Engine Efi System PDF

CHERYA21 SERVICE MANUAL ENGINE EFI SYSTEM
CONTENT
1. NOTICE TO THE EFI SYSTEM SERVICE .........................................................................................3

1.1. GENERAL SERVICE ...........................................................................................................................3
1.2. NOTICE DURING THE SERVICE.............................................................................................3
1.3. SERVICE TOOLS .........................................................................................................................4
1.4. EXPLANATIONS OF THE ABBREVIATION IN THE MANUAL.........................................6
2. ME7.9.7 SYSTEM INTRODUCTION....................................................................................................6
2.1. SYSTEM BASIC PRINCIPLE.....................................................................................................6
2.1.1 SYSTEM GENERAL INTRODUCTION: ME7.9.7-MOTRONIC EMS .......................6
2.2. CONTROL SIGNAL: ME7.9.7 SYSTEM INPUT/OUTPUT SIGNAL....................................8
2.3. INTRODUCTION OF SYSTEM MALFUNCTION DIAGNOSIS FUNCTION.....................9
2.3.1. MALFUNCTION INFORMATION RECORD ...............................................................9
2.3.2, CONTROL STRATEGY OF FAILURE LAMP ..............................................................9
2.3.3, DIAGNOSIS METER CONNECTION..........................................................................10
2.3.4, READ MALFUNCTION INFORMATION BY WINK CODE....................................10
3. WORKING PRINCIPLE AND CHARACTER OF EFI SYSTEM ELEMENT...............................10
3.1 ELECTRONIC CONTROL UNIT - ECU..................................................................................10
3.2 COOLANT TEMPERATURE SENSOR....................................................................................14
3.3 KNOCK SENSOR ........................................................................................................................15
3.4 OXYGEN SENSOR......................................................................................................................16
3.5 SPEED SENSOR (CRANKCASE POSITIONING SENSOR).................................................17
3.6 PHASE SENSOR (CAM SHAFT POSITIONING SENSOR)..................................................19
3.7 ELECTRIC FUEL PUMP ...........................................................................................................20
3.8 ELECTROMAGNETIC INJECTOR.........................................................................................21
3.9 AIR FLOW SENSOR ...................................................................................................................22
3.10 DOUBLE SPARK IGNITION COIL........................................................................................23
3.11 CARBON CANISTER SOLENOID VALVE............................................................................25
3.12 FUEL PRESSURE REGULATOR............................................................................................26
3.13 ELECTRONIC THROTTLE VALVE AND ACCELERATOR..............................................27
3.14 FAN CONTROL .........................................................................................................................28
3.15 AIR CONDITIONER CONTROL............................................................................................29
4 ME7 SYSTEM TEST AND REPAIR ACCORDING TO TDC ...........................................................30
4.1 ENGINE DTC (DIAGNOSTIC TROUBLE CODE) LIST.......................................................30
4.2 DIAGNOSIS FLOW WHEN THERE IS DIFFERENT DTC ..................................................32
5. TYPICAL FAILURE AND ITS DIAGNOSIS FLOW.........................................................................52
5.1 EXPLANATION...........................................................................................................................52
5.2 TYPICAL FAILURE DIAGNOSIS FLOW ...............................................................................53
1. The engine does not rotate or rotate slowly when it is started ............................................53
2. The engine can draw rotating but can not start successfully when it is started. ...............54
3. It is hard to start the heating car. ..........................................................................................55
4. Its hard to start the cold car..................................................................................................56
5. Normal engine speed but hard to start at any time. ............................................................57
6. Regular starts but the idle speed is not steady at any time. ................................................58
7. Regular starts but the idle speed is not steady during engine heating. ..............................59
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8. Regular starts but idle speed is not steady after the engine heating...................................60
9. Regular starts but idle speed is not steady or dying out when there is partial loading. ...61
10. Regular starts with high idle speed. ....................................................................................62
11. Low engine speed or dying out exists when it is accelerated. ............................................63
12. React slowly when it is accelerated......................................................................................64
13. The performance is poor when it is accelerated.................................................................65

EFI SERVICE MANUAL

A21 car is equipped with ME7.9.7 EFI system which developed by UAES. This manual will
introduce the general service and the operational principle and character of sensor elements
of EFI system in detail. At last there will be some diagnostic method and flow for the typical
problems.
1. NOTICE TO THE EFI SYSTEM SERVICE
1.1. GENERAL SERVICE
Digital multimeter is the only permitted instrument to inspect the EFI system.
Please use the quality spare parts for service, otherwise can not make sure the EFI work
properly.
Please use lead free gasoline during service.
Please be obedient to the service and diagnose flow.
It is forbidden to disassembly the EFI part during service.
It should be careful to take the electronic component (ECU, sensor, etc.) for preventing
from dropping to the ground.
Please protect the environment, deal with the rejectamenta carefully and effectively.
1.2. NOTICE DURING THE SERVICE

Do not disassemble any part or inserts of the EFI system from its original position at
random to prevent from damaging parts or that moisture and dirt oil come into the inserts.
And that will keep the system from working properly.
Please leave the ignition switch at shut off position when you disconnect and connect the
inserts otherwise it will damage the electric element.
It is must keep the ECU under 80, when you do the work of hot status simulation and
other works which may cause the temperature increase.
The supplying oil pressure is high(around 300kPa), all the fuel pipe is made up of anti
high pressure pipe. There is high pressure in fuel pipe even the engine does not run. So do
not disassemble the fuel pump at random when carrying out service for fuel system.
Before disassemble the fuel pipe please carry out discharge pressure procedure. The
method is as below: Disassemble the fuel pump relay (or disconnect the connector plug),
start engine at its idle running and it dies out by itself. After the service supply fuel to
engine fuel pipe at first, the method is: turn ignition key to ON position and wait a while,
repeat this four or five times. Disassembly of fuel pipe and fuel filter should be carried
out at a place with good ventilation and done by professional maintainer.
Do not give electricity to fuel pump when the electrical pump is taken out of fuel tank in
order to prevent from electrical spark and cause fire.
Fuel pump is not allowed to carry out running test at dry or water situation, which will

decrease its life. And do not exchange anode and cathode of the pump.
Carry out jump spark inspection at necessary time when inspect the ignition system, and
the time to inspect must be short. Do not open the throttle valve to prevent a lot of
unburned gasoline entering exhaust pipe and damage the 3-way catalytic converter ( It is
better to take off the corresponding injector insert during the jump spark testing)
The adjustment of idle speed is done completely by EFI without manual work. The
accelerator stop screw of throttle valve has been fixed well in advance by manufacturer so
that it is not allowed to change it original position by the customer.
Do not exchange the anode and cathode of the accumulator to prevent damaging the
electronic component. This system uses cathode ground.
Do not disassemble accumulator cable when the engine is running.
Disassemble the cable of accumulator anode and cathode, and ECU when there is welding
work on the car.
Do not inspect the input and output signal of component by impaling the lead surface.
1.3. SERVICE TOOLS
Tool name:
EFI system diagnostic tester
Function:
Read/clear the breakdown code in EFI and
inspect data, test part motion.
Tool name:
Ignition timing lamp
Function:
Inspect engine ignition timing.

Tool name:
Digital multimeter
Function:
Inspect the character parameter of voltage,
current, resistance.
Tool name:
Fuel pressure gauge
Function:
Inspect the pressure in fuel system, judge the
status of fuel pump and fuel pressure
regulator.
Tool name:
Pressure gauge for cylinder
Function:
Inspect the pressure in every cylinder.
Tool name:
Fuel injector cleaner and analyzer
function:
Analyze and clean the injector.
Tool name:
Vacuum meter
function:
Inspect the pressure of intake manifold

1.4. EXPLANATIONS OF THE ABBREVIATION IN THE MANUAL

DG Speed Sensor DVE Electronic Throttle Valve
DR Fuel Pressure Regulator FPM Accelerator Pedal
ECU Electronic Control Unit (Computer) EKP Fuel Pump
EMS Engine Management System EV Fuel Injector
LSH Heating Oxygen Sensor KS Knock Sensor
KSZ Fuel Distributing Pipe Assembly KVS Fuel Distributing Pipe
ROV Ignition System with Distributor PG Phase Sensor
RUV Ignition System without Distributor TEE Oil Pump Bracket Assembly
TF-W Coolant Temperature Sensor TEV Purge Canister Control Valve
HFM Air Flow Sensor ZSK Ignition Coil
2. ME7.9.7 SYSTEM INTRODUCTION

2.1. SYSTEM BASIC PRINCIPLE
2.1.1 SYSTEM GENERAL INTRODUCTION: ME7.9.7-MOTRONIC EMS
Engine management system (EMS)is composed mainly by three components: sensor, ECU,
and actuator. And these three parts control the intake air quantity, fuel injection quantity and
ignition advance angle. The basic frame is shown in chart 2.1.
Diagnose Diagnose
Sensor ECU Actuator
Engine
Chart 2.1 compose of engine electronic control system

In engine electronic control system, the sensor is the input part used for measuring all kinds
of physics signal (temperature and pressure etc.) and change them to corresponding electronic
signal; the function of ECU is accepting the signal and calculate it according to the
programmed program and generate corresponding output signal to power drive circuit; and
the power drive circuit makes the engine running according to established strategy by driving
every actuator to do different action; at the same time the malfunction diagnosis system of
ECU monitors all parts or control function, and if a malfunction is detected and confirmed it
will memorize malfunction code, transferring limping home function, and when the
malfunction is deleted, the normal value will be desterilized.

Engine electronic control system schematic of ME7.9.7 chart 2.2
Phase Sensor
Ignition Coil
Canister Control Valve Fuel Distribution Pipe Assembly

Phase Sensor
Air intake temperature sensor
Oxygen Sensor
Front Catalytic Converter

Knock Sensor
Temperature Sensor
Throttle Valve Oxygen Sensor
Speed Sensor
Main Catalytic Converter
Accelerator Pedal
Trouble Light
Diagnosis Access
Electric Fuel Pump
Anti Theft
Electronic Accelerator UAES Parts

Onboard Diagnosis (Europe)
Returnless Fuel Supply System
Chart 2.2
The basic component of ME7.9.7 engine electronic control system:
Electronic Control Unit(ECU) Accelerator Electronic Throttle Valve
Air Quality Flow Meter Injector Electronic Fuel Pump
Coolant temperature sensor Fuel Pressure Regulator Throttle position sensor
Fuel Pump Bracket Camshaft Position Sensor Fuel Distributing Pipe
Speed Sensor Oxygen Sensor Canister Control Valve
Knock Sensor Ignition Coil

ME7.9.7 engine management system is an electronic gasoline control system, and it can
provide lots of control characters about operator and vehicle or equipment. The system adopts
a combination method of open loop and closed loop (feed back) control to provide all kinds
of control signal to engine. The main function of the system:
1) The basic functions of applying physics mode engine
u For the system structure based on torque, the airflow sensor will confirm the loading
of cylinder and improve the mixture air control function closed loop control.
u Fuel injects ignition timing on the order of cylinder order, including knock control
and emission control functions.
u 3 way catalytic convert heating
u Canister control
u Idle speed control
u Limping home
2.2. CONTROL SIGNAL: ME7.9.7 SYSTEM INPUT/OUTPUT SIGNAL
The main sensor input signal of ECU of ME7 system:
l Air flow signal
l Throttle valve corner signal
l Coolant temperature signal
l Engine speed signal
l Phase signal
l Knock sensor signal
l Oxygen sensor signal
l Speed signal
l Air conditioner pressure signal
The above information after the transaction of ECU, there will generate required actuator
control signal, and this signal will be magnified in output driving circuit and was transferred
to its corresponding actuator. The signals include below information:
l Injection timing and injection continuous time
l Fuel pump relay
l Opening degree of canister control valve
l Ignition coil closing angle and ignition angle of advance
l Air conditioner compressor relay

l Cooling fan relay
2.3. INTRODUCTION OF SYSTEM MALFUNCTION DIAGNOSIS FUNCTION
2.3.1. MALFUNCTION INFORMATION RECORD

The ECU monitors sensor, actuator, related circuit, malfunction indicator and accumulator
voltage etc., and EUC itself continuously. At the same time the ECU inspect the reliability
test on sensor signal output, actuator driving signal and internal signal (e.g.: closed loop
control, coolant temperature, knock control, idle engine speed and accumulator voltage etc.).
ECU will set the malfunction record on RAM malfunction memory immediately once the
malfunction or the unlikelihood signal is detected. The malfunction information is recorded
by malfunction code and displayed according to its appeared order, dividing malfunction into
steady malfunction and contingency malfunction (for example the malfunction is caused
by short time cable braking or bad contact of the inserts) according to its appeared frequency.
Function Diagnosis Function Diagnosis
ECU
Control Order
Data Collection
Sensor Actuator
Engine
Chart 2.4 EFI System Malfunction Diagnosis Principle Chart

2.3.2, CONTROL STRATEGY OF FAILURE LAMP
When there is no trouble:
The failure lamp is lighting and die out within 4 seconds after the ignition switch is ON
Starting within 4 seconds, the failure lamp dies when the engine speed signal is found;
The failure lamp winking at 2HZ frequency when the K cable contact to ground more
than 2.5 seconds.
When there is a trouble:
The failure lamp always on light when the ignition switch is ON;
Start and die out when the engine speed signal is detected; if the failure lamp was defined
as lighting mode, it will always on light after reach its confirmed conditions;

Output winking code that is P-CODE value after the K cable contact with the ground
more than 2.5 seconds. For example: the winking mode of P0203 is: wink 10 times
continuously intermission wink 2 times continuously intermission - wink 10 times
continuously intermission wink 3 times continuously.
2.3.3, DIAGNOSIS METER CONNECTION
This system adopts K cable communication protocol and use ISO 9141-2 standard
diagnosis joint, please see chart 2.5. This standard diagnosis joint is connected to engine
harness fixed. The pins of No.4, 7 and 16 on the standard diagnosis joint are used for EMS.
The pin of No. 4 on standard diagnosis joint is ground wire; Pin of No.7 is connecting to
No.71 pin of ECU, which is engine data K cable; No.16 pin is connecting to accumulator
anode.
Chart 2.5 ISO9141-2 Standard Diagnosis Joint

2.3.4, READ MALFUNCTION INFORMATION BY WINK CODE
Switch on ignition switch and use engine data K cable(that is standard diagnosis joint 7#)to
ground(use one lead connect pin of diagnosis joint 4# and pin of 7#) more than 2.5 seconds,
if there are malfunction code in ECU malfunction memorizer, the malfunction light wink
code of engine now is P-CODE value. Such as: P0203 winking type is: wink 10 times
continuously intermission wink 2 times continuously intermission - wink 10 times
continuously intermission wink 3 times continuously.
3. WORKING PRINCIPLE AND CHARACTER OF EFI SYSTEM ELEMENT
3.1 ELECTRONIC CONTROL UNIT - ECU
1)Exterior drawing
2)Purpose: ECU accepts and deals with engine status signals inputted from sensors and
drives the actuators to work. Making engine working as the established program, insure
power good, fuel consuming effectively and low emission.
3)Mounting position: Passenger compartment
4)Functions
l Multipoint injection in order
l Control ignition
10

l Idle speed control

l Knock control
l Provide sensor power: 5V/100mA
l Closed loop control
l Control carbon canister solenoid valve
l Air conditioner switch
l engine malfunction indicator
l Fuel fix quantity modification
l Engine speed signal output(TN signal)
l Input of speed signal
l Malfunction self diagnosis
l Accept engine loading signal etc.
5)Definition of pin
Pin point Pin Connection point

1 Oxygen sensor heating 42 Air intake temperature
2 Ignition coil 2 43
3 Ignition 44 Non persistent power
4 Oxygen sensor heating 45 Non persistent power
5 Ignition coil 1 46 Canister valve
Injection nozzle 3(cylinder
6 Injection nozzle 4(cylinder No. 2) 47
No.4)
7 Injection nozzle 2(cylinder No.3) 48
8 Engine speed 49
9 Coolant temperature 50 Fan control 1
10 Fuel consuming 51 electronically 2
11 Trouble light 52
12 Persistent power 53 electronically 1
13 Ignition coil 54 Electronic throttle valve
position
14 Main relay 55 Downstream oxygen sensor
15 Engine speed sensor A 56
11

16 Accelerator position sensor 57

17 Sensor 1 58 Brake switch
18 Upstream oxygen sensor 59 Speed signal
19 Knock sensor A 60 Medium switch
20 Knock sensor B 61 Power 1
21 Brake light 62 CAN communication
22 63 Non persistent power
23 Accelerating sensor 64 Electronic throttle valve
control
24 65 Electronic throttle valve
control
control
control
27 Injection nozzle 1(cylinder No.1) 68 Cooling fan
28 69 Air conditioner relay
29 70 Fuel pump relay
30 71 Diagnosis K cable
31 EOBD inspection light 72
32 5V power supply 2 73 Anti theft device
33 5V power supply 1 74 Clutch switch
34 Engine speed sensor B 75 Air conditioner switch
35 Sensor 3 76 Power steering switch
36 Sensor 2 77 Headlamp switch
37 Air flow sensor 78 Sensor
38 Electronic throttle valve control 79 Phase sensor
39 Engine coolant temperature sensor 80 Power 2
40 Accelerator position sensor 81 CAN communication
41 Air conditioner pressure
6)Normal working voltage: 9--16V

Normal working temperature: -40--70
7)Malfunction phenomena and diagnosis method
12

l Malfunction phenomena: idle speed not stable, accelerating not good, can not start, idle
speed is too high, exhaust gas exceed standard, difficult to start, air conditioner failure,
injector control failure, engine dies out etc..
l Reasons for general malfunction: 1, ECU component was burnt down caused by
overloading of the exterior connected electrical device; 2, circuit board was rust and
erode caused by water in ECU.
l Service notice: 1, do not disassemble ECU at random during the service; 2, disassemble
accumulator 5 minutes prior to disassemble ECU; 3, keep the disassembled ECU
carefully; 4, prohibit to connect any circuit to ECU connecting line.
l Simple measurement method:
1(connect ECU joint)Read engine malfunction record by K line.
2(disassemble ECU joint)Check the connecting line of ECU, and pay more attention to
check the power supply and ground line of ECU;
3Check the working conditions of exterior sensor and its output signal and its circuit;
4Check actuator and its circuit;
5At last change ECU and have a test.
13

3.2 COOLANT TEMPERATURE SENSOR

1)exterior drawing and pin
This sensor has two exchangeable pins.
2)Purpose: The sensor provide the coolant
temperature signal to ECU for ignition timing
and modifying fuel injection of starting, idle
speed and normal working.
3)Installation position
Coolant temperature sensor was installed on the
water outlet of cylinder block and the copper Chart 3-2 Outlook drawing of the
heat conducted socket was inserted into water. coolant temperature sensor
There are thread on the socket, and screw in
coolant temperature sensor onto the threaded
hole on cylinder block by the hexagon head of
the socket. The maximum moment is 20Nm.
4)Working principle
This sensor is a thermistor of negative
temperature coefficient (NTC), and its value
will decrease with the coolant temperature
increasing but the changes are not linearity.
There are several different resistance values at
different temperature:
T() Resistance value(k)

-10 8.62----10.28
20 2.37----2.63 Coolant Temperature Sensor
80 0.299----0.345
5)Normal working temperature: -30----130
Normal working voltage: 5V DC Chart 3-3 Circuit diagram of coolant
temperature sensor
6)Malfunction phenomenon and diagnosis
method
l Malfunction phenomenon: Difficult to
start.
l Reasons of malfunction: man made
l Simple measurement method:
14

(Disassemble the joint)leave the digital

multimeter at ohm shift and contact the No.1
and No. 2 pin of the sensor by its two meter
pens. When it is 20Rated the resistance is
2.5k5%. The other temperature can get
reference from above chart.
3.3 KNOCK SENSOR
1)Exterior drawing and pin
Chart 3-4 Exterior drawing of knock
This sensor has three pins; No.1 and No.2 pin sensor
connect with ECU, and No. 3 pin connects with
shield.
2)Purpose: This sensor provides engine
knock information to ECU, and carries
out knock control.
There is a hole in the middle of knock sensor,
and the sensor is assembled on the block
between No.2 and No.3 cylinder head. For the
aluminum alloy block, using long bolt with
30mm long; for the casting iron, using 25mm
long bolt. And the moment is 205Nm.
4)Working principle
Knock sensor is a kind of vibrating acceleration
sensor and is assembled on cylinder block. The
sense organ of the sensor is a piezoelectric
element. The vibration of cylinder block is
transferred to piezoelectric crystal by mass
block inside of sensor. The piezoelectricity
crystalloid gets pressure from mass block
vibration, producing voltage on two polar and
transferring vibration signals to voltage signal Knock sensor
and output it. Because the frequency of knock
vibration signal is much higher than the normal
engine vibration signal, the ECU can separate
Chart 3-5 circuit diagram of knock
the signal into knock signal and non knock
sensor
signal.
5)Normal working temperature: -40--130
6)Malfunction phenomenon and diagnosis
method
15

l Malfunction phenomenon: badness

accelerating.
l Normal malfunction reason: all kinds of
liquid such as oil, coolant, braking liquid
and water contact with sensor for a long
time and erode the sensor.
l Simple measuring method: (disassemble the
joint) put digital multimeter at ohm shift,
and contact the No.1, No. 2 and No.3 pin
with its two meter pens. The resistance
value should be more than 1M at normal
conditions. Leave the digital multimeter at
millivolt shift, and tap around the sensor
using little hammer, there should be voltage
signal output.
3.4 OXYGEN SENSOR
There are 4 pins on this oxygen sensor
No. 1 connect to heating power anode (white)
No. 2 connects to heating power cathode (white)
No. 3 connects to signal cathode (gray)
No. 4 connects to signal anode (black)
2)Installation position: Assemble it on the top Chart 3-6 Exterior drawing of oxygen
of exhaust pipe. sensor
3)Purpose: The oxygen sensor checks the
oxygen percent in exhaust gases and transfer the
signal to ECU, and ECU will control the fuel
closed loop according to this information. This
will make engine working at its optimum
conditions. And transfer and purify CO, HC,
NOx compound in 3-way catalytic converter of
the tail gas maximally. Main relay
4)Working principle
Sensing element of oxygen sensor is a kind of
ceramic tube with holes, and outside of tube
walls are surrounded by engine exhaust gas and Oxygen sensor
inside is air. Ceramic sensor element is a kind of
solid state electrolyte with electrical heating Chart 3-7 circuit diagram of oxygen
sensor
16

tube inside. The working of oxygen sensor is

carried out by transferring the concentration
difference of the oxygen ion outside of ceramic
tube to voltage (100mv900mv)signal and
output.
5)Working voltage:1214V
6)Malfunction and diagnosis method
l Malfunction: badness idle speed, badness
acceleration, badness tail gas, over fuel
consume etc.
l Reason: 1, moisture entering inside of
sensor, and when the temperature is
changed pin is broken; 2, sensor
poisoning( Pb,S,Br,Si)
l Notice: it is forbidden to use cleaning liquid,
oiliness liquid or volatility solid during
service.
l Measuring method: a) disassemble joint,
put digital multimeter to ohm shift, connect
meter pen to No.1(white) and No.2(white)
pins of the sensor. Normally the resistance
value is 1~6. b) Connect the joint and
keep it at idle speed status. When the
oxygen sensor reaches to its working
temperature 350, keep digital multimeter
to DC volt shift and connect meter pen to
No.3 (gray) and No.4 (black) pins of sensor.
Now the voltage should be fluctuate
between 0.1- 0.9V quickly (the data also
can be gotten from data flow inspected by
diagnosis meter).
3.5 SPEED SENSOR (CRANKCASE
POSITIONING SENSOR)
No.1pin connects to shield
No.2 and No.3 pin provide signal to ECU.
Chart 3-8 Exterior Drawing Of Speed
2)Installation position: on the flywheel plane
Sensor
at rear of engine.
17

Service notice:
l For the inductive engine speed sensor, it is
permitted to take out from its pack before it
is assembled to the auto or testing device
right away.
l Inductive engine speed sensor is assembled
by press in method but not hammer tapping.
l Tightening torque is 8.2Nm. Gas clearance
between inductive engine speed sensor and
pulse disc is 0.8 - 1.2mm.
3)Purpose: Speed sensor provides engine speed,
crankshaft angle and top dead center signal to
ECU. That will control engine ignition and
injection timing.
4)Working principle: The inductive engine
speed sensor work together with pulse disc, it is
used in ignition system without distributor
providing engine speed and crank shaft top dead
center information. Speed sensor is made up of
a permanent magnet and coil outside of magnet.
Pulse disc is a tooth disc with 60 teeth originally
but there are two teeth opening. Pulse disc is
assembled on crank shaft and rotate with
crankshaft. When the tip of the tooth passed the
end of inductive engine speed sensor, the
magnet pulse disc incises the magnetic line of
force, generating rotating speed signal and Speed sensor
output.
5)Working temperature:-40--120 Chart 3-9 Circuit diagram of speed
sensor
Resistance of coil in room T:731--989
6)Malfunction and diagnosis method:
l Malfunction: can not start etc.
l Reason: man failure
l Service notice: use pressing method but not
a hammer to install it.
l Simple measure method: disconnect the
joint, put digital multimeter to ohm shift,
connecting two meter pen to No. 2 and No.
18

3 sensor connectors. The rated resistance is

86010% When it is 20
3.6 PHASE SENSOR (CAM SHAFT
POSITIONING SENSOR)
This sensor has three pins: No. 1 grounding, No.
2 for signal output and No. 3 connecting to
power anode.
2)Installation position: on the valve cover.
There is only one hole on this sensor casing for
tightening M6, and the torque is: 80.5Nm.
3)Purpose: This sensor provides crankshaft
phase information to ECU, that is to say, to
separate crankshaft compression top dead center
and exhaust top dead center.
Chart 3-10 Exterior drawing of phase
4)Working principle sensor
It is a Hall sensor.
5)Working temperature: -30--130 Grounding point
Working voltage: 4.516V

Trigger gap: 0.11.8mm

l Malfunction: can not start, emission exceed
standard, fuel consume increased.
l Reason: Man made.
Phase sensor
l Simple measuring method: (connect the
joint) switch on ignition switch but do not Connect to main relay
start the engine; put digital multimeter on
DC volt, connect two meter pen to No. 3 Chart 3-10 Exterior drawing of phase
and No. 1 sensor connectors and make sure sensor
there is 12V reference voltage. Start the
engine, checking if it is in good conditions
of No. 2 pin by oscillograph on vehicle.
19

3.7 ELECTRIC FUEL PUMP

The electric fuel pump has two pins connecting
to pump relay. There are +and - showing
anode and cathode on the pump housing near to
pins.
2)Installation position: inside fuel tank
3)Purpose: Deliver the fuel to engine fuel
supplying pipe at certain flow and fuel pressure Chart 3-12 Exterior Drawing of Electric
and keep the stable fuel pressure (realized by Fuel Pump
fuel pressure regulator)
4)Working principle
The electric fuel pump is made up of DC
electromotor, vane pump and end cover (its an
integration of check valve, relief valve and an
anti electromagnetic interference element).
Pump and electromotor are coaxial assembly
and within the same casing. The pump and
electromotor are full of gasoline for coolant and
greasing inside of the casing. The accumulator
provide power to electric fuel pump via fuel
pump relay, and the relay switches on electric
fuel pump only when engine starting and
running. When the engine stops for some reason,
the pump will stop to run by itself.
Fuel Pump Relay
Working temperature:-30--70
System pressure: 300KPa
Electric Fuel Pump
l Malfunction: big running noise, badness Connect
acceleration, can not start (difficult to start) To Main
etc.. Relay Power Supply
l Reason: use of low quality fuel and cause 1,

Chart 3-10 Exterior Drawing Of Phase
colloid became insulation layer; 2, fuel
Sensor
pump bushing and armature come to
together; 3, components of fuel level sensor
eroded.
l Service notice: 1, the electric fuel pump can
20

has different flow according to the

requirement of engine, but with the same
exterior looking.
The pump which can be assembled to perhaps
is not the fittest. For service the replaced
electric fuel pump must has the same part
number as the original pump; 2, do not change
the pump at dry status to prevent the pump
from accident; 3, when it needs changing fuel
pump, please clean fuel tank and fuel filter.
l Simple measuring method: (disconnect joint)
leave digital multimeter at ohm shift, connect
two meter pen to two pins of pump, measure
the resistance, it is not zero or infinite(that is
non short circuit, open circuit).(connect the
joint)connect the fuel pressure meter to fuel
intake pipe and start the engine, observing if the
Chart 3-14 Exterior Drawing of Injector
fuel pump works; If it is not running, check if
there is power or not on the pin of+; if it is
running, at the condition of idle speed, check
the fuel pressure if it is around 260kPa; plug
off the fuel pressure regulator vacuum pipe if it
is around 300kPa.
3.8 ELECTROMAGNETIC INJECTOR
There are two pins on each injector. One of them is
No. 87 pin aside of casing marked with plus and
connected to main relay output; and another one 1, O Ring
connect with ECU No. 27,6,7,47 pins. 2, Screen
2)Installation position: On the air intake manifold 3, Injector with Elec. Plug
near the end of air intake port. When 4, Coil
you .disassemble and reassemble the fuel injector 5, Spring
the O ring must be changed. And pay attention not 6, Valve Pin with Coil Armature
to damage the sealing surface of the injector. 7, Valve Seat with Injection Hole
3)Purpose: Inject some fuel to its correspondent Chart 3-15 Cutaway View Of Injector
cylinder at proper time to meet the engine
requirement of different power and different torque.
4)Working principle: ECU sends electrical
impulse to injector coil and form magnetic field
force. When magnetic field force increase to
21

conquer Return spring pressure, needle valve

gravity and friction force, the needle valve begin to
rise up and start the injection process. The pressure
of return spring makes needle valve close again
when the injection impulse is stopped.
Working injection pressure: 350KPa Connect To Main
Relay Pin No. 87
l Malfunction: badness idle speed, badness
acceleration, can not start (difficult to start) etc..
l Reason: lack of maintenance causes invalid by
the colloid inside of injector became insulation Cylinder No.1, No.2, No.3, No.4
layer.
Chart 3-16 Circuit Diagram of Injector
l Simple measure method: (disconnect the joint)
leave digital multimeter at ohm shift, connect the
meter pen to the two pins of injector. The rated
resistance should be 11 - 13when it is 20.
3.9 AIR FLOW SENSOR
1)Exterior drawing and pin definition
This sensor is 5 pins: No. 1 is intake temperature
pressure signal; No. 2 is accumulator pressure; No. 3
is grounding; No. 4 is reference voltage 5V; No. 5 is
intake airflow signal output.
It is behind the air cleaner of the air intake tube.
3)Purpose:
This sensor is hot cable airflow sensor, which check
the temperature and air intake flow entering to
cylinder and provide evidence to ECU to calculate
fuel injection quantity.
Chart 3-17 Exterior Drawing of Airflow
4)Working principle
Sensor
If there are no airflow passing when the air quality
and flow meter works, temperature grads of both
sides of the heating area spread symmetry, and
temperature of these two points are same. When the
air passes here just one way, the air will be heated
when it passes the central heating area and this will
22

make the heat exchange different of the heat

diaphragm of both sides.
This will make the temperature of two sensing
element measuring point inside of the flowmeter
Changes differently and appears difference in
temperature. And the difference of the temperature
will increase with the increase of the airflow.
Big/small and positive/negative of the temperature
difference improved the quality and direction of the
airflow. And the inside evaluate circuit will transfer
the temperature difference to voltage signal and
output.
5)Working temperature:-40--125
l Reason: sensing element is polluted by the dust
particle, oil and water and causes the part invalid.
l Service notice: 1, it is prohibited to use erosion
liquid to clean sensing element during service; 2,
not to use high pressure air to impact sensing
element; 3, make sure there are no dust into air
pipe when you change air cleaner and no
unqualified air into air cleaner.
l Simple measuring method: static measurement:
(zero flow measurement) No. 3 grounding; No. 4
input 5V reference voltage; No.2 input 14V rated
voltage; check No. 5 output voltage, if the output
is bigger than 1.025V, we can confirm the
function of this sensor is not qualified. Dynamic
measurement: if it is confirmed the sensor is
broken, connect a tail gas analysis meter to
exhaust pipe and check it by using two working
conditions method: 1, idle speed working
conditions; 2, 2000rpm stable working conditions.
Check the reading of HC COCO2, normally
HC<100ppm CO<0.5%,CO2 >13.5%
3.10 DOUBLE SPARK IGNITION COIL
1)Exterior and pin definition
No. 1 coil primary winding connect with No.5 pin of
ECU; No. 2 coil primary winding connect with No. 2
pin of ECU; No. 3 and No.4 pins connect with power
23

anode.
2)Installation position: on the engine
3)Purpose: Ignition coil transfers the low voltage of
primary winding to high voltage of secondary
winding, and produce spark by spark plug discharging
then burning the combustible gas inside of the
cylinder.
4)Working principle
Ignition coil ZS - K22 is made up of two primary
windings, two secondary windings, mandrel, and
casing. When one of the primary windings grounding Chart 3-18 Exterior Drawing of Ignition
chunnel is connected, the primary winding is in Coil
charging. Once the circuit is cut off by ECU, the
charging is stopped. At the same time the high voltage
is sensed in the secondary winding and making the
spark plug discharging. There is a different with the
distributor ignition coil: for the ignition coil ZS - K22,
there is one spark plug on both side of the secondary
winding, and the both spark plugs can ignite at the
same time. These two primaries connect and
disconnect to power alternatively. And
correspondently these two secondary windings
discharge alternatively.
Working temperature:-40120
l Malfunction: can not start. Connect To Main
Relay Pin No.87
l Reason: current is too big and got burnt, damaged
by outside force etc..
l Service notice: forbid to use "short circuit test
Chart 3-19 circuit Diagram of Ignition
igniting method to test ignition function,
Coil
prevents the electronic controller from damaging.
l Simple measuring method: (disassemble the joint)
leave digital multimeter at ohm shift, connect two
meter pen to two pins of primary winding, the
resistance value is 0.42- 0.58when it is 20;
secondary winding resistance value is 11.2-
14.8k.
24

3.11 CARBON CANISTER SOLENOID VALVE

1)Exterior drawing and pin definition
Canister control valve only has two pins; one is
connect to No.87 pin of main relay output end; and
another pin connected to No. 5 pin of ECU.
2)Installation position: Canister vacuum pipe of
intake manifold
3)Purpose: Control the quantity of the cleaning
flow from canister to air intake chief pipe. The
absorption of the canister is limited so if the
Chart 3-20 Exterior Drawing of Canister
gasoline vapor adhesive to canister can not be
Solenoid
consumed the gasoline vapor will volatility to
outside and pollute the air.
4)Working principle
Canister is made up of electromagnetic coil,
armature and valve etc.. There is strainer on the
intake. The flow quantity passes canister valve is
correlate not only to electrical impulse duty ratio of
Connect To Main Relay
canister control valve output by ECU, but also to
the pressure difference between canister valve
intake and outlet. When there is no electronic
impulse, the canister control valve will shut down.
Working temperature:-30--120 Canister Solenoid Valve
Chart 3-21 Circuit Diagram of Canister
l Malfunction: Function invalidation. Solenoid
l Reason: some particle coming to inside of valve
causes erosion or poor sealing.
l Service notice: 1, let the airflow direction be
accord with the regulation; 2, when there are
black particle inside of valve and causes the
control valve invalidation, the valve need to be
changed, please check the canister working
conditions; 3, avoid the water, fuel and other
liquid into valve during the service; 4, hang the
valve on the tube to avoid the transferring of
solid sound.
l Simple measurement method: (disassemble the
25

joint) leave digital multimeter to ohm shift, two

meter pen connect to the pins of canister valve,
it is 264 when it is 20.
3.12 FUEL PRESSURE REGULATOR
1)Exterior drawing
2)Installation position: Fuel bracket assembly
3)Purpose: Adjust the pressure inside of fuel pipe,
keep the System pressure around 350Kpa.
4)Working principle: See chart 3- 23, one piece of
flexible film made up of rubber and fiber separate the
fuel pressure regulator into two compartments. The
upper compartment communicates to the air, and
there is spring inside. The lower compartment is full
of fuel entering from the fuel intake under the fuel
pressure regulator. The lower part of the film gets the
pressure from fuel and the upper part gets the pressure
from air and spring. The film can distort and drive
valve seat making the valve open and close, but the
distortion is smaller the acting force of the spring may Chart 3-22 Fuel Pressure Regulator
be seemed as not changed. So the opening and closing
of the valve is decided by the pressure difference of
the fuel pressure from lower compartment and the air
pressure from the upper compartment. If the valve is
closed at first, then the fuel pressure increased
causing the pressure difference between upper and
lower compartments increased. At last the film was
raised up by the fuel pressure and valve is opened.
The fuel return to fuel tank from oil return port of
pressure regulator, the fuel pressure decreased until
the valve is closed. If the engine changes its working
conditions now, the pressure difference of fuel system
and the air pressure is about the same.
l Malfunction: fuel pressure is too high or too low, Chart 3-23cutaway View of Fuel
difficult to start. Pressure Regulator
l Reason: long time using without maintenance

causing: 1, strainer jammed; 2, particle causes big
leaking; 3, man made mechanical damages.
l Service notice: 1, prohibit to use high pressure air
blowing film element; 2, Forbid using strong
26
Ac

causticity liquid to wash it; 3, avoid it from

distorting by outside force.
Simple measurement method: connect fuel
pressure gauge at fuel intake pipe, start the
engine and make the engine running at idle speed;
check the fuel pressure around 350kPa or not;
step on the gas until the engine speed to
2500rpm,and observe if the fuel pressure at
around 350kPa.
3.13 ELECTRONIC THROTTLE VALVE AND
ACCELERATOR
l Accelerator pin definition
Pin No.1 and No.2 is the anode of the 5V
reference voltage
Pin No.3 and No.5 is the cathode of 5V reference
voltage
Pin No. 4 and No. 6 is output voltage signal
l Electronic throttle valve pin definition
Pin No. 1 is motor anode.
Pin No. 2 is potentiometer anode.
Pin No. 3 is potentiometer cathode.
Pin No. 4 is motor cathode.
Pin No. 5 is signal output 1.
Pin No. 5 is signal output 2.
2)Installation position: Electronic throttle valve:
front end of intake manifold; accelerator: driver
cockpit.
3)Working principle: The engine on time torque
requirement was transferred from accelerator to ECU,
and ECU sends impulse electronic signal to electronic Chart 3-25 Circuit Diagram of
throttle valve according to torque requirement Accelerator
information; the motor is running and drive throttle
valve to its opening required degrees; this throttle
valve can stay at one fixed position or change to
another position upon required to meet the
27

requirement of the engine working conditions

according to the impulse signal frequency and width
of impulse.
3.14 FAN CONTROL
ECU control the fan according to water
temperature of the engine and the requirement
signal and control the fan system delay at the fit
conditions.
1) Conditions for fan running at low speed:
a) Engine coolant temperature between 96 to
102.
b) There is air conditioner requirement and the
air conditioning compressor begins to work.
2) Conditions for fan running at high speed:
a) Engine coolant temperature sensor broken
b) Engine coolant temperature higher than
102.
3) Conditions of fan continue to work after the
engine stops working
A) Engine air intake temperature sensor is
broken and delay 60 seconds.
B) Engine coolant temperature sensor is broken
and delay 60 seconds.
C) Engine coolant temperature higher than Power Supply
100.5, high speed delay 60 seconds.

D) Temperature of intake air more than 70.5,
delay 60 seconds. High-Speed Relay Of Fan
4) Malfunction diagnose
Low-Speed Relay Of Fan
Short circuits from high relay line to power Double-Speed Fan
supply
Short circuits from high-speed relay line to
ground
Chart 3-26 Fan control schematic
Open circuits of high-speed relay line
Short circuits from low-speed relay to power
supply
28

Short circuits from low-speed relay line to

ground
Open circuits of low-speed relay line
Engine coolant temperature sensor failure
Engine intake air temperature sensor failure
3.15 AIR CONDITIONER CONTROL
1)Working principle
Switch on the air conditioner and blower; air
conditioner pressure is regular; evaporator
temperature sensor inspect the right data;
requirement signal of air conditioner is sending by
these switches to ECU, and ECU controls air
conditioning relay attracting and provide rotating
speed signal to step motor and open the electronic
fan and air conditioning chart to work.
2)Air conditioner control strategy
a) The air condition can be switched on after 5
seconds of the engine starts.
b) Cut off the air conditioner when temperature of
intake air higher than 140.3.
c) Cut off air conditioner when the coolant
temperature higher than 114.8; resume the air Power Supply
conditioning control after its lower than 11.8. Request Signal
Form Air
d) Cut off air conditioner when the engine speed is
Conditioner
higher than 6520rpm or lower than 520rpm.
e) Cut off air conditioner when the pressure inside
of air conditioner high pressure pipe is higher
than 20bar and resume the control when the
pressure is lower than 9.5bar.
Air Conditioner Compressor Clutch
f) Cut off air conditioner when the evaporator
temperature is lower than 1.5; and resume the
control when it is higher than 4.5. Chart 3-27 Air conditioner control
schematic
g) Cut off air conditioner when the system pressure
is lower than 8.04V; consume the control when
it is higher than 10.01V.
3) Malfunction diagnosis
29

Blower circuit malfunction (fuse is burnt, relay

circuit is open circuit or short circuit)
Irregular pressure of air conditioner (much higher of
the high voltage or the much lower of the low
voltage)
Malfunction of evaporator temperature sensor
Air conditioner relay circuit is failure (short circuit
to ground, short circuit to power supply, open
circuit).
4 ME7 SYSTEM TEST AND REPAIR ACCORDING TO TDC

Explanation:
1. When it is confirmed that malfunction is steady we can carry out the test and repair as
below, otherwise this will cause wrong diagnosis.
2. There is multimeter mentioned below, it is referred to digital multimeter; prohibit to use
finger multimeter check the EFI system.
3. Check and repair the vehicle with anti theft system please re-program the replaced ECU
when there is the occasion of changing the ECU at flow up steps.
4. In this items when the TDC of P0171P0172P0335P0336P1651 existing, the engine
trouble light will not light on.
5. If it shows much lower of the voltage in some circuit in DTC explanation, it refers to
perhaps there is ground short circuit inside of this circuit; If it shows much higher of the
voltage in some circuit in DTC explanation, it refers to perhaps there is power supply
short circuit inside of this circuit; If it shows circuit failure in DTC explanation, it refers
to perhaps there is open circuit or multi circuit malfunction inside of this circuit.
Diagnosis help: 1. DTC can not be deleted; it is steady failure; if it is occasional failure,
check if it is because of the loosening of cable joint.
2. Check according to the above steps and find noting wrong;
3. During check and repair pay attention that the influence of vehicle
maintenance, cylinder pressure and mechanical ignition timing to
the system;
4. Change ECU and test it. If the DTC can be deleted, the malfunction
is inside of ECU; if the DTC can not be deleted, change back to the
original ECU and check it again according to above items.
4.1 ENGINE DTC (DIAGNOSTIC TROUBLE CODE) LIST
DTC Definition DTC Definition
30

Much lower voltage of the air intake

P0107 P0340 Phase sensor signal failure
pressure sensor
Much higher voltage of the air intake Much lower voltage of the phase
P0108 P0342
pressure sensor sensor
Indicated temperature is much lower of Much higher voltage of the phase
P0112 P0343
the air intake temperature sensor sensor
Temperature is much higher indicated by Canister control valve drive grade
P0113 P0443
the air intake temperature sensor control circuit failure
Much lower voltage of canister
Temperature is much lower indicated by
P0117 P0444 control valve drive grade control
engine coolant temperature sensor
circuit
Much higher voltage of canister
Temperature is much higher indicated by
P0118 P0445 control valve drive grade control
engine coolant temperature sensor
circuit
The circuit voltage of throttle position Air conditioner condenser cooling
P0122 P0480
sensor is much lower fan relay control circuit failure
The circuit voltage of throttle position
P0123 P0500 Unreasonable failure of speed signal
sensor is much higher
Unreasonable failure of the upstream Rotating speed of idle speed is lower
P0130 P0506
oxygen sensor signal than target idle speed
Much higher voltage of upstream oxygen Rotating speed of idle speed is
P0132 P0507
sensor higher than target idle speed
Idle speed regulator control circuit
P0134 Signal failure of upstream oxygen sensor P0508
voltage is too low
Heating circuit failure of upstream Idle speed regulator control circuit
P0135 P0509
oxygen sensor voltage is too high
Closed loop air fuel ratio control self Idle speed regulator control circuit
P0171 P0511
adapting exceeds it maximum limit failure
Closed loop air fuel ratio control self
P0172 P0560 System voltage signal unreasonable
adapting exceeds it minimum limit
P0201 The 1st cylinder injector circuit failure P0562 System voltage is too low
P0202 The 2nd cylinder injector circuit failure P0563 System voltage is too high
P0203 The 3rd cylinder injector circuit failure P0601 ECU testing code failure
P0204 The 4th cylinder injector circuit failure P0602 ECU diagnosis data ID code failure
Air conditioner compressor relay
P0230 Fuel pump control circuit failure P0645
control circuit failure
Much lower voltage of air
P0325 Knock sensor circuit failure P0646 conditioner compressor relay control
circuit
Much higher voltage of air
P0335 Crank shaft position sensor signal failure P0647 conditioner compressor relay control
circuit
P0336 Crank shaft position sensor signal P1651 Trouble light control circuit failure
31

unreasonable failure
4.2 DIAGNOSIS FLOW WHEN THERE IS DIFFERENT DTC
P0107 Much lower voltage of the air intake pressure sensor
No. Operating steps Result Follow up steps

Connect the diagnostic tester and commutator, put the
1 Next step
ignition switch to ON
Observe air intake pressure item in data flow, if it is Yes To step No. 5
2 about 101kpa (specific data is correlated to that time
No Next steps
air pressure).
Take off the joint of cable air intake pressure sensor, Yes To step No. 5
3 check the voltage between pin No. 3 and pin No. 1 by
No Next step
multimeter and look if it is around 5V.
Check if it is short circuit to ground between ECU pin Repair or replace
Yes
4 No. 17, No. 33, No. 37 and sensor connector No.1, cable
No.3 and No. 4. No Next step
Start the engine at idle speed. Step on the accelerator

Yes Diagnosis help
slowly approach to open completely and observe the
value changes of diagnostic tester air intake
5
pressure, the changes should be not big; step on the
accelerator quickly to complete open, the displayed
No Replace the sensor
value should be reach up to 90kpa instantaneous.
DTC: P0108 Much higher voltage of the air intake pressure sensor

1 Next step
Observe air intake pressure item in data flow, if it is Yes To step No. 5
2 about 101kpa(specific data is correlated to that time air
No Next steps
pressure)
Take off the joint of cable air intake pressure sensor, Yes To step No. 5
3 check the voltage between pin No. 3 and pin No. 1 by
No Next step
Check if it is open circuit or short circuit to power supply Repair or replace
Yes
4 between ECU pin No. 17, No. 33, No. 37 and sensor cable
connector No.1, No.3 and No. 4. No Next step
Start the engine at idle speed. Step on the accelerator Yes Diagnosis help
slowly approach to open completely and observe the
value changes of diagnostic tester air intake pressure,
5 Replace the
the changes should be not big; step on the accelerator No
sensor
quickly to complete open, the displayed value should be
reach up to 90kpa instantaneous.
32

DTC P0112 Circuit voltage is much lower of the throttle position sensor

1 Next step
Observe air intake temperature item in data flow, if it is Yes To step No. 5
same temperature with air intake pipe(specific data is
2 correlated to the engine temperature at that time)
No Next step
Notice: if the value is - 40 there is perhaps open circuit
failure in the circuit.
Take off the joint of cable air intake temperature sensor, Yes Next step
check the resistance values using multimeter between
3 sensor connector No. 1 and No. 2 and check if it is
No Replace sensor
corresponding to its temperature (please reference the
related section of this service manual)
Take off the joint of cable air intake temperature sensor, Yes To step 5
4 check the voltage between pin No.1 and pin No.2 by
No Next step
Repair or
Check if it is open circuit or short circuit to power supply
Yes replace
5 between ECU pin No. 17, No. 40 and sensor connector
cable
No.1, No.2
No Next step
Start the engine at idle speed. Observe the value changes Yes Diagnosis help
6 of diagnostic tester air intake temperature, the value Replace the
No
should increase with the increase of the engine intake air. sensor
DTC: P0113 Temperature is much higher indicated by the air intake temperature sensor

1 Next step
ignition switch to ON.
Observe air intake temperature item in data flow, if it is Yes To step No. 5
same temperature with air intake pipe(specific data is
2 correlated to the engine temperature at that time)
No Next step
Notice: if the value always is - 40 there is perhaps open
circuit failure in the circuit.
Take off the joint of cable air intake temperature sensor, Yes Next step
check the resistance values using multimeter between
3 sensor connector No. 1 and No. 2 and check if it is
No Replace sensor
corresponding to its temperature (please reference the
related section of this service manual).
Take off the joint of cable air intake temperature sensor, Yes To step 5
4 check the voltage between pin No.1 and pin No.2 by
No Next step
33

Repair or
Check if it is short circuit to ground between ECU pin Yes replace
5
No. 17, No. 40 and sensor connector No.1, No.2 cable
No Next step
Start the engine at idle speed. Observe the value changes Yes Diagnosis help
6 of diagnostic tester air intake temperature, the value Replace the
No
should increase with the increase of the engine intake air. sensor
DTC: P0117 Temperature is much lower indicated by engine coolant temperature sensor.

Connect the diagnostic tester and commutator, put
1 Next step
the ignition switch to ON.
Observe coolant temperature item in data flow, if Yes To step 6
it is same temperature with engine temperature
(specific data is correlated to the engine temperature
2
at that time). No Next
Notice: if the value always is - 40 there is perhaps
open circuit failure in the circuit.
Take off the joint of coolant temperature sensor on Yes Next step
the cable, check the resistance values using
multimeter between sensor connector No. 1 and No.
3
2 and check if it is corresponding to its temperature No Replace sensor
(please reference the related section of this service
manual).
Take off the joint of coolant temperature sensor on Yes To step 6
the cable, check the voltage between pin No.1 and
4
pin No.2 by multimeter and observe if it is around No Next step
5V.
Check if it is open circuit or short circuit to power Repair or replace
Yes
5 supply between ECU pin No.39, No. 35 and sensor cable
connector No.1, No.2. No Next step
Start the engine at idle speed. Observe the value Yes Diagnosis help
changes of diagnostic tester coolant temperature,
6
the value should increase with the increase of the No Replace sensor
engine coolant temperature.
DTC: P0118 Temperature is much higher indicated by engine coolant temperature sensor

1 Next step
Observe coolant temperature item in data flow, if Yes To step 6
2 it is same temperature with engine temperature
(specific data is correlated to the engine temperature No Next
34

at that time).
Notice: if the value always is - 40 there is perhaps
open circuit failure in the circuit.
Take off the joint of coolant temperature sensor on Yes Next step
the cable, check the resistance values using
multimeter between the sensor connector No. 1 and
3
the No. 2 and check if it is corresponding to its No Replace sensor
temperature (please reference the related section of
this service manual).
Take off the joint of coolant temperature sensor on Yes To step 6
the cable, check the voltage between pin No.1 and
4
pin No.2 by multimeter and observe if it is around No Next step
5V.
Repair or replace
Check if it is short circuit to ground between ECU Yes
5 cable
pin No.39, No. 35 and sensor connector No.1, No.2.
No Next step
Start the engine at idle speed. Observe the value Yes Diagnosis help
changes of diagnostic tester coolant temperature,
6
the value should increase with the increase of the No Replace sensor
engine coolant temperature.
DTC: P0122 Indicated temperature is much lower of the air intake temperature sensor.

1 Next step
Observe throttle valve absolute opening item in Yes Next step
2 data flow, check the value if it is between 4% and
10% (specific data is correlated to the vehicle type). No To step No. 5
Step on the accelerator slowly to complete opening Yes Next step
and observe throttle valve absolute opening item
3 in data flow, check if the value is increased to around
85-90% with the opening of the throttle valve No To step No. 5
(specific data is correlated to the vehicle type).
Repeat step 3 and observe throttle valve absolute Yes Replace the sensor
4 opening item in data flow, and check if there is
jump during the changes. No Next step
Take off the joint of throttle valve positioning sensor Repair or replace
Yes
on the cable, check if there is short circuit to ground cable
5
between pin No.17, No.32, No.16 of ECU and pin
No Next step
No.1, No.2, No.3.
Check the voltage between pin No.1 and pin No.2 by Yes Replace sensor
6
multimeter and observe if it is around 5V. No Diagnosis help
35

DTC: P0123 Circuit voltage is much higher of the throttle position sensor
1 Next step
the ignition switch to ON
Observe throttle valve absolute opening item in
Yes Next step
2 data flow, check the value if it is between 4% and
10% (specific data is correlated to the vehicle type). No To step No. 5
Step on the accelerator slowly to complete opening
Yes Next step
and observe throttle valve absolute opening item
3 in data flow, check if the value is increased to around
85-90% with the opening of the throttle valve No To step No. 5
(specific data is correlated to the vehicle type).
Repeat step 3 and observe throttle valve absolute Yes Replace the sensor
4 opening item in data flow, and check if there is
jump during the changes. No Next step
Take off the joint of throttle valve positioning sensor Repair or replace
Yes
on the cable, check if there is open circuit or short cable
5
circuit to power supply between pin No.17, No.32,
No Next step
No.16 of ECU and pin No.1, No.2, No.3 of sensor
Check the voltage between pin No.1 and pin No.2 by Yes Replace sensor
6
multimeter and observe if it is around 5V. No Diagnosis help
DTC: P0130 Unreasonable failure of the upstream oxygen sensor signal

(Notice: below diagnosis process is fit for those without P0135 at the same time; if there is
P0135 failure, please deal with P0135 failure at first and then check as below.)
1 Next step
the ignition switch to ON
Start the engine and leave it at idle speed until its
Yes Diagnosis help
coolant reaches to the normal value. Observe the
2 value changes of oxygen sensor voltage item on
diagnostic meter, the displayed value should change No Next step
rapidly from 100mV-900mV.
Check if there is short circuit to ground between pin Repair or change
Yes
No.36, No.18, of ECU and pin A (opposite to oxygen cable
3
sensor gray connecting line), B (opposite to oxygen
No Next step
sensor black connecting line).
DTC: P0132 Much higher voltage of upstream oxygen sensor

36


1 Next step
Start the engine and leave it at idle speed until its Yes Diagnosis help
coolant reaches to the normal value. Observe the value
2 changes of oxygen sensor voltage item on diagnostic
No Next step
meter, the displayed value should change rapidly from
100mV-900mV.
Check if there is short circuit to power supply between Repair or change
Yes
pin No.36, No.18, of ECU and pin A (opposite to cable
3
oxygen sensor gray connecting line), B (opposite to
No Diagnosis help
oxygen sensor black connecting line).
A, check if the exhaust system is jammed Check and repair
B, check if the injector is leaking Yes according to
4
C, check if the fuel pressure is over higher diagnosis
D, check if the valve clearance is over smaller etc. No Diagnosis help
DTC: P0134 Signal failure of upstream oxygen sensor

1 Next step
Start the engine and leave it at idle speed until its Yes Diagnosis help
coolant temperature reaches to the normal value.
2 Observe the value changes of oxygen sensor voltage
No Next step
item on diagnostic meter, the displayed value should
change rapidly from 100mV-900mV.
Check if there is open circuit between pin No.36, Repair or change
Yes
No.18, of ECU and pin A (opposite to oxygen sensor cable
3
gray connecting line), B (opposite to oxygen sensor
No Diagnosis help
black connecting line) of sensor joint.
DTC: P0135 Heating circuit failure of upstream oxygen sensor

1 Next step
Take off the oxygen sensor joint on the cable and Yes Next step
check the voltage between the pins of C (opposite to
2 oxygen sensor white connecting line) and D (opposite
No To step No.4
to oxygen sensor white connecting line) by multimeter,
and observe if it is about 12V.
3 Check the resistance value between oxygen sensor Yes Next step
37

connectors C (white) and D (white) using multimeter,

No Change sensor
and observe if it is 2-5 when it is 20.
Check the fuse inside of oxygen sensor heating circuit Yes Change fuse
4
and observe if it is blow. Next step
Check if there is open circuit or short circuit to power Repair or change
Yes
supply between ECU pin No.1, main relay sensor cable
5 No.87 and pin C (opposite to oxygen sensor white
connecting line), D (opposite to oxygen sensor white No Diagnosis help
connecting line) of sensor joint.
DTC: P0171 Closed loop air fuel ratio control self adapting exceeds it maximum limit
(Notice: below diagnosis flow is fit for when air intake pressure sensor failure, canister
control valve failure and oxygen sensor failure are not appeared at the same time; if there are
failures existing at the same time please deal with other failures at first and then do as below.)

1 Next step
Start the engine and leave it at idle speed until its Yes Next step
2 Observe the value changes of oxygen sensor voltage
No Diagnosis help
item on diagnostic meter, and the displayed value keeps
around the value of 100mV at some working conditions.
Connect the fuel pressure meter (connection position is Repair or replace
Yes
the front end of fuel distributing pipe assembly fuel the cable
intake pipe); start the engine and check the fuel pressure
3
at idle speed conditions if it is around 260kpa; take off
No Next step
the vacuum pipe on fuel pressure regulator, check the
pressure and observe if it is around 300kpa.
Check if there is short circuit to ground between ECU Repair or replace
Yes
pin No.36, No.18 and pin A (opposite to oxygen sensor cable
4
gray connecting line), pin B (opposite to oxygen sensor
No Next step
black connecting line) of sensor joint.
A, check if there is a heavy leaking in air intake system Repair according
Yes
B, check if the injector is jammed to diagnosis data
5 C, check if the clearance of spark plug is too big
D, check if the sub live wire resistance is too big No Diagnosis help
E, check if the valve clearance is too big etc.
38

DTC: P0172 Closed loop air fuel ratio control self adapting exceeds it minimum limit
(Notice: below diagnosis flow is fit for when air intake pressure sensor failure, canister
control valve failure and oxygen sensor failure are not appeared at the same time; if there are
failures existing at the same time please deal with other failures at first and then do as below.)

1 Next step
Start the engine and leave it at idle speed until its Yes Next step
Observe the value changes of oxygen sensor voltage
2
item on diagnostic meter, and the displayed value No Diagnosis help
keeps around the value of 900mV at some working
conditions.
Connect the fuel pressure meter (connection position is Repair or replace
Yes
the front end of fuel distributing pipe assembly fuel the cable
intake pipe); start the engine and check the fuel
3
pressure at idle speed conditions if it is around 260kpa; Check and repair
No
take off the vacuum pipe on fuel pressure regulator, fuel system
check the pressure and observe if it is around 300kpa.
Check if there is short circuit to power supply between Repair or replace
Yes
ECU pin No.36, No.18 and pin A (opposite to oxygen cable
4
sensor gray connecting line), pin B (opposite to
No Next step
oxygen sensor black connecting line) of sensor joint.
A, check if the injector is leaking Repair according
Yes
5 B, check if the exhaust pipe is jammed to diagnosis data
C, check if the valve clearance is too small etc. No Diagnosis help
DTC: P0201 The 1st cylinder injector circuit failure

1 Next step
st
Take off the 1 cylinder injector joint from the cable, Yes To step No.4
check the voltage value between this joint pin No.1
2
and the power cathode by multimeter and observe if it No Next step
is 12V.
Repair or replace
Check if there is open circuit or short circuit to ground Yes
3 the cable
between the 1st injector joint pin No.1 and main relay.
No Next step
st
Check the resistance value by multimeter between 1 Yes Next step
4 cylinder injector pin No.1 and No.2, and observe if it
No Change injector
is 11-13 when it is 20.
Check the voltage value by multimeter between 1st Repair according to
5 Yes
cylinder injector pin No.2 and power supply cathode, diagnosis data
39

and observe if it is around 3.7V. No Diagnosis help

Check if there is open circuit or short circuit to ground Repair or replace
Yes
6 between 1st cylinder injector joint pin No.2 and the cable
ECU pin No.27. No Diagnosis help
DTC: P0202 The 2nd cylinder injector circuit failure

1 Next step
nd
2
is 12V.
Repair or replace
3 the cable
between the 2nd injector joint pin No.1 and main relay.
No Next step
nd
Check the resistance value by multimeter between 2 Yes Next
No Change injector
Check the voltage value by multimeter between 2nd Yes Diagnosis help
5 cylinder injector pin No.2 and power supply cathode,
No Next step
and observe if it is around 3.7V.
Yes
6 between 2nd cylinder injector joint pin No.2 and the cable
DTC: P0203 The 3rd cylinder injector circuit failure

1 Next step
rd
2
is 12V.
Repair or replace
3 the cable
between the 3rd injector joint pin No.1 and main relay.
No Next step
rd
No Change injector
Check the voltage value by multimeter between 3rd Yes Diagnosis help
No Next step
6 Check if there is open circuit or short circuit to ground
Yes Repair or replace
40

between 3rd cylinder injector joint pin No.2 and the cable
DTC: P0204 The 4th cylinder injector circuit failure

1 Next step
th
2
is 12V.
Repair or replace
3 the cable
between the 4th injector joint pin No.1 and main relay.
No Next step
th
No Replace injector
Check the voltage value by multimeter between 4th Yes Diagnosis help
No Next step
Yes
6 between 4th cylinder injector joint pin No.2 and the cable
DTC: P0230 Fuel pump control circuit failure

1 Next step
ignition switch to OFF
Take off the fuel pump relay and put ignition switch to Yes To step No.4
ON; check the voltage separately between fuel
2 pump relay power supply ends - that is relay pin No.
No Next step
30 and No.86 and power supply cathode, and observe
if it is around 12V.
Repair or replace
3 the cable
of the relay power supply ends circuit.
No To step No.2
Check the voltage by multimeter between fuel pump Replace fuel
Yes
4 relay control ends that is relay pin No. 85 and power pump relay
supply cathode and observe if it is around 3.7V. No Next step
Yes
5 or to power supply between relay control ends that is cable
relay pin No.85 and ECU pin No.69. No Diagnosis help
DTC: P0325 Knock sensor circuit failure
41


1 Next step
Take off the knock sensor joint from the cable; check Yes Next step
the resistance value by multimeter between knock
2
sensor connector No.1and No.2 and observe if it is No Change sensor
1M.
Yes
3 or to power supply between circuit of knock sensor the cable
joint No.1, No.2 and ECU pin No.19, No. 20 No To step No.2
Replace the knock sensor according to the regulation; Yes Diagnosis help
try running the vehicle and make the engine speed
4 Check if it is a
exceed 2200rpm. Check if the DTC P0325 will appear No
occasional fault
again.
DTC: P0335 Crank shaft position sensor signal failure

1 Next step
Take off the speed sensor joint from the cable; check Yes Next step
the resistance value by multimeter between speed
2
sensor connector No.2and No.3 and observe if it is No Replace sensor
around 770-950Mwhen it is 20
Yes
3 or to power supply between circuit of speed sensor the cable
joint No.2, No.3 and ECU pin No.34, No. 15 No Next step
Yes Diagnosis help
Check the flywheel signal disc if it is in good
4 Replace signal
conditions. No
disc
DTC: P0336 Crank shaft position sensor signal unreasonable failure

1 Next step
the ignition switch to OFF
Take off the speed sensor joint from the cable; check Yes Next step
the resistance value by multimeter between speed
2
sensor connector No.2and No.3 and observe if it is No Replace sensor
around 770-950Mwhen it is 20
Check if there is open circuit or short circuit to Repair or replace the
Yes
ground or to power supply between circuit of speed cable
3
sensor joint pin No.2, No.3 and ECU pin No.34, No.
No Next step
15
Check the flywheel signal disc if it is in good Yes Diagnosis help
4
conditions. No Replace signal disc
42

DTC: P0340 Phase sensor signal failure

1 Next step
Take off the phase sensor joint from the cable; check the Yes To step No.4
2 voltage value by multimeter between phase sensor joint pin
No Next step
No.3 and No.1; and observe if it is around 12V.
Repair or
Check if there is open circuit or short circuit to ground
Yes replace the
between circuit of phase sensor joint pin No.3 and main
3 cable
relay pin No.87; check if there is bad contact of phase
sensor connector No.1. No Next step
Check the voltage if it is around 9.9V between phase sensor Yes To step 6
4
joint pin No.2 and power supply cathode. No Next step
Check if there is open circuit or short circuit to power Repair or
Yes
5 supply or to ground between phase sensor joint pin No.2 replace cable
and ECU pin No.79. No Next step
Yes Diagnosis help
6 Check the camshaft signal disc if it is in good conditions. Replace signal
No
disc
DTC: P0342 Much lower voltage of the phase sensor

1 Next step
Take off the phase sensor joint from the cable; check the Yes To step No.4
2 voltage value by multimeter between phase sensor joint pin
No.3 and No.1; and observe if it is around 12V. No Next step
Repair or
Yes replace the
between circuit of phase sensor joint pin No.3 and main
3 cable
sensor connector No.1. No Next step
Check the voltage if it is around 9.9V between phase sensor Yes To step 6
4
joint pin No.2 and power supply cathode. No Next step
Yes
5 supply or to ground between the circuit of phase sensor replace cable
joint pin No.2 and ECU pin No.79. No Next step
Yes Diagnosis help
6 Check the camshaft signal disc if it is in good conditions. Replace signal
No
disc
43

DTC: P0343 Much higher voltage of the phase sensor

1 Next step
Take off the phase sensor joint from the cable; check Yes To step No.4
the voltage value by multimeter between phase sensor
2
joint pin No.3 and No.1; and observe if it is around No Next step
12V.
Yes
between circuit of phase sensor joint pin No.3 and main the cable
3
No Next step
sensor connector No.1.
Check the voltage if it is around 9.9V between phase Yes To step 6
4
sensor joint pin No.2 and power supply cathode. No Next step
Check if there is open circuit or short circuit to power Repair or replace
Yes
5 supply or to ground between the circuit of phase sensor cable
joint pin No.2 and ECU pin No.79. No Next step
Yes Diagnosis help
Check the camshaft signal disc if it is in good
6 Replace signal
conditions. No
disc
DTC: P0443 Canister control valve drive grade control circuit failure

1 Next step
Take off the canister control valve joint from the cable; Yes To step No.4
check the voltage value by multimeter between this
2
joint pin No.1 and power supply cathode; and observe No Next step
Repair or replace
3 the cable
of the canister control valve power supply ends circuit.
No To step No.2
Check the resistance value if it is around 22-30when Yes Next step
4 it is 20 between canister control valve pin No.1 and
No Replace the valve
pin No.2.
Check the voltage if it is around 3.7V between canister Yes Diagnosis help
5
control valve joint pin No.1 and power supply cathode. No Next step
Repair or replace
Check if there is open circuit between the circuit of Yes
6 cable
canister joint pin No.2 and ECU pin No. 46.
No Diagnosis help
44

DTC: P0444 Much lower voltage of canister control valve drive grade control circuit
1 Next step
check the voltage value by multimeter between this
2
joint pin No.1 and power supply cathode; and observe No Next step
Repair or
Check if there is open circuit or short circuit to ground Yes replace the
3
of the canister control valve power supply ends circuit. cable
No To step No.2
Check the resistance value if it is around 22-30 when Yes Next step
4 it is 20 between canister control valve pin No.1 and Replace the
No
pin No.2. valve
Check the voltage by the multimeter if it is around Yes Diagnosis help
5 3.7V between canister control valve joint pin No.1 and
No Next step
power supply cathode.
Repair or
Check if there is short circuit to ground between the Yes
6 replace cable
circuit of canister joint pin No.2 and ECU pin No. 46.
No Diagnosis help
DTC: P0445 Much higher voltage of canister control valve drives grade control circuit

1 Next step
check the voltage value by multimeter between this joint
2
pin No.1 and power supply cathode; and observe if it is No Next step
around 12V.
Repair or replace
Check if there is open circuit or short circuit to ground of Yes
3 the cable
the canister control valve power supply ends circuit.
No To step No.2
Check the resistance value if it is around 22-30when it Yes Next step
4 is 20 between canister control valve pin No.1 and pin Replace the
No
No.2. valve
Check the voltage by the multimeter if it is around 3.7V Yes Diagnosis help
5 between canister control valve joint pin No.1 and power
No Next step
supply cathode.
Repair or replace
Check if there is short circuit to power supply between Yes
6 cable
the circuit of canister joint pin No.2 and ECU pin No. 46.
No Diagnosis help
45

DTC: P0480 Air conditioner condenser cooling fan relay control circuit failure
Follow up
No. Operating steps Result
steps
1 Next step
Take off the air conditioner condenser cooling fan relay; To step
Yes
put the ignition switch to ON position, and check the No.4
2 voltage value by multimeter between this relay power
supply end that is relay pin No.30, No.85 and power No Next step
supply cathode if it is around 12V.
Repair or
Check if there is open circuit or short circuit to ground of Yes replace the
3 the air conditioner cooling fan relay power supply end cable
circuit. To step
No
No.2
Check the voltage by the multimeter if it is around 3.7V Replace
Yes
between air conditioner condenser cooling fan relay relay
4
control ends that is relay pin No.86 and power supply
No Next step
cathode.
Repair or
Check if there is open circuit or short circuit to power Yes replace
5 supply or to ground between the circuit of relay control cable
end pin No.86 and ECU pin No. 50. Diagnosis
No
help
DTC: P0500 Unreasonable failure of speed signal

1 Next step
ignition switch to OFF.
Check and
If it is a vehicle with ABS, please check if there is Yes repair ABS
2
ABS DTC. system
No Next step
Yes Next step
Check the
3 Check if the speedometer finger works normally.
No speedometer
line
Yes Next step
4 Check if the speed sensor works normally. Replace speed
No
sensor
Yes
5 supply or to ground between the circuit of speed replace cable
sensor and ECU pin No. 59. No Diagnosis help
46

DTC: P0506 Rotating speed of idle speed is lower than target idle speed
1 Next step
Yes Next step
Carry out the
Check if the throttle valve adjusting screw, accelerator
2 necessary
cable and throttle valve working in good conditions. No
repair and
maintenance
Yes Next step
Carry out the
3 Check if the idle speed regulator works in good conditions. necessary
No
repair and
maintenance
E, check if the pressure of the fuel supplying system is too Yes Next step
low
4 Replace speed
F, check if the injector is jammed No
sensor
G, check if the exhaust system is not straightway
DTC: P0507 Rotating speed of idle speed is higher than target idle speed

1 Next step
Yes Next step
Check if the throttle valve adjusting screw, accelerator Carry out the
2 necessary repair
cable and throttle valve working in good conditions. No
and
maintenance
Yes Next step
Carry out the
3 Check if the idle speed regulator works in good conditions. necessary repair
No
and
maintenance
Carry out the
A, check if the system is leaking;
necessary repair
B, check if the injector is leaking; Yes
4 and
C, check if the pressure of fuel supplying system is too
maintenance
high
No Diagnosis help
47

DTC: P0508 Idle speed regulator control circuit voltage is too low
1 Next step
Take off the idle regulator joint and Check the resistance Yes Next step
2 value between idle speed regulator pin A and pin D, pin B Replace step
and pin C if it is around 535.3 when it is 20. No
motor
Check if there is short circuit to ground between the circuits Repair or
Yes
3 of idle speed regulator joint pin A, B, C, D and ECU pin replace cable
No. 65, No.66, No.67. No.64. No Diagnosis help
DTC: P0509 Idle speed regulator control circuit voltage is too high

1 Next step
Take off the idle regulator joint and check the resistance Yes Next step
value by multimeter separately between idle speed regulator
2 Replace step
pin A and pin D, pin B and pin C if it is around 535.3 No
when it is 20. motor
Check using multimeter separately if there is short circuit to Repair or
Yes
power supply between the circuits of idle speed regulator replace cable
3
joint pin A, B, C, D and ECU pin No. 65, No.66, No.67.
No Diagnosis help
No.64.
DTC: P0511 Idle speed regulator control circuit failure

1 Next step
Take off the idle regulator joint and check the resistance Yes Next step
value by multimeter separately between idle speed
2 Replace step
regulator pin A and pin D, pin B and pin C if it is around No
535.3 when it is 20. motor
Check using multimeter separately if there is open circuit Repair or
Yes
3 between the circuits of idle speed regulator joint pin A, B, replace cable
C, D and ECU pin No. 65, No.66, No.67. No.64. No Diagnosis help
DTC: P0560 System voltage signal unreasonable

1 Next step
Yes Next step
Check the accumulator voltage by multimeter if it is around
2 Replace
12V. No
accumulator
48

Check if there is open circuit or short circuit to ground Repair or

Yes
3 between the circuits of ECU pin No.44, No.45, No.63 and replace cable
main relay pin No.87. No Next step
Yes Next step
Start the engine and check if the entire generator recharging
4 Replace
voltage is around 9-16V at the different engine speed. No
generator
Yes Diagnosis help
Check the engine cable harness contact position if it is in
5 Repair or
good conditions. No
replace cable
DTC: P0562 System voltage is too low

1 Next step
Yes Next step
Check the accumulator voltage by the multimeter and
2 Replace
observe if it is around 12V. No
accumulator
Repair or
Check if the resistance is over big between the circuits of Yes
3 replace cable
ECU pin No.44, No.45, No.63 and main relay pin No.87.
No Next step
Yes Next step
Start the engine and check if the entire generator recharging
4 Replace
voltage is around 9-16V at the different engine speed. No
generator
Yes Diagnosis help
5 Repair or
good conditions. No
replace cable
DTC: P0563 System voltage is too high
Resu
No. Operating steps Follow up steps
lt
1 Next step
Yes Next step
Check the accumulator voltage by the multimeter and
2 Replace
observe if it is around 12V. No
accumulator
Start the engine and check if the entire generator Yes Next step
3 recharging voltage is around 9-16V at the different engine
No Replace generator
speed.
Yes Diagnosis help
4 Repair or replace
good conditions. No
cable
49

DTC: P0601 ECU testing code failure

1 Next step
Yes Next step
Clean up the DTC and check the failure once again if it
2 System if
is a steady failure. No
correct
3 Replace ECU Finish
DTC: P0602 ECU diagnosis data ID code failure
Follow up
steps
1 Next step
Yes Next step
Clean up the DTC and check the failure once again if it is
2 System if
a steady failure. No
correct
3 Replace ECU Finish
DTC: P0645 Air conditioner compressor relay control circuit failure
Follow up
steps
1 Next step
Take off air conditioner compressor relay; put ignition To step
Yes
switch to ON; check the voltage value between relay No.4
2
power supply ends that relay pin No.30, No.85 and
No Next step
power cathode and observe if it is around 12V.
Repair or
Yes replace
3 cable
of the relay power supplying ends circuit.
To step
No
No.2
Check the voltage value by the multimeter between air Replace
Yes
4 conditioner compressor relay control ends that is relay relay
pin No.86 and power cathode and observe if it is around
No Next step
3.7V.
Repair or
Check if there is open circuit between the circuit of air Yes replace
5
conditioner compressor relay control ends that is relay cable
pin No.86 and ECU pin No.70. Diagnosis
No
help
50

DTC: P0646 Much lower voltage of air conditioner compressor relay control circuit
1 Next step
Take off air conditioner compressor relay; put ignition Yes To step No.4
switch to ON; check the voltage value between relay
2
power supply ends that relay pin No.30, No.85 and No Next step
Repair or
3 replace cable
the relay power supplying ends circuit.
No To step No.2
Check the voltage value by the multimeter between air Yes Replace relay
conditioner compressor relay control ends that is relay
4
pin No.86 and power cathode and observe if it is around No Next step
3.7V.
Check if there is short circuit to ground between the Repair or
Yes
5 circuit of air conditioner compressor relay control ends replace cable
that is relay pin No.86 and ECU pin No.70. No Diagnosis help
DTC: P0647 Much higher voltage of air conditioner compressor relay control circuit
Follow up
steps
1 Next step
Take off air conditioner compressor relay; put ignition Yes To step No.4
switch to ON; check the voltage value between relay
2
power supply ends that relay pin No.30, No.85 and No Next step
Repair or
3 replace cable
the relay power supplying ends circuit.
No To step No.2
Check the voltage value by the multimeter between air Yes Replace relay
4 conditioner compressor relay control ends that is relay
pin No.86 and power cathode and observe if it is around No Next step
3.7V.
Repair or
Check if there is short circuit to power supply between Yes
5 replace cable
the circuit of air conditioner compressor relay control
Diagnosis
ends that is relay pin No.86 and ECU pin No.70. No
help
51

DTC: P1651 Trouble light control circuit failure

Follow up
steps
1 Next step
Carry out action test to engine trouble light by using Yes Next step
diagnostic meter actuator action test item; and observe
2 System is
the indicator if it is always at the status of extinguishing or No
lighting on. correct
Repair or
3 replace cable
the engine trouble light power supplying circuit.
No Next step
Repair or
Check if there is open circuit or short circuit to power Yes
replace cable
4 supply or short circuit to ground between the circuit of
Diagnosis
engine trouble light control ends and ECU pin No. 28. No
help
5. TYPICAL FAILURE AND ITS DIAGNOSIS FLOW
5.1 EXPLANATION
Carry out the primary inspection before start the diagnosing according to the engine failure
phenomenon.
1) Make sure the engine trouble light is working properly;
2) Make sure that there is no failure information record checked by diagnostic meter;
3) Make sure that the failure phenomenon exists according to the customers complaints, and
confirm the conditions causing the failure.
Then carry out the exterior inspection:
1 Check if there is any fuel pipe is leaking;

2 Check if the vacuum pipe is broken, kinked up or linked correctly;
3 Check if the air intake pipe is jammed, leaking, staved or damaged;
4 Check the high voltage line of ignition system if it is broken or aging and if the
ignition order is correct;
5 Check the cable grounding place if it is clean and fastness;

6 Check the sensor and actuator joint if it is loosening or bad contact.
Important notice: if the above phenomenon is appeared, you should repair the above the
failure at first otherwise it will influence the later service.
Diagnosis help:1 Confirm there is no engine failure record;
52

2 Confirm that the failure exists before the customer complaints;

3 Inspect the engine according to the above steps and find nothing wrong;
4 During the service please do not ignore the influence from vehicle
maintenance, cylinder pressure, mechanical ignition timing and fuel
conditions;
5 Replace ECU and carry out test. If the failure is deleted, the failure is in
ECU; if the failure can not be deleted, replace back to the original ECU and
repeat the flow and check and repair it again.
5.2 TYPICAL FAILURE DIAGNOSIS FLOW
1. The engine does not rotate or rotate slowly when it is started
The normal failure component: 1) accumulator; 2) starting motor; 3) cable or ignition
switch; 4) mechanical part of the engine.
The general diagnosis flow:
Check the voltage value between the two wiring terminals Yes Next step
1 of the accumulator by multimeter; check if it is around Replace
No
8-12V when the engine is starting. accumulator
Put the ignition switch at start position, checking the anode Yes Next step
2 terminal of starting motor by multimeter and observe the Repair or
voltage if it is above 8V. No
replace cable
Repair or
Disassemble the starting motor and check its working
Yes replace starting
3 conditions. Check if there is open circuit or jammed by
motor
poor lubricating.
No Next step
Change to
If the failure is happened in winter time, check if it is
4 Yes correct
because of the wrong engine lubricant and gearbox oil
lubricant
causes the big resistance of the starting motor.
No Next step
Repair the
Check the mechanical resistance inside of the engine if it is Yes engine inside
5 too big causes the starting motor can not rotate or rotate resistance
slowly. Repeat the
No
above steps
53

2. The engine can draw rotating but can not start successfully when it is started.
General failure component: 1) no fuel in fuel tank; 2) fuel pump; 3) speed sensor; 4)
ignition coil; 5) engine mechanical part.
Diagnosis flow:
Connect the fuel pressure meter ( connecting point is Yes Next step
the front end of fuel distributing pipe assembly fuel
intake pipe); starting the engine by starter and check Repair the fuel
1
fuel pressure if it is around 260kpa; take off the No supplying
vacuum pipe from fuel pressure regulator check the system
fuel pressure if it is around 300kpa.
Connect EFI diagnostic meter; observe engine speed Yes Next step
2 data item and start the engine and check if there is Repair the
rotation speed signal is output. No
sensor cable
Pull off one of the cylinder separating line and take off Yes Next step
this cylinder injector joint and connect spark plug to it;
3 keep the spark electrode around 5mm away from Repair the
No
engine body; start the engine by starter and check if ignition system
there is blue and white high pressure fire.
Eliminate
engine
4 Check the pressure of each engine cylinder; check if Yes
mechanical
there is engine cylinder insufficient pressure.
failure
No Next step
Yes Diagnosis help
Check if the power supply to ECU pin No.12, 13, 44,
5 45, 63 is correct; check if the pin armature of No. 3, Check the
51, 53, 61, 80 are working correctly. No corresponding
line
54

3. It is hard to start the heating car.

General failure component: 1) water inside of fuel; 2) fuel pump; 3) coolant
temperature sensor; 4) fuel pressure regulator vacuum pipe; 5) ignition coil.
General diagnostic flow
Follow up
steps
Connect the fuel pressure meter ( connecting point is the Yes Next step
front end of fuel distributing pipe assembly fuel intake
pipe); starting the engine and check fuel pressure at idle Repair the
1
speed if it is around 260kpa; take off the vacuum pipe No fuel supplying
from fuel pressure regulator check the fuel pressure if it system
is around 300kpa.
Pull off one of the cylinder separating line and connect Yes Next step
spark plug to it; keep the spark electrode around 5mm Repair the
2
away from engine body; start the engine and check if No ignition
there is blue and white high pressure fire. system
Take off the coolant temperature sensor joint and start Repair circuit
the engine; observe if the engine can be started Yes or replace
3
successfully. (or serial connecting a 300resistance at sensor
the joint of coolant temperature sensor; observe if we
No Next step
can start the engine)
Repair or
Check if there if loosen or leaking of the fuel pressure Yes
4 replace
regulator vacuum pipe..
No Next step
Yes Change fuel
Check fuel conditions and check if the failure is
5 Diagnosis
appeared after the fuel refilling No
help
Diagnosis
Connect EFI system adaptor, turn on the ignition switch; Yes
help
check the power supply of pin No.12, 13, 44, 45 and
6 Check
No.63 if it is in right conditions; check pin armature of
correspond
No.3, 51, 53, 61 and No.80 if it is in right conditions.
circuit
55

4. Its hard to start the cold car.

General failure component: 1), water in the fuel; 2), fuel pump; 3), coolant temperature
sensor; 4), injector; 5), ignition coil; 6), throttle valve and idle speed by pass port; 7),
engine mechanical part.
General diagnosis flow:
pipe); start the engine and check fuel pressure at idle
1 Repair the fuel
speed if it is around 260kpa; take off the vacuum pipe No
supplying system
from fuel pressure regulator check the fuel pressure if it
is around 300kpa.
spark plug to it; keep the spark electrode around 5mm
2 Check and repair
away from engine body; start the engine and check if No
ignition system
Take off the coolant temperature sensor joint and start the Repair circuit or
Yes
engine; observe if the engine can be started successfully. replace sensor
3
(or serial connecting a 2500resistance at the joint of
coolant temperature sensor; observe if we can start the No Next step
engine)
Clean throttle
Step on the accelerator slightly and observe if it is easy to Yes valve and idle
4
be started speed air port
No Next step
Disassemble the injector, check the injector using the Yes Replace the part
5 injector special cleaning analysis meter and observe if it
No Next step
is leaking or jammed.
Check fuel conditions and check if the failure is appeared Yes Change fuel
6
after the fuel refilling No Next step
Check pressure conditions of every cylinder and observe Yes Trouble shoot
7
if there is insufficient pressure No Next step
Connect EFI system adaptor, turn on the ignition switch; Yes Diagnosis help
check the power supply of pin No.12, 13, 44, 45 and
8 Check correspond
No.63 if it is in right conditions; check pin armature of No
circuit
No.3, 51, 53, 61 and No.80 if it is in right conditions.
56

5. Normal engine speed but hard to start at any time.

General failure component: 1), water in fuel; 2), fuel pump; 3), coolant temperature
sensor; 4), injector; 5), ignition coil; 6), throttle valve and idle speed by pass port; 7), air
intake port; 8), ignition timing; 9), spark plug; 10), engine mechanical part.
Repair the air
Check the air cleaner if it is jammed; check the air Yes
1 intake system
intake port if it is leaking.
No Next step
Connect the fuel pressure meter ( connecting point is Yes Next step
the front end of fuel distributing pipe assembly fuel
intake pipe); start the engine and check fuel pressure
2 Repair the fuel
at idle speed if it is around 260kpa; take off the No
supplying system
vacuum pipe from fuel pressure regulator check the
fuel pressure if it is around 300kpa.
spark plug to it; keep the spark electrode around 5mm
3 Check and repair
away from engine body; start the engine and check if No
ignition system
Check spark plugs in every cylinder and observe its Yes Next step
4
type and clearance if it is accord with the regulation. No Adjust or replace
Take off the coolant temperature sensor joint and start Repair circuit or
Yes
5 the engine; observe if the engine can be started replace sensor
successfully. No Next step
Clean throttle
Step on the accelerator slightly and observe if it is Yes valve and idle
6
easy to be started easily. speed air port
No Next step
Disassemble the injector, check the injector using the Yes Replace the part
7 injector special cleaning analysis meter and observe if
it is leaking or jammed. No Next step
Check fuel conditions and check if the failure is Yes Change fuel
8
appeared after the fuel refilling No Next step
Check pressure conditions of every cylinder and Yes Trouble shoot
9
observe if there is insufficient pressure No Next step
Yes Next step
Check the engine ignition order and ignition timing if
10 Repair the
it is accord with the regulation. No
ignition timing
57

6. Regular starts but the idle speed is not steady at any time.
General failure component: 1), water in fuel; 2), injector; 3), spark plug; 4), throttle
valve and idle speed by pass port; 5), air intake port; 6), idle speed regulator; 7),
ignition timing; 8), spark plug; 9), engine mechanical.
Repair the air
Check the air cleaner if it is jammed; check the air intake Yes
1 intake system
port if it is leaking.
No Next step
Clean or
Yes
2 Check idle speed regulator if it is partial blocked replace
No Next step
Yes Next step
Check spark plugs in every cylinder and observe its type
3 Adjust or
and clearance if it is accord with the regulation. No
replace
Check the throttle valve and idle speed by pass if there is Yes Cleaning
4
carbon deposition. No Next step
Disassemble the injector, check the injector using the Yes Replace part
5 injector special cleaning analysis meter and observe if it is
leaking or jammed. No Next step
6
Check pressure conditions of every cylinder and observe if Yes Trouble shoot
7
there is big pressure difference between the cylinders. No Next step
Yes Next step
Check the engine ignition order and ignition timing if it is
8 Repair the
accord with the regulation. No
ignition timing
check the power supply of pin No.12, 13, 44, 45 and No.63 Repair the
9
if it is in right conditions; check pin armature of No.3, 51, No corresponding
53, 61 and No.80 if it is in right conditions. line
58

7. Regular starts but the idle speed is not steady during engine heating.
General failure component: 1), water in fuel; 2), coolant temperature sensor; 3), spark
plug; 4), throttle valve and idle speed by pass port; 5), air intake port; 6), idle speed
regulator; 7), engine mechanical.
Repair the air
Check the air cleaner if it is jammed; check the air Yes
1 intake system
intake port if it is leaking.
No Next step
Check spark plugs in every cylinder and observe its Yes Next step
2
type and clearance if it is accord with the regulation. No Adjust or replace
Disassemble the idle speed regulator and check the Cleaning the
Yes
3 throttle valve and idle speed by pass port if there is related parts
carbon deposition No Next step
Pull off coolant temperature sensor joint and start the Repair the line or
Yes
4 engine; observe the engine if it is idle speed unsteady replace sensor
during warming up the engine. No Next step
5 injector special cleaning analysis meter and observe
if it is leaking or jammed or overflowing. No Next step
Check fuel conditions and check if the failure is Yes Change fuel
6
appeared after the fuel refilling No Next step
Check pressure conditions of every cylinder and Yes Trouble shoot
7 observe if there is big pressure difference between
the cylinders. No Next step
Connect EFI system adaptor, turn on the ignition Yes Diagnosis help
switch; check the power supply of pin No.12, 13, 44,
Repair the
8 45 and No.63 if it is in right conditions; check pin
No corresponding
armature of No.3, 51, 53, 61 and No.80 if it is in
line
right conditions.
59

8. Regular starts but idle speed is not steady after the engine heating.
General failure component: 1), water in fuel; 2), coolant temperature sensor; 3), spark
plug; 4),throttle valve and idle by pass port; 5), air intake port; 6), idle speed regulator;
7), engine mechanical part.
Repair the air
Check the air cleaner if it is jammed; check the air intake Yes
1 intake system
port if it is leaking.
No Next step
Yes Next step
2 Adjust or
replace
Disassemble the idle speed regulator and check the throttle Cleaning the
Yes
3 valve and idle speed by pass port if there is carbon related parts
deposition No Next step
Repair the line
Pull off coolant temperature sensor joint and start the
Yes or replace
4 engine; observe the engine if it is idle speed unsteady
sensor
during warming up the engine.
No Next step
5 injector special cleaning analysis meter and observe if it is
leaking or jammed or overflowing. No Next step
6
just after the fuel refilling No Next step
Check pressure conditions of every cylinder and observe if Yes Trouble shoot
7
there is big pressure difference between the cylinders. No Next step
8
60

9. Regular starts but idle speed is not steady or dying out when there is partial loading.
General failure component: 1) air conditioner system; 2) idle speed regulator; 3)
injector.
Disassemble the idle speed regulator and check the Cleaning the
Yes
1 throttle valve and idle speed by pass port if there is related parts
Observe if the engine output power increased when Yes To step No.4
the air conditioner is switched on, that is using EFI
2 system diagnosis meter observing ignition angle of
No Next step
advance, fuel injection pulse width and changes of air
intake flow.
Yes Next step
Connect EFI system adaptor; break connecting line of
3 ECU pin No.75; check the cable end if it is up level Repair air
signal when the air conditioner is switched on. No conditioning
system
Check air conditioning system pressure; check the Yes Next step
compressor solenoid clutch and air conditioner
4 Repair the air
compressor pump fuel conditions and check if it is No
conditioning sys.
working correctly.
Disassemble the injector, check the injector using the Yes Replace fault part
5 injector special cleaning analysis meter and observe if
it is leaking or jammed or overflowing. No Next step
Connect EFI system adaptor, turn on the ignition Yes Diagnosis help
switch; check the power supply of pin No.12, 13, 44,
Repair the
6 45 and No.63 if it is in right conditions; check pin
No corresponding
armature of No.3, 51, 53, 61 and No.80 if it is in right
line
conditions.
61

10. Regular starts with high idle speed.

General failure component: 1) throttle valve and idle speed by pass port; 2) vacuum
pipe; 3) idle speed regulator; 4) coolant temperature sensor; 5) ignition timing.
Yes Adjust
1 Check accelerator cable if it is blocked or over tightening
No Next step
Repair the air
Check the air intake system and its connecting vacuum pipe Yes in taking
2
if it is leaking. system
No Next step
Disassemble the idle speed regulator and check the throttle Clean related
Yes
3 valve and idle speed by pass port if there is carbon part
deposition No Next step
Repair line or
Take off the coolant temperature sensor joint; start the Yes
4 replace sensor
engine and observe if it has high idle speed.
No Next step
Yes Next step
Check the engine ignition timing if it is accord with the
5 Repair the
regulations. No
ignition timing
6
62

11. Low engine speed or dying out exists when it is accelerated.

General failure component: 1) water in fuel; 2) air intake pressure sensor and throttle
position sensor; 3) spark plug; 4) throttle valve and idle speed by pass port; 5) air intake
port; 6) idle speed regulator; 7) injector; 8) ignition timing; 9) exhaust pipe.
Repair the air
Yes
1 Check the air cleaner if it is jammed. intake system
No Next step
pipe); start the engine and check fuel pressure at idle speed Repair the fuel
2
if it is around 260kpa; take off the vacuum pipe from fuel No supplying
pressure regulator check the fuel pressure if it is around system
300kpa.
Yes Next step
3 Adjust or
replace
Disassemble idle speed regulator and check throttle valve, Clean related
Yes
4 idle speed regulator and idle speed by pass port if there is part
Yes Next step
Inspect air intake pressure sensor, throttle position sensor
5 Repair line or
and its line if it is working correctly. No
replace sensor
Disassemble the injector, check the injector using the Replace fault
Yes
6 injector special cleaning analysis meter and observe if it is part
Check fuel conditions and check if the failure is appeared Yes Replace fuel
7
Yes Next step
8 Repair ignition
timing
Yes Next step
Repair or
9 Check the exhaust pipe if the air exhausting is smooth
No replace exhaust
pipe
check the power supply of pin No.12, 13, 44, 45 and No.63 Repair
10
63

12. React slowly when it is accelerated.

General failure component: 1) water in fuel; 2) air intake pressure sensor and throttle
position sensor; 3) spark plug; 4) throttle valve and idle speed by pass port; 5) air intake
port; 6) idle speed regulator; 7) injector; 8) ignition timing; 9) exhaust pipe.
Repair the air
Yes
No Next step
pipe); start the engine and check fuel pressure at idle speed Repair the fuel
2
if it is around 260kpa; take off the vacuum pipe from fuel No supplying
300kpa.
Yes Next step
3 Adjust or
replace
Yes
Yes Next step
5 Repair line or
replace sensor
Yes
7
Yes Next step
8 Repair ignition
timing
Yes Next step
Repair or
No replace exhaust
pipe
check the power supply of pin No.12, 13, 44, 45 and No.63 Repair
10
64

13. The performance is poor when it is accelerated.

General failure component:1) water in fuel; 2) air intake pressure sensor and throttle
position sensor; 3) spark plug; 4) ignition coil; 5) throttle valve and idle speed by pass
port; 6) air intake port;7) idle speed regulator; 8) injector; 9) ignition timing; 10)
exhaust pipe.
Follow up
steps
Check if there are failures like clutch skidding, low tyre Yes Repair
1 pressure, brake dragging, wrong tyre size, and wrong four
Next step
wheel positioning etc..
Repair the air
Yes
No Next step
pipe); start the engine and check fuel pressure at idle speed Repair the
3
if it is around 260kpa; take off the vacuum pipe from fuel No fuel supplying
300kpa.
spark plug to it; keep the spark electrode around 5mm away Repair
4
from engine body; start the engine and check the high No ignition
pressure fire strength if it is regular. system
Yes Next step
Check spark plugs in every cylinder and observe its type and
5 Adjust or
clearance if it is accord with the regulation. No
replace
Yes
Yes Next step
7 Repair line or
replace sensor
Yes
9
Yes Next step
Check the engine ignition order and ignition timing if it is Repair
10
accord with the regulation. No ignition
timing
65

Yes Next step

Repair or
No replace
exhaust pipe
Diagnosis
Connect EFI system adaptor, turn on the ignition switch; Yes
help
check the power supply of pin No.12, 13, 44, 45 and No.63
12 Repair
if it is in right conditions; check pin armature of No.3, 51,
No corresponding
53, 61 and No.80 if it is in right conditions.
line
66

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What are the main components of an EFI system?

What are the main components of an EFI system?

What sensors provide input to the ECU?

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CHERYA21 SERVICE MANUAL ENGINE EFI SYSTEM

1. NOTICE TO THE EFI SYSTEM SERVICE .........................................................................................3

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EFI SERVICE MANUAL

Please be obedient to the service and diagnose flow.

It is forbidden to disassembly the EFI part during service.

1.2. NOTICE DURING THE SERVICE

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1.3. SERVICE TOOLS

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1.4. EXPLANATIONS OF THE ABBREVIATION IN THE MANUAL

2. ME7.9.7 SYSTEM INTRODUCTION

Chart 2.1 compose of engine electronic control system

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Engine electronic control system schematic of ME7.9.7 chart 2.2

Canister Control Valve Fuel Distribution Pipe Assembly

Front Catalytic Converter

Electronic Accelerator UAES Parts

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l Cooling fan relay

2.3. INTRODUCTION OF SYSTEM MALFUNCTION DIAGNOSIS FUNCTION

2.3.1. MALFUNCTION INFORMATION RECORD

Function Diagnosis Function Diagnosis

Chart 2.4 EFI System Malfunction Diagnosis Principle Chart

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Chart 2.5 ISO9141-2 Standard Diagnosis Joint

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l Idle speed control

Pin point Pin Connection point

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16 Accelerator position sensor 57

6)Normal working voltage: 9--16V

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3.2 COOLANT TEMPERATURE SENSOR

T() Resistance value(k)

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(Disassemble the joint)leave the digital

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l Malfunction phenomenon: badness

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tube inside. The working of oxygen sensor is

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3 sensor connectors. The rated resistance is

Working voltage: 4.516V

6)Malfunction and diagnosis method

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3.7 ELECTRIC FUEL PUMP

l Reason: use of low quality fuel and cause 1,

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has different flow according to the