less than
(frozen) pressure/atmospheri
less than 10 20hpa after start
c pressure sensor
fault
plug fault
Pressure displayed by
Signal of intake air  Intake manifold
 Engine speed more the pressure sensor
P010600 pressure sensor absolute
than 2000rmp. goes beyond the limit
unreasonable pressure/atmospheri
value
c pressure sensor
fault
plug fault
Air intake pressure  Intake manifold
Pressure sensor voltage
P010711 sensor signal circuit — absolute
＜0.195V
voltage is too low pressure/atmospheri
c pressure sensor
fault
plug fault
Air intake pressure  Intake manifold
Pressure sensor voltage
P010812 sensor signal circuit — absolute
＞4.883V
voltage is too high pressure/atmospheri
c pressure sensor
fault
plug fault
Power drive level fault  Intake manifold
P210612 of electronic throttle — — absolute
(short) pressure/atmospheri
c pressure sensor
fault

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DTC testing
DTC DTC Definition DTC trigger conditions Possible causes
conditions
plug fault
Power drive level fault
 Intake manifold
of electronic throttle
P210619 — — absolute
(overheat or
pressure/atmospheri
overcurrent)
c pressure sensor
fault
plug fault
(SPI bus or signal) pressure/atmospheri
c pressure sensor
fault
plug fault
(open) pressure/atmospheri
c pressure sensor
fault
plug fault
 Intake manifold
P2106 29 Load monitoring fault — absolute
pressure/atmospheri
c pressure sensor
fault
Diagnostic steps:
1. Disconnect the connector T4g of the intake manifold pressure and temperature sensor, check the connector T4g for crack
and abnormality and check its pins for corrosion and rust.
− Yes Clean the connectors and pins.
− No Proceed to step 2.

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2. Connect the intake manifold pressure temperature sensor connector;

switch the digital multimeter to the DC voltage mode, and connect the
black probe to the ground and the red probe to pin 2 and pin 4
respectively. Under idling condition, pin 2 should have 5V reference
voltage, and the voltage on pin 4 is about 1.3V (depends on the car
type); while the engine is in a non-loaded state, slowly open the throttle,
and the voltage on pin 4 doesn't change greatly; quickly open the
throttle, then the voltage on pin 4 can sharply rise to about 4V (depends
on the car type), and then decrease to about 1.5V (depends on the car
type).
− Yes Proceed to Step 3.
− No-The sensor is at fault and replace the intake manifold pressure
and temperature sensor
3. Disconnect the engine control unit connector T112.

4. With the ignition under LOCK status, check whether the wire
between pin T4g/2 of the intake manifold pressure and temperature
sensor connector and pin T112/109 of the engine control unit connector
is conductive.
− No - Repair the faulty line.

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sensor connector and pin T112/91 of the engine control unit connector is
conductive.
conductive.

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7. Check whether pin T4g/4 of the intake manifold pressure and

temperature sensor connector is short to positive terminal of the battery.
− Yes Repair the faulty wire.
8. Check whether pin T4g/4 of the intake manifold pressure and

temperature sensor connector is short to the body ground.

9. Replace the intake manifold pressure and temperature sensor, re-diagnose and read the fault code to see whether it still
exists.
− No Replace the intake manifold pressure temperature sensor.
10. Replace the engine control unit; perform road test to diagnose it again, read the fault code, and check if it is still present.
− Yes Identify other possible causes
− No-Replace the engine control unit.

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2.3 P011216 Signal circuit of intake air temperature sensor undervoltage P011317
Signal circuit of intake air temperature sensor overvoltage P011629 Signal of
intake air temperature sensor unreasonable
DTC testing
conditions
 In excess of the
plug fault
Intake air temperature  Post-start time upper limit value,
 Intake manifold
P011216 sensor signal circuit over: 240S short to ground
pressure and
voltage is too low  Fuel not cutoff  Inlet temperature＞
temperature sensor
138℃
faulty
 In excess of the
Intake air temperature  Post-start time lower limit value,
plug fault
P011317 sensor signal circuit over: 240S short to ground
 Intake temperature
voltage too high  Fuel not cutoff  Inlet temperature＜
sensor fault
38.25℃
Signal of intake air
plug fault
P011629 temperature sensor — —
 Intake temperature
unreasonable
sensor fault
Diagnostic steps:
1. Disconnect the connector T4g of the intake manifold pressure and temperature sensor, check the connector T4g for crack
is conductive.

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is conductive.
is conductive.

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5. Check whether the resistance between pin T4g/2 and pin T4g/3 of the
intake manifold pressure and temperature sensor connector is the normal
resistance.
− No The sensor is at fault and replace the intake manifold pressure
6. Disconnect negative terminal of the battery, and check whether the

wire between pin T4g/1 of the intake manifold pressure and temperature
sensor connector and positive terminal of the battery is short.

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7. Check whether the wire between pin T4g/1 of the intake manifold
pressure and temperature sensor connector and the body grounding is
short.
− Yes-Repair the faulty wire.
8. Replace the intake manifold pressure and temperature sensor, carry out road test, re-diagnose and read the fault code to
see whether it still exists.
− No Replace the intake manifold pressure temperature sensor.
9. Replace the engine control unit; perform road test to diagnose it again, read the fault code, and check if it is still present.

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2.4 P011716 Engine coolant temperature sensor circuit undervoltage P011817

Engine coolant temperature sensor circuit overvoltage
DTC testing
conditions
 In excess of the upper limit  Wiring harness or
The engine coolant
value, short to ground plug fault
temperature sensor
P011716 —  Measurement value of  Engine coolant
circuit voltage is too
coolant temperature ＞ temperature sensor
low
138℃ fault
 In excess of the lower limit  Wiring harness or
The engine coolant
value, short to ground plug fault
temperature sensor
P011817 —  Measurement value of  Engine coolant
circuit voltage is too
coolant temperature ＞ temperature sensor
high
38.25℃ fault
Diagnostic steps:
1. Disconnect the connector T3g of the engine coolant temperature sensor, check the connector T3g for crack and
abnormality and check its pins for corrosion and rust.
2. Disconnect the engine control unit connector T112.

3. When the ignition switch is in the LOCK position, check if there's
electricity between pin 1 on the engine coolant temperature sensor
connector T3g and pin 101 on the engine control unit connector T112.

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electricity between pin 3 on the engine coolant temperature sensor
connector T3g and pin 85 on the engine control unit connector T112.
between pin T3g/3 of the engine coolant temperature sensor connector
and positive terminal of the battery is short.

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between pin T3g/3 of the engine coolant temperature sensor connector
and the body is short.
7. Disconnect the engine coolant temperature sensor connector, and

measure the rated resistance between pin 1 and pin 3 on the engine
coolant temperature sensorT3g, and see if it's normal at 25℃.
− No The sensor is faulty, and replace the engine coolant temperature
sensor.
8. Replace the engine coolant temperature sensor, re-diagnose and read the fault code to see whether it still exists.
− No Replace the engine coolant temperature sensor.
9. Replace the engine control unit; diagnose it again, read the fault code, and check if it is still present.

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2.5 P032716 Knock sensor signal circuit voltage is too low

DTC trigger
conditions
 Speed not dynamic
 Load not dynamic  Detected signal
 The explosion and scope lower
Knock sensor signal vibration control  Knock  Wiring harness or
P032716 circuit voltage is too circuit is free from identification plug fault
low fault. reference  Knock sensor fault
 Limp home not voltage
activated 0.15-0.6V
 Load over 40%
Diagnostic steps:
1. Check if the knock sensor connector is correctly and safely installed.
− No Re-fasten the knock sensor connector.
2. Check if the type and tightening torque of the fixing bolt on the knock sensor are correct.
− No Replace the bolt, and tighten the knock sensor with defined tighten torque.
3. Disconnect the knock sensor connector T2o, switch the digital

multimeter to the ohms mode, and connect the two probes to the pin 1
and pin 2 on the connector T2o at the component end of the knock
sensor, and the resistance under room temperature should be greater than
1MΩ.
− No-The sensor if faulty and replace the knock sensor.

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electricity between pin 1 on the knock sensor connector T2o and pin 90
on the engine control unit connector T112.

electricity between pin 2 on the knock sensor connector T2o and pin 89
on the engine control unit connector T112.

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6. Disconnect the battery negative cable, and check if there's electricity

between pin 1 and pin 2 on the knock sensor connector T2o and the
battery positive electrode.
7. Check whether pins T2o/1 and T2o/2 of the knock sensor connector
are short to the body grounding.
8. Replace the knock sensors; diagnose it again, read the fault code, and check if it is still present.
− No Replace the knock sensor.
9. Check whether the power supply and grounding circuit of the engine control unit are normal.
10. Replace the engine control unit; perform road test again, read the fault code, and check if it is still present.

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2.6 P034100 Phase sensor signal is implausible

DTC testing
conditions
 Poor contact plug fault
Phase sensor signal is  Phase signal register value  Camshaft position
P034100 —
implausible 0 ＜ phpw ＜ 255and sensor fault
phpw≠170  Electronic engine
control unit fault
Diagnostic steps:
1. Disconnect the connector T3a of the camshaft position sensor, check the connector T3a for crack and abnormality and
check its pins for corrosion and rust.
2. With the ignition under ON status, disconnect the camshaft position
sensor connector T3a and check whether there is 12V voltage between
its pin T3a/1 and pin T3a/3.
− Yes The sensor if faulty and replace the camshaft position sensor.

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3. Disconnect the electronic engine control unit connector T112.

between pin T3a/2 of the camshaft position sensor connector and pin
T112/93 of the electronic engine control unit connector is conductive.


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7. Disconnect negative cable of the battery, and check whether the wire
between pin T3a/2 of the camshaft position sensor connector and
positive terminal of the battery is short.

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8. Check whether the wire between pin T3a/2 of the camshaft position
sensor connector and the body grounding is short.
9. Replace the camshaft position sensor, carry out another road test, and read the fault code to see whether it still exists.
− No Replace camshaft position sensor
10. Replace the electronic engine control unit; and perform road test again, read the fault code, and check if it is still present.
− No, replace the engine control unit.

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2.7 P048014 Control circuit fault of cooling fan relay (low speed) P048114 Control
circuit fault of cooling fan relay (high speed) P069212 Control circuit of cooling fan
relay short to power supply (low speed) P069311 Control circuit of cooling fan
relay short to ground (high speed) P069412 Control circuit of cooling fan relay
short to power supply (high speed)
DTC testing
conditions
 Wiring harness or plug
Cooling Fan Relay
fault
P048014 Control Circuit Fault — —
 Electronic fan relay fault
(Low Speed)
 Electronic fan fault
Cooling fan relay
fault
P048114 control circuit fault — —
(high speed)
 Electronic fan fault
Cooling fan relay  Wiring harness or plug
 Signal current
control circuit short Drive level switch fault
P069111  Short to power
to ground(low speed open status  Electronic fan relay fault
supply
speed)  Electronic fan fault
Cooling fan relay
control circuit short to
P069212 — — fault
power supply (low
speed)
Cooling fan relay  Wiring harness or plug
P069311 control circuit short to — — fault
ground (high speed)  Electronic fan relay fault
Cooling fan relay
control circuit short
P069412 — — fault
to power supply (high
speed)
Diagnostic steps:
1. Remove the electronic fan relay 1 J101 and electronic fan relay 2 J102, and check if there's abnormality or rust on the
connecting plug.
− Yes - Clean the connector and the pin.

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2. Turn off the ignition, remove the electronic fan relays J101 and J102
from the front compartment electric box, and check if the relay is
normal.
Multimeter
Conditions Rated value
connecting pins
Common status
Constant state Connectivity
85-86
Between pin 85 and
pin 86, apply supply 30-87 Connectivity
voltage
− No Replace the cooling fan relay J101 and J102.
3. Disconnect the engine control unit connector T112, and check

whether the wire between pin T20a/19 of the front compartment
electrical box connector and pin T112/56 of the engine control unit
connector and the wire between pin T20a/6 of the front compartment
electrical box connector and pin T112/31 of the engine control unit
connector are conductive with the ignition under LOCK status.

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between pin T14a/8 of low speed fan connector of the front
compartment electrical box and pin T4c/C of the electronic fan
connector and the wire between pin T20a/10 of the front compartment
electrical box connector and pin T4c/D of the electronic fan connector
are conductive.

between pin 56 and pin 31 on the engine control unit connector T112
and the battery positive electrode.

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6. Check whether the wires between pins T112/56 and T112/31 of the
engine control unit connector and the body grounding are short.

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2.8 P032200 Vehicle speed sensor signal fault

DTC testing
conditions
 No speed is detected
plug fault
after certain phase
Vehicle speed sensor Engine speed too  Crankshaft position
P032200 speed sensor
signal fault low sensor fault
 Number of phase signal
 Engine control unit
jump ＞18
fault
Diagnostic steps:
1. Disconnect the connector T3h of the crankshaft position sensor, check the connector T3h for crack and abnormality and
− Yes: Clean the connectors and pins.
2. Turn the digital multimeter to ohm position and check whether the
resistance between pin T3h/1 and pin T3h/3 of the sensor connector is
normal resistance.
− No-The sensor is faulty and replaced the crankshaft position
sensor.

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3. Disconnect the engine control unit connector T112 and check whether
the wire between pin T3h/2 of the crankshaft position sensor and pin
T112/96 of the engine control unit connector is conductive with the
ignition under LOCK status.
between pin T3h/1 of the crankshaft position sensor and pin T112/108 of
the engine control unit connector is conductive.

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5. With the ignition under LOCK status, check whether the wires
between pins T3h/1, T3h/2 and T3h/3 of the crankshaft position sensor
connector and positive terminal of the battery are short.
between pins T3h/1, T3h/2 and T3h/3 of the crankshaft position sensor
connector and the body grounding are short.
7. Replace the crankshaft position sensor, carry out another road test, and read the fault code to see whether it still exists.
− No Replace the crankshaft position sensor.

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2.9 P070400 Fault of clutch pedal switch voltage

DTC testing
conditions
 Detect gearshift  Wiring harness or
The vehicle speed is times plug fault
Fault of clutch pedal over 50km/h and the  The times of clutch  Clutch pedal switch
P070400
switch voltage delay time is longer operations detected fault
than 4s are more than 20 or  Engine control unit
less than 2 fault
Diagnostic steps:
1. Disconnect the connecting plug T6e of the clutch switch, check the connecting plug T6e for crack and abnormality and
2. With the ignition under LOCK status, check whether the wire between
pin T6e/C of the clutch pedal switch connector and pin T112/6 of the
engine control unit connector is conductive.

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3. Check whether the wire between pin T6e/C of the clutch switch
connector and positive terminal of the battery is short.
4. Check whether the wire between pin T6e/C of the clutch switch
connector and the body grounding is short.

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5. Check whether the wire between pin T6e/D of the clutch switch
connector and the body grounding is conductive.
6. Replace the clutch switch, carry out another road test, and read the fault code to see whether it still exists.
− No Replace the clutch switch.

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2.10 P000A26 Operating fault of intake VVT (delay) P000A29 Operating fault of
intake VVT (jamming) P001013 Fault of VVT intake control valve circuit P001200
Intake VVT not at the default position at start P208811 VVT intake control valve
circuit undervoltage P208912 VVT intake control valve circuit overvoltage P210612
Power drive level fault of electronic throttle (short)
DTC trigger
conditions
 VVT self-learning
completed
 Oil temperature：
（-40～130）  Wiring harness or
 Water temperature： Difference between plug fault
A Slow response of
（39.75～120） VVT actual angle  VVT intake control
P000A26 camshaft position
 Speed range：（600～ and the target angle valve fault
actuator
6000）＞9  Engine control unit
 No fault of VVT fault
control valve
 Engine operating time
＜1.5s
plug fault
Operating fault of  VVT intake control
P000A29 — —
intake VVT (jamming) valve fault
fault
Diagnose by signal
plug fault
voltage
Fault of VVT intake  VVT intake control
P001013 Drive level switch open Alarm of fault
control valve circuit valve fault
during circuit open
loop
fault

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DTC trigger
conditions
 VVT self-learning
completed
 Oil temperature：
（-40～130）
 Water temperature：
Difference between plug fault
The Intake VVT Is not （0～130）
the actual angle and  VVT intake control
P001200 in the Default Position  The target angle is less
the default position valve fault
at Starting than 5°around the
angle is ＞=15  Engine control unit
default position
fault
 No fault of VVT
control valve
 Engine operating time
＜1.5s
plug fault
VVT intake control  Signal current
Drive level switch open  VVT intake control
P208811 valve circuit  Short to
status valve fault
undervoltage ground
fault
plug fault
VVT intake control  Signal current
Drive level switch open  VVT intake control
P208912 valve circuit  Short to power
status valve fault
overvoltage supply
fault
Diagnostic steps:
1. Disconnect the connecting plug T2ef of VVT intake control valve, and check whether the T2ef plug has cracks or
abnormality, and whether there's corrosion or rust on the pin.
− Yes: Clean the connectors and pins.
2. Check if the fuse FB03 (10A) in the front compartment electric box is normal.
− No Replace the fuse FB03.

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electricity between pin 2 on the VVT intake control valve T2ef and pin
71 on the engine control unit connector T112.
4. Check whether the wire between pin T2ef/1 of VVT intake control
valve connector and pin T20a/8 of the front compartment electrical box
fuse is conductive.

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Engine
5. Disconnect negative terminal of the battery and check whether the

wires between pins T2ef/1 and T2ef/2 of VVT intake control valve
connector and positive terminal of the battery are short.
6. Check whether the wires between pins T2ef/1 and T2ef/2 of VVT
intake control valve connector and the body grounding are short.

7. Replace the VVT intake control valve, carry out another road test, and read the fault code to see whether it still exists.
− No Replace VVT intake control valve.
− No, replace the engine control unit.

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2.11 P001621 Deviation of relative position between crankshaft and intake

camshaft lower than the minimum limit P001622 Deviation of relative position
between crankshaft and intake camshaft higher than the maximum limit P001629
Signal of relative position deviation between crankshaft and intake camshaft
unreasonable
DTC testing
conditions
 Camshaft position
sensor signal
unstable
 Crankshaft position
sensor fault
Deviation of relative
Crankshaft and  Difference of the sensor fault
position between
camshaft crankshaft and camshaft  Impulse ring of the
P001621 crankshaft and intake
self-adaption sync study vale and camshaft position
camshaft lower than
activated reference valve＞23KW sensor gear ring
the minimum limit
 Impulse ring of the
crankshaft position
sensor gear ring
sensor signal
unstable
sensor signal
unstable
sensor fault
Deviation of relative
position between
P001622 crankshaft and intake
camshaft higher than
activated reference valve＜-23KW sensor gear ring
the maximum limit
crankshaft position
sensor gear ring
sensor signal
unstable

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DTC testing
conditions
sensor signal
unstable
sensor fault
Relative position
deviation signal
P001629 between crankshaft and
intake camshaft
activated reference valve＜14KW sensor gear ring
unreasonable
crankshaft position
sensor gear ring
sensor signal
unstable
Diagnostic steps:
1. Check if the connector of the camshaft position sensor is damaged, bent, pulled out or rusted.
− Yes Clean the connecting plug.
2. Check whether impulse ring of the camshaft position sensor gear ring is damaged and with impurities or has excessive
movement.
− Yes Perform relevant repair.
3. Check whether wiring harness of the camshaft position sensor is normal => Refer to Page 226.
− No, repair the failed wires.
4. Check if the connector of the crankshaft position sensor is damaged, bent, pulled out or rusted.
− Yes Clean the connecting plug.
5. Check if the gear/impulse ring of the crankshaft position sensor is damaged, has impurities or has been moved too much.
− Yes Perform relevant repair.
6. Check whether wiring harness of the crankshaft position sensor is normal => Refer to Page 234.
− No, repair the failed wires.

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2.12 P066013 Variable intake manifold solenoid valve circuit open P066111
Variable intake manifold solenoid valve circuit short to ground P066212 Variable
intake manifold solenoid valve circuit short to power supply
DTC testing
conditions
Variable intake  Actuator Fault
P066013 manifold solenoid — —  Circuit fault
valve circuit open  Control unit fault
Variable intake
 Actuator Fault
manifold solenoid
P066111 — —  Circuit fault
valve circuit short to
 Control unit fault
ground
Variable intake
 Actuator Fault
manifold solenoid
P066212 — —  Circuit fault
valve circuit short to
power supply
Diagnostic steps:
Tips
After the fault is solved, verify DTC again and check whether the symptom is still present.
1. Disconnect the engine control unit connector T112 and check the connector for crack and abnormality, and the pins for
corrosion and rust.
2. Check if the fuse FB03 (10A) in the front compartment electric box is blown
− Yes Replace with a new fuse.

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3. Disconnect the connecting plug T2ef of the intake manifold length

switch.
4. Check whether pin T112/70 of the engine control unit connector and
pin T2ef/2 of the intake manifold length switch connector is open.
− Yes Repair the faulty line
6. Check whether pin T2ef/2 of the intake manifold length switch

connector is short to positive terminal of the battery.

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7. Check whether pin T2ef/2 of the intake manifold length switch

connector is short to the body grounding.
8. Check whether power supply and grounding circuits of the intake manifold length switch are normal.
9. Replace the intake manifold length switch and perform road test; re-diagnose and read the fault code to see whether the
fault code and the symptom still exist.
− Yes Replace the intake manifold length switch.
10. Check whether the power supply and grounding circuit of the engine control unit are normal.
11. Replace engine control unit, and implement the road test; diagnose again, read the DTCs, and confirm the existence of
DTCs and symptoms.
− Yes Find the cause from other symptoms.
− No Replace the engine control unit.
2.13 P05711C Brake signal unreasonable P057129 Brake signal unreasonable

DTC detection
DTC DTC Definition DTC trigger conditions Possible fault causes
conditions
Brake signal plug fault
P05711C — —
unreasonable  Brake switch fault
 The fuse is damaged

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DTC detection
conditions
Brake signal plug fault
P057129 — —
unreasonable  Brake switch fault
 The fuse is damaged
Diagnostic steps:
1. Disconnect the connector T4h of the braking switch, check the connector T4h for crack and abnormality and check its
pins for corrosion and rust.
2. With the ignition under LOCK status, extract fuse FB52 (10A) and fuse FB41 (5A) in the engine compartment electrical
box and check whether they are blown.
− Yes Replace the fuse.
3. Press down the brake pedal, and check if there's electricity between
pin T4h/1 and pin T4h/3 on the brake switch; then release the brake
pedal, and check if there's electricity between pin T4h/2 and pin T4h/4.
− No Replace the brake switch.

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4. Check whether the wire between pin T16d/5 of the engine

compartment electrical box fuse connector and pin T4h/4 of the vehicle
switch is conductive.
5. Check whether the wire between pin T20d/8 of the engine

compartment electrical box fuse connector and pin T4h/3 of the vehicle
switch is conductive.

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the wire between pin T4h/1 of the brake switch connector and pin
T112/2 of the engine control unit connector is conductive.
7. Check whether the wire between pin T4h/2 of the brake switch
connector and pin T112/23 of the engine control unit connector is
conductive.

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8. Check whether the wires between pins T4h/2 and T4h/1 of the brake
switch connector and the body grounding are short.
9. Replace the brake switch, carry out another road test, and read the fault code to see whether it still exists.
− No Replace the brake switch.

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2.14 P012129 Electronic throttle position sensor 1 signal unreasonable PP012216

Electronic throttle position sensor 1 signal circuit undervoltage P012317 Electronic
throttle position sensor 1 signal circuit overvoltage P022129 Electronic throttle
position sensor 2 signal unreasonable P022216 Electronic throttle position sensor 2
signal circuit undervoltage P022317 Electronic throttle position sensor 2 signal
circuit overvoltage P060100 Fault of electronic throttle security monitoring
function (ECU EEPROM fault) P060600 Fault of electronic throttle security
monitoring function (security monitoring fuel cutoff fault) P06061C Fault of
electronic throttle security monitoring function (throttle body signal, wiring
harness or ECU fault) P060647 Fault of electronic throttle security monitoring
function (monitoring model feedback fault) P060648 Fault of electronic throttle
security monitoring function (monitoring erroneous response fault) P060649 Fault
of electronic throttle security monitoring function (monitoring model inquiry fault)
P060655 Fault of electronic throttle security monitoring function (deformation code
monitoring fault) P060661 Fault of electronic throttle security monitoring function
(ignition angle signal, wiring harness or ECU fault) P060662 Fault of electronic
throttle security monitoring function (reasonableness fault of second layer
accelerator pedal signal) P060663 Fault of electronic throttle security monitoring
function (reasonableness fault of second layer accelerator pedal signal) P060664
Fault of electronic throttle security monitoring function (load signal, wiring
harness or ECU fault) P060667 Fault of electronic throttle security monitoring
function (ECU erroneous response monitoring fault) P060675 Fault of electronic
throttle security monitoring function (path test off fault) P060692 Fault of
electronic throttle security monitoring function (second layer engine speed
monitoring fault) P060694 Fault of electronic throttle security monitoring function
(second layer torque monitoring fault) P060696 Fault of electronic throttle security
monitoring function (AD converter monitoring fault) P154521 Throttle body DLR
adjustment lower than the minimum limit value P154522 Throttle body DLR
adjustment higher than the minimum limit value P155900 Second self-learning
fault of throttle lower mechanical dead center P155929 Throttle limp position
self-learning fault P156400 System voltage hardly meets self-learning conditions of
electronic throttle P156500 Initialization self-learning fault of electronic throttle
lower limit position P156800 Excessive return resistance of electronic throttle
P157900 Electronic throttle self-learning conditions unsatisfied P133600 Torque
limit function of electronic throttle security monitoring
DTC detection
conditions
Signal of Electronic
 Rationality check plug fault
P012129 Throttle Position —
 TPS1-TPS2＞6.3%  Electronic throttle
Sensor 1 is implausible
fault

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DTC detection
conditions
Signal circuit voltage  In excess of the lower  Wiring harness or
of Electronic Throttle limit plug fault
P012216 12s after start
Position Sensor 1 is too  Signal voltage TPS1  Electronic throttle
low ＜1.176V fault
Signal circuit voltage  In excess of the upper  Wiring harness or
of Electronic Throttle Engine speed more limit plug fault
P012317
Position Sensor 1 is too than 1200rmp.  Signal voltage TPS1  Electronic throttle
high ＞4.629V fault
Signal of Electronic
 Rationality check plug fault
P022129 Throttle Position —
 TPS1-TPS2＞6.3%  Electronic throttle
Sensor 2 is implausible
fault
Signal circuit voltage  In excess of the lower  Wiring harness or
of Electronic Throttle limit plug fault
P022216 12s after start
Position Sensor 2 is too  Signal voltage TPS1  Electronic throttle
low ＜0.176V fault
Signal circuit voltage  In excess of the upper  Wiring harness or
of Electronic Throttle Engine speed more limit plug fault
P022317
Position Sensor 2 is too than 1200rmp.  Signal voltage TPS1  Electronic throttle
high ＞4.629V fault
Fault of electronic  Wiring harness or
throttle security plug fault
P060100 — —
monitoring function  Electronic throttle
(ECU EEPROM fault) fault
Fault of electronic
throttle security
plug fault
P060600 monitoring function — —
 Electronic throttle
(security monitoring
fault
fuel cutoff fault)
Fault of electronic
throttle security  Wiring harness or
monitoring function plug fault
P06061C — —
(throttle body signal,  Electronic throttle
wiring harness or ECU fault
fault)
Fault of electronic
throttle security
plug fault
(monitoring model
fault
feedback fault)
Fault of electronic
throttle security
plug fault
(monitoring erroneous
fault
response fault)
Fault of electronic
throttle security
plug fault
(monitoring model
fault
inquiry fault)

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DTC detection DTC trigger

DTC DTC Definition Possible fault causes
conditions conditions
Fault of electronic throttle
security monitoring
P060655 — — fault
function (deformation code
 Electronic throttle fault
monitoring fault)
security monitoring  Wiring harness or plug
P060661 function (ignition angle — — fault
signal, wiring harness or  Electronic throttle fault
ECU fault)
P060662 function (reasonableness — — fault
fault of second layer  Electronic throttle fault
accelerator pedal signal)
P060663 function (reasonableness — — fault
fault of second layer  Electronic throttle fault
accelerator pedal signal)
P060664 function (load signal, — — fault
wiring harness or ECU  Electronic throttle fault
fault)
security monitoring
P060667 — — fault
function (ECU erroneous
response monitoring fault)
security monitoring
P060675 — — fault
function (path test off
fault)
P060692 function (second layer — — fault
engine speed monitoring  Electronic throttle fault
fault)
security monitoring
P060694 — — fault
function (second layer
torque monitoring fault)
security monitoring
P060696 — — fault
function (AD converter
monitoring fault)
DVE position deviation
P154500 — — fault
fault

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DTC detection
conditions
 Monitoring of PID
setting range, duty
ratio is more than
Throttle body DLR  Wiring harness or
80%
adjustment lower than plug fault
P154521 —  Monitoring of
the minimum limit  Electronic throttle
position, compare the
value fault
throttle opening and
the calculation value,
larger by 4-50%
Throttle body DLR  Monitoring of PID  Wiring harness or
adjustment higher than setting range, duty plug fault
P154522 —
the minimum limit ratio is more than  Electronic throttle
value 80% fault
 Monitor learning
position of the lower
mechanical dead
 Self-learning
center  Wiring harness or
Second self-learning activated
 Signal voltage TPS1 plug fault
P155900 fault of throttle lower  Initialization
is larger than 0.865 or  Electronic throttle
mechanical dead center self-learning
less than 0.212 fault
completed
 Signal voltage TPS2
is larger than 4.841 or
less than 4.142
Throttle limp position plug fault
P155929 — —
self-learning fault  Electronic throttle
fault
System pressure cannot  Wiring harness or
meet the requirements plug fault
P156400 — —
for electronic throttle  Electronic throttle
self-learning fault
 Monitor learning
position of the lower
mechanical dead
Initialization  Self-learning
center  Wiring harness or
self-learning of activated
 Signal voltage TPS1 plug fault
P156500 electronic throttle  Initialization
is larger than 0.865 or  Electronic throttle
lower limit position has self-learning
less than 0.212 fault
fault completed
 Signal voltage TPS2
is larger than 4.841 or
less than 4.142

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DTC detection
conditions
 Water
temperature  Check spring open
higher than reasonableness
5.3℃  Closing time ＞0.3s
 Intake air  Test threshold value:
Return resistance of the temperature 2.49%
plug fault
P156800 electronic throttle is too higher than  Closing time ＞0.56s
great 5.3℃  Test threshold value:
fault
 The ignition 3%
switch is on  Closing time ＞0.56s
 Speed lower  Test threshold value:
than or equal to 1.489%
250
Electronic throttle
plug fault
P157900 self-learning — —
requirement is not met
fault
Safety monitor torque
plug fault
P133600 of electronic throttle — —
limits the function
fault
Diagnostic steps:
1. Disconnect throttle value controller connector T6a, and check whether the T6a connector has cracks or abnormality, and
whether there's corrosion or rust on the pin.
− Yes, clean connector.
2. Remove the electronic throttle, and check if there's too much carbon deposit on the electronic throttle.
− Yes Clean the electronic throttle.

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3. Manually move the throttle valve flap, measure the resistances

between pin T6a/2 and pin T6a/5 when closed, completely open, and
from closed to completely open, and see if there's any change.
− No There is throttle position sensor fault; replace the throttle.
4. Manually move the throttle valve flap, measure the resistances

between pin T6a/2 and pin T6a/6 when closed, completely open, and
from closed to completely open, and see if there's any change.
− No There is throttle position sensor fault; replace the throttle.

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5. Measure whether pin T6a/1 and pin T6a/4 on the throttle position
sensor connector is connected.
− No There is fault in throttle position drive motor; replace the
throttle.
6. Disconnect the engine control unit connector T112, check if there's

electricity between pin 2 on the electronic throttle T6a and pin 86 on the
engine control unit connector T112.

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7. Check if there's electricity between pin 6 on the electronic throttle T6a

and pin 77 on the engine control unit connector T112.
8. Check if there's electricity between pin 5 on the electronic throttle T6a

and pin 78 on the engine control unit connector T112.

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9. Check if there's electricity between pin 3 on the electronic throttle

T6a and pin 107 on the engine control unit connector T112.



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between pin T6a/5 and pin T6a/6 on the throttle position sensor
connector and the battery positive electrode.

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13. Measure whether pin T6a/5 and pin T6a/6 on the throttle position
sensor connector is connected to the vehicle ground.

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2.15 P212216 Electronic accelerator pedal position sensor 1 signal undervoltage

P212317 Electronic accelerator pedal position sensor 1 signal overvoltage P212716
Electronic accelerator pedal position sensor 2 signal undervoltage P212817
Electronic accelerator pedal position sensor 2 signal overvoltage P213800
Electronic accelerator pedal position sensor signal unreasonable P213829
Electronic accelerator pedal position sensor signal unreasonable
DTC detection
conditions
 In excess of the lower  Wiring harness or
Electronic accelerator
limit plug fault
P212216 pedal position sensor 1 —
 Signal voltage ＜  Electronic throttle
signal undervoltage
0.605V fault
limit plug fault
 Signal voltage ＞  Electronic throttle
signal overvoltage
4.824V fault
limit plug fault
 Signal voltage ＜  Electronic throttle
signal undervoltage
0.43V fault
limit plug fault
 Signal voltage ＞  Electronic throttle
signal overvoltage
4.824V fault
 Rationality check
Electronic accelerator  Compare signal
plug fault
P213800 pedal position sensor — voltage of pedal
signal unreasonable position sensor 1 and
fault
sensor 2
plug fault
P213829 pedal position sensor — —
signal unreasonable
fault
Diagnostic steps:
1. Disconnect accelerator pedal position sensor connector T6c, and check whether the connecting plug has cracks or

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2. Disconnect the connecting plug, set the multimeter to ohm position

and use the multimeter to check whether the resistance between pin
T6c/1n and pin T6c/5 of the electronic accelerator pedal position sensor
connector is normal.
3. Use the multimeter to check whether the resistance between pin T6c/2
and pin T6c/3 of the electronic accelerator pedal position sensor
connector is normal.
4. Check the resistance between pin T6c/3 and pin T6c/4 as well as
between pin T6c/5 and pin T6c/6 of the electronic accelerator pedal
position sensor connector respectively, turn the pedal and the resistance
shall vary uniformly with pedal rotation.
− No Replace the electronic accelerator pedal.
the wire between pin T6c/1 of the electronic accelerator pedal position
conductive.

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6. Check whether the wire between pin T6c/2 of the electronic

accelerator pedal position sensor connector and T112/37 of the engine
control unit connector is conductive.


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11. Disconnect negative cable of the battery and check whether pins
T6c/4 and T6c/6 of the electronic accelerator pedal position sensor
connector are short to positive terminal of the battery.

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12. Check whether pins T6c/4 and T6c/6 of the electronic accelerator
pedal position sensor connector are short to the body grounding.
13. Replace the electronic accelerator pedal position sensor, carry out another road test, and read the fault code to see
whether it still exists.
− No Replace the electronic accelerator pedal position sensor.

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2.16 P044413 Control circuit fault of carbon canister control valve P045816
Control circuit of carbon canister control valve undervoltage P045917 Control
circuit of carbon canister control valve overvoltage
DTC detection
conditions
plug fault
Control circuit fault of
Drive level switch open  Signal voltage  Canister control
P044413 carbon canister control
status  Open loop valve fault
valve
 Electronic engine
control unit fault
plug fault
Carbon canister control
Drive level switch open  Signal voltage  Canister control
P045816 valve control circuit
status  Short to ground valve fault
voltage too low
control unit fault
plug fault
Carbon canister control  Signal voltage
Drive level switch open  Canister control
P045917 valve control circuit  Connected to the
status valve fault
voltage too high power supply
control unit fault
Diagnostic steps:
1. Disconnect canister control valve plug T2y, and check whether the T2y connector has cracks or abnormality, and whether
there's corrosion or rust on the pin.
2. Check if the fuse FB03 (10A) in the front compartment electric box is normal.

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3. Disconnect the engine control unit connector T112 and check

whether the wire between pin T2y/2 of the carbon canister control valve
and pin T112/94 of the engine control unit connector is conductive.
between pin T2y/1 of the carbon canister control valve and pin T20a/8
of the front compartment electrical box connector is conductive.

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5. Disconnect negative cable of the battery and check whether the wire
between pin T2y/2 of the carbon canister control valve and positive
terminal of the battery is short.
6. Check whether the wire between pin T2y/2 of the carbon canister
control valve and the body grounding is short.
7. Replace the carbon canister control valve, carry out another road test, and read the fault code to see whether it still exists.
− No Replace the carbon canister control valve.

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2.17 P003013 Heating control circuit fault of upstream oxygen sensor P003111
Heating control circuit of upstream oxygen sensor undervoltage P003212 Heating
control circuit of upstream oxygen sensor overvoltage P00531E Heating internal
resistance of upstream oxygen sensor unreasonable
DTC detection
conditions
Upstream oxygen plug fault
Drive level switch
P003013 sensor heating control Circuit open loop  Front oxygen sensor
open status
circuit fault fault
Drive level switch
P003111 sensor heating control Short to ground  Front oxygen sensor
open status
circuit voltage too low fault
Drive level switch
P003212 sensor heating control Short to power supply  Front oxygen sensor
open status
circuit voltage too high fault
 The exhaust
temperature is
within the
diagnosis
range 300℃～
500℃  Wiring harness or
Upstream oxygen
 Intake air The current resistance is plug fault
sensor heating
P00531E temperature is larger than the threshold  Front oxygen sensor
resistance not
over -7℃ and valve fault
reasonable
shutdown time  Engine control unit
is longer than
120s
 No heating
drive level
fault
Diagnostic steps:
1. Disconnect the front oxygen sensor connector T4e, and check if the T4e plug has cracks or other abnormality, and if the
pins are corroded or rusted.
2. Check if the fuse FB04 (7.5A) in the front compartment electric box is normal.

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3. Check whether the resistance between pin T4e/D and pin T4e/C of the
front oxygen sensor connector is normal
− No The front oxygen sensor is faulty, and replace it.
4. Check if the voltage between pin 4 on the front oxygen sensor

connector T4e and the vehicle ground is the same as the battery voltage.

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5. With the ignition under OFF status, check whether the wire between
pin T4e/D of the front oxygen sensor and pin T20a/3 of the front
compartment fuse box connector is conductive.
6. Check whether the wire between pin T4e/C of the front oxygen sensor

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between pin T4e/B of the front oxygen sensor and positive terminal of
the battery is short.
8. Check whether the wire between pin T4e/B of the front oxygen sensor
and the body grounding is short.

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9.Disconnect negative cable of the battery, and check whether the wire
between pin T4e/A of the front oxygen sensor and positive terminal of
the battery is short.
10. Check whether the wire between pin T4e/A of the front oxygen
sensor and the body grounding is short.
11. Replace the front oxygen sensors; and perform road test again, read the fault code, and check if it is still present.
− No Replace the front oxygen sensor.

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2018 P003613 Heating control circuit fault of downstream oxygen sensor P003711
Heating control circuit of downstream oxygen sensor undervoltage P003812
Heating control circuit of downstream oxygen sensor overvoltage P00541E Heating
internal resistance of downstream oxygen sensor unreasonable
DTC detection
conditions
Downstream oxygen plug fault
Drive level switch
P003613 sensor heating control Circuit open loop  Rear oxygen sensor
open status
circuit fault fault
Drive level switch
P003711 sensor heating control Short to ground  Rear oxygen sensor
open status
circuit voltage too low fault
Drive level switch
P003812 sensor heating control Short to power supply  Rear oxygen sensor
open status
circuit voltage too high fault
 The exhaust
temperature is
within the
diagnosis range
250℃～500℃  Wiring harness or
Downstream oxygen
 Intake air The current resistance is plug fault
sensor heating
P00541E temperature is larger than the threshold  Rear oxygen sensor
resistance not
over -7℃ and valve fault
reasonable
shutdown time  Engine control unit
is longer than
120s
 No heating drive
level fault
Diagnostic steps:
1. Disconnect the rear oxygen sensor connecting plug T4f, and check if the T4f plug has cracks or other abnormality, and if
the pins are corroded or rusted.

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3. Check whether the resistance between pin T4f/C and pin T4f/D of the
rear oxygen sensor connector is normal.
− No The rear oxygen sensor is faulty, and replace it.
4. With the ignition under OFF status, check whether the wire between
pin T4f/C of the rear oxygen sensor and pin T20a/3 of the front
compartment fuse box connector is conductive.

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5. With the ignition under ON status, check whether the voltage between
pin T4f/C of the rear oxygen sensor and the body grounding is the
battery voltage.

electricity between pin D on the front oxygen sensor connector T4e and
pin 110 on the engine control unit connector T112.

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between pin T4f/D of the rear oxygen sensor and positive terminal of the
battery is short.
8. Check whether the wire between pin T4f/D of the rear oxygen sensor
9. Replace the rear oxygen sensors; and perform road test again, read the fault code, and check if it is still present.
− No Replace rear oxygen sensor

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2.19 P013000 Upstream oxygen sensor signal unreasonable P013116 Upstream

oxygen sensor signal undervoltage P013217 Upstream oxygen sensor signal circuit
overvoltage P013300 Upstream oxygen sensor aging P013400 Signal circuit fault of
upstream oxygen sensor P219500 Upstream oxygen sensor aging-signal constantly
thick P219600 Upstream oxygen sensor aging-signal constantly thin
DTC detection
conditions
 Voltage of the rear
oxygen sensor lower
than 0.01 and voltage
 The oxygen of the front oxygen
sensor can sensor larger than 0.6  Wiring harness or
Upstream oxygen sustain heat for and lower than 1.2V plug fault
P013000 sensor signal not 900s.  Or voltage of the rear  Front oxygen sensor
reasonable  Exhaust oxygen sensor larger fault
temperature than 0.5V and voltage  Engine control unit
higher than 600 of the front oxygen
sensor larger than
0.06 and lower than
0.1V
 Front oxygen
Engine speed more undervoltage
P013116 sensor signal low  Front oxygen sensor
than 25rmp.  Oxygen sensor
voltage fault
voltage ＜0.06V
 Voltage larger
than 10.98V
 Speed higher
than 25
 Catalytic Front oxygen sensor
converter overvoltage and output
P013217 sensor signal circuit  Front oxygen sensor
temperature voltage of upstream
voltage too high fault
lower than oxygen sensor ＞1.2V
800℃
 Rear oxygen
sensor hot
enough

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DTC trigger
DTC DTC Definition DTC detection conditions Possible fault causes
conditions
 Valid counting cycle
larger than 12
 Closed-loop control of
front oxygen sensor
activated
 No fault on pressure
sensor Upstream signal
 No fault on water delay through filter is  Wiring harness or
temperature sensor larger than the plug fault
Upstream oxygen
P013300  No intake temperature threshold value and  Front oxygen sensor
sensor aging
sensor fault upstream signal delay fault
 Mixture gas self-adaption through filter is ＞  Engine control unit
normal 0.7s
 Speed：880～3000r/min
 Load：24～45
 Exhaust temperature
higher than 500℃
 Front oxygen passed
heating diagnosis
 Oxygen sensor
signal open,
overtemperature
and high
resistance
The oxygen sensor can sustain  Voltage range of
P013400 sensor circuit signal  Front oxygen sensor
heat for 100s. upstream
circuit fault fault
oxygen sensor
0.401-0.602V
 Oxygen sensor
resistance ＞
20000Ω
 The vehicle speed keeps
around gear V, 70km/h
 Rear oxygen
 Catalytic converter
control integral  Wiring harness or
fault-free
Upstream oxygen is beyond the plug fault
 No other fault of oxygen
P219500 sensor aging-signal upper limit.  Front oxygen sensor
sensor
constantly thick  Integral value of fault
 Diagnosis time counter
rear oxygen  Engine control unit
larger than 100s
control ＞0.95s
 Exhaust temperature is
high enough

X25 2015
Engine
DTC detection
conditions
 The vehicle
speed keeps
around gear V,
70km/h
 Catalytic
 Rear oxygen control
converter  Wiring harness or
integral is beyond the
Upstream oxygen fault-free plug fault
lower limit.
P219600 sensor aging-signal  No other fault of  Front oxygen sensor
 Integral value of rear
constantly thin oxygen sensor fault
oxygen control ＜
 Diagnosis time  Engine control unit
-0.95s
counter larger
than 100s
 Exhaust
temperature is
high enough
Diagnostic steps:
1. Take out some fuel from the fuel tank and check if the quality meet relevant requirement.
− No Clean the fuel system, and replace it with qualified fuel.
3. Disconnect the front oxygen sensor connector T4e, and check if the T4e plug has cracks or other abnormality, and if the
pins are corroded or rusted.
4. Remove the front oxygen sensor, and visually check if there's carbon deposition, and if the color is white, brown or black.
− Yes The sensor is faulty; clean or replace the front oxygen sensor.

X25 2015
Engine
pin T4e/D and pin T4e/C of front oxygen sensor is normal
− Yes Replace the front oxygen sensor.

electricity between pin B on the front oxygen sensor connector T4e and

X25 2015
Engine
7. Check whether the wire between pin T4e/A of the front oxygen sensor
8. Disconnect negative cable of the battery, and check whether the wires
between pins T4e/B and T4e/A of the front oxygen sensor and positive
terminal of the battery are short.

X25 2015
Engine
9. Check whether the wires between pins T4e/B and T4e/A of the front
oxygen sensor and the body grounding are short.

X25 2015
Engine
2.20 P013600 Downstream oxygen sensor signal unreasonable P013716

Downstream oxygen sensor signal undervoltage P013817 Downstream oxygen
sensor signal circuit overvoltage P014000 Fault of downstream oxygen sensor
circuit signal P227000 Downstream oxygen sensor aging-signal constantly thin
P227100 Downstream oxygen sensor aging-signal constantly thick
DTC detection
conditions
 Signal short to
ground during cold
Rear oxygen sensor state
P013600 sensor signal not  Rear oxygen sensor
hot enough  Voltage signal of rear
reasonable fault
oxygen sensor ＜
0.06V
 Low signal of rear  Wiring harness or
Downstream oxygen oxygen sensor plug fault
Engine speed more
P013716 sensor signal low  Voltage signal of rear  Rear oxygen sensor
than 25rmp.
voltage oxygen sensor ＜ fault
0.06V  Engine control unit
 Voltage larger
than 10.98V
 Speed higher
than 25
 Temperature of  Wiring harness or
 Rear oxygen voltage
Downstream oxygen catalytic plug fault
signal too high
P013817 sensor signal circuit converter high  Rear oxygen sensor
 Voltage signal of rear
voltage too high than: 320℃ fault
oxygen sensor＞1.2V
 Rear oxygen  Engine control unit
sensor hot
enough
 Target air-fuel
ratio:1
 Oxygen sensor signal
open,
overtemperature and  Wiring harness or
Downstream oxygen high resistance plug fault
P014000 sensor circuit signal —  Voltage signal of rear  Rear oxygen sensor
fault oxygen sensor ： fault
0.4014～0.5V  Engine control unit
 Oxygen sensor
resistance＞40000Ω
 Rear oxygen voltage  Wiring harness or
Downstream oxygen is constantly higher plug fault
P227000 sensor aging-signal —  Voltage of rear  Rear oxygen sensor
constantly thin oxygen sensor ＞ fault

X25 2015
Engine
DTC detection
conditions
 Rear oxygen voltage  Wiring harness or
Downstream oxygen is constantly lower plug fault
P227100 sensor aging-signal —  Voltage of rear  Rear oxygen sensor
constantly thick oxygen sensor ＜ fault
Diagnostic steps:
1. Take out some fuel from the fuel tank and check if the quality meet relevant requirement.
− No Clean the fuel system, and replace it with qualified fuel.
3. Disconnect the rear oxygen sensor connector T4f, and check if the T4f connector has cracks or other abnormality, and if
the pins are corroded or rusted.
4. Remove the rear oxygen sensor, and visually check if there's carbon deposit, and if the color is white, brown or black.
− Yes The sensor is faulty; clean or replace the rear oxygen sensor.
5. Turn on the ignition and check whether the voltage between pin T4f/A
and pin T4f/B of the rear oxygen sensor is normal.
− Yes Replace the rear oxygen sensor.

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Engine

electricity between pin B on the front oxygen sensor connector T4f and
7. Check whether the wire between pin T4f/A of the front oxygen sensor

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Engine
8. Disconnect negative cable of the battery, and check whether the wires
between pins T4f/A and T4f/B of the front oxygen sensor and positive
terminal of the battery are short.
9. Check whether the wires between pins T4f/A and T4f/B of the front
oxygen sensor and the body grounding are short.
10. Replace the front oxygen sensors; and perform road test again, read
the fault code, and check if it is still present.
− No Replace the front oxygen sensor.

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Engine
2.21 P020113 Control circuit fault of first cylinder fuel injector P026111 Control
circuit of first cylinder fuel injector undervoltage P026212 Control circuit of first
cylinder fuel injector overvoltage
DTC detection
conditions
 Fuse fault
Drive level switch  Actuator fault
P020113 first cylinder fuel Signal voltage open loop
open status  Wire fault
injector
 Fuse fault
Control circuit of first
Drive level switch Signal voltage short to  Actuator fault
P026111 cylinder fuel injector
open status ground  Wire fault
undervoltage
 Fuse fault
Control circuit of first
Drive level switch Signal voltage short to  Actuator fault
open status power supply  Wire fault
overvoltage
Diagnostic steps:
2. Disconnect the connector T2x of the first cylinder fuel injector, check the connector T2x for crack and abnormality and

X25 2015
Engine
pin T2x/1 of the first cylinder fuel injector connector and the body
grounding is the battery voltage.
4. Check whether the resistance between pin T2x/1 and pin T2x/2 of the
first cylinder fuel injector connector is normal.
− No The fuel injector is faulty, and replace it.

X25 2015
Engine
5. Disconnect the engine control unit connector T112, and check if the
connector T112 has cracks or other abnormality, and if the pins are
corroded or rusted.
between pin T2x/2 of the first cylinder fuel injector connector and pin
7. Check whether the wire between pin T2x/2 of the first cylinder fuel
injector connector and the body grounding is short.

X25 2015
Engine

between pin 2 on the cylinder-1 injector connector T2x and the battery
positive electrode.
9. Replace the first cylinder fuel injector, carry out another road test, and read the fault code to see whether it still exists.
− No Replace the first cylinder fuel injector.

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Engine
2.22 P020213 Control circuit fault of second cylinder fuel injector P026411 Control
circuit of second cylinder fuel injector undervoltage P026512 Control circuit of
second cylinder fuel injector overvoltage
DTC detection
conditions
 Fuse fault
Drive level switch open  Actuator fault
P020213 second cylinder fuel Signal voltage open loop
status  Wire fault
injector
 Fuse fault
Control circuit of
Drive level switch open Signal voltage short to  Actuator fault
P026411 second cylinder fuel
status ground  Wire fault
injector undervoltage
 Fuse fault
Control circuit of
P026512 second cylinder fuel
status power supply  Wire fault
injector overvoltage
Diagnostic steps:
2. Disconnect the connector T2w of the second cylinder fuel injector, check the connector T2w for crack and abnormality
and check its pins for corrosion and rust.

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Engine
3. With the ignition under ON status, check whether the voltage

between pin T2w/1 of the second cylinder fuel injector connector and
the body grounding is the battery voltage.
4. Check whether the resistance between pin T2w/1 and pin T2w/2 of
the second cylinder fuel injector connector is normal.

X25 2015
Engine
corroded or rusted.
between pin T2w/2 of the second cylinder fuel injector connector and
pin T112/67 of the engine control unit connector is conductive.
7. Check whether the wire between pin T2w/2 of the second cylinder
fuel injector connector and the body grounding is short.

X25 2015
Engine

between pin 2 on the cylinder-2 injector connector T2w and the battery
positive electrode.
9. Replace the second cylinder fuel injector, carry out another road test, and read the fault code to see whether it still exists.
− No Replace the second cylinder fuel injector.

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Engine
2.23 P020313 Control circuit fault of third cylinder fuel injector P026711 Control
circuit of third cylinder fuel injector undervoltage P026812 Control circuit of third
cylinder fuel injector overvoltage
DTC detection
conditions
 Fuse fault
P020313 third cylinder fuel Signal voltage open loop
injector
 Fuse fault
Control circuit of third
undervoltage
 Fuse fault
Control circuit of third
overvoltage
Diagnostic steps:
2. Disconnect the connector T2v of the third cylinder fuel injector, check the connector T2v for crack and abnormality and

X25 2015
Engine

between pin T2v/1 of the third cylinder fuel injector connector and the
body grounding is the battery voltage.
4. Check whether the resistance between pin T2v/1 and pin T2v/2 of the
third cylinder fuel injector connector is normal.

X25 2015
Engine
corroded or rusted.
between pin T2v/2 of the third cylinder fuel injector connector and pin
7. Check whether the wire between pin T2v/2 of the third cylinder fuel

X25 2015
Engine
between pin T2v/2 of the third cylinder fuel injector connector and
9. Replace the third cylinder fuel injector, carry out another road test, and read the fault code to see whether it still exists.
− No Replace the third cylinder fuel injector.

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Engine
2.24 P020413 Control circuit fault of fourth cylinder fuel injector P027011 Control
circuit of fourth cylinder fuel injector undervoltage P027112 Control circuit of
fourth cylinder fuel injector overvoltage
DTC detection
conditions
 Fuse fault
P020413 fourth cylinder fuel Signal voltage open loop
injector
 Fuse fault
Control circuit of
P027011 fourth cylinder fuel
injector undervoltage
 Fuse fault
Control circuit of
P027112 fourth cylinder fuel
injector overvoltage
Diagnostic steps:
2. Disconnect the connector T2u of the fourth cylinder fuel injector, check the connector T2u for crack and abnormality and

X25 2015
Engine
3. Disconnect the connector T2u of the fourth cylinder fuel injector,

check the connector T2u for crack and abnormality and check its pins
for corrosion and rust.
pin T2u/1 of the fourth cylinder fuel injector connector and the body
grounding is the battery voltage.
5. Check whether the resistance between pin T2u/1 and pin T2u/2 of the
fourth cylinder fuel injector connector is normal.

X25 2015
Engine
corroded or rusted.
pin T2u/2 of the fourth cylinder fuel injector connector and pin T112/74
of the engine control unit connector is conductive.
8. Check whether the wire between pin T2u/2 of the fourth cylinder fuel

X25 2015
Engine
between pin T2u/2 of the fourth cylinder fuel injector connector and
10. Replace the fourth cylinder fuel injector, carry out another road test, and read the fault code to see whether it still exists.
− No Replace the fourth cylinder fuel injector.

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Engine
2.25 P030021 Occurrence of several cylinder fire leading to ultra-limit emission

P030022 Occurrence of several cylinder fire leading to catalytic converter damage
P030029 Occurrence of several cylinder fire in the first statistic cycle of fire
detection
DTC detection
conditions
 Miss fire rate
destroying the
catalytic converter
 Threshold value for
fire rate leading to
the catalytic
converter damage
(dependent on
working conditions)
 According to the
 No diagnosis of fire rate leading to
broken circuit emission
 Fuel is not cut off deterioration, fire
 No torque fault counter related
 Wire fault
interference to emission of every
Occurrence of several  Actuator fault
 Engine RPM: cylinder is larger
P030021 cylinder fire leading to  Ignition coil circuit
600～6000 than the threshold
ultra-limit emission fault
 Load：21%～ value of fire rate
51% leading to emission
 Intake air deterioration,
temperature generally 3%.
higher than -28℃  Fire fault counter
related to emission
of every cylinder is
larger than the
threshold value of
fire rate leading to
emission
deterioration in the
first counting cycle
after start, generally
3%.

X25 2015
Engine
DTC detection
conditions
 Miss fire rate destroying
 Threshold value for fire
rate leading to the
catalytic converter
damage (dependent on
working conditions)
 No diagnosis of
 According to the fire rate
broken circuit
leading to emission
 Fuel is not cut off
deterioration, fire fault
 No torque
counter related to  Wire fault
Occurrence of interference
emission of every  Actuator fault
several cylinder fire  Engine RPM:
P030022 cylinder is larger than the  Ignition coil
leading to catalytic 600～6000
threshold value of fire circuit fault
converter damage  Load：21%～
rate leading to emission  Control unit fault
51%
deterioration, generally
 Intake air
3%.
temperature
 Fire fault counter related
higher than -28℃
to emission of every
cylinder is larger than the
threshold value of fire
rate leading to emission
deterioration in the first
counting cycle after start,
generally 3%.
 Miss fire rate destroying
 Threshold value for fire
rate leading to the
catalytic converter
damage (dependent on
working conditions)
 No diagnosis of
 According to the fire rate
broken circuit
leading to emission
 Fuel is not cut off
deterioration, fire fault
 No torque
Occurrence of counter related to  Wire fault
interference
several cylinder fire emission of every  Actuator fault
 Engine RPM:
P030029 in the first statistic cylinder is larger than the  Ignition coil
600～6000
cycle of fire threshold value of fire circuit fault
 Load：21%～
detection rate leading to emission  Control unit fault
51%
deterioration, generally
 Intake air
3%.
temperature
 Fire fault counter related
higher than -28℃
to emission of every
cylinder is larger than the
threshold value of fire
rate leading to emission
deterioration in the first
counting cycle after start,
generally 3%.
Diagnostic steps:

X25 2015
Engine
1. Check for vacuum leakage at the channels and connections related to the intake system.
− Yes Repair the air leakage fault.
2. Check the injection volume and leakage of the nozzle. (Refer to relevant fault diagnosis of the fuel injector)
3. Check if the pole clearance of the spark plug and the combustion are normal.
− No Replace the spark plug.
4. Check if the ignition coil is normal. (Refer to relevant fault diagnosis of the ignition coil)
− No Replace the ignition coil.
5. Check the water temperature sensor and read whether water temperature value is normal.
− No Replace the water temperature sensor.
6. Check if the fuel supply pressure is normal. (Refer to fuel pressure test)
− No Solve the fuel supply pressure fault.
7. Check whether compression pressure of the misfiring cylinder is normal. (Refer to cylinder pressure test)
− No Solve the cylinder pressure fault.
8. Check if the valve timing is normal.
− No Adjust valve timing
9. Check whether power supply circuit and grounding circuit of the engine control unit are normal.
− No Troubleshooting

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Engine
2.26 P030121 Occurrence of first cylinder fire leading to ultra-limit emission

P030122 Occurrence of first cylinder fire leading to catalytic converter damage
P030129 Occurrence of first cylinder fire in the first statistic cycle of fire detection
P030221 Occurrence of second cylinder fire leading to ultra-limit emission P030222
Occurrence of second cylinder fire leading to catalytic converter damage P030229
Occurrence of second cylinder fire in the first statistic cycle of fire detection
P030321 Occurrence of third cylinder fire leading to ultra-limit emission P030322
Occurrence of third cylinder fire leading to catalytic converter damage P030329
Occurrence of third cylinder fire in the first statistic cycle of fire detection P030421
Occurrence of fourth cylinder fire leading to ultra-limit emission P030422
Occurrence of fourth cylinder fire leading to catalytic converter damage P030429
Occurrence of fourth cylinder fire in the first statistic cycle of fire detection
 Ignition coil fault
Occurrence of first  Spark plug fault
P030121 cylinder fire leading to — —  Ignition coil circuit fault
ultra-limit emission  Electronic engine control unit
fault
Occurrence of first
 Spark plug fault
cylinder fire leading to
P030122 — —  Ignition coil circuit fault
catalytic converter
 Electronic engine control unit
damage
fault
Occurrence of first
cylinder fire in the first
statistic cycle of fire
detection
fault

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Engine

Occurrence of second  Spark plug fault
fault
Occurrence of second
catalytic converter
damage
fault
Occurrence of second
detection
fault
Occurrence of third  Spark plug fault
fault
Occurrence of third
catalytic converter
damage
fault

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Engine

Occurrence of third
P030329 —  Ignition coil circuit fault
detection
fault
Occurrence of fourth  Spark plug fault
fault
Occurrence of fourth
catalytic converter
damage
fault
Occurrence of fourth
detection
fault
Diagnostic steps:
1. Extract the fuse FB03 (7.5A) of the front compartment electrical box and check whether it is blown.
− Yes Replace the fuse.
2. Check if the injector is normal.
3. Check if the spark plug is normal
− No Replace the spark plug.

X25 2015
Engine

between pins T2ea/1, T2eb/1, T2ec/1 and T2ed/1 of the ignition coil
connector and the body grounding is the battery voltage.
5. Disconnect the engine control unit connector T112, check whether

the wires between pins T2ea/2, T2eb/2, T2ec/2 and T2ed/2 of every
cylinder ignition coil connector and pins T112/100, T112/88, T112/99
and T112/76 of the engine control unit connector are conductive
respectively.

X25 2015
Engine

between pins T2ea/2, T2eb/2, T2ec/2 and T2ed/2 of the ignition coil
connector and the body grounding is the battery voltage.
7. Check whether the wires between pins T2ea/2, T2eb/2 and T2ec/2 of
the ignition coil connector and the body grounding are short.
8. Check if the ignition coil is normal.

− No Replace the ignition coil.
− No Troubleshooting

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Engine
2.27 P021900 Engine speed higher than the maximum speed limit P050600 Idle
control speed lower than target idle speed P050700 Idle control speed higher than
target idle speed
DTC trigger
DTC DTC Definition DTC detection conditions Possible fault causes
conditions
 Fuel System
Engine speed  Maximum engine Malfunction
higher than the speed incredible  Intake system fault
P021900 —
maximum speed  Engine speed ＞  Electronic throttle
limit 7000 fault
 The idle speed
actuator is stuck
in the relative
small opening
position  Fuel System
 Engine coolant
Controlled idling  Difference Malfunction
temperature is higher
speed is lower than between static  Intake system fault
P050600 than 80.3℃.
the target idling target idle speed  Electronic throttle
 Intake air temperature
speed and actual speed: fault
higher than 20.3℃
100  Control unit fault
 Idle speed control
integral portion is
at the maximum
value.
 Carbon canister under
high washing rate
 Under idle speed Idle speed actuator is
working condition jammed at a large
 Fuel System
 The vehicle speed opening position, the
Controlled idling Malfunction
sensor is checked difference between
speed is higher than  Intake system fault
P050700 fault-free (required static target idle speed
the target idling  Electronic throttle
under the conditions and actual speed is less
speed fault
when vehicle speed is than 200 and integral
higher than 20km/h, part of idle speed
then slide the vehicle control is the minimum
and cut off its fuel by
more than 5s)
Diagnostic steps:
1. Check whether the generator is working properly.
− No Repair generator fault.
2. Check whether working status of the air conditioner is consistent with actual operation of the air conditioner.
− No-Repair fault of the air conditioning system.
3. Remove the intake pipe and check whether the throttle rollover plate is too dirty.
− Yes Wash the throttle.

X25 2015
Engine
4. Remove the carbon canister solenoid valve and check whether the carbon canister solenoid valve is normally open.
− Yes Replace the canister solenoid valve.
5. Connect the diagnostic tester, start the engine and check whether dataflow of the intake manifold pressure sensor is
normal.
− No-Repair fault of the intake manifold pressure sensor.
6. Connect the diagnostic tester, start the engine and read whether dataflow of the coolant temperature sensor is normal.
− No-Refer to diagnosis of the coolant temperature sensor and eliminate the fault.
7. Disconnect the fuel pump relay J104.
8 .Connect cylinder pressure gauge and check whether pressure of every cylinder is normal.
− No-Repair low pressure fault of the cylinder.
9. Disconnect the fuel pipeline and connect the fuel pressure gauge.
10. Start the engine and check whether fuel system pressure is normal.
− No-Repair the fuel system fault.
11. Remove fuel injector of every cylinder.
12. Connect the fuel injector tester and check whether the fuel injector is normal.
− No Replace the faulty fuel injector.
DTCs and symptoms.

X25 2015
Engine
2.28 P056000 System battery voltage signal unreasonable P056216 System battery
undervoltage P056317 System battery overvoltage P062211 Generator load
feedback signal undervoltage P062212 Generator load feedback signal overvoltage
DTC detection
conditions
 Wire fault
System battery voltage  Generator fault
P056000 — —
signal is implausible  Battery fault
 Exceeding the
 Vehicle speed  Wire fault
lower limit value
System battery voltage over: 25Km  Generator fault
P056216  Battery voltage
is too low  After finish of  Battery fault
ADC value ＜
start: 180s  Control unit fault
10.02V
 Exceeding the
 Wire fault
upper limit value
System battery voltage After finish of start:  Generator fault
P056317  Battery voltage
is too high 180s  Battery fault
ADC value ＞
17.02V
 Wire fault
Generator load
 Generator fault
P062211 feedback signal — —
 Battery fault
undervoltage
 Wire fault
Generator load
 Generator fault
P062212 feedback signal — —
 Battery fault
overvoltage
Diagnostic steps:
1. Check whether the battery voltage is normal.
− No Overhaul or replace battery.
2. Connect the diagnostic tester, start the engine and check whether dataflow of generator voltage is around 14.5V.
− No Overhaul or replace generator.
3. Disconnect the engine control unit connector T112, and check if the connector T112 has cracks or other abnormality, and
if the pins are corroded or rusted.

X25 2015
Engine
4. Disconnect the generator connector T2s.

5. Check whether the wire between pin T112/106 of the engine control
unit connector and pin T2s/2 of the generator connector is conductive.
6. Check whether the wire between pin T2s/2 of the generator connector
7. Replace the generator, carry out another road test, and read the fault code to see whether it still exists.
− No Replace the generator.

X25 2015
Engine
2.29 P062713 Control circuit fault of oil pump relay P062811 Oil pump relay
control circuit short to ground or open P062912 Oil pump relay control circuit
overvoltage
DTC detection
conditions
 Fuse fault
Oil pump circuit A Drive level switch Signal voltage short to  Relay fault
P062713
open open status ground or open  Wire fault
 Fuse fault
Oil pump relay control
Drive level switch Drive level switch open  Relay fault
P062811 circuit short to ground
open status status  Wire fault
or open
 Fuse fault
Fuel pump relay
Drive level switch Signal current short to  Relay fault
P062912 control circuit voltage
too high
Diagnostic steps:
1. Extract fuses FB31 (10A) and FB03 (10A) of the front compartment electrical box, check whether they are blown and
check their terminals for corrosion and rust.
− Yes Replace the fuses FB31 (10A) and FB03 (10A) and clean their terminals.
2. Unplug the oil pump relay J104 of front compartment electrical box, and check it for cracks and abnormality and
terminals for corrosion and rust.
− Yes, replace the oil pump relay J104 in front compartment electrical box, and clean the terminals.

X25 2015
Engine
3. Check whether oil pump relay J104 of the front compartment

electrical box is normal.
Multimeter
Condition Specified valve
connecting pins
Normal state Normal state 85-86 Conductivity
Between pin 85 and
pin 86, apply supply 30-87 Conductivity
voltage
− No Replace the oil pump relay J104 of the front compartment
electrical box.
4. Unplug the main relay J100 in front compartment electrical box, and check it for cracks and abnormality and terminals
− Yes, replace the main relay J100 in front compartment electrical box, and clean the terminals.
5. Detect whether main relay J100 in front compartment electrical box is
normal.
Multimeter
connecting pins
Between pin 85 and
voltage
− No Replace main relay J100 in front compartment electrical box.

X25 2015
Engine
pin T16d/9 of the front compartment electrical box connector and the
body grounding is short.
pin T20a/9 of the front compartment electrical box connector and the
body grounding is short.

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Engine
between pin T20a/9 of the front compartment electrical box connector
between pin T16d/9 of the front compartment electrical box connector
and positive terminal of the battery is short.

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Engine
11. When the ignition switch is in the ON state, measure whether the
voltage between connector T18b/pin 2 of the front compartment
electrical box and body ground is the battery voltage.

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Engine
2.30 P068800 Main relay output voltage unreasonable P068816 Fault of main relay
output voltage signal
DTC detection
conditions
 Wire fault
The main relay output  Check signal
P068800 —  Relay fault
voltage is implausible  电压值（ubrsq）＜3V
 Wire fault
Fault of main relay
P068816 — —  Relay fault
output voltage signal
Diagnostic steps:

normal.
Multimeter
connecting pins
Between pin 85 and
voltage

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Engine

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Engine

wire between pin T20a/9 of the front compartment electrical box
connector and positive terminal of the battery is short.

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Engine
2.31 P064513 Control circuit fault of A/C compressor relay P064611 Control circuit
of A/C compressor relay short to ground P064712 Control circuit of A/C
compressor relay overvoltage
DTC detection
conditions
 Fuse fault
A/C compressor replay Drive level switch  Relay fault
P064513 Signal voltage open loop
control circuit fault open status  Wire fault
 Fuse fault
A/C compressor replay
P064611 control circuit short to
open status ground  Wire fault
ground
 Fuse fault
A/C compressor replay
P064712 control circuit voltage
too high
Diagnostic steps:
1. Unplug fuse FB03 (10A) of the front compartment electrical box and check whether the fuse is blown and its terminals
are corroded and rusty.
− Yes Replace the fuse FB03 and clean its terminals.
2. Check the front compartment electrical box for crack and abnormality and check its terminals for corrosion and rust.
− Yes Replace the front compartment fuse box

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normal.
Multimeter
connecting pins
Between pin 85 and
voltage
5. Unplug A/C compressor relay J103 of the front compartment electrical box, check the main relay J103 of the front
compartment electrical box for crack and abnormality and check its terminals for corrosion and rust.
− Yes Replace the main relay J103 in front compartment electrical box, and clean the terminals.
normal.
Multimeter
connecting pins
Between pin 85 and
voltage

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between pin T112/42 of the engine control unit connector and the body
grounding is short.

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wire between pin T112/42 of the engine control unit connector and

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− No Control unit of engine

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2.32 P017000 Air-fuel ratio closed-loop control self-learning in off-line detection

unreasonable P017100 Air-fuel ratio closed-loop control self-learning in off-line
detection too thin P017200 Air-fuel ratio closed-loop control self-learning in off-line
detection too thick P217700 Air-fuel ratio closed-loop control self-learning value
higher than the upper limit (intermediate load zone) P217800 Air-fuel ratio
closed-loop control self-learning value lower than the lower limit (intermediate load
zone) P218700 Air-fuel ratio closed-loop control self-learning value higher than the
upper limit (low load zone) P218800 Air-fuel ratio closed-loop control self-learning
value lower than the lower limit (low load zone)
 Mechanical fault
Air/fuel ratio closed-loop
 Actuator fault
P017000 control: offline test shows — —
 Oxygen sensor fault
self-learning is implausible
Air/fuel ratio closed-loop  Mechanical fault
control: offline test shows  Actuator fault
P017100 — —
thin mixture after  Oxygen sensor fault
self-learning  Control unit fault
Air/fuel ratio closed-loop  Mechanical fault
control: offline test shows  Actuator fault
P017200 — —
thick mixture after  Oxygen sensor fault
self-learning  Control unit fault
Speed and load are
The air-fuel ratio located within the
Fuel correction  Mechanical fault
closed-loop control self-learning zone, able
higher than the upper  Actuator fault
P217700 self-learning value is to stabilize within the
limit frau_w larger  Oxygen sensor fault
beyond the upper limit working conditions of
than 1.23  Control unit fault
(middle load area) either gear IV 50km/h
or gear V 70km/h
Speed and load are
The air-fuel ratio located within the
Fuel correction lower  Mechanical fault
closed-loop control self-learning zone, able
than the lower limit  Actuator fault
P217800 self-learning value is to stabilize within the
frau_w lower than  Oxygen sensor fault
beyond the lower limit working conditions of
0.77  Control unit fault
(middle load area) either gear IV 50km/h
or gear V 70km/h
The air-fuel ratio
 Mechanical fault
closed-loop control
 Actuator fault
P218700 self-learning value is — —
beyond the upper limit
(low load area)
The air fuel ratio close  Mechanical fault
loop control self-learning  Actuator fault
P218800 — —
value is beyond the lower  Oxygen sensor fault
limit (low load area)  Control unit fault

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Diagnostic steps:
1. With the ignition under LOCK status, check whether the exhaust system has any internal hole, crack and blocking in both
visual and physical manner.
− Yes Repair or replace as necessary.
2. Use the diagnostic tester to read dataflow of the intake air pressure and temperature sensor and check whether the
dataflow is normal => Refer to Page 211.
− Yes Repair fault of the absolute pressure sensor of the intake manifold.
3. Use the diagnostic tester to read dataflow of the electronic throttle position sensor and check whether the dataflow is
normal => Refer to Page 253.
− Yes Repair fault of the electronic throttle position sensor.
4. Use the diagnostic tester to read dataflow of the front oxygen sensor and check whether the dataflow is normal => Refer
to Page 282.
− Yes Repair fault of the front oxygen sensor.
5. Check whether the vacuum hose cracks, twists or connects.
− Yes Repair or replace the vacuum hose.
6. Check whether the intake manifold, the throttle body and the fuel injector suffer from vacuum leakage.
− Yes Repair or replace faulty position.
7. Check whether the intake pipe collapses or blocks.
8. Check whether crankcase ventilating system leaks.
9. Check whether the fuel is polluted.
10. Whether there is excessive fuel in the fuel tank.
11. Check whether evaporation and emission control system works normally.

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2.33 P210612 Power drive level fault of electronic throttle (short) P210619 Power
drive level fault of electronic throttle (overheat or overcurrent) P210692 Power
drive level fault of electronic throttle (SPI bus or signal) P210613 Power drive level
fault of electronic throttle (open) P2106 29 Load monitoring fault
fault
 VVT intake control valve
fault
(short)
 Electronic engine control
unit fault
Power drive level fault fault
of electronic throttle  VVT intake control valve
P210619 — —
(overheat or fault
overcurrent)  Electronic engine control
unit fault
fault
fault
(SPI bus or signal)
unit fault
fault
fault
(open)
unit fault
fault
P210629 Load monitoring fault — —
fault
unit fault
Diagnostic steps:

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1. Disconnect accelerator pedal position sensor connector T6c, and check whether the connecting plug has cracks or
2. Disconnect throttle value controller connecting plug T6a, and check whether the T6a connector has cracks or abnormality,
and whether there's corrosion or rust on the pin.
3. Check whether wiring harness of the accelerator pedal position sensor is normal => Refer to Page 264.
4. Check whether wiring harness of the electronic throttle position sensor is normal => Refer to Page 253.

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2.34 P305400 Engine stalling or starter and flywheel not meshing fault P305500
Feedback voltage signal line (KL50r) of key starting switch (KL50r) short to
ground fault P305600 Feedback voltage signal line (KL50r) of key starting switch
(KL50r) short to power supply fault P308800 Starter damaged or starter power
supply circuit interrupted
Engine stalling or  Actuator fault
P305400 starter and flywheel not — —  Wire fault
meshing fault  Control unit fault
Feedback voltage
signal line (KL50r) of  Actuator fault
P305500 key starting switch — —  Wire fault
(KL50r) short to power  Control unit fault
supply fault
 Actuator fault
Starter control relay
P305600 — —  Wire fault
overvoltage
Starter damaged or  Actuator fault
P308800 starter power supply — —  Wire fault
circuit interrupted  Control unit fault
Diagnostic steps:
1. Extract the starter relay J110 of the front compartment electrical box, check it for crack and abnormality and check its
terminals for corrosion and rust.
− Yes Replace the starter relay J110 of the front compartment electrical box and clean its terminals.

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2. Check whether the starter relay J110 of the front compartment

Multimeter
connecting pins
Between pin 85 and
voltage
− No Replace the front compartment electrical box starter relay J110.
4. Disconnect the connecting plug T20a of the front compartment electrical box, check the connecting plug T20a for crack
5. Disconnect the connecting plug T1c of the starter, check the connecting plug T1c for crack and abnormality and check its
between pin T112/22 of the engine control unit connector and pin
T20a/13 of the front compartment electrical box connector is open.

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between pin T112/22 of the engine control unit connector and positive
terminal of the battery is short.
between pin T112/22 of the engine control unit connector and the body
grounding is short.

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between pin T112/22 of the engine control unit connector and pin T1c/1
of the starter connecting plug is open.
between pins T112/8 and T112/58 of the engine control unit connector
and pin T20a/1 of the front compartment electrical box connector are
open.

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11. With the ignition under LOCK status, check whether pins T20a/1
and T20a/13 of the front compartment electrical box connector are short
to positive terminal of the battery.
12. With the ignition under LOCK status, check whether pins T20a/1
and T20a/13 of the front compartment electrical box connector are short
to the body grounding.

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2.35 P061513 Starter control relay open P061611 Starter control relay
undervoltage P061712 Starter control relay overvoltage
DTC detection
conditions
 Actuator fault
open
 Actuator fault
undervoltage
 Actuator fault
overvoltage
Diagnostic steps:
1. Extract the starter control relay J139 of the front compartment electrical box, check it for crack and abnormality and
check its terminals for corrosion and rust.
− Yes Replace the starter control relay J139 of the front compartment electrical box and clean its terminals.
2. Check whether the starter control relay J139 of the front compartment
Multimeter
connecting pins
Between pin 85 and
voltage
− No Replace the starter control relay J139 of the front compartment
electrical box.
corrosion and rust.

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4. Disconnect the connecting plug T20a of the front compartment electrical box, check the connecting plug for crack and
5. Check whether the wire between pin T112/58 of the engine control
unit connector and pin T20a/18 of the front compartment electrical box
connector is open.
6. Check whether pin T112/58 of the engine control unit connector is

short to positive terminal of the battery.

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7. Check whether pin T112/58 of the engine control unit connector is

short to the body grounding.

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2.36 U012287 Loss of communication with brake control unit ABS/ESP U000188
CAN communication related diagnosis U014087 Loss of communication with body
control module BCM
DTC detection
conditions
Loss of communication
 Wire fault
U012287 with brake control unit — —
ABS/ESP
CAN communication  Wire fault
U000188 — —
related diagnosis  Control unit fault
Loss of communication
 Wire fault
U014087 with body control — —
module BCM
DTC detection procedures:

and pins T16j/6 and T16j/14 of the diagnostic interface connector are
conductive.
3. Disconnect the connector T24a of the automatic transmission control unit, check the connector T24a for crack and

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and pins T24a/17 and T24a/7 of the automatic transmission control unit
connector are conductive.
5. Disconnect the connector T40a of the body controller, check the connector T40a for crack and abnormality and check its
6. With the ignition under LOCK status, check whether wires between
pins T112/1 and T112/17 of the engine control unit connector and pins
T40a/8 and T40/9 of the body controller connector are open.
7. Disconnect the connector T20b of the electronic power-assisted steering controller, check the connector T20b for crack

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T20b/16 and T20b/15 of the electronic power-assisted steering
controller connector are open.
9. Disconnect the connector T38b of the ABS control unit, check the connector T38b for crack and abnormality and check
its pins for corrosion and rust.
T38b/26 and T38b/14 of the ABS control unit connector are open.
11. Check whether power supply and bonding of the engine control unit are normal.

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2.37 P161000 ECM not learning SecretKey P161100 PIN code input error P161200
ECM not receiving IMMO P161300 The last IMMO certification is responded Busy
DTC detection
conditions
ECM not learning CAN communication CAN communication
P161000 —
Secret Key wiring harness short wiring harness fault
CAN communication CAN communication
P161100 PIN code input error —
wiring harness short wiring harness fault
ECM not receiving CAN communication CAN communication
P161200 —
IMMO wiring harness short wiring harness fault
The last IMMO
CAN communication CAN communication
P161300 certification is —
wiring harness short wiring harness fault
responded Busy
Diagnostic steps:
2. Disconnect the connector T40a of the body controller, check the connector T40a for crack and abnormality and check its
and pins T40a/8 and T40a/9 of the body controller connector are
conductive.
4. Check whether power supply and bonding of the engine control unit are normal.

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5. Check whether power supply and bonding of the body controller are normal.
7. Replace the body controller, re-diagnose, and read the fault code to see whether it still exists.
− No Replace body controller

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2.38 P042000 Three way catalytic converter capacity aging (drain over limit)
DTC detection
conditions
 Average amplitude of
the rear oxygen
 Exhaust Leak
sensor corrected by
 Failure of the
critical catalytic
three-way catalytic
Vehicle speed gear IV converter model
Three way catalytic converter
50km/h or gear V (applicable to
P042000 converter capacity  Coolant temperature
100km/h stable amplitude method) >
aging (drain over limit) sensor has fault
working conditions 0.711
 Fuel system
 Ageing factor is less
overpressure
than 0.2 (applicable
to oxygen storage
capacity method)
Diagnostic steps:
1. With the ignition under LOCK status, check whether the exhaust system has any internal hole, crack and blocking in both
visual and physical manner.
− Yes Repair or replace as necessary.
2. Use the diagnostic tester to read dataflow of the coolant temperature sensor and check whether the dataflow is normal =>
Refer to Page 220.
− Yes Repair fault of the coolant temperature sensor.
3. Use the diagnostic tester to read dataflow of the front oxygen sensor and check whether the dataflow is normal => Refer
to Page 282.
− Yes Repair fault of the front oxygen sensor.
4. Use the diagnostic tester to read dataflow of the rear oxygen sensor and check whether the dataflow is normal => Refer to
Page 288.
− Yes Repair fault of the rear oxygen sensor.
5. Check fuel contamination
6. Check whether fuel system pressure is normal
− No Repair or replace faulty parts.
7. Replace the three-way catalytic converter assembly, re-diagnose, and read the fault code to see whether it still exists.
− No Replace the three-way catalytic converter assembly.

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2.39 P060443 Electronic control unit RAM fault P060543 Electronic control unit
ROM fault
Control module RAM unit fault
P060443 — —
error  Engine controller
matching fault
Test error of control unit fault
P060543 — —
module ROM  Engine controller
matching fault
Diagnostic steps:
1. Match the engine control unit; diagnose it again, read the fault code, and check if it is still present.
− No Match the fault and perform engine control signal matching.

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2.40 P168300 Airbag signal unreasonable P152381 Airbag exploded

DTC detection
conditions
Airbag signal Airbag sends bus report, CAN bus poor contact or
P168300 —
unreasonable no response open
P152381 Airbag exploded — —
Diagnostic steps:
corrosion and rust.
2. Disconnect the connector T40a of body control unit.
3. Check whether wires between pins T112/17 and T112/1 of the engine
control unit connector and pins T40a/9 and T40a/8 of the body control
unit connector are open.
− Yes Repair the faulty line.

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4. Disconnect connector T32b of SRS control unit.

5. Check whether wires between pins T40b/36 and T40b/37 of the body
control unit connector and pins T32b/2 and T32b/17 of SRS control unit
connector are open.
− Yes Repair the faulty line.
6. Check whether power supply circuit and grounding circuit of SRS control unit are normal.
7. Replace SRS control unit, and implement the road test; diagnose again, read the DTCs, and confirm the existence of
DTCs and symptoms.
− No Replace SRS control unit
8. Check whether power supply circuit and grounding circuit of BCM control unit are normal.
9. Replace BCM control unit, and implement the road test; diagnose again, read the DTCs, and confirm the existence of
DTCs and symptoms.
− No Replace BCM control unit.
DTCs and symptoms.

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3 System: Basic Control Logic

3.1 Ignition Switch: Control Logic
Turn the ignition to ON position
Main relay is connected and oil pump operates for 1.5S
Turn the ignition switch off Start and operate the engine
System post-operation Turn the ignition switch off
System shutdown System post-operation
System shutdown

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3.2 Fuel Supply System: Control Logic

Fuel pumps logic
 Oil pump ON logic
Once the ignition switch is activated, the fuel pump will run for 1.5 seconds.If no valid signal is detected for the crankshaft
position, the fuel pump will stop running; after the engine starts running, once the ECU detects 2 valid signals for the
crankshaft position, the fuel pump will get started.
 Oil pump OFF logic
Oil pump stops operations 0.8s after the speed signal is lost or required by the burglar alarm to stop.
Start Pre-injection
The start of pre-injection only occurs once during the normal start process. It shall meet the following conditions:
 The engine has started running (the ECU detects at least 2 valid signals from the crankshaft position sensor).
 Fuel pump relay actuates.
 The running duration of the fuel pump exceeds accumulation delay.
 Pre-injection has not occurred before.
If all of the conditions above are met, start pre-injection will begin simultaneously in all cylinders.
Fuel injection pulse width calculation

 Air-fuel ratio
Starting air-fuel ratio: air-fuel ratio in normal starting and air-fuel ratio in elimination of cylinder immersion.
Air-fuel ratio while the engine is operating: air-fuel ratio under cold status, air-fuel ratio under warm-up status, theoretical
air-fuel ratio, power thickening air-fuel ratio, air-fuel ratio during catalytic converter overheat protection and air-fuel ratio
during engine overheat protection.
 Intake manifold absolute pressure
Absolute pressure of the manifold is directly read by its absolute pressure sensor installed on the intake pipe.
 Inflation temperature
The inflation temperature refers to the temperature of air entering the engine cylinder, which is obtained through calculation
according to coolant temperature and intake air temperature.
 Inflation efficiency
Inflation efficiency is the ratio of the actual air flow entering into the cylinder to that calculated in accordance with the ideal
state equation.
 Self-learning value
Self-Learning is used to amend the changes as the engine running time increases, or the engine and vehicle manufacturing
errors.
 Closed-loop feedback correction
Close-loop feedback correction controls the actual Air-Fuel ratio close to the theoretical Air-Fuel ratio through the oxygen
sensor feedback signals.

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 Acceleration thickening
When the system detects substantial increase in readings of throttle position sensor (TPS) and intake air temperature and
pressure sensor, it thickens oil to improve the overall power in order to prevent instantaneous engine thin oil.
 Deceleration thinning
When the system detects substantial decrease in readings of throttle position sensor (TPS) and intake air temperature and
pressure sensor, it thins oil to improve emission and drivability in order to prevent instantaneous engine thick oil.
 Deceleration and fuel cutting
When the system detects the engine and the entire vehicle enter the deceleration working conditions, it cuts off fuel to
reduce emission and fuel consumption.
 Protective fuel cutoff
When any one of the following conditions is met, the system will stop fuel injection:
− Fuel is cut off when engine speed is higher than 6000 r/min and fuel supply is recovered when engine speed is lower
than 5900 r/min.
− Fuel is cut off when system detects a failure from ignition system;
− Fuel is cut off when system voltage is >18V and engine speed is >1100 r/min and fuel supply is recovered when
voltage is <18V.
 Basic fuel injection constant
Whether the basic fuel injection constant indicates the relationship between engine displacement and nozzle fuel flow rate.
 Correction of battery voltage
When the battery voltage changes, the voltage will be amended to ensure the correct amount of fuel injection.

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3.3 Ignition: Control Logic

Coil Magnetizing Control
The magnetizing time of the ignition coil determines the ignition power of the spark plug. Overlong magnetizing time can
damage coil or coil driver; too short can cause a fire.
Start Mode
In start mode, the system uses a fixed ignition angle to ensure the mixture inside the cylinder is ignited and offers positive
torque. After the engine gets started, RPM increases and it runs automatically, the ignition angle control activates the start
mode.
Ignition Advance Angle
Main ignition angle
Water temperature Deceleration Fuel

correction Stoppage Correction
Power Thickening
Air temperature Correction
correction
Ignition Advance Angle
Correction of altitude A/C correction
Idle correction Acceleration Correction
Ignition Advance
Angle
 Main ignition advance angle

After the engine coolant temperature becomes normal, the main ignition angle when the throttle is open is the minimum
ignition angle corresponding to the optimal torque point (MBT), i.e. the knock critical point (KBL); the ignition angle shall
be smaller than the optimal torque point (MBT) while the throttle is closed in order to achieve the idle speed stability.
The basic ignition angle may not be the ignition angle corresponding to the optimal torque point (MBT) or the knock critical
point (KBL) in the course of catalytic converter heating on the condition that the cold state drivability is not affected in
order to ignite the catalytic converter as soon as possible. It shall be delayed to the extent possible as long as it has no effect
over the drivability.
 Ignition Advance Angle Adjustment

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Including corrections in coolant, intake air temperature, altitude compensation, idle control, acceleration, power thickening,
deceleration fuel stoppage, air-conditioning control.
 Acceleration Correction
Ignition advance angle acceleration adjustment is used to mitigate the engine speed fluctuations caused by drive system
torque shock, and eliminate possible detonation during acceleration, making the acceleration smoother.
Make the acceleration process smooth.
 Correction of power increase
Near the special exterior point, for better power and torque, it thickens the air/fuel ratio to the Leanest A/F for Best Torque
(LBT), and thus implements ignition angle correction for Minimum Advance Angle for Best Torque (MBT).
 Deceleration Fuel Stoppage Correction
When the system exits the deceleration fuel stoppage, it may correct the ignition angle and ensure a smooth transition when
exiting the closed state of the throttle.
 Control Correction
To turn off the A/C when the engine is idling can correct the ignition advance angle, so that the RPM is steadily transmitted.

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3.4 Idling: Control Logic

Idle speed air flow control is that the engine control system maintains the target speed when throttle body is fully closed.
The system maintains a smooth transition with the throttle body fully closed to prevent the stall. When the engine load
changes at idle speed, system maintains a steady engine speed.
Basic target idle speed
Voltage compensation Fan compensation
Vehicle speed Target idle calculation Headlight compensation

compensation
Deceleration regulation A/C compensation
Target idle speed
 Basic target idle speed

Setting of the basic target idle speed with different coolant temperature:
Coolant Target idle Coolant Target idle Coolant Target idle Coolant Target idle
temperature speed temperature speed temperature speed temperature speed
(℃) (r/min) (℃) (r/min) (℃) (r/min) (℃) (r/min)
< -28 1300 8 1200 56 950 104 825
-28 1300 20 1200 68 850 116 925
-16 1300 32 1200 80 850 > 116 925
-4 1200 44 1075 92 850
 System voltage compensation
When the voltage is below 11V, the system automatically increases the target idle speed to increase generator output. The
system increases 12.5 r/min in every second until to the peak value of 150 r/min.

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 Speed Compensation & Deceleration Regulation

To improve driving performance during deceleration and parking, the target idle speed while driving is 50 r/min higher than
that during parking, which during parking and deceleration gradually drops to the target idle speed.
3.5 Knock: Control Logic

Knock control function is used for eliminating engine knock which would occur during combustion and optimizing power
performance of engine and economical efficiency of fuel.
Knock Control: Working Conditions
The knock control system will engage when all of the following conditions are met
 The vehicle is equipped with a knock sensor and the knock control function engages.
 The engine load is higher than certain value.
 The engine coolant temperature is higher than 40℃.
Knock Control Mode
If a knock does or may occur, the system will quickly and properly delay the ignition advance angle. Basic advance angles
of ignition of system are divided into two tables: table for normal advance angle of ignition and table for safety advance
angle of ignition which are used for adjusting the knock control. The control solution features the following modes:
 Steady-state knock control
When the engine is in normal operation, the ECU collects and analyzes the signals generated by engine combustion via the
knock sensor, and after filtering, it will be able to detect knocks.If the knock strength exceeds acceptable levels, the system
will quickly delay the ignition advance angle of the cylinder with knock, and eliminate the knock in the subsequent
combustion circulation.The ignition advance angle will then gradually return to its normal angle.
 Transient-state knock control
Knock often occurs during sudden acceleration or when engine RPM changes sharply.The system anticipates the possibility
of knock and automatically delays the ignition advance angle to avoid the occurrence of excessive (intensive) knock.
 Rapid delay of ignition angle
Once knock is detected, the system quickly delays the ignition advance angle by 3-5 degrees, depending on engine speed,
and returns back to normal within the next 2-3 seconds.
 Adaptive correction of ignition angle
Due to manufacturing error and wear over time, there are differences among engines. When the system and engine are
initialized or the ECU is reconnected, knock may occur during engine operation.The system will record it and, after a period
of adaption, it will automatically generate adaptive ignition correction value (self-learning value).When the engine runs
under the same condition, the system will automatically implement adaptive correction on the ignition advance angle to
avoid the occurrence of intensive knock. The adaptive learning value of the system is continuously updated while the
engine is running.

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3.6 Air-conditioning: Control Logic

The ECU monitors the inputs from the A/C and the A/C evaporator temperature sensor, and controls A/C compressor clutch
via A/C relay. System can automatically identify air-conditioning system with plug-and-play manner.
Air-conditioning working conditions
The A/C system is enabled when all of the following conditions are met:
 The vehicle is equipped with A/C.
 The engine has been running for more than 5 seconds.
 A/C switch is on.
 Intake air temperature higher than 3.75℃
 Engine speed more than 600rmp.
 All A/C cutoff modes are off.
Cutoff Mode
In some cases, to ensure the dynamic performance or protect the engine or A/C system, the ECU must cut off the A/C
compressor or prevent the A/C system from starting. Meanwhile, to prevent the compressor clutch from frequent
connection and disconnection, once in A/C cutoff mode, the ECU ensures the A/C clutch will only be reconnected after a
certain amount of time, by means of delay or other methods. It features the following modes:
 A/C cutoff mode under excessive engine RPM: to protect the A/C system
− A/C compressor cannot start unless engine speed is lower than 6000r/min with A/C closed.
− When A/C is on, the A/C compressor will be cut off if the engine RPM > 6200 r/min.
 A/C cutoff mode under excessively high engine coolant temperature: to protect the engine
− When the A/C is off, the A/C compressor can only be started if the coolant temperature < 116℃.
− When A/C is on, the A/C compressor will be cut off if the coolant temperature > 120℃.
 A/C cutoff mode under excessively low A/C evaporator temperature: to protect the A/C system
When any of the following conditions are met, the vehicle will enter the A/C cutoff mode upon starting in high ambient
temperature:
− No failure in the A/C evaporator temperature sensor.
− Front A/C evaporator < 1.5℃.
When both of the following conditions are met, the vehicle will exit the A/C cutoff mode under excessively low A/C
evaporator temperature:
− No failure in the A/C evaporator temperature sensor.
− Front A/C evaporator > 3.75℃.
3.7 Canister Solenoid Valve: Control Logic

Canister electromagnetic valve controls the switching duration and moment of passage from charcoal canister to air inlet
pipe to control amount and time of fuel vapor entering cylinder so as to reduce vapor emission of vehicle maximumly and
reduce affect on motor performance as much as possible.
Working conditions of canister electromagnetic valve

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In order to reduce the impact on the normal combustion and doing work from the fuel vapor entering the cylinder, the
following conditions must be met before the canister solenoid valve is open
 9V < system voltage < 16V.
 Engine operation > 150 seconds (coolant temperature < 55℃ upon engine start) or engine operation > 30 seconds
(coolant temperature > 55℃ upon engine start).
 The engine is in closed-loop mode or the fuel stoppage lasts over 2 seconds.
 Engine coolant temperature is higher than 55℃.
 No relevant system failure.
Working mode of canister electromagnetic valve
The canister control valve consists of the magnetic coil, armature, valve, etc. The air flow through the canister control
valve is related to the duty ratio of the pulse input to the canister control valve input by the ECU on one hand and to the
pressure difference of the inlet and outlet of the canister control valve. When the electric pulse is not available, the canister
control valve closes.
3.8 Three-way Catalytic Converter Protection: Control Logic

During engine running, system predicts the working temperature of three-way catalyst. When predicted temperature is
higher than protection value, timer is activated. If working temperature of catalyst is higher than protection value constantly
within specified period, system regulates fuel supply amount and enriches the air-fuel ratio to reduce working temperature
of catalyst; after a while, once predicting reduction of catalyst temperature, system recovers the original air-fuel ratio and
keeps predicting the working temperature of catalyst to carry out protection.
3.9 Electronic Fan : Control Logic

The system controls the electronic fan. Depending on the engine coolant temperature and whether or not it meets the
conditions required for enabling the A/C, the ECM determines whether to turn on the fans. The electronic fan works as
follows:
 When the coolant temperature > 95℃, the low-speed fan gets started.
 When the coolant temperature < 95℃, the low-speed fan stops.
 When the coolant temperature > 102℃, the high-speed fan gets started.
 When the coolant temperature < 102℃, the high-speed fan stops.
3.10 Mileage Count: Logic

The mileage count function of the engine is designed for after-sale and warranty mileage statistics, which cannot be used to
replace the existing vehicle odometer. During the warranty period, the system records the working mileage of the engine
and enables engine protection logic.
If no signal is received from the speed sensor, the system will be unable to record the mileage of the engine.Therefore, if
there is any failure in the speed sensor and its connecting wires, it will restrict the driveability of the vehicle, in order to
advise the customer and enable timely repair.

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4 Parts & Components

The engine control system is composed subsystems of control, signal collecting, fuel supply, ignition, intake/emission
control, failure diagnosis, communication, etc.
4.1 Engine Control Module (ECM)

4.1.1 Overview
The engine control unit (ECU) applied to the vehicle uses a microprocessor with a single chip as its core that tests and
calculates the required air-fuel mixing ratio and engine ignition advance angel according to the input data of different
sensors to control directly intake airflow and corresponding fuel supply volume, fuel injection timing, high-pressure ignition
timing, ignition closing angle and idle speed of the engine under different working conditions, as well as working status of
other vehicle accessories (such as A/C compressor and electronic fan). It is designed to process the data from sensors
throughout the vehicle, identify the working status of the engine and accurately control the engine via the actuator.
The ECU features the function to constantly monitor and control the normal operation of the engine.
Parameters
 Working voltage range:
− Normal voltage range: 9.0 - 16 V
− Limit value and time for withstanding battery over-voltage：26 V
< 60sec.
 Installation:
− It is installed on the body inside the cab.
 Temperature:
− Storage temperature:-40 ～ 70℃
− Working temperature:-40 ～ 90℃
Service & Maintenance
 Avoid crashes, intense shocks, compression and other external impact

 Keep the connectors clean and prevent liquid splashing into it
 Don't scratch or touch the connector terminals with hands or hard objects
 Don't pull the harness when the connector is connected
 Keep the connectors firm and reliable
4.1.2 Removal and Installation of Engine Control Module (ECM)

Removal
1. Close ignition switch and all the electrical equipments
3. Remove A-pillar lower trim panel =>Vehicle body and painting; Repair group: 84; Interior equipment; Removal and
installation of A-pillar lower trim panel.

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4. Disconnect the wiring harness connector -Arrow A- and -Arrow B- of

the engine control unit (ECM).
5. Unscrew the fixing nut -Arrow C- of the engine control unit (ECM)
and remove the engine control unit-1-.
Nut -Arrow C- tightening torque: 9~12 Nm
Nut-Arrow C- tool: 10mm hexagon sleeve
Tips
To replace the ECU, connect it to a diagnostic unit for testing and matching.
Installation
Installation is in reverse order of removal procedures.

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4.2 Crankshaft Position Sensor

4.2.1 Overview
The model is equipped with a passive speed sensor which works
without power supply and outputs sinusoidal voltage signals.
Working principle of the passive sensor uses magneto-electric effect.
When the crankshaft revolves, it drives the sensing signal gear to
revolve with it and thus teeth on the sensing signal gear produce cutting
effect to magnetic line of the sensor. Such change in the magnetic flux
causes the sensor coil produces output voltage at certain frequency at
both ends and outputs the voltage to the electronic controller. The
output signal may represent for crankshaft speed and position.
Parameters
 Storage temperature:-40 ～ 80℃
 Speed range：50～8000 rpm
 Supply voltage range: 4.75～16V
 Repair of the sensor in any form is forbidden.
4.2.2 Removal and Installation of the Crankshaft Position Sensor

Removal

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3. Unscrew the fixing bolt -Arrow- on the A/C compressor, and suspend
it on the body with a sturdy rope or wire.
4. Unscrew the fixing bolt -Arrow A- and -Arrow B- of A/C compressor

bracket and remove the A/C compressor bracket assembly -1-.
Bolt -Arrow A- tightening torque: 20~30 Nm
5. Disconnect connecting plug -Arrow A- of the crankshaft position

sensor.
6. Unscrew the fixing bolt -Arrow B- of the crankshaft position sensor
and remove the crankshaft position sensor -1-.

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Notes
 Completely clean residual sealant on the crankshaft position

sensor and the cylinder block surface before installing the
 As shown in the figure blow, apply continuous beaded sealant
with diameter of 1.2-2.2 mm to position -a- of the cylinder block.
Installation
4.2.3 Check the Crankshaft Position Sensor

Fault symptoms
It cannot get started or has some other problems.
Common Check
1. Set the multimeter to ohm mode and measure the coil resistance of the
speed sensor -1- with the multimeter, as shown in figure.
Rated resistance：(20 °C)：860(1±10%)
Tips
If the test data is incompliant with the standard value, replace the

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4.3 Intake Manifold Absolute Pressure Sensor

4.3.1Overview
The air intake temperature/pressure sensor is designed to detect and
sense the actual air intake condition of the engine when it is running.
For the engine management system based on speed/density air intake
measurement, the ECU quickly calculates the instant air intake volume
of the engine based on the outputs of the sensor and the inputs of other
sensors in the system. Therefore, the air intake temperature/pressure
sensor is one of the key components that indicate the actual working
conditions and load status of the engine.
The air intake temperature sensor component is a resistor with negative

temperature coefficient (NTC), which changes with the air intake
temperature and delivers a voltage showing the changes of air intake
temperature to the controller.
The air intake temperature/pressure sensor is composed of a silicon chip. A piece of pressure diaphragm is etched on the
silicon chip. There are four resistances and signal processing circuit on the pressure diaphragm. When pressure is
formed in the intake manifold, it will lead to the mechanical deformation of the pressure diaphragm. So do the four
piezoresistances, whose resistances would change accordingly. After being processed by the signal processing circuit of
cilicon chip, it changes into voltage signals that are linearly related to the pressure.
Parameters
Limit data
Numerical value
Description Unit
Min Typical Max
Withstand power voltage — — 16 V
Withstand pressure — — 500 kPa
Withstand storage
-40 — +130 ℃
temperature
Characteristic data
Pressure test range 10.13 — 117.79 kPa
Operation temperature -40 — 130 ℃
Working power supply
4.75 5.0 5.25 V
voltage
Current at Power Supply
— — 12.5 mA
Voltage = 5.0V
Load current of output
-0.1 — 0.5 mA
circuit
Load resistance to power 5 (pull up) 10 (pull
— — kΩ
supply or to ground down)
Response time — — 1.0 ms
Weight — 25.3 — g

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4.3.2 Removal and Installation of the Intake Manifold Pressure and Temperature
Sensor
Removal
4. Disconnect the connector -Arrow A- of the intake manifold pressure

and temperature sensor.
5. Unscrew the fixing bolt -Arrow B- for the absolute pressure and
temperature sensor of the intake manifold.
6. Remove the absolute pressure sensor -1- of the intake manifold.
Tips
 Sealing ring of the intake manifold pressure and temperature
sensor shall be replaced as necessary.
 Apply a thin layer of vaseline or similar product to the sealing ring
while installing.
Installation

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4.5.3 Check on Air Intake Temperature Pressure Sensor

Fault symptoms
Shutdown and poor idle speed etc.
Common Causes
1. Abnormal overvoltage or reserved large current occurs during use.
2. The pressure chip is damaged during repair.
Temperature Sensor Part

1. Remove the air intake temperature/pressure sensor.
2. Set the multimeter to ohm mode and connect its terminals to pin 1 and
pin 2 of the air intake temperature/pressure sensor respectively. Read
the resistance value shown on the multimeter.
The rated resistance at 20℃ is 2.5kΩ ± 5%.
Pressure Sensor Part

3. Install the air intake temperature/pressure sensor, and connect the
connector.
4. Start engine.
5. Set the multimeter to D/C voltage mode and connect its black probe
to the body for grounding. Connect its red probe to pin 3 and pin 4 of
the air intake temperature/pressure sensor respectively. Read the
voltage value shown on the multimeter.
6. During idling, the reference voltage of pin 3 is 5V and about 1.3V for
pin 4. While the engine is in a non-loaded state, slowly open the
throttle, and the voltage in pin 4 doesn't change greatly. Quickly open
the throttle, the voltage on pin 4 can sharply rise to about 4V, and then
decrease to about 1.5V.

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4.4 Camshaft position sensor

4.4.1 Overview
Camshaft position sensor is a Hall-effect sensor which is installed in the
vicinity of the intake camshaft, and works together with camshaft signal
wheel. The signal wheel is corresponding to the specific engine position.
ECM measures digital voltage signal through this sensor, therefore
determining the working cylinder of the engine and implementing
one-to-one control. Accordingly, the ECU can work out the actual fuel
injection sequence.
In case of the loss of the camshaft position sensor signal during the
engine operation, the fuel injection system is switched to the final fuel
sequence injection mode calculated based on the fuel injection pulse.
The engine will continue to operate. If the engine starts after being
shut down, the fuel injection sequence will be converted from sequential
injection to group injection. Even if the fault exists, the engine can be
restarted.
Working Parameters
Parameters Min Typical Max Unit
Output current — — 20 mA
Speed range — — 4000 rpm
Air clearance 0.5 1.0 1.5 mm
Phase precision
-6 — 6 deg
(descending edge)
Phase precision
-6 — 6 deg
(ascending edge)
Output low voltage 0 — 0.5 V
Output high voltage Us,o-0.5 Us,o-0.3 — V
Supply voltage range 4.75 5.0 16 V
Supply current 6.5 10 mA
Output signal supply
0 — 16 V
voltage
Output current 0 — 20 mA


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4.4.2 Removal and Installation of the Camshaft Position Sensor

Removal
2. Disconnect the battery negative cable=>Electrical Equipment: Repair Group: 60; Disconnection and Connection of
Battery Negative Cable.
4. Disconnect the connecting plug -1- of the camshaft position sensor.

5. Unscrew the fixing bolt -Arrow- of the camshaft position sensor -2-.
6. Remove the camshaft position sensor -2-.
Installation

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Tips
 It is only permitted to take the sensor out of the package before its
installation.
 Take the sensor out of the package and check it. Make sure it is not
damaged or polluted.
 Sealing ring -Arrow- of the camshaft position sensor shall be
replaced as necessary.
 Before the installation, apply a small amount of lubricant to the
O-ring and then press it onto the sensor.
 Repair of the sensor in any form is forbidden.
 It is necessary to apply continuous beaded sealant with diameter of
1.2-2.2 mm to the cylinder head while installing.
4.4.3 Check the Camshaft Position Sensor

Fault symptoms
Exhaust not within limits, increased fuel consumption, etc.
Common Check
1. Turn the multimeter to direct voltage position, and connect its red
probe with pin 1 of the camshaft position sensor and its black probe with
pin 3 of the camshaft position sensor. Make sure the voltage measured
reaches 12V (reference voltage).

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4.5 Coolant Temperature Sensor

4.5.1 Overview
The coolant temperature sensor uses quickly responsive Negative
Temperature Coefficient (NTC) thermistor as its core temperature
sensing element, which contains two thermistors whose resistances drop
with the increase of the coolant temperature, yet not in a linear relation.
The coolant temperature sensor is mounted in the main water outlet of a

cylinder head. The engine control unit (EMS) will calculate the
optimal control scheme according to the signal provided by the coolant
temperature sensor and the temperature information will be transmitted
to the instrument for display of the current working temperature of the
engine.
Limit value
Description Valve Unit
Working voltage 5 V
Working temperature -30～130 ℃
Max measured current via sensor 1 mA
Rated resistance at 25℃ 1.825～2.155 kΩ
Characteristic data
Temperature range (℃) Resistance at end A and end C (KΩ)
-20±0.1 13.71～16.49
25±0.1 1.825～2.155
80±0.1 0.303～0.326
110±0.1 0.1383～0.1451
Resistance at end B (Ω)
70±0.2 137.7～160
90±0.2 75～97
110±0.2 40～50
124±0.2 32.9～37.9

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4.5.2 Removal and Installation of Coolant Temperature Sensor

Removal
3. Drain the coolant=>Overview; Repair Group:01: General Information; Service and Maintenance:Work
Description:Coolant:Replace.
6. Disconnect the connector -Arrow- of the coolant temperature sensor.

7. Unscrew the coolant temperature sensor -1-.
Tightening torque of the coolant sensor -1-: 12～14 Nm
Installation
Notes
Apply sealant to thread part of the sensor. Sealant specification:LOCTITE 263 or equal
4.5.3 Check on Coolant Temperature Sensor

Fault symptoms
Difficult starts, etc.
Simple measuring method:

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1. Remove the coolant temperature sensor, set the multimeter to ohm

mode and measure the coil resistance of the sensor -1- with the
multimeter, as shown.
Rated resistance：(25℃)：1.825～2.155Ω
Tips
Analogous method can be used during the measurement, that is, to put
the work area of the sensor into the boiling water (notice: the soak time
shall be sufficient), observe the changes of the sensor resistance, and at
the moment, the resistance shall drop to 170Ω～180Ω(the detail value is
dependent on the temperature of the boiling water).
If the measurement doesn't comply with the standard value, replace the
coolant temperature sensor.

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4.6 Knock Sensor

4.6.1 Overview
The shock sensor is based on vibrational acceleration, which is installed
on the most knock-sensitive part on the engine cylinder block: the lower
part of the intake manifold. The EMS detects the knock strength with
the knock sensor, corrects the ignition advance angle and effectively
controls knock, which improves the dynamic performance, fuel
economy and emission level of the engine. If knock occurs in the
engine, the EMS will receive this signal; after it filters the non-knock
signal and then works out the engine's position in the operation cycle
according to the camshaft/crankshaft position sensor. Based upon this,
the EMS figures out in which cylinder the knock occurs and delay the
ignition advance angle till the knock disappears. Then, the EMS
advances the ignition advance angle again till it reaches the optical
position for the current working condition. Due to weak sensor
signals, the sensor wire has a shielded cable.
Parameters
 Resistance (room temperature) ：>1MΩ
 Working temperature:-40 ～ 130 ℃
 Characteristic data
Description Valve Unit
Sensitivity of new sensor to 9kHz signal 24～35 mV/g
Sensitivity of new sensor to 17kHz signal 26～43 mV/g
Principal resonant frequency ＞30 kHz
Resistance ( insulation) ＞6 MΩ
Impedance
Capacitance 1150±200 pF
Leakage resistance (the resistance between two output pins
4.9±20% MΩ
of the sensor)
Sensitivity variation caused by temperature (at 9kHz) ≤-0.04 mV/g℃

 The sensor must be closely attached to the cylinder block with its metallic surface facing against the cylinder.
 During the installation, don't use any washer.
 When wiring the sensor signal system, avoid the resonance between the signal wires, or it may lead to breakage.
 Don't put any high voltage electricity between Pins 1 and 2 of the sensor, because it may damage the piezoelectric
components.
4.6.2 Removal and Installation of Knock Sensor

Removal

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3. Disconnect the connector -Arrow A- of the knock sensor -1-.
4. Unscrew the fixing bolt -Arrow B- of the knock sensor and remove
the knock sensor -1-.
Installation
4.6.3 Check on Knock Sensor

Fault symptoms
Poor acceleration, etc.
Common Causes
1. The sensor is in long-term contact with liquids, such as engine oil, coolant, brake fluid or water, which corrode the sensor.
1. Remove the knock sensor, set the multimeter to ohm mode, and
measure the coil resistance of the knock sensor -1- with the multimeter,
as shown.
Rated resistance (normal temperature): >1MΩ
Tips
knock sensor.

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2. Install the knock sensor, set the multimeter to mV mode, and connect
it to the plug -Arrow- of the knock sensor.Slightly tap the cylinder block
with a small hammer, near the knock sensor. At that time, the
multimeter should detect weak voltage.
Tips
If there is no response, replace the knock sensor.

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4.7 Oxygen Sensor

4.7.1 Overview
The oxygen sensor is an important signature part in the closed-end fuel
control system. It is used to detect the concentration of oxygen in the
combustion waste gas emitted by the vehicle engine, in order to identify
the actual air/fuel ratio during the real-time fuel supply of the engine. It
also feeds back the generated signals to the EMS, so that the fuel
management system can more precisely control and regulate the air/fuel
ratio under various working conditions of the engine, and thus achieve
better emission control and fuel economy. When the air/fuel ratio in
engine combustion drops, the oxygen concentration increases in the
exhaust and the output voltage of the oxygen sensor declines. Otherwise,
the output voltage will increase. Thus, it feeds back the of air/fuel ratio
to the EMS.
There are two oxygen sensors—the front oxygen sensor and the rear oxygen sensor, the former mounted on the front
converter assembly and the latter on the rear.
The sensing element of the oxygen sensor is the ceramic tube with clearance; the pipe exterior is wrapped by the engine
emission, large flow passing from inside The sensing ceramic wall tube is the solid eletrolyte, with electric heating tube
inside.
The function of the oxygen sensor is to convert the difference of the oxygen ion condensation inside and outside the sensing
ceramic tube into voltage signal. When its temperature reaches 350℃, it develops the features of solid electrolyte. Due
to the special nature of the tube material, the oxygen ions can pass through the ceramic tube freely. It is also this texture
that the concentration difference can be changed into potential difference and then forms electrical signal output. If the gas
mixture is a little thicker, the concentration difference of the oxygen ions inside and outside the ceramic tube is higher, the
potential difference is higher, a lot of oxygen ions move from the inside to the outside, the output voltage is higher (nearly
800mV-1000mV); if the gas mixture is a little thinner, the oxygen ions inside and outside the ceramic tube is lower, the
potential difference is lower, a small quantity of oxygen ions move from the inside to the outside, the output voltage is lower
(nearly 100mV).
The signal voltage mutates near the theoretical equivalent air-fuel ratio （λ=1）.
Parameters
Limit data
Valve
Description Unit
Min Typical Max
Storage temperature -40 — 100 ℃
Ceramic tube end
150 — 930 ℃
(exhaust temperature)
Housing hexagon
Working head (exhaust — — ≤570 ℃
temperature temperature)
Cable metal buckle
— — ≤250 ℃
and connecting cable
Connecting plug — — ≤120 ℃

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Limit data
Valve
Description Unit
Min Typical Max
Maximum Exhaust gas at the
permissive end of ceramic — 930 ℃
temperature when tube
the heating
element is
connected (at
Cable metal
most 10 minutes
buckle and — 280 ℃
every time, and
connecting cable
the accumulated
time can be up to
40 hours at most )
The accumulated Exhaust gas at the
time shall not end of ceramic — 1030 ℃
exceed 250h tube
within the entire Shell hexagon
— 650 ℃
trail use period head
Random vibration
— ≤1000 m/s2
(peak value)
Permissive Simple harmonic
vibration of shell vibration
— ≤0.3 mm
(vibration
displacement)
Simple harmonic vibration (vibration
≤300 m/s2
acceleration)
Absolute
Continuous direct current below 350℃ μA
value≤10
The maximum continuous alternating
current while exhaust temperature is — ≤10 μA
≥350℃and f is ≥1Hz
Permitted fuel additive Unleaded gasoline (refer to service life of oxygen sensor)
Engine oil consumption and
Rated valve：≤0.7L/1000km
combustion
Characteristic data
Description New After 500 hours' bench test
Exhaust temperature for effective
350 850 350℃ 850℃
characteristics data
Voltage of sensing element at λ=0.97
745～855 645～755 740～860 630～750
(CO=1%)
Voltage of sensing element at λ=1.10 20～80 20～80 10～90 10～90
Internal resistance of sensing element (kΩ) ≤0.5 ≤0.25 ≤1.0 ≤0.5
Response time (ms) (600mV to 300mV) ＜250 ＜250 ＜125 ＜125
Response time (ms) (300mV to 600mV) ＜100 ＜60 ＜60 ＜125
Heating current (A) 0.38～0.58 0.35～0.49 0.38～0.58 0.35～0.49

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Service life of the oxygen sensor

Lead content in the petroleum (g/L) Service life（km）
≤0.6 20000
≤0.4 30000
≤0.15 60000

 The threaded surface of new oxygen sensors is coated with an anti-sintering, once removed and re-installed, the sensor
shall be re-coated with the anti-sintering additive.dditive.
4.7.2 Removal and Installation of Front Oxygen Sensor

Removal
3. Remove A-pillar lower trim panel =>Body and painting: Repair group: 84: Interior equipment: Trim part and trim panel:
A-pillar trim panel: Removal and installation of A-pillar lower trim panel.

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and unscrew the front oxygen sensor -1- with removal and installation
tool -T41132201- for oxygen sensor.
Tips
 Protect the oxygen sensor from impact with hard objects. Don't forcefully pull the harness of the oxygen sensor.It
cannot be used if it is dropped or otherwise falls.
 Apply little oil to threads of the oxygen sensor while removing to facilitate its removal.
 Before installation, clean the threads and the threaded installation hole of the oxygen sensor, and apply an additional
layer of anti-sintering additive onto the threads of the oxygen sensor.
Installation
4.7.3 Removal and Installation of Rear Oxygen Sensor

Removal
oxygen sensor.

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5. Disconnect the connector -Arrow- of the rear oxygen sensor and

unscrew the rear oxygen sensor -1- with removal and installation tool
-T41132201- for oxygen sensor.
Tips
 Protect the oxygen sensor from impact with hard objects. Don't forcefully pull the harness of the oxygen sensor.It
cannot be used if it is dropped or otherwise falls.
 Apply little oil to threads of the oxygen sensor while removing to facilitate its removal.
 Before installation, clean the threads and the threaded installation hole of the oxygen sensor, and apply an additional
layer of anti-sintering additive onto the threads of the oxygen sensor.
Installation
4.7.4 Check on Oxygen Sensor
Tips
The checking and performance parameters of the front and rear oxygen sensors are identical. Here, we will take the
checking of the front oxygen sensor as the example.
Fault symptoms
Poor idling, poor acceleration, exhaust being out of limit, excessive fuel consumption, etc.
Common Causes
1. Humidity or steam enters the sensor, which leads to sudden change in temperature or breaks the probe.
2. The oxygen sensor is "poisoned". （Pb，S，Br，Si）

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3. Remove the oxygen sensor, set the multimeter to ohm mode, and
measure the resistance of pin 1 and pin 2 on the oxygen sensor-1- with
the multimeter, as shown.
Rated resistance (normal temperature): 7～11Ω
Tips
oxygen sensor.
4. Remove the oxygen sensor, set the multimeter to voltage mode, and
measure the resistance of pin 3 and pin 4 on the oxygen sensor-1- with
the multimeter, as shown in figure.
Rated voltage (normal temperature) : 0.1～0.9V
Tips
oxygen sensor.

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4.8 Engine Oil Control Valve

4.8.1 Overview
Working power supply of V.V.T valve is supplied by the main relay
under EMS control. EMS controls bonding of the oil control valve by
impulse width modulation signal to constantly change timing
relationship between crankshaft and camshaft so as to allow the engine
to have the optimal valve timing under different operating conditions
and control the valve timing. This will help to increase engine
efficiency, improve idle stability, and provide more torque and power,
while helping to improve the fuel economy and lower emissions of
hydrocarbons and nitrogen oxides.
4.8.2 Removal and Installation of V.V.T Valve

Removal
3. Disconnect connecting plug -Arrow A- of V.V.T valve.
4. Unscrew the fixing bolt -Arrow B- of V.V.T valve and remove the
V.V.T valve -1-.
5. Unscrew bolt -Arrow- of V.V.T valve filter and take out V.V.T valve
filter component.
Notes
After removal of V.V.T valve and V.V.T valve filter, seal the installation
hole on the cylinder head with plug to prevent entry of dust and other
impurities into the cylinder head.

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Installation
Notes
1. Replace the O-type sealing ring after it is removed.

2. Pay attention to avoid adhesion of foreign matters while installing V.V.T valve filter.
3. Install the O-ring onto the V.V.T valve after applied with clean oil.
4. To install the engine oil control valve, it is necessary to apply some clean engine oil to the O-type sealing ring to
prevent it from being damaged.

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4.9 Throttle Control System

4.9.1 Overview
The major function of the electronic throttle body is to adjust the size of
the air intake channel according to the driving purpose of the driver.In
this way, it controls the volume of air intake flow, so as to meet the
engine's air intake requirement under various working
conditions.Meanwhile, it provides feedback on position signals of
throttle valve plate to the EMS for precise control.
The input signal that controls the opening degree of valves in the
electronic throttle body assembly are controlled by the EMS through the
acceleration pedal. The EMS collects input signal from the
acceleration pedal, as well as input signals from other various sensors on
the engine and the rest of the vehicle, to pre-analyze the in-time driving
purpose of the driver and figure out the power output of the engine
required for the vehicle at the very time and under the very status.Also,
based upon these signals, the EMS controls the adjustment of the valve
opening degree of the throttle and corresponding fuel supply
(injection).Meanwhile, the throttle position sensor equipped on the
electronic throttle body assembly can monitor the actual valve opening
degree at the very time timely and send the signals to the EMS,
according to which the EMS will optimize the vehicle control
parameters, ensuring the engine as well as the vehicle operate under the
optimal control.
High-Speed EMS can quickly analyze the driver's intention and calculate
the basic throttle opening parameter values, based on the throttle pedal
signal, the signal variation and signal change rate. At the same time,
EMS adjusts and optimizes the basic throttle opening parameter, based
on various sensors input signal status, so that the system further
calculates the optimum throttle opening control parameters and
implements the actual throttle control. EMS sends the output control
signal to the ETC motor drive circuit to open the throttle according to the
calculated opening parameter, based on the revised throttle opening and
pre-determined control strategy. Thanks to the high-speed system
calculation, the changing of engine RMP keeps very smooth during the
transition, and the control is achieved within several milliseconds,
ensuring a good drivability of the vehicle.
The main components of the throttle control system include the following:
 Throttle body
 Throttle valve position sensor (embedded in the throttle valve body)

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4.9.2 Removal and Installation of Electronic Throttle Body Assembly

Removal
3. Unscrew the fixing clamp -Arrow- of the air filter outlet pipe,
disengage venting pipe -1- and remove the air filter outlet pipe -2-.
5. Disconnect the connecting plug -Arrow A- of the electronic throttle

and disengage the connection between cooling water pipe -3- and the
bracket.
6. Loosen the retaining clamp -Arrow B-, disconnect the outlet pipe -1-
and the throttle.
7. Loosen the retaining clamp -Arrow C-, disconnect the inlet pipe -2-
and the throttle.
Tips
the cooling pipe.

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8. Unscrew the fixing bolt -Arrow A- on the electronic throttle, and

remove the retaining bracket -2- of the water pipe.
9. Unscrew the fixing bolt -Arrow B- on the electronic throttle -1-, and
remove the electronic throttle.
Tips
 The throttle gasket must be replaced.
 While installing the sealing ring of the throttle valve flange, keep its bulging part aligning with recess part of the intake
manifold.
Installation

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4.10 Removal and Installation of Electronic Accelerator Pedal Assembly

Removal
3. Unscrew the fixing nut -Arrow- of the electronic accelerator pedal
assembly.
Nut -Arrow - tightening torque: 5.5 - 6.6 Nm
4. Disconnect the connecting plug -Arrow- of the electronic accelerator

pedal assembly and take out the electronic accelerator pedal assembly
-1-.
Installation

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5 Emission Control System

5.1 Overview
Engine emission control system consists of crankcase ventilating oil-gas separating system and fuel evaporation control
system.
Crankcase ventilating oil-gas separating system
There is inevitable some blow-by while the engine is operating under normal conditions. However, such blow-by of the
crankcase over a long time could cause condensation of fuel vapor and water vapor that mix with oil in the oil pan to
deteriorate the oil and pollute engine parts. If the blow-by gas is not discharged in time, then the crankcase will have large
internal pressure in long time operating and installation junction of the oil pan will be vulnerable to air leakage and oil
leakage. As the piston bears resistance from the crankshaft internal pressure when it is moving down, engine power
increases and oil consumption rises with increase in blow-by volume. Therefore, it is required to use the crankcase
ventilating system to send the engine blow-by gas back to the intake pipe and feed into the cylinder together with fresh air
for combustion.
The crankcase blow-by gas carries oil particles that cannot be completely combusted and thus will block the catalytic
converter once they are fed to the cylinder for combustion and emission. It is therefore necessary to use the oil-gas separator
to separate oil and gas in the blow-by gas of the crankcase ventilating system. The separated gas will enter the intake pipe
through PCV pipe assembly, discharge valve and PCV one-way valve and the separated oil will flow back to the oil pan
through PCV hose.
Main parts of the crankcase ventilating oil-gas separating system include:
 Oil-gas separator
 PCV pipe assembly
 PCV hose
 Discharge valve
 PCV one-way valve
Fuel Evaporation Control System
As gasoline is highly volatile, it rapidly evaporates into the air at room temperatures. During driving, the temperature of
the fuel system in the engine is above room temperatures.Thus, the gasoline in the fuel system is even more volatile.
The evaporation emission control system is required in order to control fuel evaporation, prevent it from entering the air and
causing environmental pollution, reduce hydrocarbon emissions of the vehicle and ensure the vehicle emissions meet local
regulations. To put it simple, the evaporation emission control system collects the gasoline vapor from the fuel tank and
makes it combust in the engine.
The fuel evaporation control system uses absorption principle of the activated carbon to absorb fuel vapor with the activated
carbon. While the engine is working, the carbon canister solenoid valve controls break-make of the vapor pipeline according
to different operating conditions so as to control desorption of the gasoline vapor, separate the gasoline vapor absorbed by
the activated carbon once more and feed into the engine for combustion.
Main parts of the fuel evaporation control system include:
 Carbon canister
 Carbon canister solenoid valve
 Evaporation pipeline

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5.2 Crankcase Ventilating Oil-gas Separating System

5.2.1 Overview on Crankcase Ventilating Oil-gas Separating System
1 - Cylinder head cover assembly 2 - PCV valve

 Removal and installation=>Refer to Page 104  Check=>Refer to Page 397
3 - PCV hose 4 - Air intake manifold
5 - PCV gasket
 Check, replace as necessary
5.2.2 Removal and Installation of PCV Valve

Removal

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2. Disengage venting pipe -1- of the PCV valve
3. Unscrew the PCV valve -1-.

Tightening torque：4～6 Nm
Installation
Tips
The PCV gasket is a disposable part, which should be replaced after being removed.

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5.2.3 Check on PCV Valve
Tips
The PCV valve is a check valve in nature.
1. Connect the manual vacuum pump to one end of the PCV valve -1-
and vacuumize the PCV valve -1- (the air flows inside the valve as
shown by -Arrow A-).There should be no resistance, and no vacuum is
formed.
2. Connect the manual pump, and pump the PCV valve -1- (the air flows
inside the valve as shown by -Arrow B-).It should be air-tight.
Tips
If the checked results aren’t as described above, it indicates that there is
failure in the PCV valve -1- and that replacement is required.

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5.3 Fuel Evaporation Control System

5.3.1 Overview
The engine management system used on modern vehicles controls fuel
vapor to prevent environmental pollution caused by the gasoline vapor
in the vehicle oil tank and improve fuel economy. The canister
solenoid valve is one of the key components in the fuel vapor emission
control system.
In the fuel vapor emission control system, fuel vapor in the fuel tank is
absorbed by activated carbon in the carbon canister. The engine
control unit (ECM) controls break-make of the carbon canister solenoid
valve by outputting impulse width signal according to actual working
status of the engine. Fuel vapor is absorbed into the intake air channel of
the engine on the basis of vacuum of the intake manifold and fed into
the engine cylinder for combustion so as to realize the purpose of
washing fuel vapor in the carbon canister and control fuel evaporation
and pollution emission.
Parameters
 Working voltage : 8～16 V
 Working temperature:-40 ～ 120 ℃
 Coil resistance：19～22 Ω
 Coil induction：12～15 mH
 Flow rate (full opening status): 25-35 L/min

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5.3.2 Overview on Fuel Evaporation Pipeline
1 - Carbon canister 2 - Venting pipe of the carbon canister

3 - Venting hose of the carbon canister 4 - Clamp
5 - Venting hose of the carbon canister solenoid valve 6 - Air intake manifold
7 - Carbon canister solenoid valve 8 - Venting hose of the carbon canister solenoid valve
9 - Venting rigid tube of the carbon canister 10 - Venting rigid tube of the carbon canister
11 - Fuel tank 12 - Carbon canister bracket

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13 - Nuts of the carbon canister fixing bracket

 Specification：M8×1.25
 Total: 2
5.3.3 Removal and Installation of Carbon Canister

Removal
3. Remove the air filter assembly=>Refer to Page 147.
4. Pry up the fixing clip -Arrow A- of the carbon canister, loosen the
fixing clamp -Arrow B- of the venting hose and remove the venting hose
-1- and -2-.
5. Move up the carbon canister and remove the carbon canister assembly
-1-.
Installation
5.3.4 Removal and Installation of Canister Solenoid Valve

Removal

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3. Unscrew the fixing clamp -Arrow B- of the air outlet pipe, pry up the
fixing clip -Arrow A- of the air filter upper shell and remove the air
filter upper shell -1-.
Clamp -Arrow - tightening torque: 5 - 7 Nm
4. Disconnect the connecting plug -Arrow- of the carbon canister

solenoid valve.
5. Disengage the connection of venting hose -1- and venting hose -2-
with carbon canister solenoid valve -3-.
6. Remove control valve-3- of the carbon canister.
Installation
Notes
During the installation, pay attention to the airflow direction of the canister solenoid, and connect the end with the
connecting plug to the intake manifold.
5.3.5 Check on Canister Solenoid Valve

Fault symptoms
Fault Malfunction, etc.
Common Causes
Impurities enter the valve, which causes corrosion or poor sealing.

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1. Remove the canister solenoid valve, set the multimeter to ohm mode,
connect the probes of the multimeter to the connector terminals of the
canister solenoid valve -1-, and measure the coil resistance of the
canister solenoid valve.
Rated resistance:26Ω（20℃）
Tips
If it doesn't meet the standard, replace the canister solenoid valve.
2. Connect a manual vacuum pump to the connecting end of the canister

solenoid valve -1-, and pump the canister solenoid valve without
connecting it to the power supply. There should be no airflow.
Tips
If there is air moving through the valve, it indicates that the canister
solenoid valve is blocked or leaking, thus kept open all the time. Replace
the canister solenoid valve.
3. Connect 12V DC to the connector terminals of the canister solenoid

valve -1-, and pump the canister solenoid valve -1- with a manual air
pump; there should be airflow.
Tips
If there is no airflow, it indicates that the canister solenoid valve is
blocked or leaking or the coil is burnt.

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21 Fuel Supply System

1 Overview
The fuel supply system includes two parts: the fuel supply and fuel injection.
The fuel is sucked in from the fuel tank by the fuel pump, then filtered by the fuel filter and delivered to the fuel rail through
the fuel piping. The fuel rail allocates the fuel into individual injectors, which inject the fuel into the air inlet. Then the
fuel enters the cylinders through the open air inlet.
Fuel supply
Fuel level sensor in the fuel supply device applies sliding resistance type, of which wires are directly welded with pins of
the fuel pump connector and generally replaced together with the fuel pump assembly.
The fuel system has the function of fuel pressure stability control, which mainly consists of fuel pressure regulator and fuel
return pipeline. The fuel pressure regulator, also known as fuel return valve, is under the control of system fuel pressure
and intake manifold pressure (negative pressure). It is connected with the fuel rail at one end, with fuel return pipe at
another end and with vacuum joint on the intake manifold at the rest end. It uses fuel pressure in the fuel rail and negative
pressure in the intake manifold to adjust automatically opening and closing of the fuel return valve in order to keep fuel
supply pressure of the entire fuel system at a certain value. Therefore, the fuel supply pressure is not directly related to
atmospheric pressure but keeps a constant ratio with vacuum inside the intake manifold.
The main components of the fuel supply system include the following:
 Filler pipe component

 Fuel Tank
 Fuel pump
 Fuel supply pipeline
 Fuel filter
 Fuel rail
 Injector
Fuel Injection
Inside the fuel injection device, the electronic control fuel injection system (EFI) takes the engine control unit (ECM) as its
control center and controls accurate fuel injection volume and fuel injection time by control over the fuel injector with the
control program set in the computer according to various working parameters of the engine provided by different sensors
mounted on the engine so that the engine may get the mixture gas with the optimal concentration under various working
conditions and realize such functions as start thickening, warm-up thickening, acceleration thickening, full-load thickening,
deceleration thinning, compulsory fuel cutoff, automatic idle speed control, etc. In this way, the engine acquires good fuel
economy and emission and usability of the vehicle is improved.
The main components of the fuel injection system include the following:
 Fuel rail
 Injector
 Engine Control Module
1.1 Instructions for Safe Operation

Notices before operation of the fuel system
Repair Group 21 - Fuel Supply System 403

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 Before working on the fuel system, prepare fire-extinguishing equipment.

 Fuel is highly volatile. Inhaling excessive fuel vapor will lead to dizziness, nausea and even coma. Therefore, it is
important to ensure proper ventilation at the site.
 Before disconnecting the fuel piping, release the pressure in the fuel system. Otherwise, when the fuel pipe is
disconnected, fuel may spray onto the body or face of the staff, and lead to personal injury.
Notices for fuel system operation
 Wear fuel-resistant gloves and goggles and make sure your skin does not come in contact with the fuel.
 Avoid flame, sparks and electrical equipment that tend to create sparks at the site.
 To prevent wear and tear of the fuel piping, during installation, make sure it is far away from all moving or hot
parts.Don't excessively bend the pipes.
404 Repair Group 21 - Fuel Supply System

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1.2 Cleaning Basics

The following regulations on cleaning must be noted before operations of the fuel supply device to ensure the fuel system
works normally and supplies oil stably:
 Before disconnecting the fuel pipeline or removing the fuel system, clean its surface and surrounding impurities for
fear that the fuel pipeline joint and the fuel system are polluted in removal and installation.
 Place the removed components in a clean and sealed location, to prevent them from being contaminated by dust or
other impurities.
 If prompt repair is not practical, carefully cover or seal the unpacked components.
 Only install clean components. Only take the spare parts out of the packages when ready to be assembled. Don't use
any part without packaging (such as parts in the toolkit without protection).
 Do not blow the open device with compressed air as far as possible.

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2.1.1 Fuel Pressure Is Too Low
No. Check procedures Check results
0 Preliminary check Normal There's a fault Operation method
Excessive bending of
the fuel hose, cracks or
other damage on the Replace the damaged
Visually check whether the fuel pipe and other parts and properly
Proceed to Step 1.
fuel pipeline is normal parts, or signs of fuel configure and mount
leakage at connections the fuel piping
may lead to fuel
under-pressure.
1 Check fuel filter Normal There's a fault Operation method
Check if the fuel filter Fuel filter is too dirty
Proceed to Step 2. Replace fuel filter
works properly or blocked
Check the fuel pressure
2 Normal There's a fault Operation method
regulator
Check whether the fuel
Fuel pressure regulator Replace the fuel
pressure regulator is Proceed to Step 3.
faulty pressure regulator
normal
3 Check fuel pump Normal There's a fault Operation method
The screen on the fuel
suction pipe of the fuel Clean the screen or
Check if the fuel is normal Proceed to Step 4. pump is blocked, or replace the fuel pump
failure is detected in assembly
the fuel pump motor
4 End of check Faults still exist
repairs
2.1.2 Excessive Fuel Consumption

Visually inspect the fuel
pipes and parts for cracks
Overhaul or replace the
or other damage, as well as Proceed to Step 1. Fuel leakage
damaged part(s)
checking the connections
for signs of fuel leakage
sensor
Failure in the ECT
Check whether the coolant
sensor, deviation in the Replace coolant
temperature sensor is Proceed to Step 2.
correction of fuel temperature sensor
normal
injection volume
2 Check the TPS sensor Normal There's a fault Operation method

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Check if the electronic
Failure in the TPS Replace the throttle
throttle position sensor is Proceed to Step 3.
sensor position sensor.
normal
3 Check the fuel pressure. Normal There's a fault Operation method
Check whether fuel system Fuel system pressure Replace the fuel
Proceed to Step 4.
pressure is normal on the high side pressure regulator
Check intake air pressure
Intake air pressure and
Check whether the intake
temperature sensor Replace the intake air
air pressure and
Proceed to Step 5. faulty and fuel pressure and
temperature sensor is
injection volume temperature sensor
normal
correction deviated
5 Check the fuel injector Normal There's a fault Operation method
Check the injection
Dripping injector or
volume and atomization Clean or replace the
Proceed to Step 3. poor atomization is
condition of the injector injector
detected
with injector washer
repairs

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Torque
Description Specification Grade Tools
Nm
Fixing bolt on the top of fuel filler pipe M5×0.8×20 — 5～7 —
10mm Hexagon
Filler pipe assembly fixing bolt M8×1.25×16 8.8 12～14
Sleeve
15mm Hexagon
Fixing bolt of fuel tank binder M10×1.5 10 36～54
Sleeve
10mm Hexagon
Fixing bolt of fuel filter M8×1.0×20 8.8 12～15
Sleeve
10mm Hexagon
Fixing bolt of fuel filter bracket M8×1.25×25 8.8 18～20
Sleeve
12mm Hexagon
Fixing bolt of the fuel rail assembly M8×1.25×35 8.8 10～13
Sleeve
15mm Hexagon
Fixing bolt of the fuel tank M10×1.5 10 20～26
Sleeve
Fixing screw for fuel tank heat insulation plate — — 2 —
Plug fixing screw — — 3～5 —

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4 Fuel Pressure Release

When the engine is working, the fuel pressure in the fuel piping can reach about 350Kpa.For some time after the engine has
stopped running, the fuel in the pipes remains at high pressure. Therefore, before disconnecting the fuel piping, it is
necessary to release the fuel pressure in the fuel system, in order to prevent personal injury to the technicians due to fuel
spraying.
2. Remove driver foot space trim panel assembly =>Body and painting: Repair group: 82: Instrument panel; Removal and
installation of instrument panel left lower trim panel assembly.
Notes
Otherwise, it may damage the fuel pump and the ECU.
4. Turn on the ignition switch, wait until the engine operates to automatic shutdown and then turn off the ignition.
Tips
Fuel pressure in the fuel system pipeline is almost completely released then.

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5 Removal and Installation of Filler Pipe Assembly

Removal
1. Pull the open buckle -1- upwards, open filler cover panel.

3. Unscrew the filler cap -1-.
4. Unscrew the fixing bolt -Arrow A- of the filler cap, disengage the clip
-Arrow B- and remove the filler cap -1-.
Notes
Seal the fuel filler pipe orifice for fear of internal pollution.

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5. Loosen the clamp -Arrow A- and disconnect the connection between

fuel filler pipe component -1- and venting connecting hose -2-.
6. Loosen the clamp -Arrow B- and disconnect the connection between
fuel filler pipe component -1- and fuel filler connecting hose -3-.
Clamp -Arrow B- tightening torque: 3 - 4 Nm
7. Unscrew the fixing bolt -Arrow C- of the fuel filler pipe component
and remove the fuel filler pipe component-1-.
Bolt -Arrow C- tightening torque: 18~20 Nm
Installation
Notes
After the fuel filler pipe component is installed, fill gasoline to check whether there is leakage at the pipeline connection.

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6 Fuel Tank
6.1 Draining of fuel tank
Tips
In case of excessive fuel in the fuel tank while removing and installing the fuel tank, drain the fuel tank with the following
methods; in case of little fuel in the fuel tank, it is not necessary to drain the fuel tank but remove and install directly.
1. Pull the open buckle -1- upwards, open filler cover panel.

3. Unscrew the filler cap -1-.
4. Push the fuel suction device to the bottom of the fuel tank and pump
out fuel in the fuel tank completely.
5. Pull out the fuel suction device carefully.

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6.2 Removal and Installation of Fuel Tank
Notes
 Precautions for the removal and installation of the fuel tank:

 Keep the workplace well-ventilated.
 Prepare fire extinguishing equipment.
 No flames or object that generates flame can be stored around the vehicle.
 Don't excessively bend the fuel pipeline.
 Once the fuel pipeline is disconnected, seal the connectors to prevent external impurities from entering the fuel
system and avoid any blockage, unsmooth operation of the fuel system components or even damage on it.
Removal
2. Drain the fuel tank => Refer to Page 412.
4. Removal of the rear seat cushion=>Body and painting; Repair group:89; Seat; Rear seat;Removal and installation of the
rear seat cushion.
5. Unscrew the plug fixing screw -Arrow- and remove the plug -1-.
6. Disconnect the fuel pump connector -Arrow A-.

7. Disconnect fuel outlet pipe joint -Arrow D-, fuel return pipe joint
-Arrow-B and venting pipe joint -Arrow C- of the fuel pump.
8. Remove the auxiliary silencer assembly => Refer to Page 158.

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9. Disengage the connection of fuel feed pipe assembly -1-and fuel

return pipe assembly -2- with venting pipe assembly -3-.
10. Unscrew the fixing screw -Arrow A- and locking gasket -Arrow B-
of the fuel tank thermal baffle and remove the fuel tank thermal
baffle-1-.
Screw -Arrow A - tightening torque: 2 Nm
11. Support the fuel tank -1- with the lifting device.
12. Unscrew the fixing nut -Arrow A- for rear binder assembly of the
fuel tank and the fixing nut -Arrow B- of the fuel tank assembly.
Nut - Arrow A- specification：M10×1.5

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13. Unscrew the fixing nut -Arrow A- for front binder assembly of the
fuel tank and the fixing nut -Arrow B- of the fuel tank assembly.
Nut - Arrow A- specification：M10×1.5
14. Gradually lower the lifting device and remove the fuel tank -1-.
Notes
Pay attention to observe whether the fuel tank collides into the body or pulls other parts and if any, adjust position of the
fuel tank and gradually lower it down.
15. Disengage fuel feed pipe assembly -1-, venting pipe assembly -2-
and fuel return pipe assembly -3- from the fuel tank.

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16. Unscrew the snap ring -1- with removal and installation tool of the
fuel pump cover.
17. Take out the fuel pump assembly -1-.
Notes
 Pay attention to buoyancy rod of fuel level sensor while removing

the fuel pump assembly -1-.
Installation
Tips
Sealing ring of the fuel pump must be replaced.
Notes
While installing snap ring of the fuel pump, align arrow mark -1- on
the snap ring with arrow mark -2- on the fuel tank.
Tips
Reinstall the fuel pipelines on the fuel tank to their original positions,
keep enough distance from hot or moving parts and do not bend them
excessively, or otherwise the fuel pipelines may have friction due to
vibration of the body that will damage the fuel pipelines and cause fuel
leakage.

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7 Removal and Installation of the Fuel Pump Assembly
Notes
Precautions for the removal and installation of the fuel tank:

 Keep the workplace well-ventilated.
 Prepare fire extinguishing equipment.
 No flames or object that generates flame can be stored around the vehicle.
 Don't excessively bend the fuel pipeline.
 Once the fuel pipeline is disconnected, seal the connectors to prevent external impurities from entering the fuel
system and avoid any blockage, unsmooth operation of the fuel system components or even damage on it.
Removal
4. Removal of the rear seat cushion=>Body and painting; Repair group:89; Seat;Rear seat;Removal and installation of the
rear seat cushion.
5. Unscrew the plug fixing screw -Arrow- and remove the plug -1-.
6. Disconnect the fuel pump connector -Arrow A-.

7. Disconnect fuel outlet pipe joint -Arrow B-, fuel return pipe joint
-Arrow C- and venting pipe joint -Arrow D- of the fuel pump.

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8. Unscrew the snap ring -1- with removal and installation tool of the
fuel pump cover.
9. Take out the fuel pump assembly -1-.
Notes
 Pay attention to buoyancy rod of fuel level sensor while removing

the fuel pump assembly -1-.
 When replacing the fuel pump assembly, completely discharge
residual fuel in the old fuel pump assembly and properly handle
it.
Installation
Tips
Sealing ring of the fuel pump must be replaced.
Notes
While installing snap ring of the fuel pump, align arrow mark -1- on
the snap ring with arrow mark -2- on the fuel tank.

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8 Removal and Installation of Fuel Filter

Removal
2. Disconnect the connection between oil pipe -1- and fuel filter -3-
-Arrow-A.
3. Disconnect the connection between oil pipe -2- and fuel filter -3-
-Arrow-B.
4. Unscrew the fixing bolt -Arrow- of the fuel filter bracket -1-, and
remove the filter -1-.
Tips
Direction arrow mark must be marked in the fuel filter -1- housing.
Installation

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9 Overview of the Fuel Pipeline
1 - Fuel tank 2 - Return pipe

3 - Fuel feed pipe of fuel pump 4 - Fuel feed pipe of fuel pump
5 - Fixing bolt of fuel filter bracket 6 - Fixing bolt of fuel filter
 Specification：M8×1.25×25  Specification：M8×1.25×16
 Tightening torque：18～20 Nm  Tightening torque：12～15 Nm
7 - Fuel filter 8 - Return pipe
9 - Fuel feed rigid tube 10 - Fuel feed hose

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10 Fuel Rail and Injector Assembly

10.1 Overview
The fuel injector is a ball valve device controlled by an solenoid switch.
The EMS sends out electric pulses to the coil of the fuel injector, thus
generating magnetic field force. When magnetic force increases to
overcome resultant force from return spring pressure, needle valve
gravity and friction, needle valve starts to lift and injection process
begins. When injection pulse stops, return spring pressure shuts off the
needle valve again.
The top of the fuel injector has the reliable fuel pressure sealing
generated by the rubber seal ring and the fuel rail interface; the lower
part also uses the rubber seal ring and engine air intake manifold to form
the air sealing.
Parameters
Limit data
Valve
Description Unit
Min Typical Max
Storage temperature (original package) -40 — 70 ℃
Permitted temperature of fuel injector
— — 140 ℃
within the vehicle (when not working)
Continuous -40 — 110 ℃
Working
Short period after
temperature of
the hot start — — 130 ℃
fuel injector
(about 3 min.)
Permitted Continuous — — 70 ℃
temperature of
Short time (about
fuel at injector — — 100 ℃
3 minutes)
inlet
Temperature when fuel flow can
reach 5% relative to the deviation at -40 45 ℃
20C
Permitted leakage of O-ring within the
The fuel can be wet around the O-ring, but no leakage is allowed.
range of -35℃ to -40℃
Max. allowed vibration acceleration
— — 400 m/s²
(peak value)
Supply voltage 6 — 16 V
Insulation resistance 1 — — MΩ
Tolerable internal fuel pressure — — 1100 kPa
Bending stress fuel pump can
— — 6 Nm
withstand
Axial stress fuel pump can withstand — — 600 N

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Valve
Description Unit
Min Typical Max
Working pressure (pressure gap) — 400 — kPa
Injector resistance at 20℃ — 12±0.6 — Ω

 Replace the O-ring at each removal and re-installation of the fuel injector. Do not damage the sealing surface of the
fuel injector.
 For the convenience of installation, apply clean silicon-free engine oil onto the surface of the upper O-ring that is
connected to the fuel rail. Notes: engine oil must not pollute the interior of fuel injector and injecting hole.
 Install the injector vertically into the injector seat, and retain it with clips.
 Install the injector manually; never knock the injector with hammer or other tools.
 Do not pull the O-ring supporting gasket out of the injector. When installing, fuel inlet end, O ring, supporting ring,
injecting plate and electric plug of fuel injector shall not be damaged. If any damage occurs, do not use again.
 Check the leakproofness of the fuel orifice assembly after the installation.
10.2 Removal and Installation of Fuel Distribution Pipe and Fuel Injector
Assembly
Tips
These instructions are for the removal and installation of the fuel injector of Cylinder 1 but may be used as reference for the
removal and installation of fuel injectors of other cylinders.
Removal
3. Remove the engine trim panel -1-.

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4. Disengage PCV venting hose -1-.
5. Remove the fixing clamp -Arrow- of the fuel pipeline and disengage
the fuel pipeline -1-.
Tips
Place a cloth at the connections before releasing the hoses, and then
pull out the hoses carefully.
Do not reuse the fixing clip but replace with a new one.
6. Disconnect the connecting plug -Arrow A- of the fuel injector,

unscrew the fixing bolt -Arrow B- of the fuel distribution pipe and
remove the fuel distribution pipe assembly -1-.
Bolt -Arrow B- tightening torque: 16.4~20.4 Nm
Notes
 While removing the fuel rail assembly, do not remove one end separately and remove the other later, but remove
both ends slowly and uniformly. Press in two ends uniformly while installing to ensure they are installed to due
positions.
 Apply new oil to O-ring of the fuel injector and insert into the fuel injector straight until the fuel rail instead of
inserting in an inclined manner.
Installation

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10.3 Disassembly of Fuel Distribution Pipe and Fuel Injector Assembly

Removal
1. Unclamp the fuel injector clamp -1- along the direction -Arrow A-
and take it out along the direction -Arrow B-.
2. Remove the fuel injector-2-.
Tips
 Replace sealing rings -1- and -2- at two ends of the fuel injector as
necessary.
 Apply a thin layer of vaseline or similar product to sealing rings
-1- and -2- while installing.
Installation

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10.4 Check on Fuel Injector

1. Set the multimeter to ohm mode and use the multimeter to measure
the coil resistance of the injector -1-.
Rated resistance of the fuel injector coil at 20℃: 11.4～12.6 Ω
Tips
 If the measurement doesn't meet the standard, replace the injector.
 If practical, clean and check the injector with injector washer.

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23 Charging, Starting and Ignition System

1 Overview
Charging System
The generator is the major power source for the vehicle, whose job is to provide power supply to all the electrical equipment
(excluding the starter) when engine is running at a normal speed (above the idling speed) and charge the battery at the same
time.
The generator equipped on this model is a high-capacity integrated generator with a rated output voltage of 14V and a rated
current of 110A.
The main components of charging system include the following:
 Generator assembly
 Battery
 Battery charging indicator
Starter System
The starting process of the vehicle from standstill to running requires external forces. The starting of the engine depends
on the gear meshing of the starter pinion and the flywheel connected to the starter crankshaft, which drives the flywheel and
thus activates the engine.
The starter system includes two independent circuits. One offers high-ampere current for the operation of the starter, and the
other is the low-current control circuit that controls the operation of the starter relay.
The main components of starter system include the following:
 Starter relay
 Starter assembly
Ignition system
The ignition system is designed to convert the low voltage provided by the vehicle power source into high voltage;
meanwhile, the high voltage is distributed to the spark plug of each cylinder timely and accurately according to the preset
ignition timing sequence. Electric sparks are produced at the gaps of the spark plug, thus ignite the combustible mixture in
the cylinders and drive the piston to propel the smooth operation of the engine.
This model features a state-of-the-art independent ignition method, that is, each cylinder is equipped with an ignition coil
and the ignition between the different cylinders is independent. In this design, the ignition of each cylinder can be
controlled more precisely, so that the mixture will be better combusted in all cylinders and improve the stability of the
ignition system.
The main components of the ignition system include the following:
 Crankshaft position sensor
 Camshaft position sensor
 Knock sensor
 Air intake temperature/pressure sensor
 Ignition coil
 Spark plug
 Ignition switch
426 Repair Group 23 - Charging, Starting and Ignition System

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Engine

2.1.1 Generator Output Fault
Check whether there is a Remove the belt, clean
screeching sound from The belt is aged, loose off the grease on the
Proceed to Step 1.
slipping between the belt or covered with grease pulley and replace it
and the generator pulley with a new belt
1 Check related circuits Normal There's a fault Operation method
The circuit or
Restore the circuit
Check the fuse and circuits connector is loose; or
Proceed to Step 2. connection and replace
connected to the generator the generator fuse is
the burnt fuse
burnt
Check the smell of the
generator
Check whether there is a
smell of burnt electronic The regulator or coil
Replace the generator
components or wire Proceed to Step 3. inside the generator is
assembly
coating inside the burnt
generator
repairs
2.1.2 Abnormal Operation of Starter

Recharge the battery
Check the power level of The battery is
Proceed to Step 1. and replace it if
the battery discharged or damaged
necessary
The circuit or
Restore the circuit
Check the fuse and circuits connector is loose; or
Proceed to Step 2. connection and replace
related to the starter the generator fuse is
the burnt fuse
burnt
2 Check the solenoid valve Normal There's a fault Operation method
Coil resistance of
starter solenoid valve
Check whether the starter
abnormal and coil Replace the starter
solenoid valve is working Proceed to Step 3.
burnt or open or assembly
normally
solenoid valve
mechanical blocking
3 Check the starter Normal There's a fault Operation method
Repair Group 23 - Charging, Starting and Ignition System 427

X25 2015
Engine

The coil resistance of the starter
Check whether the coil is abnormal; the coil is burnt
Proceed to Step Replace the starter
resistance of the starter is out, leading to broken circuit; or
4. assembly
normal the carbon brush has poor
contact
4 Check the transmission gear Normal There's a fault Operation method
The deceleration gear of the
Check the gears and starter has a broken tooth; there
Proceed to Step Replace the starter
absorption components of is failure in the one-way
5. assembly
the starter engagement gear; there is
failure in gear disengagement
Find the cause from
5 windows and check whether End of check Faults still exist
other symptoms.
2.1.3 Spark Plug: Spark Failure

Replace it with an
Check the spark plug type Proceed to Step A spark plug that doesn't meet original spark plug
number 1. the specifications has been used meeting the
specifications
Check the surface of the
spark plug
The surface of the spark plug is Clean the spark plug
Proceed to Step
The surface is dirty wet, or covered by carbon or and replace it if
2.
impurities necessary
2 Check the spark plug poles Normal There's a fault Operation method
The clearance between the spark
Check whether the spark Proceed to Step plug poles is too large or too Replace the spark
plug poles are normal 3. small; the poles are burnt and plug.
deformed
3 Check the ignition coil. Normal There's a fault Operation method
Failure in ignition coil
Restore the ignition
Check the plugs and coil Proceed to Step connection or abnormal
coil connection or
resistance of the ignition coil 4. resistance in ignition coil can be
replace the spark plug
detected
Check the fuse and The circuit or connector is Restore the circuit
Proceed to Step
connecting circuits of the loose; or the generator fuse is connection and
5.
ignition system burnt replace the burnt fuse
5 Check the anti-theft system Normal There's a fault Operation method
Check whether the anti-theft Failure of the anti-theft system
Proceed to Step Overhaul the
system is functioning can be detected, which prevents
6. anti-theft system
normally ignition
Check the Engine Control
Unit (ECU)
Proceed to Step Failure goes away after Replace the engine
Replace it with a new ECU
7. replacing the ECU control unit

X25 2015
Engine

repairs

X25 2015
Engine
Torque
Description Specification Grade Tools
Nm
14mm Hexagon
Generator fixing bolt (M10) M10×1.25×90 10T 42～52
Sleeve
12mm Hexagon
Generator fixing bolt (M8) M8×1.25×40 7T 19～25
Sleeve
12mm Hexagon
Adjusting bolt of the generator assembly M8×1.25×80 7T 4～6
Sleeve
14mm Hexagon
Generator bracket bolt M10×1.25×35 7T 32～40
Sleeve
13mm Hexagon
Fixing nut of the generator terminal M8×1.25 8 18～22
Sleeve
12mm Hexagon
Starter fixing bolt M8×1.25×50 8.8 20～28
Sleeve
13mm Hexagon
Starter power supply post nut M8×1.25 8 10～12
Sleeve
10mm Hexagon
Ignition coil fastening bolt M6×1.0×18 8.8 8～10
Sleeve
16mm hexagonal
Spark plug — — 20～30
long sleeve

X25 2015
Engine
4 Charging System
4.1 Removal and Installation of Engine Assembly
Removal
3. Disconnect the connecting plug -Arrow A- of the generator and lift up

the generator terminal guard -Arrow C-.
4. Unscrew the fixing nut -Arrow B- of the generator terminal and put
aside the generator wiring harness -1-.
5. Loosen the fixing bolt -Arrow B- and -Arrow C- of the generator.

Bolt -Arrow C- tightening torque: 42~52 Nm
6. Rotate the adjusting bolt -Arrow A- of the generator assembly

anti-clockwise, and disconnect the belt -1- and the generator assembly.

X25 2015
Engine
Adjustment bolt -Arrow A- specification:M8×1.25×80

Adjustment bolt -Arrow A-tightening torque : 4～6 Nm
Adjustment bolt -Arrow A -tool: 12mm hexagon sleeve
Tips
Just disconnect the belt -1- and the generator assembly, but do not remove the belt.
7. Unscrew the fixing bolt -Arrow A- and -Arrow B- of the generator
and remove the generator assembly -1-.
Bolt - Arrow B - specifications：M10×1.25×90
Installation
 After the installation, apply a force of 100N on the belt at the
-Arrow-, and measure whether the deformation is within the
standard variation range.
Standard tolerance：10.9～16.5 mm
 Start engine and check the operation of the belt.

 Test the power output of the generator.
When the rated voltage of the generator is 14V, the power output is 1540W.

X25 2015
Engine
4.2 Check on Generator

Visual inspection.
 Check whether the connecting harness of the generator is in good condition.
 Check the generator appearance for cracks, deformation, etc.
Check on the Charging Indicator
 Turn on the ignition switch and check whether the charging indicator on the instrument cluster lights up.
 After the engine is running, check whether the charging indicator has turned off.If not, check the generator and its
connecting harness.
Static Test
Disassemble the harness on the B+ terminal of the generator, measure the resistance with a multimeter; then, switch the
positive and negative probes and measure it again.If both results are the same or conduction exists, it means the generator is
broken and needs replacement; if the difference is substantial, it is normal.
Dynamic Test
Start the engine, measure the output voltage between the generator output terminal and the grounding with a multimeter, and
check whether the output voltage is around 14V. If the output voltage is too low or too high, it means the generator is
defective.Turn on the headlights, air blower and other electrical equipment and check the output voltage of the generator.If
the voltage drops substantially, it means the generator is defective and needs replacement.
Check whether there is noise in the generator when the engine operates at different RPMs.

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Engine
5 Starter System
5.1 Removal and Installation of Starter Assembly
Removal
2. Disconnect the power control wiring harness connector -Arrow A- of
the starter and disengage the guard -Arrow B- of power supply wiring
harness.
3. Unscrew the fixing nut -Arrow B- of the starter power supply wiring
harness and put aside the starter power supply wiring harness -1-.
4. Unscrew the fixing bolt -Arrow- of the starter assembly -1-, and
remove the starter assembly.
Installation
5.2 Check on Starter Assembly
Danger
It is dangerous when the starter is running at a high speed.The testing personnel should take proper precautions.
The coil may get burnt if the starter is powered by the battery for an extended time; therefore, tests should be completed
with 3-5 seconds.
All tests should be performed continuously, as the objective of these tests is to check the continuous operation of the
starter.

X25 2015
Engine
1. Connect the negative terminal of the battery to the grounding on the

housing of the starter assembly.
2. Connect the positive terminal of the battery to the post -Arrow A- of
the solenoid switch, via the serial connection of the ammeter.
3. Connect the positive terminal of the battery to the plug post -Arrow
B- of the solenoid switch.At this time, the starter should run smoothly
and the result shown on the ammeter should be normal.
If the starter vibrates or emits noise, or the current result is out of the
standard range, replace the starter assembly.
4. When the starter starts running, observe whether the small star gear
-1- moves out in the axial direction and rotates along.
If not, replace the starter assembly.

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Engine
6 Ignition System
6.1 Ignition Coil
6.1.1 Overview
Within the engine ignition system of the vehicle, the ignition coil is the actuating part that provides ignition energy to air
and fuel mixture for ignition of the engine cylinder. It mainly functions based on the principle of electromagnetic
induction to receive ECU commands through the electronic controller and turn off and turn on the primary current circuit of
the ignition coil. It produces magnetic field by current of the primary coil winding for the sake of storage of magnetic
energy. When current of the primary coil winding is cut off suddenly (disconnect circuit grounding terminal through the
power transistor), the magnetic field damps and magnetic energy releases to force the secondary coil to produce induced
electromotive force. The induced electromotive force discharges through the spark plug and ignites air and fuel mixture in
the cylinder to force the engine to work. We call the ignition manner induced discharge ignition. Ignition timing is
realized by ECU control signal that controls break-make time of the ignition coil.
Parameters
Secondary voltage
Power Secondary output
Engine Ambient
supply Power-on voltage (Kv)
speed temperature
voltage time (ms)
(r.p.m) （℃） 25pF 25pF+1MΩ
（V）
Normal 13.9～
≤2000 3.4 ≥33 ≥24
temperature 14.1
Discharge capacity
Engine Ambient Power Power-on Discharge capacity
speed temperature supply time (ms) T2(ms) I2（mA）
(r.p.m) （℃） voltage
（V）
≤2000 80 13.9～ 3.4 ≥0.9 ≥75
14.1
6.1.2 Removal and Installation of Ignition Coil

Removal

X25 2015
Engine
4. Disconnect the connecting plug -Arrow-B of the ignition coil -1-.

5. Unscrew the fixing bolt -Arrow-A on the ignition coil-1-, and pull out
the ignition coil-1- upwardly.
Installation
6.1.3 Check on Ignition Coil

Fault symptoms
It cannot get started or has some other problems.
Common Causes
It is burnt due to excessive current, damaged by external force, etc.

X25 2015
Engine
1. Disconnect the connecting plug -1- of the injector.
2.. Remove the ignition coil=>Refer to Page 436

3. Install a well-functioning spark plug onto the ignition coil.
4. Engage the connecting plug of the ignition coil.
5. Ground the side pole of the spark plug, and then start the engine.
6. Check the pole clearance of the spark plug and the sparking. If the
spark is weak or doesn't appear, perform the same check with a
well-functioning ignition coil. If the spark is powerful when checked
with a well-functioning ignition coil, it indicates the ignition coil of the
spark is faulty. Replace with a new ignition coil.
If there's no spark when checked a well-functioning ignition coil, there
might be a problem with the ignition circuit. Check the ignition circuit.
Notes
When conducting a sparking test, the engine should get started within 10 seconds.

X25 2015
Engine
6.2 Spark Plug

6.2.1 Removal and Installation of Spark Plug
Removal
Tips
These instructions are for the removal and installation of the spark plug of Cylinder 1 but may be used as reference for the
removal and installation of spark plugs of other cylinders.
1. Remove the ignition coil of Cylinder 1=>Refer to Page 436.
2. Screw out the spark plug.
Tightening torque of spark plug：20～30 Nm
Spark plug type: LZFR6AI
Installation
 Pay attention to the waste disposal regulation.
6.2.2 Check on Spark Plug

1. Check the pole clearance of the spark plug -1-.
Standard clearance：0.7～0.8 mm
Tips
If the clearance doesn't meet the standard, adjust or replace the spark
plug.
2. If the spark plug is dark or covered with excessive carbon, it means that the spark plug hasn't been replaced for a while or
the throttle is not properly sealed. Clean the carbon off the spark plug or check the sealing of the valve.
3. If the spark plug is white, it means that the engine is burning engine oil. Check the sealing of the cylinder.
4. If the spark plug is wet, it may not ignite. Check the electronic control system and troubleshooting the failure in parts or
cables.

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Maintenance Manual of Senova X25

BAIC Motor Sales Co., Ltd.

Repair Group 10 - Engine Assembly 1

2 Check and Diagnosis

2 Repair Group 10 - Engine Assembly

Repair Group 10 - Engine Assembly 3

2.2 Common Fault Checking and Eliminating

4 Repair Group 10 - Engine Assembly

No. Inspection steps Check results Fault elimination

2.2.2 Engine Idle Speed Abnormal

Repair Group 10 - Engine Assembly 5

No. Inspection steps Check results

2.2.3 Poor Engine Acceleration and Power Reduction

6 Repair Group 10 - Engine Assembly

No. Inspection steps Check results

Repair Group 10 - Engine Assembly 7

2.3 Regular Tests

Special Tools and Maintenance Equipment Required:

T21451401-Oil pressure measuring

8 Repair Group 10 - Engine Assembly

3. Disconnect the connecting plug -Arrow A- of the starter, lift up the

6. Disengage the connecting plug -Arrow- of the oil pressure sensor.

Repair Group 10 - Engine Assembly 9

10 Repair Group 10 - Engine Assembly

2.3.2 Cylinder Pressure Test

4. Remove all the spark plugs=>Refer to Page 439.

Repair Group 10 - Engine Assembly 11

2.3.3 Fuel Pressure Test

12 Repair Group 10 - Engine Assembly

 Make sure there is adequate fuel.

3. Extract the fuel pump fuse -1- numbered FB31 (10A).

Repair Group 10 - Engine Assembly 13

14 Repair Group 10 - Engine Assembly

Repair Group 10 - Engine Assembly 15

T51131001-Engine balance hanger T51271002-Engine balancing stand cross rod component

1. Release fuel pressure => Refer to Page 409.

16 Repair Group 10 - Engine Assembly

Repair Group 10 - Engine Assembly 17

18 Repair Group 10 - Engine Assembly

Applicable to F15 manual transmission

Repair Group 10 - Engine Assembly 19

Applicable to the manual transmission MF513A

20 Repair Group 10 - Engine Assembly

Applicable to the automatic transmission

Repair Group 10 - Engine Assembly 21

27. Disconnect the connecting plug -Arrow A- and -Arrow B- of the

Applicable to all models

22 Repair Group 10 - Engine Assembly

29. Disconnect the connecting plug -Arrow A- and -Arrow B- of the

Repair Group 10 - Engine Assembly 23

34. Turn the steering wheel to the straight driving direction.

24 Repair Group 10 - Engine Assembly

37. Disconnect the wiring harness connector -Arrow A- and disengage

Applicable to the automatic transmission

Applicable to the manual transmission

Repair Group 10 - Engine Assembly 25

Applicable to all models

45. Disconnect the connecting plug -Arrow- of the A/C compressor

26 Repair Group 10 - Engine Assembly

Repair Group 10 - Engine Assembly 27

28 Repair Group 10 - Engine Assembly

Repair Group 10 - Engine Assembly 29

 61. Unscrew the fixing nut -Arrow- of the catalytic converter