Engine control system troubleshooting guide

Engine control system - control system 3-103
(a) Check installation of camshaft position sensor.

OK:
Sensors are installed correctly
NG reinstall the sensor firmly
OK > To the 2nd step
4. Check camshaft position sensor gear ring.
(a) Check target gear of camshaft position sensor.
clearance OK:
The target gear of the sensor is free of any cracks
or deformation.
NG Replace target gear
OK > replace ECU
~3-103~
3-104 Engine control system - control system
P0351/0352/0353/0354
DTC P0351 No.1 ignition coil fault Type of fault code：A

Instructions to functions:
Each Delphi pen-style ignition coil is corresponding to 1 cylinder.
Under car computer ECU control, charge the primary ignition coil to
go on with magnetic energy, at the same time the secondary coil
winding induces high voltage to get simultaneous arcing of ignition
plugs connected to the coils. The ignition coil driving system in
combination with ECU can have void to allow the coil to output high
voltage energy to the spark plug.
Here is its schematic diagram:
Ignition coil
Shielded
wire
The electrical characteristics of ignition coils at room temperature

(23°C±5°C) shall meet the following requirements of which the
numerical values are shown below:
Type Technical specification

Primary resistance 0.71Ω±0.071Ω
Secondary resistance 8.7kΩ±0.87kΩ
Service voltage range 6-16V
Primary charge time 2.15ms
~3-104~
Type Technical specification

Primary actuating current peak 7.5Amp
Minimum ignition duration 1.0msec
Minimum ignition energy Over 33mJ
Note
DTC Test starting conditions Fault criteria Emergency control scheme Possible causes to faults
P0351 • The ignition control
circuit between ignition
P0352
coil and ECU is short-
The ignition circuit of circuited or broken.
P0353 • The engine is running. • Stop the injection of
corresponding cylinder
• The battery voltage is corresponding cylinder • The contact between
is broken or short to
greater than 10V. • No fuel closed-loop control ignition coil connectors
power supply or ground.
P0354 is poor.
• The ignition coil breaks
down.
Wiring diagram
Ignition coil
Double-core
shielded wire
Double-core
shielded wire
(A\B\C are correspondent

with pins 1, 2 and 3)
Check procedure:
1. Check harness and connectors (ignition coil-ECU)
Ignition coil
Definition of ignition coil plug-in connector terminal
Positive power supply of ignition
A
switch
B Ground wire
C Ignition signal
~3-105~
Ignition coil (a) Disconnect the ignition coil assembly connector

(b) Disconnect the ECU connector.
(c) Check the resistance.
Detection and judgment (check whether to be open circuit)
Connection of tester Regulatory conditions
C (harness terminal)-04 (harness terminal)
The resistance is lower than 5Ω.
Schematic diagram of connector pins (seeing
from the harness side)
Detection and judgment (check whether to be short circuit)

Fault when not
Regulatory
Connection of tester meeting the
conditions
conditions
04 (harness terminal) - Body ground
01 (harness terminal) - Body ground Wiring harness-
62 (harness terminal) - Body ground 10kΩ or higher ground short
circuit
81 (harness terminal) - Body ground
(d) Reconnect ECU connector.

(e) Reconnect ignition coil connector.
NG Repair or replace harness or connectors.
OK > To the 2nd step
2. Check ignition coil assembly (power supply)
(a) Disconnect the ignition coil assembly connector
Ignition coil (b) Check resistance.
Detection and judgment (check whether to be open circuit)
B (No.1 ignition coil terminal)-Body ground
The resistance is lower than
B (No.3 ignition coil terminal)-Body ground 5Ω.
(c) Turn ignition switch to ON position.

(d) Measure the voltage between harness connector terminals.
Standard voltage
No. 1 ignition coil A (harness

terminal) ～B (harness terminal)
No.2 ignition coil A (harness
terminal) ～B (harness terminal) 11～14V

~3-106~

(e) Reconnect ignition coil assembly.

NG Repair or replace harness or connectors (ignition coil-
ignition switch, ignition coil- body ground).
OK > To the 3rd step
3. Check ECU (signals of No.1 to No.4 ignition coil)
(a) Connect oscilloscope probe to terminal 04 (01, 62, 81) of
ECU connector, and connect the other terminal to body
ground.
(b) Check waveform when the engine is at idle speed or others.
OK
Different waveforms for different engine speeds.
Prompt:
• Shown in the figure is the wave form when the engine is
at idle.
• Take the oscilloscope wave forms as an example,
excluding those of noise or vibration.
• The wave amplitude sees nuances based on the difference
between cars.
NG Replace ECU.
OK > Replace ignition coil.
~3-107~
P0420
The conversion efficiency of catalytic
DTC P0420 Trouble code type: A
converter is lower than threshold.
The converter is used to convert such noxious gases as carbon
monoxide, hydrocarbon, NOX in exhaust gases to carbon dioxide,
nitrogen, and water. The rear oxygen sensor behind the converter is
used to detect oxygen amount. If the converter is degraded, the rear
oxygen sensor will send over-rich/over-thin signals repeatedly like
the front oxygen sensor in a short period. Therefore, calculate the
voltage timing based on the rich/lean signal sent out by the rear
oxygen sensor, and compare it with the rich/lean signal sent out by
the front oxygen sensor. If the voltage exceeds the preset value and
the rear oxygen sensor responds to signals from the front oxygen
sensor much faster than the preset value, it indicates that the catalyst
has been deteriorated.
Note
• No trouble codes related to

MAP sensor, coolant
temperature sensor, TPS
sensor, cooling system,
oxygen sensor, fuel The system calculates the
correction, car speed sensor, oxygen storing time of
injector, misfire, crankshaft the catalytic converter by
position sensor, camshaft comparison of the signals
position sensor, ignition of the front and rear • The catalyst
P0420 system, idle control, system •None
oxygen sensor. When the performance is poor.
voltage, etc. weighted storing time is
• The coolant temperature is lower than a set
over 70°C. threshold, the system will
• The fuel system is in a report the trouble.
closed loop, the car stops to
run at idle speed after
moving a certain distance at
a constant speed.
Check procedure:
1. Replace catalyst.
B Check the intermittent fault
A > Check and replace ECU.
~3-108~
P0458/0459
DTC P0458 Short circuit of valve EGR to low voltage Type of fault code：E
or circuit disconnection
DTC P0459 Short circuit of valve EGR to high voltage Type of fault code：E
Flow curve
Flow (Normal Litre/min)
Carbon canister cleaning control

electromagnetic brake
Duty ratio (%)
The canister solenoid valve controls the switching time and

opportune moment of the passage between active carbon canister
and intake pipe so as to guide the fuel evaporated from the fuel tank
to the intake manifold and let it burn in cylinders in order to furthest
reduce the evaporative emission and minimize the influence on the
engine performance.
The aperture of the canister solenoid valve depends on the duty ratio
(PWM) signals determined by the engine state. In case of idling, the
maximum aperture of the canister solenoid valve is 0%, while in
case of idle-free conditions, the maximum aperture of the canister
solenoid valve depends on the closed-loop mass air flow and it is
100%. The flow curve is as shown above.
Note
Emergency control
DTC Test starting conditions Fault criteria Possible causes to faults
scheme
• The harness between canister solenoid valve

• Operating time of
ECU detects that the and ECU is short to the ground.
engine exceeds 0.5s.
canister solenoid • The contact of canister solenoid valve
P0458 • System voltage is • None
valve is short to the connectors is poor.
greater than 11V
ground or broken. • The contact between the engine harness and
and lower than 16V.
ECU canister solenoid valve pin is poor.
• The harness between canister solenoid valve

ECU detects that the and ECU is short to the power supply.
canister solenoid • The contact of canister solenoid valve
P0459 • None
valve is short to the connectors is poor.
power supply (12V). • The contact between the engine harness and
ECU canister solenoid valve pin is poor.
~3-109~
Wiring diagram
Valve EGR
Main
relay
Battery
Check procedure:
1. Check canister solenoid valve
(a) Dismantle down canister solenoid valve.
(b) Check canister solenoid valve resistance.
Measure the resistance between terminals with an ohmmeter.
Standard resistance
A–B 19Ω-22Ω (at temperature of 20°C)
(c) Check working conditions of canister solenoid valve.

(1) Check the working condition of the solenoid valve in
the case of power failure; the air shall not flow from 1
to 2 in the case of power failure.
(2) Connect two poles of car battery (free of malfunction)
1. Active carbon port to two terminals of solenoid valve (connect positive
pole to A while negative pole to B).
(3) Check the working condition of solenoid valve in the
case of energizing; the air will flow from 1 to 2 after
energizing.
(d) Reinstall canister solenoid valve.
2 Intake
manifold port
NG Replace canister solenoid valve
Carbon canister cleaning OK > To the 2nd step
control electromagnetic brake
2. Check harness and connectors (knock sensor-ECU)
~3-110~
(a) Disconnect V6 canister solenoid valve connector.

Valve EGR (b) Turn igniting switch ON.
(c) Measure the voltage between harness side connector terminal
and car body ground.
Standard voltage
Canister solenoid valve (V6-A)-Body 11-14V
Schematic diagram of connector pins ground
(seeing from the harness side)
OK > To the 4th step
NG > To the 3rd step
3. Check harness and connectors (canister solenoid valve-
main relay, canister solenoid valve-ECU)
(a) Disconnect E1 ECU connector.
(b) Disconnect V6 canister solenoid valve connector.
(c) Disconnect E1 ECU connector.
(d) Check voltage and resistance value.
Detection and judgment
Fault when not meeting the
Schematic diagram of conditions
connector pins (seeing from A (harness terminal)-main
the harness side) Lower than 5Ω
relay? (5)
Disconnection of circuit of
B (harness terminal)～ Lower than 5Ω wiring harness
E1-64 (harness terminal)
Detection and judgment

Fault when not meeting the
conditions
A (harness side)～body The resistance is 10kΩ

ground or higher.
Harness is short to the ground.
B (harness terminal)～ The resistance is 10kΩ
Body ground or higher.
B (harness terminal)～ Harness is short to power

Voltage is 0.
Body ground supply.
(e) Reconnect E1 ECU connector.
(f) Reinstall main relay.
(g) Reconnect V6 canister solenoid valve connector.
4. Check main relay.
(a) Dismantle the main relay from the main relay.
(b) Check main relay resistance.
~3-111~
Standard resistance
3-5 10kΩ or higher (before powering on)
3-5 Less than 1Ω (battery voltage is applied to

terminals 1 and 2, that is, after powering on)
(c) Reinstall the main relay.
NG Replace the main relay
OK Replace ECU
~3-112~
P0480
DTC P0480 Fan faul Trouble code type: A
When the engine coolant temperature exceeds a certain value, the
low-speed fan will be on to accelerate cooling; when the temperature
further rises to another calibration value, the high-speed fan will be
on.
Note
• The control circuit
ECU detects that control circuit • When the coolant between fans and
P0480 • The engine is running. is broken or short to power temperature is excessive, ECU is broken or
supply or ground. high-speed fan is opened. short to power supply
or ground.
Wiring diagram
Battery
Fan relay Single speed fan
Check procedure:
1. Check ECU (FANLO terminal voltage)
(a) Turn igniting switch ON.
(b) Measure the voltage between ECU connector terminals.
Standard voltage
FANLO(E1～65)–PWR GND(E1～2) 11-14V
2. Check fan relay.

Schematic diagram of connector
pins (seeing from the harness side)
(a) Dismantle down fan relay from fuse box.

(b) Check fan relay resistance.
Fan relay
Standard voltage
3～5 10kΩ or higher
3～5 Less than 1Ω (battery voltage is applied to terminals

1 and 2)
(c) Reinstall fan relay.
NG Replace fan relay.
~3-113~
3. Check harness and connectors (ECU-fan relay)
(a) Disconnect ECU connector.

(b) Dismantle down fan relay from fuse box.
Standard resistance (Check whether the open circuit happens)
FANLO (E1-65) –fan relay (1) Lower than 1Ω
Fan relay
Standard resistance (Check whether the short circuit happens)
FANLO (E1-65) or fan relay (1)-
10kΩ or higher
body ground
(e) Reinstall fan relay.
4. Check fan.
(a) Disconnect fan connectors.
(b) Measure fan resistance.
Standard resistance
(c) Reconnect fan connectors.

NG Replace fan.
~3-114~
5. Check harness and connectors (ECU-fan relay)

(a) Dismantle down fan relay from fuse box.
(b) Disconnect fan connectors.
5 (fan relay)-2 (fan connector) Lower than 1Ω

Harness:
2 (fan relay)-Body groud 10kΩ or higher
(d) Reconnect fan connectors.

(e) Reinstall fan relay.
Electronic fan OK > To the 6th step
6. Check harness and connectors (fuel pump-body ground)
(a) Disconnect fan connectors.
(b) Check resistance
1 (electronic fan)-Body groud Lower than 1Ω
(c) Reconnect fan connectors.

7. Check ECU power circuit
Electronic fan
~3-115~
P0502
DTC P0502 No vehicle speed signal Trouble code type: E
The ECU vehicle speed sensor signals are from instrument cluster
and transmitted to ECU in collector open type. ECU determines
vehicle speed based on the frequency of pulse signals.
Note
• The engine is running. Under acceleration • Poor connection

conditions, the detected
• The coolant temperature is vehicle speed is lower than • Circuit between vehicle
over 60°C. • No closed-loop control speed sensor and ECU is
P0502 10km/h; Under
• No trouble codes related to for idle speed. broken or short circuited.
acceleration conditions, the
MAP sensor and TPS detected vehicle speed is • The vehicle speed sensor
sensor. lower than 5km/h. breaks down.
Wiring diagram
Instrument cluster
Check procedure:
1. Check instrument cluster (speedometer)
(a) Drive the car to check the speedometer in instrument cluster
for normal running.
OK: The speedometer operates normally.
Result Into
OK A
NG B
B Check speedometer circuit.

A > To the 2nd step
2. Check harness and connectors (instrument cluster-ECU)
~3-116~
(a) Disconnect C4 instrument cluster connector.

(b) Disconnect E14 ECU connector.
Check for open circuit.
SPSR (C4-10) ～VSS (E1-51) Lower than 5Ω
Check for short circuit.

Schematic diagram of connector pins
(seeing from the harness side) Connection of tester Regulatory conditions
SPSR (C4-10) ～Body ground 10kΩ or higher
(d) Reconnect instrument cluster connector.

(e) Reconnect connector of ECU.
NG Repair or replace harness or connector
clip.
OK > Replace instrument cluster.
Instrument cluster connector.
~3-117~
P0506/0507
DTC P0506 Idling control system fault-the rotate Type of fault code：E
speed is too low.
DTC P0507 Idling control system fault-the rotate Type of fault code：E
speed is too high.
Note
Emergency control
DTC Test starting conditions Fault criteria Possible causes to faults
scheme
• No trouble codes related to MAP The duration of the idle • Idling control circuit
sensor, coolant temperature sensor, speed which is lower than trouble
P0506 No idling adjustment.
TPS sensor, cooling system, the target speed (100RPM) • ETC trouble
oxygen sensor, fuel correction, car set by the system is over 10s. • Ignition system fault
speed sensor, injector, misfire,
• Circuit trouble
crankshaft position sensor,
The duration of the idle between ETC and
camshaft position sensor, ignition
speed which is greater than ECU
P0507 system, etc. No idling adjustment.
the target speed (200RPM) • ETC trouble
• The engine is running.
set by the system is over 10s. • Ignition system fault
• The coolant temperature is over
• Vacuum leak
60°C.
~3-118~
P0011/0012/0016/0026/0076/0077
DTC P0011 Lagging response of air intake VCP phase Type of fault code：A
DTC P0012 Big error to phase of air intake VCP camshaft Type of fault code：A
Learning deviation of air intake VCP cam gear

DTC P0016 Type of fault code：A
exceeds scope.
Clinching of hydraulic control valve of air intake
VCP
Low voltage or circuit disconnection of hydraulic
control valve coil of air intake VCP
High voltage of hydraulic control valve coil of air
intake VCP
Note
Possible causes to
DTC Test starting conditions Fault criteria Emergency control scheme
faults

• No VVT parts trouble, no
crankshaft position sensor
trouble, no system voltage The VVT forward change rate
trouble
detected by ECU is lower than
P0011 • VVT aperture has changed • None • None
10°/s or the backward change
over 7.5°.
rate is lower than 5°/s.
• VVT aperture change rate is
not lower than 50°/s.
• The time to measure VVT
change rate is over 0.4s.

• No VVT parts trouble, The VVT phase error detected
no crankshaft position by ECU is bigger than 15; or
sensor trouble, no when the actual VVT aperture is
system voltage trouble bigger than 5°
P0012 • None • None
• VVT aperture has while smaller than 50°, the VCP
changed over 7.5°. actual control duty cycle is
bigger than 0.9 or smaller than
• The current VVT
0.1.
aperture change rate is
lower than 15°/s.
• VVT system variation
learning finishes. • Relative camshaft
• No VVT parts trouble, ECU detects that VVT cam teeth deviation is
P0016 no crankshaft position learning deviation is smaller • None excessive in the
sensor trouble, no than 0.2 or bigger than 0.35. case of VVT parts
system voltage trouble installation.
• No VVT parts trouble,
no crankshaft position ECU detects that VVT actual
sensor trouble, no phase is 50o while the phase
system voltage trouble error is smaller than -20o; or • VVT hydraulic
P0026 • None
• The engine is running. VVT actual phase is smaller valve is blocked.
• OCV valve cleaning than 10 while the phase error is
function is without 20o.
movement.
~3-119~

between intake VCP
hydraulic control valve
coil and ECU is short to
ground or broken.
• Engine running time is 0.5s ECU detects that the intake VCP
P0076 hydraulic control valve coil is • None • The contact of intake
• System voltage is between VCP hydraulic valve
11V and 16V. with low voltage or broken.
connectors is poor.
• The contact between the
engine harness and ECU
intake VCP hydraulic
valve pin is poor.
between intake VCP
hydraulic control valve
coil and ECU is short to
power supply.
• Engine running time is 0.5s ECU detects that the intake VCP
P0077 hydraulic control valve coil is • None • The contact of intake
• System voltage is between VCP hydraulic valve
11V and 16V. short to power supply (12V).
connectors is poor.
• The contact between the
engine harness and ECU
intake VCP hydraulic
valve pin is poor.
~3-120~
Engine control system - ECU power circuit 3-121
ECU power circuit

Components
Instruction:
When the ignition switch is turned to ON position, the battery voltage is applied on ECU terminal IGN. MPR
terminal input signal has current flowed to coil to close the contacts of the main relay so as to supply power to ECU
terminal VBATPRO.
Route map
Ignition switch
Main relay
Battery
Single point grounding of engine
~3-121~
3-122 Engine control system - ECU power circuit
On-board check
1. Check ECU (VBATPRO voltage)
Continue to check the next circuit shown by trouble symptoms.

2. Check harness and connectors (ECU-car body ground)

(a) Disconnect cable of negative power supply.
(b) Disconnect E13ECU connector.
Standard resistance
Schematic diagram of connector pins 02 - Body ground Lower than 1Ω
03 - Body ground Lower than 1Ω
(d)
Reconnect ECU connector.
(e)
Reconnect cable of negative power supply.
3. Check ECU (IGN voltage)
Standard voltage
68–02 or 03 11-14V
4. Check fuse (ECU fuse)
(a) Dismantle down ECU fuse from fuse box.
(b) Check ECU fuse resistance.
Standard resistance:
Lower than 1Ω
(c) Reinstall ECU fuse.
NG Check all harness and connectors connected to fuse for
short circuit, and replace fuse.
ECU fuse OK > To the 5th step
~3-122~
Engine control system - ECU power circuit 3-123
5. Check ignition or engine switch assembly

(a) Disconnect ignition switch connector.
Combination side:
Ignition switch (b) Check ignition switch resistance.
Standard resistance
Ignition switch position Connection of tester Regulatory conditions
LOCK All terminals 10kΩ or higher
ACC 1-3
1–2–3
ON
5-6 Lower than 1Ω
1-2
START
4+ -5×-6
(c) Reconnect ignition switch connector.
NG Replace ignition or engine switch assembly
6. Check ECU (MPR voltage)
Standard voltage
44–02 or 03 11-14V
NG Replace ECU.
7. Check fuse (main relay fuse)
(a) Dismantle down main relay fuse from fuse box.
(b) Check main relay fuse resistance.
Standard resistance:
Lower than 1Ω
(c) Reinstall main relay fuse.
NG Check all harness and connectors connected to fuse for
short circuit, and replace fuse.
Main relay
fuse
~3-123~
3-124 Engine control system - ECU power circuit
Main relay
(a) Dismantle down main relay from fuse box.
(b) Check main relay resistance.
Standard resistance
3-5 10kΩ or higher
3-5 Less than 1Ω (battery voltage is

applied to terminals 1 and 2)
(c) Reinstall the main relay.
NG Replace main relay
OK > To the 9th step.
9. Check harness and connectors (main relay-ECU)

(a) Dismantle the main relay from the main fuse box.
(b) Disconnect the ECU connector.
Main relay

Main relay (1)-MPR(44)
Lower than 1Ω
Main relay (5)-VBATPRO(05)

Main relay (1) or MPR (44) - Body groud
10kΩ or higher
Main relay (5) or VBATPRO(05) - Body groud

(e) Reinstall main relay.
OK Check and repair harness or connectors (main relay
terminal 3-battery positive terminal)
~3-124~
Engine control system - Camshaft Timing Oil Control Valve 3-125
Camshaft timing oil control valve

Components
The camshaft timing oil control valve assembly can continuously vary the timing relation of crankshaft to camshaft
to provide optimal port timing for the engine in different running conditions so as to realize the control on port
timing. It is conductive to the promotion of engine efficiency, improvement of idling stability, and can provide much
bigger torque and power; meanwhile it contributes to the enhancement of fuel economy and the emission reduction
of hydrocarbon (HC) and nitrogen oxide (NOx). Phaser consists mostly of stators and rotors. By oil pressure control,
the relative rotation of stators and rotors and the continuous variation of the phase between camshaft (rigid
connection with rotors) and crankshaft can be realized; as a result, valve timing variation can be realized.
Camshaft timing oil control valve assembly
~3-125~
3-126 Engine Control System - Camshaft Timing Oil Control Valve
On-board check
OCV valve check:
1. Check appearance
Example:
(a) If OCV is not started, the spring lets the valve core return to
normal position.
2. Apply force on valve core
(a) OCV valve core shall be free of blocking at any positions,
and it shall be able to return to its normal position in the
case of hand release.
Battery Slide valve
3. Check working conditions

Example: (a) Connect positive and negative pole of car battery (it shall be
12V–14V, i.e. the battery is free of any problems)
respectively to connecting terminals of control valve (oil
control valve terminal has no demands for polarity).
Ohm meter Observe the working conditions of slide valve. The valve
core overcomes the effect of spring and moves. When
voltage is removed, the valve core shall return to its normal
position.
Note:
Confirm that the slide valve can move smoothly
and will not be stuck at any positions.
Prompt:
The existence of any foreign bodies may result in subtle
pressure leakage. DTCs may be produced in this condition.
4. Check resistance
(a) Measure resistance with an ohmmeter.
The resistance value is 7.2Ω ± 0.4Ω
1（+）～2（-）
under 20°C.
If the resistance value is not satisfactory to the requirements,

replace camshaft timing oil control valve.
~3-126~
Engine control system - Camshaft Timing Oil Control Valve 3-127
Dismantle
1. Disconnect cable of battery negative terminal.
2. Dismantle down camshaft timing oil control valve assembly
(a) Disconnect camshaft timing oil control valve connector.
(b) Dismantle down bolts, and then dismantle down camshaft
timing oil control valve.
Installation
1. Install camshaft timing oil control valve assembly
(a) Apply a thin layer of engine oil on O-ring.
(b) Install camshaft timing oil control valve with bolts.
Torque：7～9N.m
Note:
Do not twist O-ring.
(c) Connect up camshaft timing oil control valve connector.
2. Connect cable to battery negative terminal
Torque ：8～12N.m
3. Check engine oil for leakage.
~3-127~
3-128 Engine control system - Camshaft position sensor
Camshaft position sensor

Components
Camshaft position sensor
~3-128~
E
Engine control system - Camshaft position sensor 3-129
n
Dismantle
2. Dismantle down camshaft position sensor.
(a) Disconnect camshaft position sensor connector.
(b) Dismantle down bolts and camshaft position sensor.
~3-129~
3-130 Engine control system - Camshaft position sensor
On-board check
1. Check the sensor output voltage wave form.
(a) The oscilloscope probe is connected with corresponding
ECU terminal.
(b) Check the waveform when the engine is at idle speed or at a
speed.
ECU terminal name Tester Range Regulatory conditions
Plugin pin schematic diagram ECU(74)-ECU(77) The engine is idling or

(from harness terminal) at a certain speed.
OK:
Different waveforms for different engine speed
Prompt:
• Shown in the diagram is the wave form when the engine
is at idle.
between cars.
• In case of grounding of shielded wires, the wave forms
will produce noises.
Installation
1. Install camshaft position sensor.
(a) Apply a thin layer of engine oil on O-ring, and then use
bolts to install camshaft position sensor.
Torque：7～9N.m
Note:
Confirm that the O-ring is free of cracks or
extruding before installation.
(b) Connect up camshaft position sensor connector.
Torque ：8～12N.m
~3-130~
Engine control system – Crankshaft position sensor 3-131
Crankshaft position sensor

Components
Transmission assy
Crankshaft position
sensor
~3-131~
3-132 Engine control system - Crankshaft position sensor
Dismantle
2. Dismantle down crankshaft position sensor.
(a) Disconnect crankshaft position sensor connector.
(b) Dismantle down bolts and crankshaft position
sensor.
~3-132~
Engine control system -Crankshaft position sensor 3-133
On-board check
1. Check ECU output voltage.
(a) Connect the oscilloscope probe with the ECU connector
terminals 30 and 11.
ECU terminal name Tester Range Operating conditions
Terminals 30 and 11 2V/DIV,20msec/DIV Idle speed or others
OK:
Prompt:
• Shown in the diagram is the wave form when the engine
is at idle.
between cars.
• In case of grounding of shielded wires, the wave forms
will produce noises.
2. Check crankshaft position sensor.
Crankshaft position sensor
(a) Disconnect crankshaft position sensor connector.
Definitions of crankshaft position sensor connector terminals
A Positive signal output terminal
B Negative signal output terminal
C System shield ground
(b) Measure the crankshaft position sensor resistance.

Standard resistance
A (sensor end) ~ B (sensor end) 1000W ±10% Temperature is
25±5°C
(c) Reconnect the crankshaft position sensor.
replace crankshaft position sensor.
Installation
1. Install crankshaft position sensor.
(a) Apply a thin layer of engine oil on O-ring, and then use
bolts to install crankshaft position sensor.
Torque: (7~9)N∙m
Note:
Confirm that the O-ring is free of cracks or
extruding before installation.
(b) Connect up crankshaft position sensor connector.
Torque ：8～12N.m
~3-133~
3-134 Engine control system - coolant temperature sensor
Coolant temperature sensor

Components
Coolant temperature sensor
~3-134~
Engine Control System - coolant temperature sensor 3-135
Dismantle
2. Dismantle down engine coolant temperature sensor.
(a) Disconnect engine coolant temperature sensor connector.
(b) Dismantle down hex nuts and engine coolant temperature
sensor.
~3-135~
3-136 Engine control system - coolant temperature sensor
On-board check
1. Check engine coolant temperature sensor.
(a) Check resistance
(1) Measure the resistance between terminals with an
ohmmeter.
Ohm meter Standard resistance
A–C It is between 2.29k and 2.60kΩ under 20°C.
B – shell It is between 0.302k and 0.327kΩ under 80°C.
If the resistance value is not satisfactory to the

requirements, replace engine coolant temperature
sensor.
Note:
If the engine coolant temperature sensor needs to
be checked in water, confirm that no water enters
terminals. After checking, wipe off water from the
engine coolant temperature sensor.
Installation
1. Install engine coolant temperature sensor.

(a) Connect up engine coolant temperature sensor connector.
(b) Install hex nuts and engine coolant temperature sensor.
Torque：13～17N.m
2. Connect up cable of battery negative terminal.
Torque ：8～12N.m
3. Check coolant for leakage (refer to related sections)
~3-136~
Engine Control System – Intake pressure and temperature sensor 3-137
Intake pressure temperature sensor

On-board check
1. Check intake air temperature sensor
(a) Disconnect cable from battery negative terminal.
Intake air temperature/pressure sensor (b) Disconnect sensor connector.
(c) Dismantle down bolts; take down intake pressure temperature
sensor.
Definition of sensor terminal
A Output terminal of air intake pressure voltage
B 5V reference voltage terminal
C Output terminal of air intake temperature
resistance
D Signal grounding terminal
(d) Check resistance

(1) Use a tester to check the resistance between terminal
MAT (E1-Pin71)-V5RT and N2 (E1-Pin76).
Standard resistance
Testing conditions Regulatory conditions
At 20±1°C 2308~2726Ω
At 80±1°C 309~350Ω

requirements, replace intake air temperature sensor.
(e) Install fixed bolts of intake pressure temperature sensor.
Torque ： 5～6N.m
(f) Connect up connector.
(g) Connect cable to battery negative terminal.
Torque ：8～12N.m
2. Check ECU terminal voltage.
(b) Measure voltage of E1 ECU connector.
Standard voltage
V5REF2(E1-Pin66)-V5RTN2(E1-
5.0±0.1V
Pin76)
Plugin pin schematic diagram (from

ECU terminal)
~3-137~
3-138 Engine Control System - Intake pressure and temperature sensor
3. The vacuum pump provides different pressures to check

the output voltage of intake manifold absolute pressure
sensor.
(a) Connect vacuum pump to vacuum hose.
(b) Turn igniting switch ON.
(c) Connect voltmeter to corresponding terminals of ECU (54-76).
Plugin pin schematic diagram (from (d) Use vacuum pump to apply different vacuum degrees, and
harness terminal) measure the voltage of E1 ECU connector.
~3-138~
Engine control system – Electronic throttle body 3-139
Electronic throttle body

Components
Electronic throttle body
~3-139~
3-140 Engine Control System - Electronic throttle body
Dismantle
2. Disconnect crankcase vent pipe from the intake pipe on air
filter.
3. Disconnect the intake pipe on air filter connected to
electronic drive control throttle valve body.
4. Disconnect harness connector clip.
5. Dismantle down 4 assembling bolts.
6. Take down harness retaining bracket, and take out
electronic drive control throttle valve body assembly.
~3-140~
Engine control system – Electronic throttle body 3-141
On-board check
1. Check throttle valve assembly
(a) Check and confirm that the throttle valve axle will not
generate "cluck" noise.
2. Electronic throttle valve self-learning
Observe the following steps for electronic throttle valve self-
learning in case of electronic throttle valve or ECU replacement,
or reconnection of battery negative terminal.
(1) Turn ignition switch to "ON" position (no engine start) and
wait for 5s.
(2) Turn ignition switch to "OFF" position and wait for 15s.
(3) Turn ignition switch to "ON" position and start the engine.
Installation
1. Install 4 assembling bolts and fasten the harness retaining
bracket.
Torque：7～9N.m
2. Connect harness connector clip.
3. Connect up the intake pipe on air filter connected to
electronic drive control throttle valve body.
4. Connect crankcase vent pipe to the intake pipe on air filter.
Torque ：8～12N.m
~3-141~
3-142 Engine control system - knock sensor
Knock sensor
Components
Knock sensor
Specified torque
~3-142~
Engine control system - knock sensor 3-143
Dismantle
2. Dismantle down auxiliary instrument panel (refer to
related sections)
3. Dismantle down engine middle cover plate and disconnect
shift cable (refer to related sections).
4. Dismantle down intake manifold (refer to related sections)
5. Disconnect harness connector.
6. Dismantle down assembling bolts and take down knock
sensor.
~3-143~
3-144 Engine control system - knock sensor
On-board check
1. Check knock sensor.
(a) The oscilloscope probe is connected with corresponding
ECU terminal.
Knock sensor
(1) Check wave forms when the engine is idling or
at a certain speed.
ECU terminal Tester Range Regulatory
name conditions
ECU(36)-ECU(37) The engine is at idle
speed or at a certain
speed.
If the results are not satisfactory to related specification,
replace knock sensor.
2. Check knock sensor.
(a) Dismantle down knock sensor.

Ohm meter (b) Measure the resistance between terminals.
Standard resistance
A–B It is greater than 1MΩ under 20±5°C.
(c) Reinstall knock sensor.

If the resistance value is not satisfactory to related
specification, replace knock sensor.
Installation
1. Install knock sensor mounting bolts.
Torque ：16～24N.m
2. Connect harness connector clip.
3. Install intake manifold (refer to related sections)
4. Install engine middle cover plate and disconnect shift cable
(refer to related sections).
5. Install auxiliary instrument panel (refer to related sections)
Torque ：8～12N.m
~3-144~
Engine Control System – Main relay 3-147
Main relay On-board check

Main relay (1) Measure the resistance between terminals with an
ohmmeter.
Standard resistance
3-5 10kΩ or higher
3-5 Less than 1Ω (battery voltage

is applied to terminals 1 and 2)
requirements, replace EFI relay.
~3-145~
3-146 Engine Control System - Fuel Pump Relay
Fuel pump relay

On-board check
1. Check fuel pump replay
(1) Measure the resistance between terminals with an
ohmmeter.
Standard resistance
3-5 10kΩ or higher
Less than 1Ω (battery voltage

3-5 is applied to terminals 1 and 2)

requirements, replace fuel pump relay.
~3-146~
Engine Control System – Valve EGR 3-147
Valve EGR
On-board check
1. Dismantle down canister solenoid valve.
2. Check canister solenoid valve resistance.
Measure the resistance between terminals with an ohmmeter.
Standard resistance
A–B 19Ω-22Ω (at temperature of 20°C)
3. Check working conditions of canister solenoid valve.

(a) Check the working condition of the solenoid valve in the
1. Active carbon port
case of power failure; the air shall not flow from 1 to 2 in
the case of power failure.
(b) Connect two poles of car battery (free of malfunction) to two
terminals of solenoid valve (connect positive pole to A
while negative pole to B).
(c) Check the working condition of solenoid valve in the case of
2 Intake manifold energizing; the air will flow from 1 to 2 after energizing.
port
Carbon canister cleaning 4. If the result is not satisfactory to specifications, replace
control solenoid valve canister solenoid valve.
~3-147~
3-148 Engine Control System - Heated Oxygen Sensor
Heated oxygen sensor
On-board check
1. Check the front and rear oxygen sensor output voltage
wave form.
(a) Connect the oscilloscope probe and ECU connector terminal
47 (front oxygen sensor) to car body and connect terminal
48 (rear oxygen sensor) to ground.
ECU terminal name Terminals 30 and 11
Tester Range 2V/DIV, 20msec/DIV
Operating conditions Idle speed or others
OK:
Prompt:
Plugin pin schematic diagram • Shown in the diagram is the wave form when the engine
(from harness terminal)
is at idle.
• The wave amplitude sees nuances based on the
difference between cars.
OK > Check intermittent trouble
NG > To the next step
2. Check heated oxygen sensor (the same to both front and
Oxygen sensor rear oxygen sensor).
Terminal Number Definition of terminal Colors of connecting wires
A Signal output low level Gray
B Signal output high level Black
C Cathode of heating element White
D Anode of heating element Purple
(a) Disconnect heated front oxygen sensor connector.

(b) Measure the resistance.
Standard resistance
D (sensor terminal) ~ A (sensor side) 9.6±1.5Ω
D (sensor terminal) ~ A (sensor side) 1MΩ or higher
(c) If the results are not satisfactory to related specification,

replace oxygen sensor.
~3-148~
Engine Control System – Fuel Injector 3-149
Fuel injector
On-board check
1. Check resistance.
Measure the resistance between terminals with a universal meter.
(a) Disconnect injector connector.
M3.5 Injector (b) Measure the resistance of injector.
Standard resistance
When the temperature is 20°C, the
A–B
resistance is 12.0±0.6Ω.
Schematic diagram of connector pins (c) Reconnect the fuel injector connector.
(seeing from the injector end)
Note:
Do this operation in a well-ventilated area for
fire prevention.
replace injector.
2. Check injection amount.
Note:
Carry out the test in an area with good ventilation
and keep away from fire.
(a) Disconnect fuel hose from No.1 fuel pipe.
(hose)
(b) Install a new O-ring on fuel injector.
(b) Install SST and ethylene tube on fuel injector.
(connector)
Clamp SST 09268-31012 (09268-41110, 09268-41300,
spring 95336-08070)
(d) Connect SST (one hose) to No.1 fuel pipe.
(e) Place fuel injector in measuring cylinder.
(clamp)
Ethylene tube
(f) Execute fuel pump operation.
(g) Install SST on fuel injector.
(h) Connect SST to battery and measure the injection amount
for 15s. Carry out twice or 3 times check and then calculate
the average.
Injection amount: 2.4g/s
Note:
Switching operation shall be carried out on the side of
battery.
Measuring If the results are not satisfactory to related specification,
Battery
cylinder replace fuel injector.
3. Check for leakage.
~3-149~
3-150 Engine Control System - Fule Injector
(a) In order to check the injection amount, dismantle down SST

from battery. Check fuel injector for oil leaks.
Standard:
1 drop or little per minute.
If the results are not satisfactory to related specification,
replace fuel injector.
~3-150~
Engine Control System - Ignition Coil 3-151
Ignition coil
On-board check
1. Check DTC
Note:
If there are DTCs, analyze to discover the trouble based on the
detailed specification of corresponding DTC.
2. Dismantle down ignition coil
3. Dismantle down all ignition plugs.
4. Disconnect all injector connectors.
5. Check ignition plug.
Process ignition plugs accordingly.
6. Install the ignition plugs in ignition coil, and then connect
up ignition coil connector.
7. Check and confirm the correct connections between
connectors.
8. Have the ignition plugs grounded, use tester drive to
execute the test functions of ignition coil to check the
ignition sparks of ignition plugs.
Note:
If anything unusual happens to sparks, replace ignition plugs to
test again; if the ignition spark remains abnormal, connect
ignition coil to normal parts for conversion testing; and if the
ignition coil is confirmed as abnormal after comparison
validation, replace ignition coil.
~3-151~
~3-152~
Engine machinery
Engine 4-2
On-board check v 4-2
Transmission Belt 4-4
Component 4-4
Dismantle 4-5
Check 4-5
Installation 4-5
Valve clearance 4-7
Adjustment 4-7
Camshaft 4-19
Component 4-19
Dismantle 4-21
Check 4-24
Installation 4-25
Engine assembly 4-29
Component 4-29
Dismantle 4-37
Installation 4-44
Engine Unit 4-51
Component 4-51
Dismantle down 4-58
Check 4-70
Re-install 4-83
Repair 4-103
~4-1~
4-2 Engine Machinery - Engine
Engine
On-board check
1. Check coolant.
2. Check engine oil.
3. Check battery.
4. Check air filter filter-element subassembly.
(a) Dismantle down air filter filter-element subassembly.
(b) Visually check the air filter filter-element for dust, blocking,
or damages.
Prompt:
• If there is dust or blocking on air filter filter-element, clean
with compressed air.
• If there is still dust or blocking on air filter filter-element
after cleaning with compressed air, replace it.
5. Check ignition plug.
6. Check ignition timing
(a) Check and confirm that the ignition timing is subject to the
specified value range.
Ignition timing: 4-8 BTDC
Note:
During the check of ignition timing, the transmission
gear shall be on Park/Neutral position.
Prompt:
After the engine runs for 5s at the speed of 1,000 to 1,300,
release the accelerator and check whether the engine speed
returns to idle speed.
7. Check engine idle speed.
Idle speed: 750rpm
Note:
 During the check of idle speed, the transmission gear shall be
on Park/Neutral position.
 Turn all electrical systems and A/C to OFF position.
 For the check of engine idle speed, the cooling fan shall be
turned to OFF position.
8. Check pressure
(a) Warm up the engine and then stop it.
(b) Dismantle down air filter assembly.
(c) Dismantle down ignition coil.
(d) Dismantle down ignition plug.
(e) Disconnect fuel injector connector.
~4-2~
Engine machinery - Engine 4-3
(f) Check pressure.

Pressure meter (1) Insert a pressure gauge into ignition plug hole.
(2) Open throttle valve completely.
(3) Start the engine and measure the compression pressure.
Compression pressure: 1,470KPa
Minimum pressure: 1,079KPa
The different between various
cylinders: 147KPa
Note:
 Choose fully charged batteries in order to have the
engine speed elevated to 330rpm or above.
 Check other cylinders with the same method.
 Measure the compression pressure in the shortest
possible time.
(4) If the compression pressure is relatively low, pure little
engine oil into cylinders and check again.
Prompt:
 After adding of engine oil, if the compression
pressure rises, the piston ring may be subject to
wear-out.
 If the pressure remains low, valve may be blocked.
the sealing may be improper, or gasket may be
subject to leaks.
9. Check CO/HC.
~4-
4-4 Engine machinery - transmission belt
Transmission Belt
Components
Fan and generator V belt
~4-4~
Engine machinery - transmission belt 4-5
Dismantle
1. Dismantle down fan and generator V belt.
(a) Loosen fixed bolt A and B.
(b) Loosen adjusting bolt C, and then dismantle down V belt.
Check
1. Check fan and generator V belt.
(a) Visually check the belt for excessive wear or absence of
cord thread wear. In case any flaws are found, replace the
belt.
Prompt:
It is allowed to have some cracks on the shoulder side of the
belt. If the teeth on the belt break down in pieces, the belt
shall be replaced.
Installation
1. Install fan and generator V belt.
(a) Install V belt on various belt pulleys temporarily.
2. Adjust fan and generator V belt.
(a) Turn the adjusting bolt C and adjust the tension of the V
belt.
(b) Tighten fixed bolt A and B.
Torque
19N.m for bolt A
44N.m for bolt B
~4-5~
4-6 Engine machinery - transmission belt
3. Check fan and generator V belt.
(a) Check the belt for deformation by pressing the position
indicated by the arrows in the diagram.
Deformation
Item Regulatory conditions
New belt 5.0-6.0mm
Old belt 8.0-9.0mm
Tension
Item Regulatory conditions
New belt 785-981N
Old belt 441N to 539N
If the belt is not satisfactory to related specification, carry

out adjustment.
Prompt:
 Check V belt for deformation on specified positions.
 Set the tension as the specified value in the case of new
belt installation.
 For the check of the belts which have been used for over
5 minutes, the standards for "old belts" shall be observed.
 For the reinstallation of the belts which have been used
for over 5 minutes, adjust their deformation and tension
based on the intermediate values of various parameters
of "old belt".
 The V belt tension and deformation shall be checked
after 2 weeks' running of the engine.
 If tension meter is needed, a standard meter shall be used
for the confirmation of accuracy.
~4-6~
Engine machinery - valve clearance 4-7
Valve clearance Adjustment

1. Disconnect cable from battery negative terminal.
2. Dismantle down ignition coil assembly
(a) Disconnect 4 connectors.
(b) Dismantle 4 bolts, and then dismantle down ignition coil
assembly.
3. Dismantle down vent hose

Crankshaft (a) Dismantle down PVC valve breather pipe.
vent pipe (b) Dismantle down crankcase vent pipe.
PVC valve 4. Dismantle down engine harness
breather pipe
5. Dismantle down cylinder head cover subassembly

(a) Dismantle down 11 bolts and 2 nuts according to the
sequence shown in the diagram, and then dismantle down
cylinder head.
6. Check valve clearance.

Note:
Check valve clearance when the engine is at
cold state.
(a) Set No.1 cylinder as TDC/compression.
(1) Rotate crankshaft clock-wise, and align the timing
mark of the crankshaft belt pulley to the indication
Timing mark mark of the chain cover.
~4-7~
4-8 Engine machinery - valve clearance
(b) Check the positioning mark of the camshaft timing chain

wheel for being upward. If it is not upward, rotate the
crankshaft for one cycle to make it upward.
Positioning mark
(c) As is shown in the figure, check valve clearance.

(1) Use a clearance gauge to measure the clearance
between valve tappet and camshaft.
Valve clearance (cold state):
Intake air 0.15mm to 0.23mm
Exhaust 0.28mm to 0.36mm
Prompt:
If the clearance is not satisfactory to related
specifications, record the measured value which
exceeds standard.
(d) Rotate crankshaft for 1 cycle, and place No.4 cylinder on
TDC/compression.
(e) As is shown in the figure, check valve clearance.
(1) Use a clearance gauge to measure the clearance
between valve tappet and camshaft.
Valve clearance (cold state):
Intake air 0.15mm to 0.23mm
Exhaust 0.28mm to 0.36mm
Prompt:
If the clearance is not satisfactory to related
specifications, record the measured value which
exceeds standard.
7. Adjust valve clearance.
Note:
For the dismantling of camshaft, in order to avoid the
interference from the valves with pistons, rotate the
crankshaft about 90° from No.1 cylinder TDC/compression
position in the direction of engine running.
(a) Dismantle down 2 nuts and No.2 timing chain cover.
~4-8~
(b) Rotate crankshaft belt pulley clock-wise, and dismantle

down 2 of 3 bolts.
(c) Rotate crankshaft clock-wise, and align the timing mark of

the crankshaft belt pulley to the indication mark of the chain
cover.
Timing mark
(d) Check the positioning mark of the camshaft timing chain

crankshaft for one cycle to make it upward (No.1 cylinder is
at TDC/compression position).
Positioning mark
(e) Make paint marks on timing chain disc to make it align to

the positioning marks on camshaft timing chain wheel and
Paint mark camshaft timing gear.
Positioning mark (f) Loosen the bolts for the fastening of camshaft timing chain
wheel at the same time of camshaft hexagonal top fastening.
Note:
All that is needed to loosen the bolts, do
not dismantle down bolts and chain wheel.
Prompt:
Loosen the bolts in advance. If the bolts are loosened after
the chain wheel is dismantled, the chain wheel might be
disturbed by the chain.
~4-9~
(g) Use an 8mm sleeve hex wrench to dismantle down chain
cover service hatch screw plug.
(h) Insert a screwdriver into chain cover service hatch, and then
move downwards the lock plate of the tensioner and keep it
at unlocked state.
Prompt:
• The operation will open the plunger of the tensioner.
• If it is not easy to open the lock plate, use the hexagonal
top of the camshaft to rotate the camshaft right and left.
(i) Rotate the camshaft to the right with the hexagonal top of
the camshaft in order to make the chain push the tensioner
plunger.
(j) Dismantle down screwdriver from chain cover service hatch.

Align the holes of lock plate to those of tensioner, and insert
1 hex wrench with diameter of 2.5mm.
Note:
• Fix the camshaft with the hexagonal top of the
camshaft.
• Fix the 2.5mm hex wrench with adhesive tapes to
make it unavailable to be pulled out.
Prompt:
The operation will fix the plunger of the tensioner in place.
(k) Dismantle down the rest bolts, and then dismantle down
camshaft timing chain wheel.
~4-10~
(1) Dismantle down bolts and camshaft timing chain wheel

assembly.
(m) Dismantle down 20 bolts.

(n) Dismantle down No.1 bearing cap and 8 2# bearing caps as
the sequence shown in the figure.
(o) Hold the timing chain with hands, and then dismantle down
camshaft.
(p) After the dismantling of camshaft, insert 1 rod to fix the

chain to prevent it from dropping.
(q) Dismantle down valve tappet.
(r) Use a micrometer to measure the thickness of the

dismantled valve tappet.
(s) Calculate the thickness of the valve tappet and make the
valve clearance subject to specified values.
A Chosen valve tappet
B Dismantled valve tappet thickness
C Measured valve clearance
Specified value (at cold state):

Intake air A=B + (C-0.18mm)
Exhaust A=B + (C-0.31mm)
(t) Choose 1 new tappet with thickness as near as possible to
the calculated value.
Prompt:
• There are tappets with 29 sizes (from 5.12mm to 5.68mm)
for choice, and the difference between two adjacent sizes
is 0.02mm.
~4-11~
Valve Tappet Option Table (Exhaust)
The thickness of the installed

tappet
Measured
clearancea
~4-12~
Intake air valve clearance (cold state):

0.15-0.23 mm
Example:
A 5.260mm tappet is installed and the measured
clearance is 0.400mm.
Use a new 48# tappet to replace the 5.260mm
tappet.
New tappet thickness

Tappet No. Thickness Tappet No. Thickness Tappet No. Thickness
12 5.120 32 5.320 52 5.520
14 5.140 34 5.340 54 5.540
16 5.160 36 5.360 56 5.560
18 5.180 38 5.380 58 5.580
20 5.200 40 5.400 60 5.600
22 5.220 42 5.420 62 5.620
24 5.240 44 5.440 64 5.640
26 5.260 46 5.460 66 5.660
28 5.280 48 5.480 68 5.680
30 5.300 50 5.500 -
~4-13~
Valve Tappet Option Table (Exhaust)
The thickness of the

installed tappet
Measured clearance
~4-14~
Exhaust valve clearance (cold state):

0.28-0.36 mm
Example:
A 5.340mm tappet is installed and the measured
clearance is 0.440mm.
Use a new 48# tappet to replace the 5.340mm tappet.
New tappet thickness
Tappet No. Thickness Tappet No. Thickness Tappet No. Thickness
12 5.120 32 5.320 52 5.520
14 5.140 34 5.340 54 5.540
16 5.160 36 5.360 56 5.560
18 5.180 38 5.380 58 5.580
20 5.200 40 5.400 60 5.600
22 5.220 42 5.420 62 5.620
24 5.240 44 5.440 64 5.640
26 5.260 46 5.460 66 5.660
28 5.280 48 5.480 68 5.680
30 5.300 50 5.500 - -
(u) Install the chosen valve tappets.

(v) Apply engine oil on cam, cylinder cover journal and the top
of valve tappet.
(w) Place camshaft to make the cam top of No.3 and No.4
cylinder on the side of intake (camshaft) to push the valve
tappet, and make the cam top of No.2 and No.4 cylinder on
the side of exhaust (No.2 camshaft) to push the valve tappet.
(x) Check forward marks and number and check the sequence
based on that as is shown in the diagram. Tighten the bolts
by steps as the sequence shown in the figure.
Torque: 13N.m
(y) Install camshaft timing chain wheel with bolts temporarily.
~4-15~
(z) Install No.2 camshaft with 1 bolt temporarily.
(aa) Install chain, and make the mating mark of the camshaft
Paint mark
timing chain wheel align to the paint mark made before the
dismantlement of the chain.
Prompt:
Firstly, install the chain on any one camshaft. Rotate the
camshaft left and right with the hexagonal top of the
camshaft to make the mating mark of the chain wheel align
to the paint mark of the chain.
Mating mark
(ab) Dismantle down the hex wrench with diameter of 2.5mm
from the tensioner.
Prompt:
Rotate the camshaft to the left slightly with the hexagonal
top of the camshaft, and then dismantle down the hex
wrench with diameter of 2.5mm when the tensioner side
chain is loosened.
(ac ) Tighten the bolts to specified torque for the installation of
camshaft timing chain wheel at the same time of camshaft
hexagonal top fastening.
Torque: 63～77N.m
(ad) Apply adhesive on 2 or 3 threads at the end of the chain
cover service hatch screw plug bolt.
Warning:
Wipe off the engine oil from the bolts and bolt holes.
(ae) Rotate crankshaft belt pulley clock-wise, and install the rest
2 bolts on No.2 camshaft chain wheel. And then tighten the
3 bolts to the specified torque.
Torque:8.0N.m
~4-16~
(af) Apply adhesive on 2 or 3 threads at the end of the chain

Warning:
Do not allow any foreign bodies and engine oil
to attach to the bolts and bolt holes.
(ag) Use an 8mm sleeve hex wrench to install the chain cover
service hatch screw plug.
Torque:17N.m
(ah) Install No.2 timing chain cover.

(1) Apply sealing material as is shown in the figure.
Sealing material:
Tianshan 1598, Loctite 5900
Sealing material:
(2) Install No.2 timing chain cover with 2 bolts.

Torque:10N.m
Warning:
Wipe off engine oil from the contact surface.
Install No.2 timing chain cover within 3 minutes
after the application of sealing material.
Do not start the engine within 2 hours after
installation.
8. Install cylinder head cover subassembly

(a) Install 1 new cylinder cover spacer on the spacer slot of the
cover, and then insert 1 new spacer into the boss in the
middle of the cover.
Warning:
Pad
The spacer shall be inserted securely
until it contacts the shoulder.
(b) Apply sealing material as is shown in the figure.

Sealing material: Tianshan 1598, Loctite 5900
Prompt:
Sealing
The application scope of the sealing material is wide 5mm
material
and thick 2mm.
~4-17~
(c) Temporarily use 1 bolt and 2 nuts to install the cylinder

cover.
(d) Tighten bolts and nuts by steps as the sequence shown in the
diagram.
Torque:
12N.m for bolts
9.0N.m for nuts
9. Install engine harness
10. Install ignition coil assembly

(a) Install ignition coil assembly with 4 bolts.
Torque ：7.5N.m
(b) Connect up 4 connectors.
11. Install vent hose

Crankshaft (a) Connect up PVC valve breather pipe and crankcase vent pipe.
vent pipe 12. Install intake pipe assembly-engine (refer to related sections)
PVC valve 13. Connect cable to battery negative terminal
breather pipe Torque ：8～12N.m
~4-18~
Engine machinery - camshaft 4-19
Camshaft
Components
Crankshaft vent pipe
PVC valve
breather pipe
Cylinder cover
subassembly
Cylinder cover
sealing strip
Specified torque
~4-19~
4-20 Engine machinery - camshaft
Camshaft 1st bearing cap

Camshaft bearing cap
VVT (variable phase, cam adjuster)

Intake camshaft
Exhaust camshaft
Exhaust camshaft chain wheel
VVT cover plate
Specified torque
~4-20~
Dismantle
1. Disconnect cable from battery negative terminal.
2. Dismantle down ignition coil assembly (refer to related
sections)
3. Disconnect vent hose (refer to related sections)
4. Dismantle down engine harness
5. Dismantle down cylinder head cover assembly
(a) Dismantle down 11 bolts and 2 nuts according to the
sequence shown in the diagram, and then dismantle cylinder
head cover.
6. Dismantle down VVT cover plate

(a) Dismantle down 2 nuts and VVT cover plate.
7. Dismantle down camshaft

(a) Rotate crankshaft belt pulley clock-wise, and dismantle
down 2 bolts.
(b) Rotate crankshaft clock-wise, and align the timing mark of

the crankshaft belt pulley to the indication mark of the chain
cover.
Note:
For the dismantling of camshaft, in order to avoid the
interference from the valves with pistons, rotate the
crankshaft about 90° from No.1 cylinder TDC/compression
Timing mark position in the direction of engine running.
~4-21~
(c) Check the positioning mark of the camshaft timing chain

crankshaft for one cycle to make it upward (No.1 cylinder is
at TDC/compression position).
Positioning mark
Paint mark
(d) Make 2 paint marks on timing chain disc to make them
align to the positioning marks on camshaft timing chain
wheel and camshaft timing gear.
Positioning mark
(e) Loosen the bolts for the fastening of camshaft timing chain
wheel at the same time of camshaft hexagonal top fastening.
Note:
All that is needed to loosen the bolts, do
not dismantle down bolts and chain wheel.
Prompt:
Loosen the bolts in advance. If the bolts are loosened after
the chain wheel is dismantled, the chain wheel might be
disturbed by the chain.
(f) Use an 8mm sleeve hex wrench to dismantle down chain

cover service hatch screw plug.
(g) Insert a screwdriver into chain cover service hatch, and then
move downwards the lock plate of the tensioner and keep it
at unlocked state.
Prompt:
• The operation will open the plunger of the tensioner.
• If it is not easy to open the lock plate, use the hexagonal
top of the camshaft to rotate the camshaft right and left.
~4-22~
(h) Rotate the camshaft to the right with the hexagonal top of
the camshaft in order to make the chain push the tensioner
plunger.
(i) Dismantle down screwdriver from chain cover service hatch.

Align the holes of lock plate to those of tensioner, and insert
1 hex wrench with diameter of 2.5mm.
Note:
• Fix the camshaft with the hexagonal top of the camshaft.
• Fix the 2.5mm hex wrench with adhesive tapes to make
it unavailable to be pulled out.
Prompt:
The operation will fix the plunger of the tensioner in place.
(j) Dismantle down the fixed bolts of the camshaft timing gear
or chain wheel, and dismantle down chain wheel from the
exhaust camshaft.
(k) Dismantle down bolts and camshaft timing chain wheel.

(1) Dismantle down 20 bolts.
(m) Dismantle down No.1 bearing cap and 8 2# bearing caps as

the sequence shown in the figure.
(n) Hold the timing chain with hands, and then dismantle down
camshaft.
~4-23~
(o) After the dismantling of camshaft, insert 1 rod to fix

the chain to prevent it from dropping.
Check
1. Check camshaft timing chain wheel assembly.
Note:
Do not Dismantle down camshaft
timing chain wheel assembly.
(a) Clamp camshaft with a bench vise.
Note:
Do not damage the camshaft.
(b) Tighten the timing chain wheel temporarily with bolts.
(c) Cover one of the 2 advance interfaces with fingers.
Advance interface
(d) Apply pressure on another advance interface.

Note:
Be careful to prevent engine oil from spilling out.
~4-24~
(e) Check lock pins for loosening with hands, and check the
chain wheel for stable moving within 30°.
Note:
The timing chain wheel is locked at the maximum
delay position.
(f) Lock the timing chain wheel at the maximum delay position,
and then dismantle down bolts and timing chain wheel.
Installation
1. Install camshaft.
Note:
For the installation of camshaft, in order to avoid the
interference from the valves with pistons, rotate the crankshaft
about 90° from No.1 cylinder TDC/compression position in the
direction of engine running.
(a) Apply engine oil on cam, cylinder cover journal and the top
of valve tappet.
(b) Place camshaft to make the cam top of No.3 and No.4
cylinder on the side of intake (camshaft) to push the valve
tappet, and make the cam top of No.2 and No.4 cylinder on
the side of exhaust (No.2 camshaft) to push the valve tappet.
(c) Check the forward marks and number on the bearing cap as
the sequence shown in the figure. And then tighten the bolts
by steps as the sequence shown in the figure.
Torque: 13N.m
(d) Install camshaft timing chain wheel with bolts temporarily.
~4-25~
(e) Install exhaust camshaft with 1 bolt temporarily.
Paint mark (f) Install chain, and make the mating mark of the camshaft
timing chain wheel align to the paint mark made before the
dismantlement of the chain.
(g) Dismantle down the hex wrench with diameter of 2.5mm
from the tensioner.
Prompt:
Rotate the camshaft to the left slightly with the hexagonal
top of the camshaft, and then dismantle down the hex
Mating mark wrench with diameter of 2.5mm when the tensioner side
chain is loosened.
(h) Tighten the bolts to specified torque for the installation of

camshaft timing chain wheel at the same time of camshaft
hexagonal top fastening.
Torque: 63～77N.m
(i) Rotate crankshaft belt pulley clock-wise, and install the rest 2
bolts on exhaust camshaft chain wheel. And then tighten the 3
bolts to the specified torque.
Torque:8.0N.m
(j) Apply adhesive on 2 or 3 threads at the end of the chain

Note:
Wipe off the engine oil from the bolts and bolt holes.
(k) Use an 8mm sleeve hex wrench to install the chain cover
service hatch screw plug.
Torque:17N.m
~4-26~
2. Install VVT cover plate

(a) Apply sealing material as is shown in the figure.
Sealing material
(b) Install VVT cover plate with 2 bolts.

Torque:10N.m
Note:
• Wipe off engine oil from the contact surface.
• Install No.2 timing chain cover within 3 minutes after
the application of sealing material.
• Do not start the engine within 2 hours after
installation.
3. Check valve clearance (refer to related sections)
4. Adjust valve clearance (refer to related sections)
5. Install cylinder head cover subassembly
(a) Install cylinder cover spacer on the spacer slot of the cover,
and then insert the spacer into the boss in the middle of the
cover.
Note:
Pad
The spacer shall be inserted securely until it contacts the
shoulder.
(b) Apply sealing material as is shown in the figure.

Sealing
material Prompt:
The application scope of the sealing material is wide
5mm and thick 2mm.
(c) Temporarily use 11 bolts and 2 nuts to install the cylinder

cover.
(d) Tighten bolts and nuts by steps as the sequence shown in the
diagram.
Torque:
12N.m for bolts
9.0N.m for nuts
6. Install engine harness
7. Install vent hose (refer to related sections)
8. Install ignition coil assembly (refer to related sections)
~4-27~
Torque ：8～12N.m
~4-28~
Engine machinery - engine assembly 4-29
Engine assembly
Components
No.1 radiator bracket
Water inlet pipe of radiator
Radiator delivery hose
Radiator assembly
V-ribbed belt
Specified torque
~4-29~
4-30 Engine machinery - engine assembly
Oxygen sensor assembly
Seal ring
Catalytic converter welding assembly
Gasket assembly
Non-reusable parts
~4-30~
Water pump assembly
Water pump
sealing gasket
Water pump pulley
Specified torque
Non-reusable parts
~4-31~
Exhaust pipe gasket
Exhaust pipe gasket heat
Exhaust pipe
Specified torque
Non-reusable parts
~4-32~
Seal water cover

plate pad
Seal water
cover plate
Discharging Thermolator seat assembly

tube pad
Thermolator assembly
Discharging tube
assembly
Water connecting hose

inlet assembly
O-ring
Specified torque
Non-reusable parts
~4-33~
Specified torque
~4-34~
Fuel guide assembly
Injector snap ring

Throttle valve body
Injector lower seal ring
Throttle valve O-ring Intake manifold
Intake manifold seal ring
Ignition coil
Knock sensor
Specified torque
Non-reusable parts
~4-35~
One-piece flywheel ring gear assembly
Flywheel baffle
Clutch cover assembly
Clutch driven disc assembly
Specified torque
~4-36~
Dismantle
1. Disconnect battery negative terminal.
2. Discharge engine coolant, engine oil, and transmission oil
(refer to related sections)
3. Dismantle down driver's and co-driver's seat assembly
4. Dismantle down engine intake hose and crankcase vent
pipe (refer to related sections)
5. Disconnect engine harness.
6. Disconnect all connectors of engine control system actuator
and sensor harness (refer to related sections).
7. Disconnect engine water inlet/discharging pipe (refer to
related sections).
8. Disconnect the discharging tube connected to the engine
and radiator (refer to related sections).
9. Disconnect fan heater water pipe.
10. Disconnect canister solenoid valve exit pipe (refer to related

sections).
~4-37~
11. Disconnect boost vacuum hose from the intake manifold.
12. Disconnect the fuel pipe on fuel guide rail from the engine.
Note:
Release fuel pressure before fuel pipe disconnection. Wrap up
the oil rail with clean rags to avoid oil-way blocking caused by
the entrance of foreign bodies. (refer to related sections)
13. Dismantle down air condition compressor and bracket

from the engine.
14. Dismantle down respectively the clutch stay wire and gear
shifting/selecting cable from clutch tumbler and
transmission box (refer to related sections).
15. Disconnect turbine assembly and reversing switch harness
from the transmission.
16. Dismantle down catalytic converter welding assembly.

(a) Disconnect oxygen sensor connector.
(b) Dismantle down 2 silencer flange bolts and 2 springs.
(c) Dismantle down 6 nuts.
17. Dismantle down drive shaft (refer to related sections)
18. Dismantle down manual transmission (refer to related
sections)
19. Dismantle down clutch cover assembly and driver disc
assembly (refer to related sections)
20. Dismantle down flywheel ring gear assembly

(a) Fix crankshaft belt pulley with SST.
SST 09330-00021, 09213-54015, (91651-60855)
(b ) Dismantle down 6 bolts, and then dismantle down flywheel
ring gear assembly.
~4-38~
21. Dismantle down flywheel baffle.

(a) Dismantle down bolts and flywheel baffle.
22. Dismantle down engine assembly.

(a) Let the lifter fall slowly, and dismantle down the engine
front suspension cross member assembly when the engine falls
on the bracket.
23. Dismantle down throttle valve assembly.

Crankshaft
(a) Dismantle down the crankcase vent pipe and intake hose at
vent pipe
the positions shown in the diagram.
PVC valve
breather pipe
~4-39~
(b) Dismantle down 4 bolts at the positions shown

in the figure and take down the throttle valve.
(c) Dismantle down throttle valve O-ring.
24. Dismantle down intake manifold assembly.

(a) Dismantle down the 2 bolts and 3 nuts at the position shown
in the diagram and Dismantle down intake manifold assembly.
(b) Dismantle down the connecting bolts at the positions shown

in the diagram.
Dismantle down intake manifold.
25. Dismantle down knock sensor.
26. Dismantle down fuel guide rail and injector assembly.

(a) Dismantle down the 2 bolts shown in the diagram, and take
down fuel guide rail and injector assembly.
Note:
Have the injector opening upward when placing fuel
guide rail and injector assembly in order to avoid
injector orifice blocking due to pollutant; clean plastic
bags may be used to seal the fuel guide rail and injector
assembly for placing.
~4-40~
27. Dismantle down left/right bracket and exhaust manifold

assembly.
(a) Dismantle down the 5 bolts at the positions shown in the
figure.
Take down the left/right bracket.
Dismantle down oxygen sensor harness.
(b) Dismantle down exhaust manifold heat shield assembly.

Dismantle down the 4 bolts at the position shown in the
diagram and dismantle down intake manifold assembly.
(c) Dismantle down oxygen sensor.
Note:
Do not dismantle down oxygen sensor at thermal state in
order to prevent the sensor from damages and scald.
~4-41~
(d) Dismantle down the 5 bolts at the positions shown in the

diagram and dismantle down exhaust manifold assembly.
(e) Dismantle down exhaust manifold assembly.
28. Dismantle down belt pulley.

(a) Dismantle down bolts, and then dismantle down vane pump
rear supportor.
29. Dismantle down water pump.

30. Dismantle down alternator.
(a) Dismantle down generator adjustment bracket.
(b) Dismantle down generator mounting bolts and generator.
~4-42~
31. Dismantle down water inlet and discharging tube.

(a) Dismantle down the 4 bolts shown in the figure and take down
the water inlet and discharging tube.
32. Dismantle down thermostat

(a) Dismantle down the 2 spring clamps, 2 bolts shown in the
figure and take out thermostat.
33. Dismantle down PCV valve.
34. Dismantle down PCV valve rubber mat.
35. Dismantle down ignition coil and camshaft position sensor.
~4-43~
36. Dismantle down water temperature sensor assembly.

(a) Dismantle down engine coolant temperature sensor with
special tools.
37. Dismantle down seal water cover plate and seal water cover
plate gasket.
Installation
1. Install seal water cover plate and seal water cover plate
gasket.
2. Install water temperature sensor assembly.

Bolt torque: 20N.m
~4-44~
3. Install camshaft position sensor and ignition coil.

(a) Install camshaft position sensor.
Bolt torque: 12N.m
(b) Install ignition coil.

Bolt torque: 7.5N.m
4. install PCV valve rubber base.
5. Install PCV valve.
6. Install thermostat.
(a) Place the thermostat and install the 2 spring clamps, 2 bolts
shown in the figure.
~4-45~
7. Install inlet and discharging tube

Torque: 20N.m
8. Install alternator.
(a) Install generator with generator mounting bolts.
Bolt torque: 44N.m
(b) Install generator adjustment bracket.

Bolt torque: 20N.m
9. Install water pump.

(a) Install new water pump sealing gasket.
(b) Install water pump assembly.
Torque:9N.m
10. Install water pump pulley.

Torque:12N.m
~4-46~
11. Install left/right bracket and exhaust manifold assembly.

(a) Install exhaust manifold assembly.
(b) Install exhaust manifold as the sequence shown in the diagram.
(c) Install oxygen sensor.
(d) Install exhaust manifold heat shield assembly.
12. Install fuel guide rail and injector assembly.

(a) Apply a thin layer of engine oil on the injector seal ring shown
in the diagram.
(b) Insert the injector into the injection hole on the cylinder cover
as the direction shown in the diagram.
13. Install knock sensor.

Bolt torque: 20N.m
14. Install intake manifold assembly.

(a) Install intake manifold sealing gasket.
(b) Install intake manifold assembly.

Torque:19N.m
~4-47~
15. Install throttle valve assembly.

(a) Install a new O-ring on the throttle valve, and then install the
throttle valve.
(b) Install the crankcase vent pipe and intake hose.

Crankshaft 16. Install engine assembly.
vent pipe (a) Install the engine front suspension cross member assembly on
PVC valve the engine.
breather pipe (b) Use engine bracket to set up the engine and move it below the
lifter to align to the mounting nut holes on the engine
suspension and frame. Make the vehicle lifter fall slowly.
(c) Connect the engine suspension cross member assembly to the

frame with 4 bolts.
Torque:40～70N.m
~4-48~
17. Install flywheel baffle.

Torque ：7.5N.m
18. Install flywheel ring gear assembly.
(a) Install flywheel retainer ring.
(b) Apply little thread sealant to the front of the flywheel bolt.
adhesive Sealant: 262 Thread-locking Adhesives
(c) Install flywheel ring gear assembly.
(d) Tighten the flywheel bolts as the sequence shown in the

diagram.
Torque ：78N.m
Note:
Do not start the engine within 1 hour after installation.
19. Install clutch cover assembly and driver disc assembly
20. Install manual transmission (refer to related sections)
21. Install drive shaft (refer to related sections)
22. Install catalytic converter welding assembly (refer to
related sections)
23. Connect up turbine assembly and reversing switch harness
on the transmission.
24. Install respectively the clutch stay wire and gear
shifting/selecting flexible shaft on the clutch tumbler and
transmission box (refer to related sections).
25. Install air condition compressor and bracket.
Torque ：18～28N.m
26. Connect up fuel hose and fuel guide rail (refer to related
sections).
~4-49~
27. Connect boost vacuum hose to intake manifold.

28. Connect up canister solenoid valve exit pipe (refer to
related sections).
29. Connect up heater water pipe.

30. Connect up engine water inlet/discharging pipe (refer to
related sections).
31. Connect up all connectors of engine control system actuator
and sensor harness (refer to related sections).
32. Connect up engine harness.
33. Connect up engine intake hose and crankcase vent pipe
34. Install driver's and co-driver's seat assembly (refer to
related sections)
35. Add engine coolant, engine oil, and transmission oil (refer
to related sections)
36. Connect up battery negative terminal.
Torque ：8～12N.m
~4-50~

Engine control system troubleshooting guide

Caricato da

Informazioni sul documento

Descrizione originale:

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Engine control system troubleshooting guide

Caricato da

Copyright:

Formati disponibili

Engine control system - control system 3-103

(a) Check installation of camshaft position sensor.

DTC P0353 No.3 ignition coil fault Type of fault code：A

DTC P0354 No.4 ignition coil fault Type of fault code：A

The electrical characteristics of ignition coils at room temperature

Type Technical specification

Type Technical specification

(A\B\C are correspondent

Ignition coil (a) Disconnect the ignition coil assembly connector

Detection and judgment (check whether to be short circuit)

(d) Reconnect ECU connector.

(c) Turn ignition switch to ON position.

No. 1 ignition coil A (harness

No.3 ignition coil A (harness

Connection of tester Regulatory conditions

(e) Reconnect ignition coil assembly.

• No trouble codes related to

Flow (Normal Litre/min)

Carbon canister cleaning control

The canister solenoid valve controls the switching time and

• The harness between canister solenoid valve

• The harness between canister solenoid valve

(c) Check working conditions of canister solenoid valve.

(a) Disconnect V6 canister solenoid valve connector.

Detection and judgment

A (harness side)～body The resistance is 10kΩ

B (harness terminal)～ Harness is short to power

3-5 Less than 1Ω (battery voltage is applied to

FANLO(E1～65)–PWR GND(E1～2) 11-14V

2. Check fan relay.

(a) Dismantle down fan relay from fuse box.

3～5 10kΩ or higher

3～5 Less than 1Ω (battery voltage is applied to terminals

(a) Disconnect ECU connector.

(c) Reconnect fan connectors.

5. Check harness and connectors (ECU-fan relay)

Standard resistance (Check whether the short circuit happens)

(d) Reconnect fan connectors.

(c) Reconnect fan connectors.

• The engine is running. Under acceleration • Poor connection

B Check speedometer circuit.

(a) Disconnect C4 instrument cluster connector.

Check for short circuit.

SPSR (C4-10) ～Body ground 10kΩ or higher

(d) Reconnect instrument cluster connector.

Instrument cluster connector.

Learning deviation of air intake VCP cam gear

• The engine is running.

• The engine is running.

• The control circuit

ECU power circuit

Single point grounding of engine

Schematic diagram of connector pins

2. Check harness and connectors (ECU-car body ground)

5. Check ignition or engine switch assembly

3-5 10kΩ or higher

3-5 Less than 1Ω (battery voltage is

Schematic diagram of connector pins

Standard resistance (Check whether the open circuit happens)

Standard resistance (Check whether the short circuit happens)

(d) Reconnect ECU connector.

Camshaft timing oil control valve