Gw491qe PDF

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Preface
Based on the model GW491Q (4Y) carburetor petrol engine, the GW491QE petrol
engine produced by our company is of one petrol engine able to electrically inject fuel
at multiple points, and is developed from electrical control components made by Delphi
company, USA, and Shanghai United Electronic Company. This model shows a
predominant improvement in aspects of power and economical efficiency, and is in
compliance with GB18352.2-2001 “Limits and measurement methods for exhausts
of pollutants from light vehicles (II) ”(equivalent to European Class-II standard), and
conforms to stipulations at phase III for GB18352.3-2005 “Limits and measurement
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methods for exhausts of pollutants from light vehicles (at phase III &IV in China)”
(equivalent to European Class-III standard).
To meet the needs from numerous maintenance /technical / management
personnel, we prepare this “GW491QE Petrol Engine Service Manual” based on the
latest technical materials.
All contents, specifications, and data stated in this manual are the latest information
before printing and this service manual will be subject to a supplemental, revision, and
completion from time to time.
This manual may be used for the reference by mechanics, drivers, and technical /
management personnel as the manual is complete in contents, definite in requirements,
and simple in maintenance.
Constrained by the level of the writer, it’s unavoidable to have some defects in
this manual, and your comments and suggestions are highly appreciated.

Model GW491QE petrol engine
Service Manual
Engine service &maintenance data...................................................................................... G1

United Electronic engine management system.................................................................. EF.1
Delphi engine management system...................................................................................... EF.2
Engine body.............................................................................................................................. EM.1
Cylinder head............................................................................................................................ EM.2
Valve mechanism...................................................................................................................... EM.3
Cooling system......................................................................................................................... CO
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Lubrication system.................................................................................................................. LU
Ignition system......................................................................................................................... IG
Starting system........................................................................................................................ ST
Charge device.......................................................................................................................... CH
Clutch......................................................................................................................................... CL

GI-1
Engine service /Maintenance data

Page
Key technical parameters for model GW491QE petrol engine.......................
Specification &adjustment parameters for key components ...........................
Technical data for maintenance......................................................................
Tightening torque for fastening elements.........................................................
Troubleshooting............................................................................................
Engine service /maintenance data..................................................................

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GI-2 Engine service /maintenance data-Key technical parameters for Model GW491QE petrol engine
Key technical parameters for Model GW491QE petrol engine
S.N. Item Specification and parameters

1 Model Model GW491QE
Four-cylinder, inline, water-cooled, overhead valve，4-stroke
2 Pattern
petrol engine
3 Fuel supply pattern Electronic controlled jet injection by group at multiple points
Measurement method for air intake
4 Velocity &density type
amount
5 Pattern of combustion chamber Wedge typed
6 Diameter of cylinder bore 91mm
7 Piston stroke 86mm
8 Displacement 2.237L
9 Compression ratio 8.8:1(European class-II) 9.1：1 European class-III
78kw/4600 r/min(European class-II)
10 Rated power
78kw/4600 r/min(European class-III)
11 Max. torque 190·m/2400~2800 r/min
≤265g/kw·h(European class-II) ≤250g/kw·h(European
12 Min. fuel consumption rate
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class-III)
13 Fuel spec RON Not lower than 93# GB17930-1999
14 Stable idle-speed 750±50 r/min
15 Idle-speed control pattern Electronically closed-loop control
16 Piston average velocity 13.18m/s
17 Average valid pressure 874kpa
18 Compression pressure of cylinder 1128kpa(European class-II); 1350kpa European class-III
when at 250r/min
19 Ignition sequence 1-3-4-2
Without ignition distributor, and direct ignition under an
20 Ignition control pattern
electronic control
21 Spark plug clearance 1.0~1.2mm
22 Model of spark plug F6RTC
23 Valve clearance 0mm hydraulic tappet
Valve timing:
Inlet-valve open lead angle; 12°before the top dead center,
24 Inlet-valve close lag angle; 48°before the bottom dead center;
Exhaust-valve open lead angle; 54°before the bottom dead center;
Exhaust-valve close lag angle; 10°before the top dead center;
25 Pattern of lubrication A combined pattern of pressure and splash.
SG grade machine oil API10W-40 GB11121-1995 for petrol
26 Oil spec
engine
Main passage oil pressure
27 When at idle-speed 750±50 r/min 49 kpa
or 3000r/min (245-490) kpa
28 Oil capacity 4.2L
29 Oil temperature (85~90)℃

Engine฀service฀/maintenance฀data-key฀technical฀parameters฀for฀Model฀GW491QE฀petrol฀engine GI-3
S .N . I tem S pecification and parameters
30 M ax . oil temperature 110
31 C onsumpti on rate of oil 2 g/kw·h
32 F uel consumption ratio of machine oil
33 C ooling method U se forced water circulation for cooling purpose.
34 C omplete mass 150kg
35 P attern of startup E lectrical

E x terior dimension
36 (754.5×518×651)mm ( electronic fan)
length×width×height
37 D ual idle-speed emission G B 18285-2005
W ith a three-way catal ytic converter, and a closed
E mission control level when under loop control for air/fuel rati o, and the with light-duty
38
operating condition vehicl e satisfies requirements from G B 18352.2-2001
and G B 18352.3-2005 standards.
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39 D ifference between cylinders 98 kpa

V acuum inside air intake pipe when at
40 53.3 kpa
idle-speed
41 T emperature of outlet cooling water (80~90)
T ension degree of fan belt
42 B elt deviation: 7~8 mm
P ressure 98N

Engine฀service฀/maintenance฀data-฀specification฀/adjustment฀parameters฀/฀maintenance฀technical฀data
GI-4 data฀for฀key฀componeats
S pecification /adj ustment par ameter s

for k ey components
S .N . Item Specification and parameters
1 S park plug F6R T C
D ecelerating type when under an electromagnetic
2 Starter motor
control U =12V P=1K W
3 G enerator and voltage regulator U =14V I=65A /90A
4 Petrol pump B lade-type electrical pump
5 Oil pump R otor typed
6 C ooling water pump C entrifugal type
7 T hermostat Wax type
Steel cover, with super high molecular weight, and
8 Petrol filter
filtration core
Full-flow & integral type, screw installed filtration
9 Oil filter
paper cores
10 Ignition coil U =12V
11 C lutch D iaphragm spring type
M aintenance technical data

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1. E ngine mechanism
U nit mm
N ame Test items Standard value U se limit
Planeness on the contact surface of 0.05 0.15
body;
Planeness on the contact surface of 0.05 0.10
manifold pipe;
C ylinder head Slope angle of valve seat
A ir intake 30 ,45 ,60
A ir exhaust 30 ,45 ,60
C ontact angle 45
C ontact width 1.2~1.6
+0.030
Inner diameter 8 +0.010
E xterior diameter 13+0.050
+0.038
Valve guide Increased size 0.05 13.088~13.100
Temperature when changing on the H eat to 80~100
side of cylinder head
W hole length of valve
A ir intake 108.2 0.10 107.7
A ir exhaust 108.5 0.10 108.0
Valve A ngle of valve working surface
A ir intake and exhaust 44.5
D iameter of valve rod
-0.015
A ir intake 8 -0.030
A ir exhaust 8 -0.020
-0.035
G ap of valve rod A ir intake 0.025~0.060 0.10
A ir exhaust 0.030~0.065 0.12
Valve
E dge thickness of valve plate
A ir intake 0.5
A ir exhaust 0.8
Free length 47 0.5
Installation height 40.6
Valve spring
Installation tension (282~345)N 282
N onperpendicularity 2.0

Engine฀service฀/maintenance฀data-฀specification/adjustment฀parameters฀/maintenance฀technical
data฀for฀key฀components GI-5
Name Test items Standard value Use limit

Inner diameter of rocker hole 18.5 +0.013
R ocker and axis 0
-0.018
Diameter of rocker shaft 18.5 -0.033
for valve
Gap between rocker and rocker shaft 0.018~0.046 0.08
Intake manifold
Planeness 0.05 0.4
pipe
W hen the sagging of chain is 98N, 13.5
Diameter of rear chain wheel (with chain)
0
Crankshaft 58.2 -0.2
0
Timing gear / chain C amshaft 113.23 -0.23
gear
L ength of chain warp after use 291.4
T hickness of chain tensioner 12.5
T hickness of shock absorber 5
Max. circumferential radial beat 0.05
eccentricity
Height of cam Min. convex value
A ir intake 38.6791
A ir exhaust 38.6869
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-0.025
Camshaft and A xial diameter of camshaft No.1 46.5 -0.041
-0.025
bearing No.2 46.25 -0.041
-0.025
No.3 46 -0.041
-0.025
No.4 45.75 -0.041
-0.025
No.5 45.5 -0.041
C learance of axial diameter 0.025~0.081 0.10
A xial clearance 0.07~0.22 0.30
Planeness 0.05
Diameter of bore hole 91+0.030
0 91.24
Cylinder block increased size 0.50 91.74
increased size 0.75 91.99
increased size 1.00 92.24
Piston diameter 90.938~90.968
increased size0.50 91.425~91.455
Piston and piston C learance of piston 0.042~0.062 0.065~0.085
ring Side play of annular groove 0.03~0.075
Opening gap of piston ring
First gas ring 0.20~0.40 1.11
Second gas ring 0.35~0.55 1.07
Oil ring 0.20~0.80 1.10
A xial clearance of main body for 0.16~0.31 0.18~0.32
connection rod on big head end
A xial clearance of connection-rod 0.021~0.051
cover
B end of connection rod every 100mm 0.03 0.05
Piston pin and Distort of connection rod every
connection rod 100mm 0.03 0.15
Inner diameter of connection rod on
small head 22.010~22.016
E xterior diameter of piston pin
Gap of inner hole on small head side 22.003~22.006
of piston pin and connection rod 0.004~0.013

GI-6 Engine฀service฀/maintenance฀data-maintenance฀technical฀data
Unit mm
A xial clearance 0.02~0.22 0.30
T hickness of thrust washer 2.450~2.490
Increased by 0.125 2.575~2.615
Increased by 0.250 2.700~2.740
Main journal diameter 58 0-0.015
Clearance of main journal diameter 0.021~0.053 0.10
C rankshaft and
journal diameter of connection rod 48 0-0.015
bearing
journal clearance of connection rod 0.021~0.053 0.10
Circumferential play of main axial
diameter 0.03 0.06
R oundness /diameter of column,
for main axial diameter and 0.01 0.02
connection rod diameter
2. Cooling system

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C apacity of
cooling fluid in 7.9L
engine
Min. value
Pressure when the pressure relief
R adiator (73.6~103)kpa not less than
valve of cover is opened.
58.9kpa
Temperature when valve is opened. (80 84) <76
T hermostat
L ift distance of valve 95 8mm <8mm
B ending deflection of transmission
belt when a 98N force is applied.
Transmission belt
New belt (5~7) mm
Used belt (7~8) mm
3. L ubrication system

Total capacity of oil dry injection 4.2L
R e-injection after the removal
Capacity of oil
Without oil filter 3.0L
With oil filter 3.5L
Clearance between rotor and pump (0.10~0.15)mm >0.20mm
Clearance between mastery rotor (0.07~0.12)mm 0.20mm
Oil pump
and slavery rotor
E nd clearance of rotor (0.03~0.07)mm 0.15mm
(750 50)r/min at idle-speed 49kpa
(2000 50)r/min 170kpa
Pressure of oil
(3000 50)r/min (245.2~490.3) kpa <245.2kpa
Max. temperature of oil 110

Engine฀service฀/maintenance฀data-tightening฀torque฀for฀fastening฀elements GI-7
4.Ignition system
Model F6RT C
Spark plug
Clearance 1.0~1.2 mm
High-tension
wiring R esistance 16k /m
5.Starting system
R ated voltage 12V
Output power 1kw
Zero-load characteristics size of 90A >90A
current specified when it’s 11.5V
Starter R ectifier E xterior diameter 30mm <29mm
Depth of T channel (0.50~0.80)mm <0.20mm
Circumferential radial play 0.05mm >0.05mm
L ength of electric brush 13mm <8.5mm
Work load of spring (17.5~23.7)N <17.56N
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6. Charge device
Density of electrolyte for battery
B attery 1.25~1.27
When full charge of battery at 20
R esistance of rotor coils 4.0
A C generator Diameter of slip ring (32.3~32.5)mm <32.1mm
E xposed length of electric brush 12.5mm 5.5mm
R egulator A djustment voltage at20 (13.95~14.4)V
A 98N bending-deflection force is
applied to driving belt between AC
Driving belt generator and water pump.
New belt (5~7)mm
Used belt (7~8)mm
T ightening torque for fastening elements

1. Tightening torque for special components
Frequently tightened spare parts N m
Valve rocker arm shaft cylinder head M8 24
Cylinder head bolt 10-M12 1.25 90
3-M8 20
A ir intake/exhaust manifold pipe cylinder head 50
Spark plug cylinder head 18
Camshaft timing chain gear camshaft 90
Camshaft flange cylinder body 18
Water pump box of timing chain chamber 18

GI-8 Engine฀service฀/maintenance฀data-Tightening฀torque฀for฀fastening฀elements
Frequently tightened spare parts N m

Water pump cylinder body 40
B ox of timing chain chamber cylinder block B olt 18
Nut 18
B earing cover of connection rod connection rod 50
B earing cover of crankshaft cylinder block 80
Crankshaft belt pulley crankshaft 160
Flywheel crankshaft 85
Oil bottom oil pan cylinder block 13
Generator adjustment support cylinder block 40
R ear oil-seal seat cylinder block 12
Drain plug of oil pan 20~25
2. Standard bolt tightening torque
Tightening torque
screw pitch
Grade diameter mm hexagonal-headed hexagonal flange bolt
mm
bolt N m N m
6 1 5 6
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8 1.25 12.5 14
10 1.25 26 29
4T
12 1.25 47 53
14 1.5 74 84
16 1.5 115
6 1 6.5 7.5
8 1.25 15.5 17.5
10 1.25 32 36
5T
12 1.25 59 65
14 1.5 91 100
16 1.5 140
6 1 8 9
8 1.25 19 21
10 1.25 39 44
6T
12 1.25 71 80
14 1.5 110 125
16 1.5 170
6 1 10.5 12
8 1.25 25 28
10 1.25 52 58
7T
12 1.25 95 105
14 1.5 145 165
16 1.5 230
8 1.25 29 33
8T 10 1.25 61 68
12 1.25 110 120
8 1.25 34 37
9T 10 1.25 70 78
12 1.25 125 140

Engine฀service฀/maintenance฀data-Troubleshooting GI-9
Tightening torque
Grade diameter mm screw pitch Hexagonal
mm Hexagonal-headed
flange bolt
bolt N m
N m
8 1.25 38 42
10T 10 1.25 78 88
12 1.25 140 155
8 1.25 42 47
11T 10 1.25 87 97
12 1.25 155 175
Common failures and troubleshooting

1.E ngine not start or start with difficulty
C ause of failure Methods of elimination
1. Failure in starting system 1.
1 B attery has insufficient voltage (1) Charge with power.
2 B attery not connected well (2) Clean wiring terminals and tighten battery line.
3 Fuse broken (3) Change the fuse
4 Failure in starter (4) R epair or change starter
5 Failure in ignition switch (5) R epair or change ignition switch
2.Failure in ignition system 2.
1 High-tension damping wiring damaged or 1 Change the high-tension resistance line
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not connected well.

2 Ignition coil damaged 2 Change the ignition coil
3 Inappropriate clearance between 3 A djust the clearance between both electrodes.
both electrodes of spark plug.
4 Spark plug is damped or the 4 Have it baked or clear away the carbon deposit.
electrode has carbon deposit.
5 Insulator on spark plug is ruptured. 5 Change the spark plug
3. Failure in the fuel supply system 3.
1 Petrol pipeline is blocked or with air 1 Wash the petrol-oil pipeline or clear away the air
resistance. resistance.
4. E ngine under a bad condition 4.
1 Valve is leaking air or damaged by 1 R epair or change valve
burning.
2 Pad of cylinder is damaged. 2 Change it.
3 Piston, piston ring, and cylinder are 3 R epair or change it.
much abraded.
4 Intake manifold is leaking air, or 4 Check the intake manifold pipe and gasket, tighten
vacuum plug is lost. the nut, and block well the vacuum tube.
5 Pipeline from the vent valve of 5 Fix the connection pipe tightly.
crankshaft box to the thermal baffle
of solenoid valve is leaking air.
2.E ngine can not be accelerated or is slack accelerated.

1.Failure in the ignition system 1.
1 Spark plug not working well 1 C heck or change the spark plug
2 T he high-tension damping wiring is 2 C hange the high-tension damping wiring
damaged.
3 T he ignition coils are damaged. ( 3) Change the ignition coil
2. Failure in engine
1 Valve is leaking air or damaged by 2.
burning. 1 R epair or change valve
2 C ylinder is under a bad compression 2 R epair or change relevant spare parts
condition.
3 Pad of cylinder is leaking air. 3 C hange the cylinder pad
4 Intake manifold pipe is leaking air. 4 C heck the intake manifold pipe and gasket , and
tighten the nut.

GI-10 Engine฀service฀/maintenance฀data-Troubleshooting
3.engine is slack.

1 E ngine is under a bad compression condition. 1
1 Valve is leaking air. 1 A brade the valve.
2 Hydraulic retaining column not 2 Check or change or wash the hydraulic tappet
working well. .
3 Valve spring is with an insufficient 3 Change the valve spring.
force or even broken.
4 Pad of cylinder is leaking air. 4 Change the cylinder pad.
5 Piston ring is stuck or broken. 5 Change the piston ring.
6 Piston or cylinder is much abraded. 6 R epair or change relevant spare parts.
2 Failure in ignition system 2 Clean, adjust or change the spark plug.
Spark plug not working well.
3 Petrol supply is blocked. 3
1 Petrol tank has contaminant deposits. 1 Clean or change the oil tank.
2 Petrol pipe is blocked. 2 Clean the oil pipe or make it through.
3 Petrol filter is blocked. 3 Change the petrol filter.
4 Petrol pump not working well. 4 R epair or change petrol pump
5 A ir exists in the fuel system. 5 Check and tighten each joint.
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4 Petrol not conforming to the specification. 4 Make it subject to technical specifications.

5 Intake manifold pipe is leaking air. 5 Check the intake manifold pipe and gasket.
6 A ir entering the air pipe is insufficient. 6
1 A ir filter is blocked. 1 Wash the cover, and clean the filtration core by
2 C hoke valve has not been opened purging.
completely. 2 R epair and adjust its control mechanism.
7. E ngine too hot. 7 R efer to the “ methods of elimination” in case
of failure “ engine too hot” .
4.E ngine is backfired or deflagrated.

1 Failure in ignition system 1
1 Joint on the ignition line is loose. 1 Check and tighten each joint.
2 Spark plug not working well. 2 Wash, adjust or change the spark plug.
3 T he heat characteristics of spark plug 3 R eplace with spark plug having appropriate heat
are inappropriate. characteristics.
2 Inappropriate content of mixed gas 2
1 Petrol supply is blocked. 1 R efer to article 3 in the “ engine slack”.
3 Failure in the valve mechanism 3
1 Valve is stuck or leaking air. 1 A brade or change the valve.
2 T he valve hydraulic retaining column 2 Change or wash the hydraulic retaining
not working well. column.
3 Valve spring is with insufficient 3 Change the valve spring.
strength. 4
4 T he cover of cylinder under a bad condition
1 C ombustion chamber has carbon 1 Clear away the carbon deposit.
deposit.
2 T he cover of cylinder is over hot or the 2 Clear air away from the cooling water sleeve.
cooling is insufficient.
3 T he cover of cylinder is damaged. 3 Change the cylinder head
5. T he high-tension resistance line is 5 Correct or change it.
misconnected or damaged.

Engine฀service฀/maintenance฀data-Troubleshooting GI-11
5.Unstable idle-speed for engine

1 With air leakage 1
1 T he intake manifold pipe is leaking air. 1 Check the intake manifold pipe and gasket.
2 Failure in ignition system 2 A rticle 2 of “engine not start or start with difficulty ”.
3 Failure in valve mechanism 3
1 B ad sealing of valve; 1 A brade the valve.
2 Hydraulic tappet is not working well; 2 C hange the hydraulic retaining column.
3 Clearance between the valve rod and 3 C hange the valve or the guiding rod of valve
the valve guiding rod is much big.
4 The pad of cylinder is leaking air. 4 Change the cylinder pad
5 The supply of petrol is not smooth. 5 R efer to article 3 of “engine slack”.
6.A bnormal sound occurred in engine

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1 Clearance produced due to the failure in 1 Check and change the hydraulic retaining column.
hydraulic retaining column
2 Piston pin too much loose. 2 Change the piston pin or piston.
3 Piston, piston ring, and cylinder abraded 3 Check, repair, and change the rank.
too much.
4 The bushing of connection rod abraded too 4 Change it.
much.
5 Main bushing abraded too much. 5 Change it.
6 T hrust piece of crankshaft abraded too much. 6 Change it.
7 Much clearance between camshaft and the 7 Change the thrust plate of camshaft.
thrust plate of camshaft.
8 Timing chain and timing chainwheel abraded 8 Change it.
too much.
9 Chain tensioner null and void. 9 Change it.
10 Too much carbon deposit in the combustion 10. C lear away the carbon deposit.
chamber of cylinder.
11 Petrol is not consistent to the specification. 11 Follow the technical specifications.
7.L arge consumption of petrol

1 Pipeline has leakage of petrol oil. 1 Tighten connectors and clamps at each point.
2 A ir filter is blocked. 2 Check and clean the air filter.
3 Failure in ignition system 3
1 E rror timing of ignition. 1 A djust the timing.
2 Failure in spark plug. 2 C heck or change the spark plug
4 B ad compression of engine. 4 R efer to article 1 of “engine slack “
5 Slippery of clutch. 5 Check and adjust the clutch.

GI-12 Engine฀service฀/maintenance฀data-Troubleshooting
E ngine service /maintenance data-T roubleshooting L arge consumption of machine oil
Cause of failure M ethods of elimination

1 L eakage of machine oil 1
1 T he oil-discharge bolt on bottom oil pan 1 T ighten the oil-discharge bolt.
is loose.
2 T he fixing bolt on bottom oil pan is 2 T ighten the fixing bolt.
loose.
3 Gasket of bottom oil pan is damaged. 3 C hange the gasket.
4 Fixing bolt for the cover of chainwheel 4 T ighten the fixing bolt or change the gasket.
chamber is loose.
5 Sealing ring of shield cover for valve 5 C hange the sealing ring
chamber is damaged.
6 Front /back oil seal for crankshaft is 6 C hange the oil seal
damaged.
7 Fixing bolt for oil pump is loose, or 7 T ighten the fixing bolt or change the gasket.
gasket is damaged.
8 Fixing bolt for oil filter is loose, or 8 T ighten the fixing bolt or change the gasket.
gasket is damaged.
2 Combined piston oil rings are abraded too 2 Change the combined piston oil rings.
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much or even damaged.

3 Piston and cylinder are abraded too much. 3 Sent it on service.
4 Oil seal on valve rod is damaged. 4 Change the valve oil seal
5 Valve rod and guiding rod are abraded too 5 Change the valve and guiding rod.
much.
6 T he ventilation system of crankshaft box is 6 Check, clean and make it through.
blocked.
7 E ngine is running with small load at high 7 Avoid the engine running with small load and at
speed for a long-term period. high speed when possible.
9.E ngine not flame our after the ignition switch is closed.
C ause of failure M ethods of elimination

1 E ngine too hot. 1 Have engine running at idle speed, decrease the water
2 Spark plug too hot. temperature below 80 , and close the ignition switch.
3 Too much carbon deposit in combustion 2 Select the specified model of spark plug.
chamber. 3 C lear away the carbon deposit.
10.E ngine too hot
C ause of failure M ethods of elimination

1.Insufficient amount of cooling fluid 1.A dd cooling fluid
2.Fan belt loose or damaged 2.A djust the tension degree of belt or change the belt.
3.Failure in water pump 3.R epair or change the water pump.
4.Failure in thermostat 4.C hange the thermostat.
5.R adiator, cylinder block, cover / pipeline/ 5.C lean, repair or change relevant spare parts.
passage of cylinder blocked or leaked
6.Failure in silicon-oil clutch 6.C heck or change.
7.M achine oil insufficient or the density is low; 7.A dd or change the machine oil.
8.Too much carbon deposit in cylinder head or 8.C lear carbon deposit away.
combustion chamber;
9.E xhaust system not through 9.C lean or change spare parts for the exhaust system.

Engine฀service฀/maintenance฀data-฀engine฀service฀/maintenance฀data GI-13
11.Pressure of machine oil is too low

1 The leakage of machine oil 1 R efer to article 1 in “Too much machine oil
2 Much insufficient machine oil or the density consumption”;
is too low; 2 A dd machine oil, or change the machine oil;
3 T he temperature of machine oil is beyond the 3 Check the cooling system when the engine cools
limit. down.
4 Failure caused by the pressure relief valve on 4 Send the pressure relief valve on service.
oil pump.
5 Failure caused by oil pump 5 R epair or change the oil pump.
6 Oil filter is blocked, or connection 6 Wash, clean, and tighten the connector.
pipe is leaking oil.
7 Oil filter is blocked. 7 Change the oil filter
8 Failure caused by the oil pressure sensor 8 Change the oil pressure sensor
9 Main bushing, the bushing or camshaft for 9 Change the bushing or bearing.
connection rod abraded too much.
10 Failure of oil manometer. 10 C hange the machine oil manometer
11 Too much oil leakage at rocker shaft or 11 Check, repair, and fix it.
where chain is tensioned.
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E ngine service /maintenance data

1.SST special maintenance tools
Note sort
A =used in the routine repair during the inspection of vehicles, or used as general tools;
B = used in the overhauling as to dismantle components;
C= used in the rare and special works which are not similar to A and B .
Outlined Sor Chapter R em

Part No. Part name
diagram t IV V V I V II V II I IX X X I X II ark
09032-00 Tools used to cut oil
A
100 seal on bottom oil pan
09043-88 8mm hexagonal nut
A
010 spanner
09201-41 Tools used to change
B
020 the oil seal on valve rod
09201-60 Tools used to dismantle
011 and repair guiding rod A
on valve
09202-43 Spring presser for valve
A
013
09213-31 R emover for belt pulley
A
021 on crankshaft
09213-70 Tools used to fix the
010 belt pulley onto A
crankshaft
09215-00 Tools used to dismantle
100 and repair the camshaft C
bearing
09216-00 B elt tension-gauge
020 A
09216-00 B elt tension cable

030

GI-14 Engine฀service฀/maintenance฀data-฀engine฀service฀/maintenance฀data
Tools used to dismantle

and change the piston
pins
Main body
Spring
sleeve A
guiding rod A
guiding rod B
Tools used to change
the oil seal before the
crankshaft
Tools used to change
the oil seal after the
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co-axis.
Spanner for oil filter
Tools used to repair
radiator
Spanner used to adjust
idle-speed screws
Rocker support tools
Valve pushrod tools

Cone-shaped tools used
for the crankshaft
bearing on injection
pump
Tools used to dismantle
the splined shaft from
injection pump
Oil-seal remover
Tools used to fix Belt฀pulley

flanges in pairs for
crankshaft
Universal remover

Engine฀service฀/maintenance฀data-฀engine฀service฀/maintenance฀data GI-15
Clutch
guiding tools
Tools used to
dismantle
guide bearing
from
crankshaft
Tools used to
dismantle
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guide bearing
from
crankshaft
Tools used to
align with
clutch film
spring
2.SSM special repair data
Name of material Product No. Usage, etc.

1282B sealant Cooling-water bypass flange
08823-00100
1282B T hree bond or similar products R ear-end cover plate for cylinder
T hermostat for manifold pipe
1324 bond
08833-00070 B olts for flywheel or driving plate
1324 T hree bond or similar products
Fixing screws for induction coil
1324 bond Cooling-fluid discharge valve for engine
1324 T hree bond 08833-00080
242 L etai or similar products Oil pressure switch

EF.1-1
United Electronic engine management system

Page
Description of system.................................................................................................
Precautions to the maintenance of electric-injection system..........................................
Analysis of the function /principal /failure for system parts &components .....................
General troubleshooting and steps to engine ...............................................................
Criterion to flashing code /mounting torque of components within M1.5.4 system........
Description of the diagnosis function on M7.9.7 system failure....................................
M7.9.7 system service &diagnosis flow process based on fault code..........................

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EF.1-2 UASE Electronic Control Engine Management System -System Introduction
Description of system
Model GW491QE petrol engine adopts BOSCH Motronic1.5.4 and Motronic7.9.7 engine management system
for electric-injection: As for the exhaust, the former is in compliance with European Class-II standard, and the
latter is in compliance with European Class-III standard.
BOSCH Motronic1.5.4 engine management system for electric-injection
As one set of advanced engine management system, M1.5.4 system has one engine electronic control unit
abbreviated to ECU used as the control center, and is able to measure various working parameters of
engine using appropriate sensors installed at different position of engine, to precisely control the oil injection
amount and the ignition lead-angle as per control programs set in engine electronic control unit, and to have
engine working with best performance under various conditions, ie. optimum dynamic output, most cost-
effective oil consumption, and best tail gas exhaust.
M1.5.4 system is subject to a multi-point oil injection control as per some sequence, and its control strategy
covers: starting control, closed-loop control of idle-speed, closed-loop control of air /fuel ratio, carbon-canister
control, transition working condition control, ignition angle control, knock control, air-conditioner control, slide
oil cut control, over-speed oil cut control, heating &protection control by three-way catalytic converter, and
system self-diagnosis, etc. The system has provided ABS, automatic gear box, air bag, etc, with applicable
communication interfaces, and is with theft-prevention function. The system is composed of three parts: sensor
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air inlet pressure /temperature sensor, throttle position sensor, cooling-fluid temperature sensor, knock sensor,
oxygen sensor LSH25, rotating speed sensor, phase sensor , actuator idle-speed adjustor EWD3, oil injector
EV6, electrical fuel pump, fuel pressure adjustor DR, carbon-canister control valve TEV, and ignition coil
ZSK , and ECU electronic controller.
BOSCH Motronic7.9.7 engine management system for electric-injection
The key feature of M7.9.7 engine electronic control management system is the application of a control
strategy based on torque aimed at linking a number of various controlled objects together. And this is the only
fixed method to have various functions integrated on ECU flexibly in accordance with the model of engine and
vehicle.
Basic components within the M7.9.7 engine electronic control system include: electronic controller ,
air inlet pressure /temperature sensor, air mass flowmeter, cooling-fluid temperature sensor, throttle position
sensor, phase sensor, rotating speed sensor, knock sensor, oxygen sensor, idle-speed adjustor, oil injector,
electronic fuel pump, fuel pressure adjustor, oil pump support, fuel distributing pipe, carbon-canister control
valve, and ignition coil.
M7.9.7 engine management system, namely a petrol engine electronic control system, is available with many
control characteristics fit for operator, vehicle, and device, and is the combination of open-looped control and
closed loop control feedback to provide various control signals while engine is running. Key function of
system includes:
1. An application physical model of basic engine management function
(a) System structure based on torque
(b) The cylinder loading capacity to be determined by the air inlet pressure sensor /air-flow sensor
(c) Improve the function as to control the gas mixture under a static or dynamic status;
(d) typed closed-loop control
(e) Fuel injection by cylinder as per some sequence
(f) Ignition timing, inclusive of knock control by cylinder

UASE Electronic Control Engine Management System -System Introduction EF.1-3
(g) Exhaust control function

(h) Heating function of catalytic converter
(i) Carbon-canister control
(j) Idle-speed control
(k) Limped back home
(l) Speed sensing through an incremental system
2. Additional function
(a) Theft-detector function
(b) Connection between torque and exterior system eg. transmission mechanism, or vehicle dynamic control
(c) Control over several types of engine parts and components
(d) Provide a matching interface across EOL-programming tool and maintenance tools.
3. Online diagnosis OBD
(a) Fulfill a series of OBD function
(b) A management system used for diagnosis function
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UAES Electronic Control Engine Management System-Notes for Electronic Injection
EF.1-4 System Service
Precautions to the maintenance of electric-injection system
cases)
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UAES Electronic Control Engine Management System-Notes for Electronic Injection
System Service EF.1-5
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6. Precautions to the replacement with new ECU:

(a)Prior to the change of ECU, remove the negative electrode line from accumulator jar.
(b)Check whether the power supply and the overlapped steel on ECU wiring harness are under a normal condition.
(c)As for the first engine starting process after new ECU has been installed, do not start the engine immediately,
instead, open the ignition switch before wait for ten seconds to restart the engine, Following a successful
starting process, perform a ECU self-learning as per following sequence:
Have the engine running at idle-speed for at least ten minutes;
Flameout for at least ten minutes;
Open the ignition switch rather than an immediate starting process, and wait for at least ten seconds;

United Electronic engine management system-Analysis of function /principal /
EF.1-6 failure for system parts &components
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Analysis of function /principal /failure for system parts &components

1. System circuit diagram and the definition of ECU Pins
(a)United Electronic M1.5.4 system circuit diagram

failure for system parts &components EF.1-7
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(b)Definition of ECU pins within Motronic 1.5.4 system
S.N. Description of function Type S.N. Description of function Type

1 Ignition coil(pin 2) Output 28 Signal of oxygen sensor(pin 4) Input
Pin A on step motor, or
2 Power ground Ground 29 Output
at EWD3.1 case: idle pin
Holding coil of oil pump relay (pin
3 Output 30 Sensor ground Ground
86)
Pin B on step motor or Holding coil of
4 pin 1 on EWD3 Output 31 cooling-fan relay, or Output
when without fan relay：idle pin
Control valve of
5 Output 32 Idle pin
carbon-canister(pin 2)
6 Function reserved 33 Idle pin
Signal of inlet-air pressure
7 Input 34 Injector (pin 2) for cylinder 4 Output
sensor(pin 4)
8 Signal of phase sensor Input 35 Injector (pin 2) for cylinder 3 Output
9 Signal of vehicle speed 36 Function reserved
Power
10 Ground of oxygen sensor(pin 3) Ground 37 Power supply of main relay(pin 87)
supply
11 Signal of knock sensor(pin 1) Input 38 Idle pin
Power Signal of air-conditioner temperature
12 Internal power supply(5V) 39 Input
supply sensor
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Connect to the electromagnetic clutch

relay output for air-conditioner
13 Function reserved 40 compressor(pin 87), or short-circuit Input
connected to Pin 1 of cylinder 4
depending on the type of vehicle
Ground of driving stages for oil
14 injector and carbon-canister control Ground 41 Signal o A/C switch Input
valve
15 Function reserved 42 Idle pin
16 Oil injector (pin 2) for cylinder 2 Output 43 Idle pin
Oil injector (pin 2) for cylinder 1 Signal of air-inlet temperature sensor(pin
17 Output 44 Input
2)
Power
18 8A fuse-accumulator voltage 45 Engine water-temperature signal(pin 1) Input
supply
19 Electronic ground Ground 46 Signal of main relay Output
Second ground of idle pin, and
20 Output 47 Idle pin
dual-spark ignition coil(pin 1)
Pin D on step motor, or at EWD3.1 Ground of Hall sensor(pin 1)，or
21 Output 48 Ground
case; idle pin Ground of rotating speed sensor (pin B)
Electromagnetic clutch relay for
holding coil of air-conditioner Ground of Hall sensor(pin 1)，or
22 Output 49 Input
compressor ground of rotating speed sensor (Pin A)
(pin 86)
Fault indicator lamp, or at a case
23 without fault indicator lamp; idle Output 50 Pre-set
pin
Power ground for other driving Correction of basic ignition timing, or at
24 stages(air-conditioner compressor, Ground 51 a case without ignition distributor: idle Input
motorized fuel pump) pin
Ground enhanced, or at a case without
25 Function reserved 52 Input
ignition distributor: idle pin
Pin C on step motor,
26 Output 53 Signal of throttle position sensor(pin 3) Input
or Pin 2 on EWD3
27 Key switch Input 54 Engine tachometer output Output
Fault diagnosis interface
55 Input/Output
(line K)

United฀Electronic฀engine฀management฀system-Analysis฀of฀function฀/principal฀/
failure฀for฀system฀parts฀&components EF.1-9
c Definition of E CU pins within Motronic 7.9.7 system
Pin C onnection point Type Pin C onnection point Type

Heating point A ir-conditioner
1 Output 42 I nput
of oxygen sensor temperature sensor
2 Ignition coil 2 Output 43
3 Ignition ground Ground 44 Intermittent power supply I nput
4 45 Intermittent power supply I nput
Solenoid valve of
5 Ignition coil 1 Output 46 Output
carbon-canister
Oil injection nozzle 4 (cylinder Oil injection nozzle 3 (cylinder
6 Output 47 Output
No.2) No.4)
Oil injection nozzle 2 (cylinder
7 Output 48
No.3)
8 I N output Output 49
9 50 Fan control 1 Output
10 51 E lectronic ground 2 Ground
11 52
12 Uninterrupted power supply I nput 53 E lectronic ground 1 Ground
13 I gnition switch I nput 54
14 M ain relay Output 55
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E ngine
15 I nput 56
rotating-speed sensor A
T hrottle position sensor A ir-conditioner
16 I nput 57 I nput
compressor switch
17 Sensor ground 1 Ground 58
18 Oxygen sensor I nput 59 Vehicle speed signal I nput
19 K nock sensor A I nput 60
20 K nock sensor B I nput 61 Power ground 1 Ground
21 62
22 63 Intermittent power supply I nput
23 64 Phase D on step motor Output
24 65 Phase A on step motor Output
25 66 Phase B on step motor Output
26 67 Phase C on step motor Output
Oil injection nozzle 1 (cylinder
27 Output 68
No.1)
28 69 Oil pump relay Output
A ir-conditioner
29 Detector lamp Output 70 Output
compressor relay
Output,
30 71 Diagnosis line K
input
31 72
32 A 5V power supply 2 Output 73
33 A 5V power supply1 Output 74
E ngine
34 I nput 75 Air-conditioner switch I nput
rotating-speed sensor B
35 Sensor ground 3 Ground 76
Pole changer
36 Sensor ground 2 Ground 77 I nput
for booster pump
37 Inlet-air pressure sensor I nput 78
38 79 Phase sensor I nput
E ngine cooling-fluid temperature
39 I nput 80 Power ground 2 Ground
sensor
40 A ir-inlet temperature sensor I nput 81
41

2. Air inlet pressure /temperature sensor DS-S-TF

(a) Function: this sensor is used to measure the absolute-pressure /
temperature of inlet manifold, and to provide information concerning engine
load and air-inlet temperature.
(b) Principal: The part measuring the inlet-air pressure is of a piezoelectric
sensor, which is able to provide the controller with “load signal” depending
on the difference of atmospheric pressure and the pressure of inlet manifold;
And the controller will produce a 5V voltage, and a 0-5V voltage will be
feedback to the controller depending on the different inlet-air pressure.
The part measuring the inlet-air temperature is one NTC typed negative
temperature coefficient sensor, whose resistance will be changed by the
change of air-inlet temperature. And the sensor will transmit a voltage
reflecting the change of air-inlet temperature to the controller.
(c) Installation position on the inlet manifold.
(d) Symptom flameout, inferior idle-speed, etc.
(e) Cause of general failures
There’s abnormal high voltage or reversedly large current during operation;
Vacuum elements are damaged during maintenance.
(f) Precautions to maintenance during maintenance, it’s prohibited to
use highly pressurized air to impact vacuum elements; Whereby the sensor
needs to be changed in case of failure, check whether the output voltage and
current from generator is under a normal condition.
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(g) Simple measurement method

Temperature sensor part: after disconnection of joint Have digital
multimeter adjusted to the ohm position, and connect two pens with
characteristic curve of temperature sensor Pin 1 and Pin 2 of sensor respectively; And the rated resistance when at 20
shall be 2.5k 5%, Other corresponding resistances may be measured
from the characteristic curve shown above. A simulation method may be
applied during measurement, details as shown below: send air to the sensor
using an electric blower Keep some distance when blowing , and observe
the change of sensor resistance, and the resistance shall be decreased.
Pressure sensor part: after connection of joint Have digital multimeter
adjusted to the DC voltage position, and connect the black pen to ground,
the red pen to Pin 3 &4 successively. When under an idle-speed status, a 5V
resistance reference voltage will be produced on Pin 3, and an approx. 1.3V voltage
temperature
will be produced on Pin 4; When under a zero load status, slowly open the
throttle valve, and the voltage on Pin 4 will be with slight changes; Quickly
open the throttle valve, the voltage on Pin 4 will reach approx. 4V
instantaneously before being decreased to 1.5V gradually.
1.sealing ring
2. stainless liner
3. PCB plate
4. sensing element
5. shell body
6. stress support
7. welded connection
8. bonded connection

failure for system parts &components EF.1-11
(h)Technical &characteristic parameter

Limit data
Measurement Value
Unit
Min. Typical Max.
Tolerable supply voltage 16 V
Tolerable pressure 500 kPa
Tolerable storage
-40 +130 ℃
temperature
Performance data
Measurement Value
Unit
Min. Typical Max.
Scope of testing pressure 20 115 kPa
Operation temperature -10 125 ℃
Operation supply voltage 4.5 5.0 5.5 V
Current when US=5.0V 6.0 9.0 12.5 mA
Load current in output loop -0.1 0.1 mA
Load resistance to ground or to accumulator 50 kΩ
Response time 0.2 ms
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Weight 27 g
3. Throttle position sensor DKG

(a)Function: this sensor is used to provide ECU with information concerning
the rotation angle of throttle valve. Based on such information, ECU may
obtain relevant information concerning engine load, working condition, (eg.
starting, idle-speed, reverse, partial load, full load), acceleration and
deceleration.
(d)Symptom bad acceleration, etc.

(e)Cause of general failures artifical failure.
(f)Precautions to maintenance take note of the installation position.
(g)Simple measurement method
(after disconnection of joint Have digital multimeter adjusted to the ohm position, connect two pens with Pin 1 and Pin 2 of
sensor respectively; And the resistance value at room temperatrure shall be 2k 20%; Connect two pens with Pin 1 and Pin 3 of
sensor respectively, rotate the throttle valve, and the resistance value will be subject to a linear change with the opening of throttle
valve; When connected with Pin 2 and Pin 3, an opposite situation will be produced.
Remark: When observing the change of resistance value, the main focus is to observe whether the resistance value has a larger leap.
(after connection of joint Open the ignition switch rather than to start the engine, have digital multimeter adjusted to the DC
voltage position, and connect the black pen to ground, the red pen to Pin 2, and a 5V reference voltage shall be produced; Connect the
red pen to Pin 3, and the voltage shall be at about 0.3V when throttle valve is at a full closed position, or about 3V when throttle valve
is at a full open position.

EF.1-12 failure฀for฀system฀parts฀&components
(h)฀Technical฀&characteristic฀parameter
Limit฀data
M easurement Value U nit
M echanic rotation angle between two extreme positions D egree
Available electrical rotating angle between two extreme positions D egree
A llowable current on sliding contact arm
Storage temperature
A llowable vibration acceleration
Performance฀data
M easurement V alue
U nit
M in. T y pical M ax .
T otal resistance P in 1-2
P rotection resistance on sliding contac t arm ( w hen
sliding c ontac t arm
is at zero position P in 2-3)
O peration tem perature
S upply voltage
V oltage ratio on right ex treme position
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V oltage ratio on lef t ex trem e position

I ncrement rate of U p/U s
degree
f or the rotation angle of throttle valv e
W eight
4.฀Knock฀sensor฀KS
(a)Function:this฀sensor฀is฀used฀to฀provide฀the฀electronic฀controller฀ECU
with฀engine฀knock฀฀information฀for฀a฀knock฀control฀purpose.
(b)Principal Being฀one฀type฀of฀vibration฀acceleration฀sensor,฀the฀knock
sensor฀is฀installed฀on฀the฀engine฀body;฀Its฀sensing฀element฀is฀of฀one
piezoelectric฀crystal,฀to฀which฀the฀vibration฀on฀engine฀body฀may฀be฀transmited
via฀mass฀block฀inside฀the฀sensor.฀Under฀the฀vibration฀stress฀of฀mass฀block,฀a
voltage฀will฀be฀produced฀on฀two฀pole฀faces฀of฀piezoelectric฀crystal฀to฀converse
European฀Class-II European฀Class-III the฀vibration฀signal฀into฀voltage฀signal
(d)Mounting฀torque
(e)Symptom Bad฀acceleration,฀etc.
(f)Cause฀of฀general฀failur The฀sensor฀might฀be฀corroded฀when฀contacting
with฀various฀liquids฀for฀long฀term฀period,฀such฀as฀machine-oil,฀cooling-fluid,
braking-fluid,฀water,฀etc.
Precautions฀to฀maintenance The฀sensor฀must฀have฀its฀metal฀surface฀closely
contacted฀with฀the฀engine฀body,฀and฀any฀type฀of฀washer฀is฀unallowable฀for
use฀during฀installation.฀During฀the฀signal฀cable฀pavement฀for฀sensor,฀it’s
noted฀that฀do฀not฀allow฀any฀syntony฀produced฀on฀signal฀cable฀to฀avoid
rupture.฀Always฀avoid฀the฀connection฀of฀high-voltage฀current฀between฀Pin฀1
1.shock฀block
and฀Pin฀2฀of฀sensor,฀otherwise,฀piezoelectric฀elements฀will฀be฀damaged.
2.exterior฀cover Simple฀measurement฀method after฀disconnection฀of฀joint£©Have฀digital
3.piezoelectric multimeter฀adjusted฀with฀Pin฀1฀and฀Pin3฀respectively.฀And฀the฀resistance
ceramic฀body value฀at฀roomtemperatureshall฀be฀greaterthan1M¦ ¸ Have฀digital฀multimeter
4.contact฀head adjusted฀to฀the฀฀millivolt฀position,฀and฀use฀a฀small฀hammer฀to฀gently฀knock
5.electrical฀plug on฀the฀area฀nearby฀the฀knock฀sensor,฀and฀a฀voltage฀signal฀output฀will฀be
produced.

( i ) Technical฀&characteristic฀parameter
Limit฀data
Measurement Value
Unit
Min. Typical Max.
Working temperature
Performance฀data
M easur em ent V al ue U ni t
S ensi ti v i ty o f new sens or agai nst a
26 8 m V /g
5 k H z si gnal
1 5% of
L i neari ty w hen w i thin 3 -5 kH z
5 k H z v al ue
L inear ity under a sy nto ny 1 5 -3 9 m V /g
C hange w i thi n w ho l e li f e ti m e per i od -1 7 %
M ai n sy nto ny f requenc y >20 K Hz
R esi stanc e >1 M
C apac i tanc e 1200 400 PF
I m pedanc e
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C apac i tanc e o f
280 60 P F /m
c abl e
L eak age res is tanc e
r esi stanc e betw een tw o output pi ns of 4.8 15% M
s ens or
F l uc tuatio n o f sens iti v i ty af f ec ted by
-0 .0 6 % m V /g k
tem per atur e
5. Cooling-fluid temperature sensor TF-W

(a)Function: this sensor is used to provide engine cooling-fluid
Measuremen temperature information so that a modifcation to oil injection and
ignition may be performed by controller.
R ated voltage
(b)Principal：This sensor is materially a thermal resistor having
R ated resistance when at 20 negativetemperature coefficient（NTC）, its resistance value will
Scope of operation temperature be decreased.
ured M ax. current passing the sensor while the temperature is rising, but does not show a linear correlation.
llowable vibration acceleration Thethermal resistor is installed in one copper heat condution sleeve.
(c)Installation position：on the water oulet mouth of engine.
(d)Mounting torque: 20 N·M（Max）
(e)Symptom:฀start฀with฀difficulty,฀etc.
(f)Cause฀of฀general฀failures artifical฀failure.
Structure฀diagram
(g)Simple฀measurement฀method after฀disconnection฀of฀joint Have
digital฀multimeter฀adjusted฀to฀the ohm position,฀connect฀two
Connector penswith฀Pin฀1฀&2฀of฀sensor฀respectively;฀And฀the฀rated฀resistance฀when
2.Shell at฀ 2 shall฀ be฀ 2.5k 5%,฀ others฀ may฀ be฀ measured฀ from฀ the
3.NTC฀resistor characteristiccurve฀shown฀above.฀A฀simulation฀method฀may฀be฀applied
during฀measurement,฀฀details฀as฀shown฀below:฀have฀the฀working฀zone
of฀sensor฀submerged฀into฀฀boiled฀water ensure฀the฀submerge฀is฀with
sufficient฀time ,฀then฀observe฀the฀change฀of฀sensor฀resistance,฀and
the฀resistance฀shall฀be฀decreased฀to฀an฀extent฀within฀300 -400
Specific฀ value฀ depends฀ on฀ the฀ temperature฀ of฀ boiled฀ water .
(h)฀Technical฀&characteristic฀parameter:
Limit฀data

Performance฀data
R esistance value k
Temperature
S.N. Tolerance of temperature 1 Tolerance of temperature 0
Min. Max. Min. Max.
6.฀Oxygen฀sensor฀LSH
(a)Function£ºto฀measure฀the฀oxygen฀content฀in฀exhausted฀gas฀from฀engine,฀and฀to฀determine฀a฀sufficient฀or฀insufficient฀combustion
of฀petrol฀and฀air.฀Based฀on฀such฀information,฀the฀electronic฀controller฀may฀perform฀a฀closed-loop฀control฀to฀reach฀an฀excessive ฀air
coefficient฀equal฀to฀1,฀and฀to฀assure฀Max.฀conversion฀efficiency฀of฀three฀contaminants฀(HC,฀CO฀and฀NOx)฀in฀exhausted฀gas฀by฀the
three-way฀catalytic฀converter.
1.cables 6.heating฀stick
2.disk฀ring 7.contact฀washer
3.insulated฀bush 8.sensor฀seat
9.ceramic฀probe
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4.protective฀jacket
5.heating฀element 10.protective฀tube
clamp฀connector
(b)Principal The฀sensing฀element฀is฀one฀ceramic฀pipe,฀whoseinner฀side
European฀Class-II links฀ the฀ exhausted฀ gas,฀ and฀ outer฀ side฀ links฀ the฀ atmosphere.
When฀at฀a temperature฀of฀350 ,฀the฀sensing฀ceramic฀pipe฀will฀have฀the
characteristic฀of฀solid฀electrolyte,฀through฀which฀the฀density฀difference฀of
oxygen฀may฀be฀conversed฀into฀a฀difference฀of฀potential฀to฀produce฀a฀current
signal฀output.฀And฀a฀relatively฀dense฀gas฀mixture฀results฀in฀a฀large฀difference
of฀density฀for฀oxygen฀ion฀inside฀and฀outside฀the฀ceramic฀pipe,฀and฀a฀larg e
difference฀of฀potential฀as฀well฀that฀a฀large฀number฀of฀oxygen฀ions฀will฀move
from฀the฀inside฀to฀the฀outside,฀and฀the฀output฀voltage฀will฀be฀high close
to฀900mV ;฀And฀a฀relatively฀thin฀gas฀mixture฀results฀in฀a฀smaller฀difference
of฀density฀for฀oxygen฀ion฀inside฀and฀outside฀the฀ceramic฀pipe,฀and฀a฀smaller
difference฀of฀potential฀as฀well฀that฀a฀small฀number฀of฀oxygen฀ions฀will฀move
from฀the฀inside฀to฀the฀outside,฀and฀the฀output฀voltage฀will฀be฀low close฀to
European฀Class-III 100mV .
(c)Installation฀ position on฀ the฀ front฀ end฀ of฀ exhaust฀ pipe.
(d)Mounting฀torque (40 60)N m
(e)Symptom inferior฀idle-speed,฀bad฀acceleration,฀tail฀gas฀out฀of฀limit,
large฀oil฀consumption,฀etc.
(f)Cause฀of฀general฀failures
Damp฀moisture฀content฀inside฀sensor,฀sharp฀change฀of฀temperature,฀rupture
of฀ probe. Oxygen฀ sensor pisoning . Pb S ,
Br Si
(g)Precautions฀to฀maintenance During฀maintenance,฀it’s฀prohibited฀to
apply฀any฀cleaning฀liquid,฀oily฀liquid,฀or฀volatile฀solid฀onto฀oxygen฀sensor.
(h)Simple฀measurement฀method
after฀disconnection฀of฀joint ฀Have฀digital฀multimeter฀adjusted฀to฀the ohm position,฀and฀connect฀two฀pens฀with฀Pin฀1
white and฀ Pin฀ 2 white of฀ sensor฀ respectively;฀And฀the฀resistance฀value฀at฀normal฀temperature฀shall฀be฀1 6 .
after฀connection฀of฀joint When฀the฀working฀temperature฀of฀oxygen฀sensor฀reaches฀350 ฀while฀engine฀is฀running฀at฀idle-speed,
have฀digital฀multimeter฀adjusted฀to฀the฀DC฀voltage฀position,฀and฀connect฀two฀pens฀with฀Pin฀3 grey ฀and฀Pin฀4 black of
sensor฀respectively.฀And฀the฀voltage฀is฀subject฀to฀a฀quick฀fluctuation฀within฀0.1-0.9V.

Value
Measurement Unit
Min. Typical Max.
Storage temperature -40 +100 ℃
End of ceramic pipe 200 850 ℃
Hexagonal headed shell ≤570 ℃
Working temperature Cable grommet and
≤250 ℃
connection cable
Connection plug ≤230 ℃
Allowable Max. Exhausted gas
temperature when heating on the end of ceramic pipe 930 ℃
element is connected the
Hexagonal headed shell 630 ℃
longest connection time
each time is 10 minutes, Cable grommet and
and Max. accumulation 280 ℃
connection cable
time is 40 hours.
Allowable temperature
≤100 K/s
variation rate on the end of ceramic pipe
Allowable temperature on ceramic elements when
≤350 ℃
condensed water is produced on the exhausted side.
random vibration peak
≤800 m/s2
value
Allowable simple harmonic vibration
≤0.3 mm
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vibration on shell vibration displacement

simple harmonic vibration
≤300 m/s2
vibration acceleration
Absolute
Uninterrupted DC current at 350℃ μA
value≤10
Interrupted Max. AC current when the exhausted gas is
at a temperature 350℃, 20 μA
and a frequency f 1Hz
Lead-free petrol, or petrol
Allowable fuel additive
with allowable lead content up to 0.15g/L
Allowable values and data to be determined by
Consumption &combustion of machine-oil client as per appropriate tests. Guiding value：
≤0.7L/1000km

Performance data
After a
Measurement New
250-hour bench test
Temperature of
350℃ 850℃ 350℃ 850℃
exhausted gas based on performance data
Voltage mV of
840±70 710±70 840±80 710±70
sensing element whenλ=0.91(co=1%)
Voltage mV of
20±50 50±30 20±50 40±40
sensing element whenλ=1.10
Inner resistance of sensing element kΩ ≤1.0 ≤1.0 ≤1.5 ≤0.3
Response time ms (600mV-300mV) ＜200 ＜200 ＜400 ＜400
Response time ms (300mV-600mV) ＜200 ＜200 ＜400 ＜400
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Electrical data of sensor
Measurement Value Unit
The resistance between At room temperature,
30 MΩ
the heating element of and under a power cut to heating element
new sensor and the When exhausted gas is at temperature 350℃ 10 MΩ
connector When exhausted gas is at temperature 850℃ 100 KΩ
Rated voltage 12 V
Continue working voltage 12-14 V
Uninterrupted working voltage
Working voltage
15 V
sustaining 1% whole life at most
Power of the connector
exhausted gas temperature≤850℃
Working voltage
sustaining for 75 seconds at most 24 V
exhausted gas temperature≤350℃
Testing voltage 13 V
Heating power under a heat balance at working voltage 13V
When the exhausted gas is at 12 W
a temperature of 350℃, and a flow rate of approx. 0.7m/s
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Heating current under a heat balance at working voltage 13V

When the exhausted gas is at 5 A
a temperature of 350℃, and a flow rate of approx. 0.7m/s
Fuse in heating circuit 8 A
Service life
The service life of oxygen sensor depends on the lead content in petrol, refer to the list below:
Lead content in petrol Life duration km

≤0.6 20000
≤0.4 30000
≤0.15 60000
≤0.005(lead-free petrol) 160000

7.฀Rotating฀speed฀sensor฀DG
(a)Function:฀When฀the฀induction฀type฀of฀rotating฀speed฀sensor฀is
working฀with฀pulse฀disc,฀relevant฀information฀concerning฀engine
rotating-speed฀and฀the฀upper฀stop฀point฀of฀crankshaft฀will฀be฀provided
to฀the฀ignition฀system฀(without฀ignition฀distributor).
(b)Principal:The฀sensor฀shall฀work฀with฀pulse฀disc,฀which฀is฀one
fluted฀disc฀having฀60฀teeth฀(the฀respective฀place฀for฀two฀other฀teeth฀is
empty),฀installed฀on฀crankshaft,฀and฀rotate฀simultaneously฀with
crankshaft.
When฀the฀disc฀passes฀by฀in฀a฀degree฀that฀its฀tooth฀tip฀just฀touches
the฀ endof฀ sensor,฀ the฀ pulse฀ disk฀ made฀ from฀ ferromagnetic
materialwillcutthemagnetic฀ force฀ line฀ of฀ permanent฀ magnet
insidesensorto฀ produce฀ an฀ induced฀ voltage฀ on฀ coil฀ used฀ for
arotating-speedsignaloutput.
(c)Installation฀position:฀above฀the฀cover฀of฀chainwheel฀chamber(M1.
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5.4)and฀on฀the฀same฀plane฀of฀rear฀flywheel฀of฀engine .
(d)฀Mounting฀torque
(e)฀Symptom:unable฀to฀start,฀etc.
(f)฀฀Cause฀of฀general฀failures:artifical฀failure.
(g)฀Precautions฀to฀maintenance:Check฀whether฀the฀clearance
betweensensor฀ and฀ the฀ signal฀ tooth฀ on฀ belt฀ pulley฀ is฀ within
mm,฀it฀may฀be฀adjusted฀using฀spacer฀when฀necessary.
(h)฀฀Simple฀measurement฀method
after฀disconnection฀of฀joint Have฀digital฀multimeter฀adjusted฀to
the ohm position฀connect฀two฀pens฀with฀Pin฀2฀&3 Pin฀1฀&2
1 shielded฀wire฀฀2 permanent฀magne for฀M7.9.7)฀systemof฀sensor฀respectively฀The฀rated฀resistance฀when
3 cover฀of฀sensor฀4 installation฀support at฀20 ฀shall฀be .
5 soft฀magnet฀core฀6 coil (after฀connection฀of฀joint)Have฀digital฀multimeter฀adjusted฀to฀the฀A C
7 ฀Air฀clearance฀฀฀8 60-2฀gear voltage฀position,฀connect฀two฀pens฀with฀Pin฀2฀&3 Pin฀1฀&2฀for฀M7.
9.7฀ system)of฀ sensor฀ respectively,฀ and฀ start฀ the฀ engine,฀ and
itsupposed฀to฀have฀voltage฀output.
(i)฀Technical฀&characteristic฀parameter
฀฀฀฀Performance฀data
Measurement Value
Unit
Min. Typical Max.
R esistance at room temperature20
Inductance m
Output voltage when crankshaft
m
is rotating at a speed of 416 revolutions per minute.

Limit฀data
Value Unit
Measurement
M in. Typical Max Min.
Coil zone -40 +150
Transition zone B lended blended
Tolerable L ead-wire zone -40 +120
temperature Storage temperature -20 +50
for PUR A mbient temperature when not starting -40 +120
lead-wire L ong-term ambient temperature when

-40 +120
induced starting
type of Short-term ambient 150 hours +150
rotating temperature when
380 hours +140
speed starting
sensor L ead-wire zone within 150 hours +150
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the whole service life 380 hours +140

period 1130 hours +130
Coil zone -40 +150
Transition zone B lended blended

Tolerable
L ead-wire zone -40 +130
temperature
Storage temperature -20 +50
for H& S
A mbient temperature when not starting -40 +130
lead-wire
L ong-term ambient temperature when
induced -40 +130
starting
type of
Short-term ambient temperature when
rotating +150
starting
speed
L ead-wire zone within 500 hours +150
sensor
the whole service life
200 hours +160
period
The 168-hour anti-vibration 20 70Hz Acceleration 40 m/s2
capability on each plane 71 220Hz V ibration amplitude 0.2 mm
Allowable strength
2 kA /m
of external magnetic field in a reversed direction
New form 1 M
Insulation resistance (10s,
Termination
test voltage 100V ) 100 k
of use period
Voltage-withstand 1 3 second, 1200VA C No puncture allowed

8.฀Phase฀sensor฀PG
a)Function:The฀sensor฀is฀applicable฀to฀the฀case฀that฀the฀ignition฀system฀(without
ignition฀distributor)฀is฀working฀with฀rotating฀speed฀sensor,฀and฀may฀provide
ECU฀with฀information฀concerning฀the฀phase฀of฀crankshaft,฀which฀is฀usable฀to
identify฀the฀upper฀compression฀stop฀point฀inside฀cyinder฀1฀from฀the฀the฀upper
exhaust฀stop฀point.
(b)Principal:The฀sensor฀is฀composed฀of฀one฀Hall฀sensor,฀and฀one฀rotor฀made
from฀steel฀plate:฀the฀former฀shall฀be฀fixed,฀and฀the฀latter฀is฀of฀steel฀blade฀with
180 columned฀surface,shall฀be฀installed฀on฀camshaft.
(c)Installation฀position:on฀the฀end฀cover฀of฀camshaft.
(d)Symptom:฀exhaust฀beyond฀the฀limit,฀increment฀of฀oil฀consumption,฀etc.
(e)Cause฀of฀general฀failures artifical฀failure.
(f)Precautions฀to฀maintenance:Avoid฀the฀dismantle฀of฀end฀cover฀during฀maintenance฀to฀prevent฀foreign฀materials฀from฀entering,
otherwise,฀the฀magnetic฀door฀will฀be฀abnormal฀or฀damaged;
(g)Simple฀measurement฀method:
M1.5.4:(connect฀with฀lead-wire)Open฀the฀ignition฀switch฀rather฀than฀to฀start฀the฀engine,฀have฀digital฀multimeter฀adjusted฀to฀the฀DC
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voltage฀position,฀connect฀two฀pens฀with฀the฀red฀/black฀lead-wire฀of฀sensor฀respectively,฀and฀ensure฀a฀5V฀reference฀voltage฀is฀provided.
And฀a฀voltage฀output฀shall฀be฀available฀between฀green฀lead-wire฀and฀black฀lead-wire฀while฀the฀engine฀is฀running.฀It’s฀recommended฀to
apply฀a฀vehicle฀oscillograph฀to฀the฀test.฀M7.9.7:connect฀with฀lead-wire)Open฀the฀ignition฀switch฀rather฀than฀to฀start฀the฀engine,฀have
digital฀multimeter฀adjusted฀to฀the฀DC฀voltage฀position,฀connect฀two฀pens฀with฀Pin฀1฀&3฀of฀sensor,฀and฀ensure฀a฀12V฀reference฀voltage
is฀provided.฀While฀the฀engine฀is฀starting,฀the฀signal฀of฀Pin฀2฀may฀be฀checked฀using฀a฀vehicle฀oscillograph.
rotating฀direction
phase฀signal฀wheel
output฀signal
฀฀฀฀฀Limit฀data
Value
Measurement Unit
Min. Typical Max.
Ambient temperature
Ambient temperature 130-5 for 50
Space vibration hours
acceleration Ambient temperature 130-5 for 50
hours

9.฀ Idle-speed฀ adjustor฀ EWD3 M 1.5.4

(a)Function:฀to฀provide฀a฀bypass฀air฀duct฀for฀idle-speed,฀control฀the฀bypass
air฀capacity฀by฀changing฀the฀cross-section฀area฀of฀channel,฀and฀effect฀a฀closed-
loop฀control฀over฀the฀rotating-speed฀while฀engine฀is฀running฀at฀idle-speed.
(b)Principal:One฀piece฀of฀permanent฀magnet,฀which฀may฀rotate฀freely฀on
shaft฀inside฀the฀idle-speed฀adjustor,฀is฀rigidly฀connected฀with฀one฀piece฀of
rotating฀slide฀block;฀And฀the฀permanent฀magnet฀is฀able฀to฀rotate฀when
driven฀ by฀ the฀ magnetic฀ field฀ of฀ coil,฀ and฀ the฀ slide฀ block฀ will฀ rotate
simultaneously;฀The฀size฀of฀bypass฀air฀capacity฀could฀be฀adjusted฀as฀the
opening฀degree฀of฀bypass฀air฀duct฀depends฀on฀the฀angle฀position฀of฀slide
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block,฀which฀is฀controllable฀by฀the฀electrical-pulse฀occupation฀rate฀output
from฀the฀electronic฀controller.
(c)Installation฀position:฀on฀the฀throttle฀valve฀unit.
(d)Symptom:฀too฀much฀high฀idle-speed,฀idle-speed฀flameout,฀etc.
(e)Simple฀measurement฀method:
(after฀ disconnection฀ of฀ joint Have฀ digital฀ multimeter฀ adjusted฀ to
the’ohm’position,฀connect฀two฀pens฀with฀Pin฀1฀&2฀of฀adjustor฀respectively;
The฀rated฀resistance฀when฀at฀20 ฀shall฀be฀17.5 after฀connection฀of
joint Start฀the฀engine฀and฀have฀it฀running฀at฀idle-speed;฀Put฀your฀hand
gently฀on฀EWD3,฀you฀will฀feel฀a฀slight฀trembling.
10.฀Idle-speed฀actuator-step฀motor M7.9.7
(a)Function:฀to฀provide฀a฀bypass฀air฀duct฀for฀idle-speed,฀control฀the฀฀bypass
air฀capacity฀by฀changing฀the฀cross-section฀area฀of฀channel,฀and฀฀effect฀a฀closed-
loop฀control฀over฀the฀rotating-speed฀while฀engine฀is฀running฀at฀idle-speed.

cover cup฀shaped฀component
stator฀assembly touch฀plate
spring฀washer bobbin
o฀ring lead-wire฀of฀electromagnet
compressive฀spring
rotor฀sleeve
front฀bearing
connector
dust฀cap
pin
shaft฀pin rear฀bearing
ball฀bearing
rotor฀assembly sleeve฀bearing
o฀ring
straight฀line฀axis
steel฀core฀of฀rotor
(b)Principal:Being฀one฀mini-typed฀unit,฀the฀step฀motor฀is฀composed฀of฀one฀roll฀of฀steel฀stators฀and฀rotors฀(as฀shown฀in฀the฀fig ure
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above):฀each฀steel฀stator฀has฀been฀wrapped฀with฀one฀coil;฀and฀the฀rotor฀is฀of฀one฀permanent฀magnet฀materially,฀at฀the฀center฀of฀which
is฀one฀nut.฀All฀coils฀on฀stator฀are฀always฀energized,฀and฀the฀change฀of฀current฀direction฀on฀any฀coil฀will฀have฀the฀rotor฀passing฀one
rotating฀angle.฀If฀the฀direction฀of฀current฀on฀each฀stator฀coil฀is฀changed฀as฀per฀some฀sequence,฀a฀rotating฀magnetic฀field฀will฀be฀produced
to฀drive฀the฀rotor฀made฀from฀permanent฀magnet฀to฀rotate฀in฀some฀direction;฀if฀the฀direction฀of฀current฀is฀changed฀in฀a฀reversed฀direction,
the฀rotating฀direction฀of฀rotor฀will฀be฀reversed฀as฀well.฀The฀nut฀at฀the฀center฀of฀rotor฀is฀able฀to฀have฀one฀piece฀of฀threaded฀rod฀moving
simultaneously,฀and฀could฀only฀move฀along฀the฀direction฀of฀axis฀as฀constrained฀by฀the฀design฀of฀screw฀rod,฀that฀why฀the฀so฀called฀name
traignt฀line฀axis’฀comes฀into฀being.฀On฀the฀end฀of฀the฀threaded฀rod฀is฀one฀choke฀plug,฀which฀is฀able฀to฀extend฀out฀or฀retract฀so฀as฀to
increase฀or฀decrease฀the฀cross-section฀area฀of฀bypass฀air฀inlet฀channel฀for฀idle-speed฀actuator฀until฀itblocked฀completely.฀The฀so-called
step฀length฀refers฀to฀a฀fixed฀rotating฀angle฀of฀rotor฀once฀the฀direction฀of฀current฀on฀coil฀is฀changed,฀and฀its฀value฀is฀equal฀to฀the฀number
of฀stator฀or฀coil฀divided฀by฀360 ,฀and฀the฀step฀length฀of฀rotor฀for฀the฀said฀step฀motor฀is฀15 .฀Therefore,฀the฀moving฀distance฀of฀screw
rod฀on฀eact฀step฀is฀fixed฀accordingly.฀The฀number฀of฀moving฀steps฀for฀step฀motor฀may฀be฀controlled฀by฀ECU฀through฀a฀control฀over
the฀change฀times฀of฀current฀on฀coil฀so฀as฀to฀adjust฀the฀cross-section฀area฀of฀bypass฀channel฀plus฀the฀flowed฀air฀capacity.฀The฀air฀flow
capacity฀VS.฀step฀length฀shows฀a฀linear฀correlation.฀And฀there฀one฀spring฀behind฀choke฀plug฀on฀the฀end฀of฀screw฀rod,฀as฀shown฀in฀the
figure฀above.฀The฀size฀of฀utilizable฀force฀along฀the฀extension฀direction฀of฀choke฀plug฀is฀equal฀to฀the฀force฀of฀step฀motor฀plus฀the฀spring
force;฀while฀the฀size฀of฀utilizable฀force฀along฀the฀retracted฀direction฀of฀choke฀plug฀is฀equal฀to฀the฀spring฀force฀reduced฀by฀the฀force฀of
step฀motor.
(c)Installation฀position:on฀the฀throttle฀valve฀unit.
(d)Symptom:฀too฀much฀high฀idle-speed,฀idle-speed฀flameout,฀etc.
(e)Cause฀of฀general฀failures:฀The฀accumulation฀of฀dusts฀and฀oil฀gas,฀etc฀causes฀partial฀blockage฀inside฀the฀bypass฀air฀duct,฀and฀leads
to฀an฀abnormality฀when฀adjusting฀the฀idle-speed฀of฀step฀motor.
(f)Precautions฀to฀maintenance:
1.฀Do฀not฀apply฀any฀force฀in฀axial฀direction฀to฀pull฀out฀the฀shaft฀or฀press฀it฀into฀place;
2.฀Prior฀to฀the฀installation฀of฀idle-speed฀adjustor฀(installed฀with฀step฀motor)฀into฀the฀throttle฀valve฀unit,฀its฀shaft฀shall฀ be฀at฀a฀place
able฀to฀be฀retracted฀completely;
3.฀Remember฀to฀clean฀and฀service฀the฀bypass฀air฀duct;
4.฀Following฀the฀removal฀of฀accumulator฀jar฀or฀ECU,฀an฀immediate฀self-learning฀shall฀be฀performed฀on฀step฀motor.
M7.9.7฀system฀self-learning฀method:
Open฀the฀ignition฀switch฀and฀start฀the฀engine฀five฀minutes฀later฀If฀any฀abnormality฀with฀engine฀idle฀speed฀is฀found,฀settle฀it฀by
peatingabove฀steps.
(g)Simple฀measurement฀method (after฀disconnection฀of฀joint)Have฀digital฀multimeter฀adjusted฀to฀the ohm position,
andconnect฀two฀pens฀with฀Pin฀AD฀and฀BC฀of฀adjustor฀respectively;฀The฀rated฀resistance฀when฀at shall฀be฀

(h)฀Technical฀&characteristic฀parameter£º
Limit฀data
M easurement V alue
U nit
M in. T ypical M ax .
W ork ing temperature
M ax . contacting times of
T imes
chok e plug on step motor w ith the seat
Characteristic฀data
M easurement V alue
U nit
R esistance of each coil w hen at 25
R esistance of each coil when
w ithin a scope of w ork ing temperature
I nductance of each coil w hen at 25 , 1000H z
N ormal w ork ing voltage V
P ossible work ing v oltage V
S tep length of rotor for step motor D egree
P ressure drop on two ends
k pa
w hen the bypass passage is opened
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M ax . ax ial force
N
caused by air pressure difference
11.฀injector฀ E V 6
(a)Function:Based฀on฀specfic฀command฀given฀by฀ECU,฀the฀injector
may฀inject฀fuel฀within฀a฀specified฀time฀limit฀to฀provide฀engine฀with
evaporated฀fuel.
(b)Principal:When฀the฀coil฀of฀injector฀is฀energized฀by฀ECU,฀a฀magnetic
field฀force฀will฀be฀produced;฀When฀the฀magnetic฀field฀force฀is฀increased
to฀a฀degree฀that฀it฀sufficient฀to฀overcome฀an฀resultant฀force฀of฀stress
from฀release฀spring,฀gravity฀force฀of฀needle฀valve,฀and฀force฀friction,฀the
needle฀valve฀will฀lift฀up฀to฀activate฀the฀oil฀injection฀process.฀The฀Max.
lift฀of฀needle฀valve฀shall฀not฀exceed฀0.1mm;฀When฀the฀pulse฀injection฀is
ended,฀needle฀valve฀will฀be฀re-closed฀by฀the฀stress฀from฀release฀spring;
(c)Installation฀position:on฀inlet฀manifold฀at฀one฀end฀close฀to฀air฀inlet
1 O-ring door.
2.฀filter฀screen (d)Symptom:฀Inferior฀idle-speed,฀bad฀acceleration,฀unable฀to฀start
3.฀injector฀with฀electrical฀plug start฀with฀difficulty,฀etc):
4.฀ coil (e)Precautions฀to฀maintenance:
5.฀spring ฀-฀The฀฀injector฀may฀have฀various฀types;฀During฀maintenance,฀Part฀No.
6.฀valve฀needle฀with฀coil฀anchorcore of฀฀injector฀to฀be฀re-installed฀shall฀be฀consistent฀to฀the฀original฀one฀as
7.฀valve฀seat฀with฀an฀injection-hole injectors฀looking฀alike฀and฀able฀to฀be฀installed฀might฀be฀inappropriate;
฀฀฀฀plate ฀-For฀an฀easy฀installation,฀it฀recommended฀to฀apply฀clean฀silicon-free
machine-oil฀to฀the฀surface฀of฀oring฀at฀the฀upper฀position฀where฀the฀fuel
distributing฀pipe฀will฀be฀installed.฀Do฀not฀apply฀machine-oil฀to฀the฀inner฀part฀or฀injection฀hole฀of฀฀injector;
-฀O฀ring฀needs฀to฀be฀changed฀during฀the฀dismantle฀or฀re-installation฀of฀฀injector,฀and฀be฀careful฀not฀to฀damage฀the฀sealing฀surface฀of
injector;
-If฀the฀฀injector฀has฀two฀installation฀slots,฀the฀clamping฀piece฀shall฀be฀installed฀to฀the฀correct฀slot;฀Y ou฀may฀refer฀to฀the฀installation
position฀for฀original฀component;
-It฀strictly฀prohibited฀to฀dismantle,฀wash฀or฀change฀the฀filter฀screen;
-After฀a฀dismantle฀of฀฀injector,฀keep฀its฀seat฀clean,฀and฀prevent฀foreign฀materials฀from฀entering฀cylinder.
(f)Simple฀testing฀method:(recommended฀to฀use฀a฀special฀wash฀instrument฀applicable฀to฀฀injector฀for฀a฀regular฀washing฀purpose
after฀disconnection฀of฀joint)Have฀the฀digital฀multimeter฀adjusted฀to฀the ohm position,฀and฀connect฀two฀pens฀with฀two฀pins฀of
injector฀respectively;฀And฀the฀rated฀resistance฀when฀at฀20 ฀shall฀be฀:฀(11-17) after฀connection฀of฀joint)Start฀the฀engine฀and฀have฀it
running฀at฀idle-speed;฀Put฀your฀hand฀gently฀on฀the฀฀injector,฀you฀will฀feel฀the฀pulsation฀of฀฀injector .

(g)Technical฀&characteristic฀parameter
฀฀฀฀Limit฀data
V alue
M easurement U nit
S torage temperature w hen w ith original pack age -40 +70
A llow able temperature of injector inside vehicle
+140
w hen not w ork ing
C ontinuous -40 +110
W ork ing
W ithi n a short-ti me period
temperature of
about 3minutes after heat +130
injector
starting process
A llow able fuel C ontinuous +70
temperature at the
inlet mouth of S hort time ( A bout three minutes) +100
injector
T he dev iation of fuel f low at
-40 +45
may result in a 5% temperature
F uel moisture content rather than
A llow able leak age of O ring w hen w ithin -35~-40
dripping w ithi n O ring area is allow ed.
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M ax allow able vibration acceleration peak v alue 400 m/s 2

S upply voltage 6 16 V
I nsulation resistance 1 M
B earable internal f uel pressure 1100 kP a
B earable bending stress 6 N ·m
B earable ax ial stress 600 N
Characteristic฀data Value
Quantity Unit
Min. T ypical Max.
Working pressure Pressure difference 300 kPa
Injector resistance at 20 11.4 12.6
12.฀Electrical฀fuel฀pump฀EKP
(a)Function to฀transfer฀the฀fuel฀from฀fuel฀tank฀to฀engine,฀and฀to฀produce
a฀sufficient฀fuel฀pressure,฀and฀excessive฀fuel.
(b)฀฀Principal Being฀one฀type฀of฀vane฀pumps฀driven฀by฀DC฀motor,฀the
fuel฀pump฀is฀installed฀inside฀fuel฀tank,฀and฀submerged฀under฀fuel,฀and฀its
lubrication฀and฀heat฀elimination฀may฀be฀effected฀using฀fuel;฀The฀accumulator
will฀provide฀a฀power฀supply฀to฀electrical฀fuel฀pump฀via฀pump฀relay,
which฀will฀connect฀the฀loop฀of฀electrical฀fuel฀pump฀only฀when฀the฀engine
is฀running฀or฀during฀a฀starting฀process;฀Whereby฀the฀engine฀stops฀running
due฀to฀accident,฀the฀fuel฀pump฀will฀auto.฀stop฀working.
(c)Installation฀position:฀inside฀fuel฀tank.
(d)Symptom Large฀ running฀ noises,฀ bad฀ acceleration,
unableto฀start(start฀with฀difficulty),฀etc.
1.฀end฀cover฀of฀oil฀pump
(e)Cause฀ of฀ general฀ failures The฀ use฀ of฀ inferior฀ fuel฀ might
2.฀armature
result฀in:
3.฀oil฀passage -An฀insulation฀layer฀formed฀by฀accumulative฀colloid;
4.฀impeller -A฀dead฀hug฀of฀bearing฀bush฀with฀armature฀of฀oil฀pump;
-Corrosion฀of฀oil-level฀sensor฀components.

(f)Precautions฀to฀maintenance
-Based฀on฀the฀demand฀of฀engine,฀the฀electrical฀fuel฀pump฀may฀have฀various฀flow฀capacities;
During฀maintenance,฀Part฀No.฀of฀fuel฀pump฀to฀be฀re-installed฀shall฀be฀consistent฀to฀the฀original฀one฀as฀fuel฀pumps฀looking
alike฀and฀able฀to฀be฀installed฀might฀be฀inappropriate;
- To฀avoid฀any฀damage,฀do฀not฀have฀the฀fuel฀pump฀running฀under฀a฀dry฀state;
-In฀cases฀that฀fuel฀pump฀needs฀to฀be฀changed,฀always฀remember฀to฀wash฀the฀fuel฀tank฀andits฀pipeline,฀and฀to฀change฀the
fuel฀filter;
(g)Simple฀measurement฀method
after฀disconnection฀of฀joint Have฀the฀digital฀multimeter฀adjusted฀to฀the฀‘ohm’฀position,฀and฀connect฀two฀pens฀with
two฀pins฀of฀fuel฀pump฀respectively;฀The฀measured฀internal฀resistance฀shall฀be฀an฀infinite฀value namely฀a฀state฀other
than฀short฀circuit฀or฀broken฀loop ,฀or฀a฀value฀other฀than฀zero.
after฀connection฀of฀joint As฀for฀the฀unit฀installed฀with฀oil-return฀system,฀connect฀the฀oil฀inlet฀pipe฀with฀fuel
manometer,฀and฀observe฀whether฀the฀fuel฀pump฀is฀able฀to฀work฀while฀engine฀is฀running;฀If฀not฀work,฀check฀the฀Pin +
for฀its฀supply฀voltage;฀If฀work,฀check฀whether฀the฀fuel฀pressure฀is฀within฀250-300Kpa;฀When฀the฀oil฀return฀pipe฀is฀being
clamped฀tightly฀using฀oil-return฀barrier,฀check฀whether฀an฀oil฀pressure฀may฀be฀produced฀rapidly.
(h)Technical฀&characteristic฀parameter
M easurement V alue
U nit
M in. T ypical M ax.
W orking voltage V (D C )
S ystem pressure kPa
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Pressure at exhaust point kPa

A mbient temperature
(applicable to storage and transport)
A llowable fuel temperature
A llowable vibration acceleration m/s 2
13.฀Fuel฀pressure฀adjustor฀DR
฀Principal:฀The฀pressure฀adjustor฀is฀of฀a฀membrane฀typed฀overflow฀valve:฀Once฀the฀system฀fuel฀pressure฀is฀increased
to฀a฀degree฀that฀the฀fuel฀pressure฀inside฀oil฀inlet฀mouth฀is฀greater฀than฀a฀resultant฀force฀of฀the฀pre-tensioned฀spring฀force
and฀the฀air฀pressure฀force฀inside฀spring฀chamber,฀the฀membrane฀will฀be฀supported฀to฀open฀the฀valve฀so฀that฀the฀fuel฀could
overflow฀via฀an฀fuel฀return฀mouth฀at฀the฀center฀of฀pressure฀adjustor,฀and฀return฀to฀the฀fuel฀tank,฀which฀will฀result฀in฀a
decrement฀of฀fuel฀pressure฀until฀the฀valve฀is฀closed.
(b)Installation฀position:฀The฀unit฀installed฀with฀oil-return฀system
shall฀ be฀ installed฀ onto฀ the฀ fuel฀ distributing฀ pipe฀ assembly.
(c)Symptom The฀fuel฀pressure฀is฀too฀low฀or฀too฀high,฀or฀hard฀to
start,฀etc.
(d)Cause฀of฀general฀failures Along-term฀use฀without฀service
results฀in
-฀A฀blockage฀on฀filter฀screen;
-฀A฀major฀leakage฀caused฀by฀grained฀foreign฀materials;
-An฀artifical฀mechanical฀damage,฀etc.
(e)Precautions฀to฀maintenance
During฀maintenance:
During฀maintenance:
-It’s฀prohibited฀to฀use฀highly฀pressurized฀gas฀to฀impact฀themembrane
elements;
-It’s฀prohibited฀to฀use฀strong฀corrosive฀liquid฀for฀washing฀purpose;
-It’s฀prohibited฀to฀apply฀any฀force฀causing฀possible฀deformation.
(f)Simple฀measurement฀method
Connect฀the฀fuel฀inlet฀pipe฀with฀fuel฀manometer฀before฀engine฀is
started;฀Have฀the฀engine฀running฀at฀idle-speed,฀and฀check฀whether
the฀fuel฀pressure฀is฀at฀about฀260Kpa;฀Have฀the฀engine฀running฀at
speed฀2000r/min,฀pull฀out฀the฀fuel฀pressure฀adjustor,฀and฀check
whether฀the฀fuel฀pressure฀is฀at฀300Kpa.

(g)Technical฀&characteristic฀parameter
฀฀฀฀฀Limit฀data
M easurement V alue
U nit
L eak age of flow at pressure diff erenc e 80k pa 9 c m 3 /min
A llow able c onstant-w ork ing temperature -40 +80
A llow able M ax . fuel temperature +80
A llow able M ax . pressure
-2% +5%
drift rev ersible w hen at -30?
A llow able M ax . pressure
-5% +2%
drift rev ersible w hen at +80?
P eak value of allow able M ax . acceleration 100 m/s 2
A llow able M ax . pulse value
100 kPa
of pressure at air inlet mouth
Performance฀data
M easuremen Value Unit
Min. Typical Max.
R ated pressure difference at flow capacity Q =80 1/h 300 kPa
V ariable value of working pressure when the flow is
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17.5 kPa
changed within 15~140 1/h
S cope of flow 10 220 L/h
S lope of characteristic curve 0.14 kPa/L/h
14. Carbon-canister control valve TEV

(a)Principal：The carbon-canister within the fuel evaporation control
system is used to absorb the evaporated gas coming from fuel tank
until it saturated; And the electronic controller is usedto control the
opening of carbon-canister control valve so that a regenerated air flow,
formed by fresh air and saturated &evaporated gas inside
carbon-canisteruel, could be induced to the air inlet pipe of engine;
Depeneding on various working conditions of engine, the electronic
controller may change the occupation rate of pulse signal transmitted
to the electromagnetic coils inside carbon-canister control valve, and
perform a control over the flow capacity of regenerated air flow. Besides,
such flow capacity will also be affected by the difference of pressure on
two ends.
(b)Installation฀position:On฀the฀vacuum฀pipeline฀of฀inlet฀manifold฀for฀carbon-
canister.
(c)Cause฀of฀general฀failures:Rust,฀corrosion,฀or฀bad฀sealing฀performance
caused฀by฀foreign฀materials฀inside฀the฀valve;
(d)Symptom:inferior฀idle-speed,฀failure฀of฀function,฀etc.
(e)Precautions฀to฀maintenance:
฀-The฀direction฀of฀air฀flow฀shall฀conform฀to฀relevant฀stipulations฀during
installation;
-Check฀the฀condition฀of฀carbon-canister฀whereby฀its฀control฀valve฀needs฀to
P฀denotes฀the฀difference฀between฀atmospheric
be฀changed฀due฀to฀its฀failure฀caused฀by฀the฀blockage฀of฀black฀grains฀inside
valve฀body;
pressure฀Pu฀and฀the฀inlet-air฀pressure฀Ps.
1.฀fuel฀gas฀coming฀from฀oil฀tank
฀-Prevent฀liquid฀(eg.฀water฀or฀oil)฀from฀entering฀the฀valve฀during฀maintenance;
2.฀carbon-canister
- To฀avoid฀the฀transmission฀of฀solid฀borne฀sound,฀it’s฀recommended฀to฀have
3.฀ambient฀atmospheric฀pressure
฀the฀carbon-canister฀control฀valve฀handged฀&installed฀onto฀hose.
4.฀ TEV฀ valve
(f)Simple฀measurement฀method:
5.฀Pipeline฀of฀regenerated฀air฀flow
(after฀disconnection฀of฀joint)฀Have฀the฀digital฀multimeter฀adjusted฀to฀th
ohm position,฀and฀connect฀two฀pens฀with฀two฀pins฀of฀carbon-canister
6.฀throttle฀valve฀of฀inlet฀manifold
control฀valve฀respectively;฀And฀the฀rated฀resistance฀when฀at฀20 ฀shall฀be
( )
(g)฀Technical฀&characteristic฀parameter
฀฀฀฀฀฀Limit฀data
M easurement V alue
U nit
W ork ing voltage
O ne-minute over voltage
M in. starting voltage
A llowable working temperature
A llowable working temperature within short ti me
A llowable storage temperature
B earable pressure difference
between air inlet mouth and ex haust hole
A llowable open /close times
A llowable vibration acceleration on product
L eak age amount when the pressure difference is 400m
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bar
15.฀Ignition฀coil฀ZSK
(a)Function:฀To฀transform฀the฀low฀voltage฀DC฀current฀from฀accumulator
into฀high฀voltage฀current,฀and฀to฀ignite฀the฀gas฀mixture฀inside฀cylinder฀via
spark฀plug฀by฀producing฀sparks฀during฀discharge฀process.
(b)Principal The฀primary฀windings฀will฀be฀charged฀up฀when฀its฀ground
connection฀channel฀is฀connected;฀and฀the฀charging฀process฀will฀be฀stopped
once฀the฀circuit฀of฀primary฀windings฀is฀broken฀by฀ECU,฀but฀high฀voltage
current฀will฀be฀induced฀simultaneously฀on฀secondary฀windings฀to฀provide
spark฀plug฀with฀energy฀for฀discharge฀process.฀Different฀from฀ignition฀coils
installed฀with฀ignition฀distributor,฀the฀ignition฀coil฀ZSK2 2฀has฀both฀ends
of฀its฀secondary฀windings฀connected฀with฀one฀spark฀plug฀respectively฀to
perform฀two฀ignitions฀simultaneously.
(c)Installation฀position:฀on฀engine.
(d)Symptom:฀unable฀to฀start,฀etc.
(e)Cause฀of฀general฀failures:฀burning฀&damage฀caused฀by฀strong฀current,
damage฀by฀exterior฀force,฀etc.
(f)Precautions฀to฀maintenance:฀During฀maintenance,฀it’s฀prohibited฀to฀test
the฀function฀of฀ignition฀using฀a฀short-circuit฀fire฀test฀method฀to฀avoid฀any
damage฀on฀electronic฀controller.
(g)Simple฀measurement฀method
After฀disconnection฀of฀joint ฀Adjust฀the฀digital฀multimeter฀to฀the ohm
position,฀and฀connect฀two฀pens฀with฀two฀pins฀of฀primary฀windings
respectively.฀And฀the฀resistance฀when฀at฀20 ฀shall฀be฀(0.42-0.58) ;฀฀The
resistance฀for฀secondary฀windings฀shall฀be฀(11.2-14.8)k .
Limit฀data

Performance฀data
Value
Measurement Unit
Min. Typical Max.
Nominal voltage
R esistance Value Primary windings
20 25 Secondary windings
Inductance value Primary windings
20 25 Secondary windings
L oad 50pF
Formed voltage
L oad 50pF//1M
16.฀Electronic฀ controller฀ ECU(M1.5.4)
฀(a)Function฀
- Control฀the฀fuel฀injection
- Control฀the฀ignition
- Control฀the฀idle-speed
- Provide฀the฀sensor฀with฀power฀supply฀5V/120mA
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- Integrated฀knock฀control฀by฀cylinder,฀with฀self-adaptability;
- E ฀closed-loop฀control,฀with฀self-adaptability;
- Control฀the฀carbon-canister฀valve
฀฀฀฀-฀฀฀฀Air-conditioner฀switch
- Engine฀fault฀indicator฀lamp
- Software฀switch฀to฀increase฀the฀density฀of฀injected฀oil
- Modification฀to฀the฀fix฀quantify฀of฀fuel
- Output฀of฀engine฀rotating-speed฀signal TN฀signal
- Input฀of฀vehicle฀speed฀signal
- Diagnosis฀of฀the฀failure฀on฀driving฀stage฀and฀sensor
- Receive฀signal฀from฀the฀engine฀rotating-speed฀sensor
- Receive฀the฀engine฀load฀signal,฀etc.
(b)Power฀supply Refer฀to฀the฀circuit฀diagram฀for฀UAES฀M1.5.4฀system
-Uninterrupted฀power฀supply฀by฀accumulator฀via฀Pin฀18;
-Power฀supply฀via฀Pin฀37฀when฀main฀relay฀has฀been฀connected;
-Power฀supply฀via฀Pin฀27฀when฀ignition฀switch฀has฀been฀connected;
(c)฀Ground:
Pin฀2,฀10,฀14,฀19,฀24,฀30,฀48.
Failure฀diagnosis฀interface
Includes฀Pin฀55฀and฀engine฀data฀line฀K.฀Using฀line฀K,฀the฀record฀of฀failure฀information฀inside฀ECU฀may฀be฀called฀out,฀or฀some
commands฀may฀be฀manually฀input,฀such฀as:฀elimination฀of฀the฀record฀of฀failure฀information,฀self-learning฀of฀idle-speed฀actuator,etc.
(d)฀Increased฀density฀of฀gas฀mixture฀at฀after-sale฀stage:
Pin฀8฀and฀52฀are฀mainly฀applicable฀to฀some฀cases฀whereby฀the฀degradation฀of฀engine฀starting฀performance฀is฀caused฀by฀the฀aging฀of
internal฀parts฀&components฀or฀the฀individual฀difference.
(e)฀ Symptom
Unstable฀idle-speed,฀bad฀acceleration,฀unable฀to฀start,฀much฀high฀idle-speed,฀tail฀gas฀out฀of฀limit,฀start฀with฀difficulty,฀air-conditioner
failed,฀the฀oil฀injector฀control฀failed,฀flameout,฀etc.
(f)฀Cause฀of฀general฀failures
-The฀electrical฀overload฀on฀peripheral฀device฀results฀in฀a฀burning฀and฀failure฀of฀parts฀and฀components฀inside฀ECU;
-The฀rust฀and฀corrosion฀on฀circuit฀board฀are฀caused฀by฀water฀inside฀ECU.

Precautions฀to฀maintenance
-Do฀not฀dismantle฀the฀ECU฀casually฀during฀maintenance.
-Prior฀to฀dismantle฀of฀ECU,฀have฀the฀head฀of฀accumulator฀jar฀being฀removed฀for฀at฀least฀five฀minutes.
-Store฀the฀ECU฀securely฀after฀it฀is฀dismantled;
-It’s฀prohibited฀to฀install฀extra฀loops฀on฀the฀ECU฀connection฀line.
(h)฀Simple฀measurement฀method Refer฀to฀the฀circuit฀diagram฀for฀UAES฀M1.5.4฀system
- after฀connection฀of฀joint ,฀read฀the฀record฀of฀engine฀failures฀via฀engine฀data฀line฀K;
- after฀disconnection฀of฀joint ,฀check฀whether฀ECU฀connection฀line฀is฀intact,฀and฀the฀main฀focus฀is฀to฀check฀whether฀the฀loop
of฀power฀supply฀/ground฀for฀ECU฀is฀normal;
-฀Check฀whether฀peripheral฀sensor฀is฀working฀normally,฀whether฀the฀output฀signal฀is฀reliable,฀and฀whether฀the฀loop฀is฀intact.
17.฀ Electronic฀ controller฀ ECU M 7.9.7

(a)Function฀
฀฀฀฀฀-฀฀฀฀Oil฀injection฀at฀multi-points฀as฀per฀the฀sequence
- Control฀the฀ignition
- Control฀the฀idle-speed
- Provide฀the฀sensor฀with฀power฀supply 5V/100mA
- Knock฀ control
- Etyped฀closed-loop฀control,฀with฀self-adaptability;
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- Air-conditioner฀switch
- Engine฀fault฀indicator฀lamp
- Modification฀to฀the฀fixed฀quantity฀of฀fuel
- Output฀of฀engine฀rotating-speed฀signal TN฀signal
- Input฀of฀vehicle฀speed฀signal
- Failure฀self-diagnosis
- Receive฀signal฀from฀the฀engine฀rotating-speed฀sensor
- Receive฀the฀engine฀load฀signal,฀etc.
(b)Symptom
Unstable฀idle-speed,฀bad฀acceleration,฀unable฀to฀start,฀too฀much฀high฀idle-speed,฀tail฀gas฀out฀of฀limit,฀start฀with
difficulty,฀air-conditioner฀failed,฀the฀oil฀injector฀control฀failed,฀flameout,฀etc.
(c)Cause฀of฀general฀failures
-The฀electrical฀overload฀on฀peripheral฀units฀results฀in฀a฀burning,฀damage฀or฀failure฀of฀parts฀and฀components฀inside฀ECU;
- Water฀inside฀ECU฀causes฀rust฀and฀corrosion฀on฀circuit฀board.
(d)฀Precautions฀to฀maintenance
-Do฀not฀dismantle฀the฀ECU฀casually฀during฀maintenance.
-Prior฀to฀dismantle฀of฀ECU,฀have฀the฀head฀of฀accumulator฀jar฀being฀removed฀for฀at฀least฀one฀minute.
-Store฀the฀ECU฀securely฀after฀it฀is฀dismantled;
-It’s฀prohibited฀to฀install฀extra฀loops฀on฀the฀ECU฀connection฀line.
(e)Simple฀measurement฀method
฀- after฀connection฀of฀joint ,฀read฀the฀record฀of฀engine฀failures฀via฀engine฀data฀line฀K;
฀- after฀disconnection฀of฀joint ,฀check฀whether฀ECU฀connection฀line฀is฀intact,฀and฀the฀main฀focus฀is฀to฀check฀whether฀the฀loop
of฀power฀supply฀/ground฀for฀ECU฀is฀normal;
-Check฀whether฀the฀peripheral฀sensor฀is฀working฀normally,฀whether฀the฀output฀signal฀is฀reliable,฀and฀whether฀its฀loops are฀intact;
-Check฀whether฀the฀actuator฀is฀working฀normally,฀and฀whether฀its฀loops฀are฀intact;
-Finally,฀perform฀a฀test฀after฀ECU฀is฀changed.

( f ) Technical฀&characteristic฀parameter
฀฀฀฀Limit฀data
V alue
M easurement U nit
M in. T y pic al M ax .
U nder a normal operation
A cc umulator v oltage
W ith li mi ted f unction
L i mit value & ti me to
R etain partial func tions,
W ithstandthe
and able to perform
over-v oltage of
failure diagnosis.
ac cum ulator
W ork ing temperature
S torage temperature
18.฀Fuel฀distributing฀pipe฀assembly
European (a)Principal The฀fuel฀distributing฀pipe฀assembly฀is฀composed฀of฀fuel
distributing฀pipe K V S ,฀oil฀injector฀ E V ,฀and฀fuel฀pressure฀adjustor
D R ,฀and฀may฀be฀used฀to฀store฀and฀distribute฀the฀fuel.
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(b)Installation฀position:฀on฀the฀inlet฀manifold.
(c)Precautions฀to฀installation:
-฀฀The฀place฀where฀the฀fuel฀inlet฀pipe฀is฀connected฀with฀rubber฀hose฀shall฀be
clamped฀tightly฀using฀clips,฀whose฀model฀needs฀to฀match฀with฀the฀rubber
hose฀to฀assure฀the฀tightness฀of฀connection฀between฀fuel฀inlet฀pipe฀and
rubber฀hose;
- It shall be free from any crack, damaged trace, groove, burr, or rust on the wall
of fuel inlet pipe;
- Prior to the installation of fuel distributing pipe assembly, clean lubricating oil
shall be applied to lubricate the lower O-ring of oil injector;
(d)Inspection on the sealing performance:
The sealability of fuel distributing pipe may be tested using pressure drop method
: perform a test on the O-ring inside injector on the fuel distributing pipe; and the
tested limit value of leakage shall be≤1.5cm3/min when at a pressure of 4.5bar.
(e) Technical &characteristic parameter：

Limit data
Measurement Value
Unit
Min. Typical Max.
Working temperature when fuel
-40 +120 ℃
Distributing pipe is correctly connected with the O ring.
15-minute Max. working temperature when being soaked +130 ℃
Peak value of Max. allowable vibration acceleration 300 m/s2
-฀฀Regarding฀the฀system฀pressure,฀refer฀to฀the฀characteristic฀parameter฀for฀pressure฀adjustment฀valve;฀Regarding฀the฀requirement฀for
fuel,฀refer฀to฀the฀characteristic฀parameter฀for฀฀injector;฀Regarding฀the฀sealability,฀it’s฀required฀to฀have฀no฀fuel฀leakage฀under฀working
pressure.
฀-฀฀The฀inner฀diameter฀of฀fuel฀rubber฀hose฀shall฀be฀( 7.9 0.3)mm2.

United Electronic engine management system-Genaral troubes hooting and steps
EF.1-30 to engine
General troubleshooting and steps to engine

General troubleshooting and steps to M1.5.4 system
1. When starting, the engine is not rotating or rotating slowly.
Check
S.N. Operation steps Follow-up steps
result
Yes Next step.
A multimeter may be used to check whether the voltage between two binding
1 Repair or change the
posts of accumulator is within 10 and 12.5V. No
accumulator
Place ignition switch to the ON”position, and a multimeter may be used to Yes Next step.
2 check whether its respective binding post connecting the positive electrode of Repair the binding posts
No
accumulator has a voltage between 10 and 12.5V. or change the lead-wire.
Keep the ignition switch on the starting”position, and a multimeter may be Yes Next step.
3 used to check whether its respective binding post connecting the positive Repair or change the
No
electrode of starter has a voltage greater than 8V.. ignition switch
Keep the ignition switch on the starting”position, and a multimeter may be Yes Next step.
4 used to check whether the binding post on the positive electrode of starter has a Repair the binding posts
No
voltage greater than 8V. or change the lead-wire.
Yes Next step.
A multimeter may be used to check whether the starter is in a broken loop or
has short circuit. No
starting motor
Yes Clear the failure away.
6 Check whether the engine has got stuck due to bad lubrication.
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No Next step.
Next step. And change
Yes
If in Winter, check whether the large resistance inside starter is caused by the with appropriate oil.
7
selection of inappropriate engine lubricating oil and gear box oil. Repair or change the
No
timing belt.
2. The hot vehicle is starting with difficulty.
Check
result
Clear the displayed
Place ignition switch to the ON”position. A fault diagnosis instrument may be Yes
1 failure away.
used to check whether there’s any record of failure information.
No Next step.
Connect the fuel manometer valve. And have the Pin 30 of fuel pump relay Yes Next step.
2 short-circuit connected with the Pin 87, and check whether the fuel pressure is
within 250kpa and 300kpa while the fuel pump is working. No 9
Yes Next step.

Disconnect the oil pipe and close the ignition switch; One hour later, observe
3 Repair the fuel pressure
whether the pressure of fuel system is able to retain within 150kpa and 200kpa. No
system.
Connect the oil pipe, and use an oil-return barrier to prevent oil from returning; Change the fuel
Yes
And close both fuel manometer valve and ignition switch; One hour later, pressure adjustor
4
observe whether the pressure of fuel system is able to retain within 150kpa and
No Next step.
200kpa.
Change the oil pipe
Check the oil pipe &injector for fuel leakage. Yes
5 &injector.
No Next step.
Check and repair the
Pull out the plug of water-temperature sensor, and start the engine to see cooling-fluid
Yes
6 whether it proves to be a success. temperature sensor and
relevant loops.
No Next step.
Connect a connector between ECU and wiring harness, and check whether the
Pin 18 /27 /37 of ECU has voltage, and whether the positive supply line
7 Yes Next step.
connecting the foresaid Pins of ECU plus the ground connection line
connecting the Pin 2 /14 /24 /19 of ECU is under a normal condition.

to engine EF.1-31
Check
result
Change the fuel, and perform a hot starting process again to see whether the Yes Ended.
8
starting is successful. No Change the ECU
Check whether the fuel pipe has been bent or blocked, and whether the Yes Next step.
9
pressure-adjustment valve of oil pump is able to work in a normal way. No Repair or change fuel pipe
Yes Next step.
A multimeter may be used to check whether there’s any accumulator voltage
on two ends of socket connector for fuel pump. No
lead-wire for fuel relay.
A multimeter may be used to check whether the resistance value of fuel Yes Next step.
11
pump is correct. No Change the fuel pump
Yes Change the fuel pump
12 Check whether the fuel pump has got stuck.
No Change the ECU
3．Despite of a normal rotating-speed, the starting is always with difficulty
Check
result
Clear the displayed failure
Place ignition switch to the ON”position. A fault diagnosis instrument may Yes
1 away.
be used to check whether there’s any record of failure information.
No Next step.
Yes Next step.
2 Check whether the passage of air filter is free.
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No Change it.
Yes Next step.
Following a successful starting process, check whether the pressure of inlet
3 Settle the air leakage within
manifold when at idle-speed is within 35-65kpa. No
air inlet system.
Check the throttle valve,
Yes
4 Observe whether it’s easy to start by gently stepping on the throttle valve. and idle-speed passage.
No Next step.
5 short-circuit connected with the Pin 87, and check whether the fuel pressure
is within 250kpa and 300kpa while the fuel pump is working. No 9
Check whether the oil injector is working after it has been provided with a Yes 8
6
12V voltage by accumulator via special connector. No Next step.
Check whether the oil injector is able to work normally after it has been Yes Next step.
7
washed. No Change the oil injector
Yes Change the fuel
8 Check whether fuel contains water or has deteriorated.
No 14
Yes Next step.
9 Check whether the fuel pressure is below 250kpa.
No 12
Close the fuel manometer valve, and re-connect the electric spark switch to Yes Next step.
10 have oil pump working for three seconds, then check whether an oil pressure
will be produced. No 12
Change the fuel pressure
Open the fuel manometer valve, and clamp the oil return pipe using oil-return Yes
adjustor
11 barrier to prevent oil from returning, then check whether an oil pressure will
Repair or change the oil
be produced. No
injector or oil pipe.
Repair or change oil inlet
Yes
12 Check whether the oil inlet pipe has leakage or has been blocked. pipe
No Change the oil pump
Repair or change oil return
Yes
pipe
13 Check whether the oil return pipe has been bent or blocked.
No
adjustor

EF.1-32 to engine
Check
S.N Operation steps Follow-up steps
result
Pull out the plug of idle-speed actuator from wiring harness before the engine Yes Next step.
14 cooling temperature reaches 35 ℃ , then observe whether the engine Repair or change the
No
rotating-speed has been decreased. idle-speed adjustor
Place ignition switch on the ON”position, and check whether respective Yes Next step.
15 voltage on following pins of ECU is normal: Whether the accumulator voltage Check the wiring harness,
No
on Pin 27 is at about 12V, and whether respective voltage on Pin 14 &19 is 0. and socket connector.
Yes Next step.
16 Check whether the compressive pressure inside engine cylinder is normal.
No Clear the failure away.
Check whether the absolute pressure /temperature sensor of inlet manifold has Yes Repair or change it.
17
been blocked. No Next step.
Yes Change ECU
18 Check whether the cooling-fluid temperature sensor is normal.
No Repair or change it
4.The cold vehicle is starting with difficulty.
Check
result
1 away.
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No Next step.
A multimeter may be used to check whether the cooling-fluid temperature Yes Next step.
sensor is normal. (Or a 1.5KΩ resistor may be serially connected between Pin
2 45 and Pin 30 of ECU to take the place of cooling-fluid temperature sensor to
start the engine; That it’s able to be started indicates an abnormality of No Change the sensor
cooling-fluid temperature sensor).
After the connection of ignition switch, connect a commutator between ECU Yes Next step.
and wiring harness, and check whether respective voltage on following pins of
3 Check the wiring harness,
ECU is normal: Whether the accumulator voltage on Pin 27 is at about 12V, No
and socket connector.
and whether respective voltage on Pin 14 &19 is 0V.
Yes Next step.
No Change it.
Yes Next step.
Following a successful starting process, check whether the pressure of inlet
5 Settle the air leakage
manifold when at idle-speed is within 35kpa and 65kpa. No
within air inlet system.
Check the throttle valve
Yes
6 Observe whether it’s easy to start by gently stepping on the throttle valve. and idle-speed actuator.
No Next step.
Pull out the plug of idle-speed actuator from wiring harness before the engine Yes Next step.
7 cooling-fluid temperature reaches 35℃, then observe whether the engine Repair and change the
rotating-speed has been decreased. No
idle-speed actuator.
Following the connection of fuel manometer valve, have the Pin 86 of fuel
Yes Next step.
pump relay directly connected to ground, and connect the ignition switch;
8
Check whether the fuel pressure is within 250~300 kpa while the fuel pump
No 12
and its relay are working.
Check whether the oil injector is able to work in a normal way after it has been Yes 11
9
provided with a 12V voltage by accumulator via special connector. No Next step.
Yes Next step.
10 Re-check whether the oil injector is working after it has been washed.
No Change the oil injector.
Yes Change the fuel
No Next step.

to engine EF.1-33
Check
result
Yes Next step.
No 16
Close the fuel manometer valve, and re-connect the ignition switch to have oil Yes Next step.
13 pump working for three seconds, then check whether an oil pressure will be
No 15
produced.
adjustor
14 barrier to prevent oil from returning, then check whether an oil pressure will be
produced. No
pipe or injector.
Yes
15 Check whether the oil inlet pipe has leakage or has been blocked. pipe
Repair or change oil
Yes
return pipe
16 Check whether the oil inlet pipe has leakage or has been bent.
No
adjustor
Yes Next step.
17 Check whether the pressure of engine cylinder is normal.
Yes Repair it.
18 Check whether the engine air-inlet system has leakage.
No Next step.
Check whether the absolute pressure /temperature sensor of inlet manifold has Yes Repair or change it
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19
been blocked. No Change the ECU
5．The idle-speed at any time is unstable.
Check
result
1 away.
No Next step.
Repair or change the
Yes
2 Check whether the idle-speed actuator has got stuck. idle-speed actuator
No Next step.
After the connection of ignition switch, connect a commutator between ECU Check the wiring harness
and wiring harness, and check whether respective voltage on Pin 14 &45(the Yes
and socket connector.
3 signal output end for air-inlet temperature sensor and cooling-fluid temperature
sensor respectively) of ECU is normal, and whether respective voltage on Pin 4 No Next step.
&26 (used as one signal output end for idle-speed actuator) of ECU is normal.
Have the engine running at idle-speed, and have the cylinder flameout one by Yes 8
4 one to observe whether the engine rotating-speed has been decreased or has
No Next step.
fluctuation.
Yes Next step.
5 Check whether the oil injector for each cylinder is under a normal condition. Check the oil injector and
No
wiring harness.
Yes Next step.
Check whether the resistance value exact value to be found in the chapter for
6 Check the oil injector and
ignition system of high-voltage line inside each cylinder is normal. No
wiring harness.
Yes Next step.
7 Check whether the spark plug is normal.
No Change the spark plug
Connect the fuel manometer valve. And have the Pin 30 of fuel pump relay
Yes Next step.
within 250kpa and 300kpa while the fuel pump is working. No 13
Check whether the oil injector is able to work in a normal way after it has been Yes 12
9

EF.1-34 to engine
Check
result
Yes Next step.
10 Check whether the oil injector is able to inject oil after it has been washed.
No Change the oil injector
Yes Change the fuel
No 18
Yes Next step.
No 17
Close the fuel manometer valve, and re-connect the ignition switch to have oil Yes Next step.
13 pump working for three seconds, then check whether an oil pressure will be
No 16
produced.
adjustor
produced. No
Yes
15 Check whether the oil inlet pipe has any leakage or has been blocked. pipe
Yes
return pipe
No
adjustor
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Yes Clean it.

Check whether sensing holes on the inlet-manifold pressure sensor and the
17
air-inlet temperature sensor have been blocked.
No Next step.
Have the engine running at idle-speed, and observe whether the oxygen sensor Yes Next step.
18 is able to work in a normal way when the cooling-fluid temperature reaches the Check the oxygen sensor
No
activated temperature under a closed-loop control. and wiring harness.
Yes Settle the leakage.
19 Check whether the engine air-inlet system has leakage.
No Next step.
Yes Next step.
20 Check whether the pressure of engine cylinder is normal.
6．The idle-speed during vehicle heating process is unstable.
Check
result
Clear the displayed
1 failure away.
No Next step.
Yes Next step.
No Change it.
Yes Next step.
Have the engine running at idle-speed, check whether the pressure of inlet
manifold is within 35kpa and 65kpa during the vehicle heating process. No
Following a closure of engine and a connection of ignition switch, connect a Yes Next step.
commutator between ECU and wiring harness, and check whether respective
4
voltage on Pin 44 &45 (the signal output end for air-inlet temperature sensor No Check and repair it.
and cooling-fluid temperature sensor respectively) of ECU is normal.
Yes Next step.
Pull out the plug of idle-speed actuator before the vehicle heating process is
5 Change the idle-speed
ended, and observe whether the engine rotating-speed could be changed. No
actuator.
Check whether the cooling-fluid temperature sensor is working in a normal Yes Next step.
6
way. No Change it.

to engine EF.1-35
7．The idle-speed is unstable after the vehicle heating process is ended.

Check
result
Clear the displayed
1 failure away.
No Next step.
Place ignition switch on the ON”position, connect a commutator between Yes Next step.
ECU and wiring harness, and check whether respective voltage on the Pin 7
output of absolute-pressure sensor for inlet manifold , Pin 44 output of
air-inlet temperature sensor , Pin 45 output of cooling-fluid temperature No
wiring harness
sensor , Pin 28 output of oxygen sensor , and Pin 4 &26 output to the
idle-speed actuator of ECU is normal.
Yes Next step.
3 Check whether the passage of air filter is free when engine is closed.
No Change it.
Yes Next step.
Check whether the pressure of inlet manifold is within 35kpa and 65kpa when
at idle-speed. No
No 9
within 250kpa and 300kpa while the fuel pump is working.
Yes 8
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Check whether the oil injector is able to work in a normal way after it has been
6
Check whether the oil injector is able to work normally after it has been Yes Next step.
7
Yes Change the fuel
No 14
Yes Next step.
No 13
Close the fuel manometer valve, and re-connect the electric spark switch to Yes Next step.
10 have oil pump working for three seconds, then check whether an oil pressure
No 12
will be produced.
adjustor
produced. No
Yes
12 Check whether the oil inlet pipe has any leakage or has been blocked. inlet pipe
Yes
return pipe
No
adjustor
Change the cooling-fluid
Observe whether the engine is working normally after the cooling-fluid Yes
14 temperature sensor
temperature sensor has been pulled out.
No Next step.
Yes Next step.
15 Check whether the compressive pressure inside the engine cylinder is normal.
Check whether the resistance value about 16kΩ/m, exact data to be found in Yes Next step.
16 the chapter for ignition system of high-voltage line inside each cylinder is
No Change it.
normal.
Yes Change the ECU

EF.1-36 to engine
8．Unstable idle-speed or even flameout when under load eg. air-conditioner, etc.
Check
result
Place ignition switch to the ON”position. A fault diagnosis instrument may be Clear the displayed failure
Yes
1 used to check whether there’s any record of failure information. away.
No Next step.
After a connection of air-conditioner switch, connect a commutator between Yes Next step.
2 ECU and wiring harness, and measure whether there’s a signal input *” Check and repair the
between the Pin 40 and Pin 41 air-conditioner switch of ECU. No
air-conditioner loop.
Check whether the pressure of air-conditioner system, the electromagnetic Yes Next step.
3 clutch of compressor, and the air-conditioner pump are under a normal Repair or change it
condition. No
Place ignition switch on the ON” position, and check whether respective Yes Next step.
4 voltage on the Pin 4 No Check the control loop.
Check whether the idle-speed actuator has got stuck or is able to run flexibly Repair or change the
Yes
5 after it has been removed. idle-speed actuator
No Next step.
Start the engine, and activate the air-conditioner function, and check for some Yes Change the ECU
6 time whether the idle-speed actuator is working in a normal way. Change the idle-speed
No
actuator
*The signal of low /high electrical level from Pin 41 may be regarded as an air-conditioner request signal by ECU: ECU is able
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to recognize the signal of low electrical level from Pin 41 as an air-conditioner signal requested by vehicle, and the signal from
Pin 41 shall be of high electrical level when A/C switch is OFF. And vice versa.
9．Periodically unstable Another self-learning is needed after a power cut to ECU
Check
result
1 away.
No Next step.
Yes Next step.
No Change it.
Yes Next step.
Check whether the pressure of inlet manifold is within 35kpa and 65kpa while Check and repair air inlet
3
engine is running at idle-speed. No components or
components leaking air.
Perform a flameout process for each cylinder while engine is running at Yes 7
4 idle-speed, and observe whether the rotating-speed of engine has some
No Next step.
fluctuation or has been decreased.
output of absolute-pressure sensor for inlet manifold , Pin 44 output of
5 air-inlet temperature sensor , Pin 45 output of cooling-fluid temperature Repair or change the
sensor , Pin 28 output of oxygen sensor , Pin 19 electronic ground , Pin No
wiring harness
27 ignition switch , and Pin 4 &26 output to the idle-speed actuator of
ECU is normal.
Check whether sensing holes on the inlet-manifold pressure sensor and the Yes Clean it.
6
air-inlet temperature sensor have been blocked. No Next step.
Yes Change the fuel
No Next step.
Yes Next step.
Check whether the oil injector is able to work in a normal way after it has been Check and repair the oil
8
provided with a 12V voltage by accumulator via special connector. No injector and its relevant
wiring harness.

to engine EF.1-37
Check
result
Check whether the resistance value of high-voltage line for each cylinder is Yes Next step.
9 under a normal condition (about 16KΩ/m, specific data as given in the chapter
No Change it.
for “ignition system” ).
Yes Change the ECU
10．The idle-speed is too high a self-learning is needed again after a power cut to ECU .
Check
result
Clear the displayed
1 failure away.
No Next step.
Check whether the slider fastener connecting the gas pedal is too tight or has Yes Adjust or change it
2
got stuck. No Next step.
Check whether the carbon-canister control valve, the fuel pressure adjustor, the Yes Adjust or change it.
3 forced-ventilation vacuum pipe of crankshaft box, and the vacuum booster
No Next step.
hose within system are securely installed or have any damage.
When engine is running at idle-speed, put shift to a neutral position, and step Yes Next step.
4 on the braking pedal, and observe whether the rotating-speed at idle speed is
No 6
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too much high.

Repair or change the
Observe whether the running at idle-speed is normal when vacuum hose is Yes
5 vacuum booster.
being clamped.
No Next step.
Observe whether the running at idle-speed is normal when the forced Yes Change the PVC valve.
6
ventilation vacuum pipe on crankshaft box is being clamped. No Next step.
Change the
Observe whether the running at idle-speed is normal when the hose of control Yes carbon-canister control
7
valve on carbon-canister is being clamped. valve
No Next step.
Yes Repair or change it.
8 Observe whether the idle-speed actuator is able to act flexibly or has got stuck.
No Next step.
Yes Repair or change it.
9 Check whether there’s any leakage at other places on air inlet pipe.
No Next step.
Yes Next step.
10 Check whether the sealing ring of oil injector is intact.
No Change the sealing ring.
Check whether the absolute pressure sensor and the air-inlet temperature Yes Change the ECU
11
sensor of inlet manifold are intact. No Change the sensor
11．The rotating-speed is unable to go up or even flameout when accelerating
Check
result
1 Yes Clear the displayed failure
Place ignition switch to the ON”position. A fault diagnosis instrument may be
away.
No Next step.
2 Yes Next step.
Check whether the passage of air filter is free.
No Change it.
3 Yes Next step.
Check whether the engine rotating-speed is normal while it’s running at No Check and repair it as per
idle-speed. the list of idle-speed
failures.

EF.1-38 to engine
Check whether the inlet-air pressure is within 35kpa and 65kpa while engine is Yes Next step.
4
running at idle-speed. No Check and repair it.
Have the engine running at idle-speed, and do not connect the Pin 51 of ECU Yes Next step.
to ground via short connection wire before the cooling-fluid temperature
5 Adjust the ignition
reaches its normal value; Check whether the ignition lead-angle is of a 6.75o No
lead-angle.
rotating angle of crankshaft.
No 11
Check whether the oil injector is working in a normal way after it’s been Yes 10
7
Re-check whether the oil injector is working in a normal way after it’s been Yes Next step.
8
Yes Change the fuel
No 15
Yes Next step.
No 14
When the valve on fuel meter is closed before a re-connection with ignition Yes Next step.
11 switch to drive the fuel pump working for another three seconds, check
No 13
whether it’s able to produce an oil pressure.
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When the valve on fuel meter is opened before oil return pipe is being clamped Yes
adjustor
12 by oil-return barrier to stop oil return, check whether it’s able to produce oil
pressure rapidly. No
Yes
Yes
return pipe
No
adjustor
signal output end of throttle position sensor , Pin 30 ground end , and Pin No
wiring harness
12 used as one 4.5V~5V power supply to sensor of ECU is normal.
Yes Change the ECU
Check whether ignition coil, high-voltage line, and spark plug are under a
16 Repair or change relevant
normal condition. No
parts and components.
12．Slow response to acceleration
Check
result
Place ignition switch to the ON”position. A fault diagnosis instrument may Yes
1 away.
be used to check whether there’s any record of failure information.
No Next step.
Yes Next step.
No Change it.
Yes Next step.
Check whether the engine rotating-speed is normal while it’s running at
3 Provide service as per the
idle-speed. No
list of idle-speed failures.
Check whether the inlet-air pressure is within 35kpa and 65kpa while engine Yes Next step.
4
is running at idle-speed. No Check and repair it.

to engine EF.1-39
Check
result
After the connection of ignition switch, connect a commutator between ECU Yes Next step.
and wiring harness, and check whether respective voltage on Pin 53 (the signal
output end for throttle position sensor), Pin 30 (ground end), and Pin 12 (used No
wiring harness
as one 4.5V-5V power supply to sensor) of ECU is normal.
Have the engine running at idle-speed, and do not connect the Pin 51 of ECU Yes Next step.
to ground via short connection wire before the cooling-fluid temperature
6 Adjust the ignition
reaches its normal value; Check whether the ignition lead-angle is of a 6.75o No
lead-angle.
rotating angle of crankshaft.
Connect the fuel manometer valve (the connection point may vary depending Yes Next step.
on the type of vehicle). And have the Pin 30 of fuel pump relay short-circuit
7
connected with the Pin 87, and check whether the fuel pressure is within No 11
250kpa and 300kpa while the fuel pump is working.
8
9
Yes Change the fuel
No 16
Yes Next step.
No 15
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No 14
When the valve on fuel meter is opened before oil return pipe is being clamped Yes
adjustor
13 by oil-return barrier to stop oil return, check whether it’s able to produce oil
pressure rapidly. No
Yes
14 Check whether the oil inlet pipe has leakage or has been blocked. inlet pipe
15 Check whether the oil return pipe has been bent or blocked. Yes
return pipe
13．The acceleration is slack and with inferior performance.
Check
result
Yes Repair it.
1 Failure like inappropriate positioning of four wheels, etc.
No Next step.
Yes Next step.
2 Check whether the throttle valve is able to be full opened. Repair or change the
No
throttle valve
A fault diagnosis instrument may be used to check whether there’s any record Yes
3 away.
of failure information after ignition switch is placed to the ON”position.
No Next step.
Place ignition switch on the ON”position, and check whether respective Yes Next step.
voltage on the Pin 7 output of absolute-pressure sensor for inlet manifold ,
Pin 53 throttle position sensor , Pin 44 output of air-inlet temperature
4 sensor , Pin 45 output of cooling-fluid temperature sensor , Pin 10 &28 used Repair or change the
No
as ground end and signal output end of oxygen sensor respectively , Pin 30 wiring harness
signal ground end of oxygen sensor , and Pin 12 used as one 4.5V~5V
power supply to sensor of ECU is normal.
Check whether the inlet-air pressure is within 35kpa and 65kpa while engine is Yes Next step.
5
running at idle-speed. No Check and repair it.

EF.1-40 to engine
Check
result
No 11
7
8
Yes Change the fuel
No 16
Yes Next step.
No 15
No 14
When the valve to fuel meter is opened, clamp the oil return pipe tightly using Yes
adjustor
12 pliers to prevent oil return, and check whether it’s able to produce oil pressure
rapidly. No
Yes
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Repair or change oil return
Yes pipe
No
adjustor
Check whether data read from the absolute-pressure sensor the air-inlet Yes Next step.
15
temperature sensor of inlet manifold are normal. No Change the sensor
Check whether spark plug, high-voltage line, and ignition coil are under a Yes Next step.
16
normal condition. No Change or adjust it.
Check air-conditioner
Yes
17 Check whether the failure is caused by air-conditioner system. system
No Change ECU
14．Failure with the air-conditioner system
Check
result
Check whether system has been provided with sufficient refrigerant, and Yes Repair it.
1 whether the air-conditioner, air-conditioner clutch, and pressure switch are
under a normal condition. No Next step.
Have the engine running at idle-speed, and connect the air-conditioner switch; Yes Next step.
2 And a fault diagnosis instrument may be used to check whether there’s any Repair or change the
failure with the air-conditioner thermal resistor. No
throttle valve
Clear away the displayed
After the connection of air-conditioner switch, measure whether the Pin 40 and Yes
3 failure.
41 air-conditioner switch of ECU has any signal input.
No Next step.
Yes Next step.

If the vehicle is under a control of low electrical level, check whether the
air-conditioner unit is still working after it is closed. No
wiring harness
Check whether the Pin 22 (connecting the ground end of holding coil of Yes Next step.
5
air-conditioner relay) of ECU has a low electrical level output. No Check and repair it.
*The signal of low /high electrical level from Pin 41 may be regarded as an air-conditioner request signal by ECU: ECU is able to
recognize the signal of low electrical level from Pin 41 as an air-conditioner signal requested by vehicle, and the signal from Pin 41
shall be of high electrical level when A/C switch is OFF. And vice versa.

to engine EF.1-41
General troubleshooting and steps to engine within M7.9.7 system

1．During startup process, the engine is not rotating or rotating slowly.
Check
result
A multimeter may be used to check and measure whether the voltage between Yes Next step.
1
two binding posts of accumulator is within 8-12 V while engine is starting. No Change the accumulator.
Keep the ignition switch at the “starting” position. And a multimeter may be Yes Next step.
2 used to check whether the positive binding post of starter has a voltage above Repair or change the
No
8V.。 wiring harness
Check the action of starter after it is dismantled. The main focus is to check for Yes Repair or change starter
3
broken loops or whether the starter has got stuck due to bad lubrication. No Next step.
If the failure only occurs in Winter, check whether the large resistance inside Change with appropriate
Yes
4 starter is caused by an inappropriate selection of engine lubricating oil and gear grade of lubricating oil
box oil. No Next step.
Check and repair the
failure resulting from the
Check whether the mechanical resistance inside engine is too large, or leads to Yes
5 internal resistance of
a slow or even no rotating of starter.
engine.
No Diagnosis help.
2．During a starting process, engine may be driven to rotate yet the starting is unsuccessful.
Check
result
After the connection with fuel manometer (the connection point is on the front
Yes Next step.
end of oil inlet pipe included in the fuel distributing pipe assembly), check
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1 whether the fuel pressure keeps about 260 kpa while engine is running at
Check and repair the oil
idle-speed; and whether the fuel pressure keeps at about 300kpa after vacuum No
supply system.
pipe has been pulled away from the fuel pressure adjustor.
Yes Next step.
After a connection with diagnosis instrument within the electronic injection
Check and repair the loop
2 system, observe the data entry “engine rotating-speed”; and observe whether
No with rotating-speed
there’s any rotating-speed signal output while engine is starting.
sensor.
Pull out the division line from one of cylinders before it’s connected with spark Yes Next step.
plug, and keep the electrode of spark plug about 5mm away from engine body,
3 Check and repair the
and check whether blue &white high-voltage fire is produced while the engine No
ignition system.
is running.
Settle the mechanical
Check and observe whether the pressure inside each engine cylinder is Yes
4 failure on engine.
insufficient.
No Next step.
After a connection with commutator within the electronic injection system, Yes Diagnosis help.
open the ignition switch to check whether respective power supply to Pin 12,
5. 13, 44, 45, 63 is under a normal condition; and whether respective metal part
No Follow-up steps
overlapped on Pin 3, 51, 53, 61, 80 is under a normal condition.
Operation steps
3. The hot vehicle is starting with difficulty.
Check
result
After the connection with fuel manometer (the connection point is on the front Yes Next step.
1 whether the fuel pressure keeps at about 260 kpa while engine is running at Check and repair the oil
No
idle-speed; and whether the fuel pressure keeps at about 300kpa after vacuum supply system.
ignition system.
is running.
Pull out the plug of cooling-fluid temperature sensor, and start the engine. Check and repair relevant
Observe for some time whether the engine may be started successfully. Or a Yes loops or change the
3 300 ohm resistor may be serially connected at the joint of cooling-fluid sensor.
temperature sensor to substitute the sensor, then observe whether engine may
No Next step.
be started successfully. 。
Check, repair, or change
Check whether the vacuum pipe of fuel pressure adjustor has been loosened or Yes
4 it.
is leaking air.
No Next step.

EF.1-42 to engine
Check
result
Check the fuel condition, and observe whether the symptom is caused by the Yes Change the fuel
1
filling with petrol. No Next step.
Open the ignition switch to check whether respective power supply to Pin 12, Yes Next step.
2 13, 44, 45, 63 is under a normal condition; and whether respective metal part
No Diagnosis help.
4．The cold vehicle is starting with difficulty.

Check
result
No
plug, and keep the electrode of spark plug about 5mm away from engine body, Check the ignition
2
and check whether blue &white high-voltage fire is produced while the engine No system.
is running.
Pull out the plug from the cooling-fluid temperature sensor, and start the Check and repair
engine; Observe whether the starting of engine proves to be a success. Or a Yes relevant loops or change
3 2500 ohm resistor may be serially connected at the joint of cooling-fluid the sensor.
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temperature sensor to substitute the sensor, then observe whether engine may
No Next step.
be started successfully.
Wash the throttle valve
Yes and the idle-speed air
4 Observe whether it’s easy to start by gently stepping on the throttle valve.
duct.
No Next step.
Change the failed
Remove the oil injector, and check whether it has any leakage or has been Yes
5 components.
blocked using a special washing analyzer instrument.
No Next step.
6 filling with petrol.
No Next step.

insufficient.
No Next step.
Open the ignition switch to check whether respective power supply to Pin 12, Yes Diagnosis help.
8 13, 44, 45, 63 is under a normal condition; and whether respective metal part Check and repair
No
overlapped on Pin 3, 51, 53, 61, 80 is under a normal condition. relevant loops.
5．Despite of a normal rotating-speed, the starting at any time is with difficulty.
Check
result
Check and repair the air
Yes
1 Check the air filter for blockage, and the air inlet passage for air leakage. inlet system.
No Next step.
After the connection with fuel manometer (the connection point is on the front
Yes Next step.
2 whether the fuel pressure keeps at about 260 kpa while engine is running at
Check and repair the oil
idle-speed; and whether the fuel pressure keeps at about 300kpa after vacuum No
supply system.
ignition system.
is running.
Check and observe whether the model and clearance of spark plug on each Yes Next step.
4
cylinder is in compliance with the specification. No Adjust or change it.

to engine EF.1-43
Check
result
Check and repair relevant
Pull out the plug from the cooling-fluid temperature sensor, and start the Yes loops or change the
5
engine; Observe whether the starting of engine proves to be a success. sensor.
No Next step.
Wash the throttle valve
Yes
6 Observe whether it’s easy to start by gently stepping on the throttle valve. and the idle-speed air duct.
No Next step.
Change the failed
7 components.
No Next step.
8
Check and observe whether the pressure inside each engine cylinder is Yes Eliminate engine failures.
9
insufficient. No Next step.
Yes Next step.
Check whether the engine ignition sequence &timing conform to relevant
specifications. No
ignition timing.
11 13, 44, 45, 63 is under a normal condition; and whether respective metal part Check and repair relevant
No
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overlapped on Pin 3, 51, 53, 61, 80 is under a normal condition. loops.

6．Despite of a normal starting process, the idle-speed is unstable at any time.
Check
result
Yes
No Next step.
Yes Wash or change it.
2 Check whether the idle-speed adjustor has got stuck.
No Next step.
3
Check whether any carbon deposit is produced on the throttle valve unit, or Yes Wash it
4
inside the idle-speed bypass air duct. No Next step.
Change the failed
5 components.
No Next step.
No Next step.
insufficient.
No Next step.
Yes Next step.
specifications. No
ignition timing.
No

EF.1-44 to engine
7．Despite of a normal starting, the idle-speed during vehicle heating process is unstable.
Check
result
Yes
No Next step.
2
After a removal of idle-speed adjustor, check whether any carbon deposit is Wash relevant parts and
Yes
3 produced on the throttle valve unit and the idle-speed adjustor, or inside the components.
idle-speed bypass air duct. No Next step.
After a removal of the plug for cooling-fluid temperature sensor, start the Check and repair relevant
Yes
4 engine and observe whether it has a stable idle-speed during vehicle heating loops or change the sensor.
process. No Next step.
Change the failed
5 components.
No Next step.
No Next step.
Check the pressure inside each cylinder, and observe whether there’s any large Yes
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difference in pressure across cylinders.

No Next step.
No
8．Despite of a normal starting process, the idle-speed is unstable after the vehicle heating process
is ended.
Check
result
Yes
No Next step.
2
cylinder is in compliance with the specification. No Adjust or change it
Yes
idle-speed bypass air duct.。 No Next step.
After a removal of the plug for cooling-fluid temperature sensor, start the
Yes loops or change the
4 engine and observe whether it has a stable idle-speed during vehicle heating
sensor.
process.
No Next step.
Change the failed
5 components.
No Next step.
No Next step.
Check the pressure inside each cylinder, and observe whether there’s any large Yes
difference in pressure across cylinders.
No Next step.
No

to engine EF.1-45
9. Despite of a normal starting process, the idle-speed when under partial load eg ：
air-conditioner is unstable or even flameout.
Check
result
Yes
Observe whether the engine output power has been increased when the Continue to proceed until
Yes
air-conditioner is activated, in another word, that's to observe the change of step 4.
2
ignition lead-angle, oil-injection pulse width, and air inlet capacity using a
No Next step.
diagnosis instrument applicable to the electronic injection system.
After a line disconnection of Pin 75 on electronic control unit, check whether Yes Next step.
3 the signal for accumulator jar is high on wire-harness end while the Check and repair the
No
air-conditioner is running. air-conditioner system.
Check whether the pressure within air-conditioner system, the electromagnetic Yes Next step.
4 clutch of compressor, and the air-conditioner compressor are under a normal Check and repair the
No
condition. air-conditioner system.
Following a removal of oil injector, use a special washing analyzer instrument Change the failed
Yes
5 to check whether the oil injector has any leakage, has been blocked, or its flow components.
is out of tolerance. No Next step.
No
10．The starting is normal yet the idle-speed is too high.
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Check
result
Yes Adjust it.
1 Check whether the pulling line to gas is too tight or has got stuck.
No Next step.
Check whether there’s any air leakage with air inlet system, and its connected Yes
2 inlet system.
vacuum pipes.
No Next step.
Yes
After pulling out the plug of cooling-fluid temperature sensor, start the engine Yes loops or change the
4
and observe whether its idle-speed is too high. sensor.
No Next step.
Yes Next step.
Check whether the timing of engine ignition conforms to relevant
specifications. No
ignition system.
No
11．The rotating-speed is unable to go up or even flameout when accelerating.
Check
result
Yes
1 Check whether the air filter has been blocked. inlet system.
No Next step.
No
3
cylinder is in compliance with the specification. No Adjust or change it
Yes

EF.1-46 to engine
Check
result
Yes Next step.
Check whether the inlet-air pressure sensor, throttle position sensor, and its
5 Check and repair relevant
loops are under a normal condition. No
loops or change the sensor.
Change the failed
6 components.
No Next step.
No Next step.
Yes Next step.

specifications. No
ignition timing.
Yes Next step.
9 Check whether the exhaust pipe is free. Repair or change the
No
exhaust pipe.
No
12．Slow response to acceleration
Check
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result
Yes
No Next step.
No
3
Yes
Yes Next step.
Check whether the inlet-air pressure sensor, throttle position sensor, and its
loops are under a normal condition. No
loops or change the sensor.
Change the failed
6 components.
No Next step.
No Next step.
Yes Next step.

specifications. No
ignition timing.
Yes Next step.
No
exhaust pipe.
No

to engine EF.1-47
13. The acceleration is slack and with inferior performance.

Check
result
Check for following failures: slide of clutch, low pressure inside tire, dragging Yes
1 inlet system.
brake, inappropriate size of tires, inappropriate positioning of four wheels, etc.
No Next step.
Yes
No Next step.
No
4
and check whether a normal high-voltage fire is produced while the engine is No Adjust or change it.
running.
5
Yes
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Yes Next step.
Check whether the inlet-air pressure sensor, throttle position sensor, and its Check and repair relevant
7
loops are under a normal condition. No loops or change the
sensor.
Change the failed
8 components.
No Next step.
9
Yes Next step.
specifications. No
ignition timing.
Yes Next step.
No
exhaust pipe.
After a connection with the commutator within the electronic injection system, Yes Diagnosis help.
open the ignition switch to check whether respective power supply to Pin 12,
13, 44, 45, 63 is under a normal condition; and whether respective metal part No
loops.

Criterion to flashing codes and the mounting torque of parts &components within
EF.1-48 M1.5.4 system
M1.5.4 system
1．List of flashing codes within M1.5.4 system
Fault
Type of
S.N. Name of failure information Flashing code indicator
failure
lamp
1 Failure with knock sensor zero test status 1 1 1
2 No failure. 11 - -
The temperature of air-conditioner evaporator is
3 13 1 0
unreliable.
4 The signal of throttle position sensor is unreliable. 14 1 1
5 The signal of knock sensor is unreliable. 15 2 1
6 The signal of inlet-air pressure sensor is unreliable. 16 1 1
7 The signal of oxygen sensor is unreliable. 17 1 1
8 The signal of inlet-air temperature sensor is unreliable. 18 1 1
The signal of cooling-fluid temperature sensor is
9 19 1 1
unreliable.
10 Injector -failure with the driving stage of cylinder 4 21 1 1
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Failure with the driving stage of carbon-canister control

14 25 1 1
valve
The air /fuel ratio, and the control &repair coefficient
15 31 2 0
are unreliable.
16 The engine is running out of Max. rotating-speed. 33 2 0
17 Failure with the electronic control unit. 34 2 1
The air /fuel ratio to control the addition modification
18 35 2 0
coefficient The scope of idle-speed plays a role
The air /fuel ratio to control the multiplication
19 modification coefficient The scope of idle-speed plays a 36 2 0
role
A self-learning of addition modification (for air leakage
20 37 2 0
amount) controlled by the air /fuel ratio
21 The accumulator voltage is unreliable. 38 2 0
22 The signal of vehicle speed is unreliable. 41 2 0
23 Failure with the cooling-fan relay. 42 1 1
24 The signal to determine cylinder is unreliable. 43 2 0
25 Failure with the driving stage of fault indicator lamp. 45 1 0
Failure with the driving stage 1
26 61 1 1
of step motor-EWD coil 1
Failure with the driving stage 2
27 62 1 1
of step motor –EWD coil 2
Type of failure： 1”denotes an open circuit, or a short circuit to ground, or a short circuit to power supply; and 2”
denotes the signal out of limit.
Fault indicator lamp： 1”denotes lighting, and 0” denotes off.

M1.5.4 system EF.1-49
2 Steps to read flashing fault codes:

(a)Connect the engine ignition switch rather than to start the engine.
(b)Connect the diagnosis plug-7# on line K ECU-55# or OBD to ground, and the connection time is longer than 2.5
seconds.
(c)And failures stored in the failure memory will be output by a flashing fault indicator lamp.
(d)Each flashing code is composed of two digits, and each is made up of one number within 0 and 9.
(e)The digit 0 will flash for ten times, and any digit within 1-9 will flash as per its literal meaning; The flashing will be stopped
instantaneously for one second between two digits forming a flashing code, and will be stopped for a long-term period between
(f) An identical fault code will be flashing continuously for three times, and all fault codes will be uninterruptedly flashing until
(g)If no any failure has been stored in the failure memory, the fault indicator lamp will have the “No failure” (ie. “11”) flashed.
(h)To clear any fault code away from the failure memory, simply connect the K line to ground for two continuous times, and each time
shall be longer than 2.5 seconds.
3. List of criterion to the mounting torque of parts &components
Name of parts Mounting torque Name of parts Mounting torque

S.N. S.N.
&components N·m &components N·m
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Air inlet pressure

1 3.3 6 Rotating speed sensor 8±2
/temperature sensor
Cooling-fluid
2 20(Max) 7 Phase sensor 8±0.5
temperature sensor
3 Knock sensor 20±5 8 Oil injector 6
4 Oxygen sensor 50±10 9 Idle-speed actuator 4±0.4
5 Throttle position sensor 2±0.5

EF.1-50 Description of the diagnosis function on M7.9.7 system failure
Description of the diagnosis function on M7.9.7 system failure

1. Record of failure information
The electronic control unit is uninterruptedly checking the sensor, actuator, relevant loops, fault indicator lamp, accumulator voltage,
or even itself; and also verifying the reliability of output signal from sensor, driving /internal signal from actuator eg.
closed-loop control, cooling-fluid temperature, knock control, rotating-speed control when at idle-speed, accumulator voltage control,
etc. . Once any failure occurs at some step, or if some signal value is unreliable, the electronic control unit will immediately set a
record of failure information in RAM failure memory. Such record is stored in a form of fault code, and displayed as per the priority
of failure display.
Depending on the frequency of display, failures may be divided into “stable failure” and “chance failure” eg. failure caused by a
short broken circuit of wiring harness, or by bad contact between connectors.
2. Three grades of failure
(a)CLASS 5
-Actions to be taken when setting the diagnosis fault code:
Once some failure displays, its corresponding fault code and relevant failure information will enter a fault codememory.
The failure will be verified after being displayed in three continuous driving cycles, but ECU will not light up the fault i n d i c a t o r
lamp.
-Condition as to eliminate the fault indicator lamp/fault code.
Upon a verification of failure, have vehicle running without failure for three continuous driving cyclestosettlethefailure.
As for verified failure, the fault code will be cleared away after 40 continuous trouble-free preheating cycles from the time of failure
settlement.
As for chance failure, the fault code will be cleared away after 40 continuous trouble-free preheating cycles.
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(b)CLASS 31
Once some failure displays, its corresponding fault code and relevant failure information will enter a fault codememory.The failure
will be verified after being displayed in three continuous driving cycles, and ECU will light up the fault indicator lamp.
-Condition as to eliminate the fault indicator lamp/fault code
When the fault indicator lamp is lighting, have vehicle running without failure for one driving cycle to settle the failure, and the fault
indicator lamp will be closed.
As for verified failure, the fault code will be cleared away after 40 continuous trouble-free preheating cycles from the time of
failure settlement.
(c)CLASS 33
Once some failure displays, its corresponding fault code and relevant failure information will enter a fault code memory.
The failure will be verified in two mintues from the display moment, but ECU will not light up the fault indicator lamp.
-Condition as to eliminate the fault indicator lamp/fault code
Upon a verification of failure, have vehicle running without failure for one driving cycle to settle the failure.
As for verified failure, the fault code will be cleared away after 40 continuous trouble-free preheating cycles from the time of failure
settlement.
3. Strategy for the control of fault indicator lamp
When no failure,
-After the ignition switch is ON, the fault indicator lamp will be lighting, then off in four seconds;
-It will be started within four seconds; and the fault indicator lamp will be off after the signal to rotating-speed is found;
-When the ground connection time of line K is longer than 2.5 seconds, the fault indicator lamp will be flashing at a frequency of 2 Hz.
When with failure,
-After the ignition switch is ON, the fault indicator lamp will be always lighting;
-It will be started, and the fault indicator lamp will be off after the signal to rotating-speed is found; If the fault indicator lamp is
defined to a ‘lighting’ mode, it will be always lighting when relevant conditions are satisified;
-When the ground connection time of line K is longer than 2.5 seconds, a flashing code (ie. P-CODE value) will be output. For
instance: P0203 will be flashing in the way below: ten continuous times- intermittance- two continuous times - intermittance- ten
continuous times - intermittance- three continuous times.

Description of the diagnosis function on M7.9.7 system failure EF.1-51
4. Four types of failure

Failure B_mxdfpMax. indicates the signal goes beyond the upper limit of normal scope;
Failure B_mndfpMin. indicates the signal goes beyond the lower limit of normal scope;
Failure B_sidfpsignal indicates some failure without signal.
Failure caused by an inappropriate B_npdf, indicates some inappropriate signal.
5. Connection with diagnosis instrument
The system adopts ISO 9141-2 standard diagnosis plug (as shown in the figure below) to be securely connected with engine wiring
harness, and is supported by line “K” communication protocol. And Pin 4, 7, 16 on diagnosis plug shall be connected respectively
with following parts under the engine management system (EMS): Pin 4 connected to the ground wire on vehicle; Pin 7 connected to
Pin 71 of ECU, namely the engine data line K ; and Pin 16 connected to the positive electrode of accumulator.
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ECU may communicate with peripheral diagnosis instruments via line K , and perform following operations:
(a)Display of engine parameters
-Rotating-speed, cooling-fluid temperature, opening degree of throttle valve, ignition lead-angle, oil-injection pulse width, inlet
airpressure, inlet-air temperature, vehicle speed, system voltage, modification to oil injection, scour rate of carbon-canister, idlespeedair
control, waveform of oxygen sensor;
-Desired rotating-speed, relative load of engine, ambient temperature, ignition closure time, temperature of evaporator, inlet air
capacity, and oil consumption.
-Signal voltage of throttle position sensor, signal voltage of cooling-fluid temperature sensor, signal voltage of inlet-air temperature
sensor, signal voltage of inlet-air pressure sensor, signal voltage for Pin 1 of knock sensor, and signal voltage for Pin 2 of knock sensor.
(b)The displayed status for electronic injection system covers:
Status of theft-prevention system, safety status, editing status, status of cooling system, status of stable working condition, status
of dynamic working condition, exhaust control status, status of oxygen sensor, idle-speed status, status of fault indicator lamp,
status under emergency, status of air-conditioner system, auto. speed changer /torque request status.
(c) Actuator test function
Fault indicator lamp, fuel pump, air-conditioner relay, fan, ignition, and oil injection single-cylinder oil cut .
(d)Display of milemeter
Mileages &time traveled.
(e)Display of version information
No. of vehicle frame VIN , No. of ECU hardware, No. of ECU software.
(f)Display of failures
Inlet-air pressure sensor, inlet-air temperature sensor, engine cooling-fluid temperature sensor, throttle position sensor, oxygen
sensor, the heating loop of oxygen sensor, modification to air /fuel ratio, oil injector inside each cylinder, fuel pump, knock sensor,
rotating speed sensor, phase sensor, carbon-canister control valve, cooling-fan relay, vehicle speed signal, rotating- speed when at
idle-speed, idle-speed adjustor, system voltage, ECU, air-conditioner compressor relay, temperature sensor of evaporator, fault
indicator lamp.
6. Read failure information via flashing code
Open the ignition switch, and have the engine data line K i e. Standard diagnosis plug No. 7 being connected to ground for at
least 2.5 seconds; The availability of fault code stored in ECU failure memory will be indicated by a flashing code (i e. P- CODE
value) output from an engine fault indicator lamp. For instance, P0203 will be flashing in the way below: ten continuous times-
intermittance- two continuous times - intermittance- ten continuous times - intermittance- three continuoustimes.

EF.1-52 M7.9.7 system service &diagnosis flow process based on fault code
M7.9.7 system service &diagnosis flow process based on fault code

1.List of fault codes within M7.9.7 system
S.N. Fault code Description Grade of failure
1 P0107 The signal voltage in the loop of inlet-air pressure sensor is too low. Class31
2 P0108 The signal voltage in the loop of inlet-air pressure sensor is too high. Class31
3 P0112 The temperature indicated by inlet-air temperature sensor is too low. Class31
4 P0113 The temperature indicated by inlet-air temperature sensor is too low. Class31
5 P0117 The temperature indicated by engine cooling-fluid temperature sensor is too low. Class31
6 P0118 The temperature indicated by engine cooling-fluid temperature sensor is too low. Class31
7 P0122 The signal voltage in the loop of throttle position sensor is too low. Class31
8 P0123 The signal voltage in the loop of throttle position sensor is too low. Class31
9 P0130 The failure is caused by an inappropriate signal of upstream oxygen sensor. Class31
10 P0132 The signal voltage in the loop of upstream oxygen sensor is too high. Class31
11 P0134 Failure with the signal of upstream oxygen sensor. Class31
12 P0135 Failure with the heating loop of upstream oxygen sensor. Class31
13 P0171 The self-adaptive value for a closed-loop control of air /fuel ratio is beyond the upper limit. Class5
14 P0172 The self-adaptive value for a closed-loop control of air /fuel ratio is beyond the upper limit. Class5
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15 P0201 Failure with the loop of oil injector inside cylinder 1 Class31
19 P0230 Failure with the control loop of oil pump Class31
20 P0324 Failure with the processing chip of knock signal, and its loops. Class5
21 P0325 Failure with the loop of knock sensor. Class31
22 P0335 Failure with the signal of crankshaft position sensor. Class33
23 P0336 The failure is caused by an inappropriate signal of crankshaft position sensor. Class33
24 P0340 Failure with the signal of phase sensor. Class31
25 P0443 Failure with the control loop of driving stage for carbon-canister control valve. Class31
26 P0444 The voltage in the control loop of driving stage for carbon-canister control valve is too low. Class31
27 P0445 The voltage in the control loop of driving stage for carbon-canister control valve is too high. Class31
28 P0550 The failure is caused by an inappropriate signal of vehicle speed. Class31
29 P0506 The rotating-speed under an idle-speed control is lower than the desired idle-speed value. Class31
30 P0507 The rotating-speed under an idle-speed control is higher than the desired idle-speed value. Class31
31 P0508 The voltage in the control loop of idle-speed adjustor is too low. Class31
32 P0509 The voltage in the control loop of idle-speed adjustor is too high. Class31
33 P0511 Failure with the control loop of idle-speed adjustor. Class31
34 P0560 Inappropriate signal of system voltage. Class31
35 P0562 The signal of system voltage is too low. Class31
36 P0563 The signal of system voltage is too high. Class31
37 P0601 The verification code of electronic controller has not been programmed yet. Class31
38 P0602 The diagnosis data ID code of electronic controller has not been programmed yet. Class31
39 P0645 Failure with the control loop of air-conditioner compressor relay. Class31
40 P0646 The voltage in the control loop of air-conditioner compressor relay is too low. Class31
41 P0647 The voltage in the control loop of air-conditioner compressor relay is too high. Class31
42 P1651 Failure with the control loop of engine fault indicator lamp SVS . Class5

M7.9.7 system service &diagnosis flow process based on fault code EF.1-53
2.M7.9.7 system service &diagnosis flow process based on fault code

Fault code：P0107“the signal voltage in the loop of inlet-air pressure sensor is too low”
Check
result
1 Connect with the diagnosis instrument, and place the ignition switch to the ON”position. Next step.
Observe whether the item inlet air pressure” in data stream is about 101kpa (specific data Yes Continue to proceed until step 5.
2
depends on the existing pressure). No Next step.
Pull out the plug of inlet-air pressure sensor from wiring harness, and a multimeter may be Yes Continue to proceed until step 5.
3
used to check whether the voltage between Pin 3 and Pin 1 of plug is about 5V. No Next step.
Repair or change the wiring
Check whether respective loops between Pin 17/33/37 of ECU and the connection Pin 1/3/4 of Yes
4 harness.
sensor are short circuit to ground.
No Next step.
Start the engine and have it running at idle-speed; Step on the gas slowly until it’s full opened
and observe the change of value at item inlet-air pressure”on diagnosis instrument, the Yes Diagnosis help.
5
displayed value shall be with slight changes; Step on the gas quickly until it’s close to a full
No Change the sensor.
open degree, the displayed value shall reach a value greater than 90kpa instantaneously.
Fault code：P0108 “the signal voltage in the loop of inlet-air pressure sensor is too high”
Check
result
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Observe whether the item “inlet-air pressure” within data stream is about 101kpa (exact data is Yes Continue to proceed until step 5.
2
subject to the existing pressure). No Next step.
Pull out the plug of inlet-air pressure sensor from wiring harness, and a multimeter may be Yes Continue to proceed until step 5.
3
used to check whether the voltage between Pin 3 and Pin 1 of plug is about 5V. No Next step.
Check whether respective loops between Pin 17/33/37 of ECU and the connection Pin 1/3/4 of Yes
4 harness.
sensor are short circuit to power supply.
No Next step.
Start the engine and have it running at idle-speed; Step on the gas slowly until it’s full opened
and observe the change of value at item inlet-air pressure”on diagnosis instrument, the Yes Diagnosis help.
5
displayed value shall be with slight changes; Step on the gas quickly until it’s close to a full
open degree, the displayed value shall reach a value greater than 90kpa instantaneously. No Change the sensor.
Fault code：P0112 The temperature indicated by the inlet-air temperature sensor is too low”
Check
result
Observe whether the value of item inlet-air temperature”in data stream is fit for the Yes Continue to proceed until step 5.
2 temperature inside the air-inlet pipe (specific value depends on the existing pressure). Note: If
the displayed value is always -40℃, it indicates a possible failure caused by a broken loop. No Next step.
Pull out the plug of inlet-air temperature sensor from wiring harness, and a multimeter may be Yes Next step.
3 used to check whether the resistance between Pin 1 and Pin 2 of sensor is fit for the
temperature.
Pull out the plug of inlet-air temperature sensor from wiring harness, and a multimeter may be Yes Continue to proceed until step 5.
4
used to check whether the voltage between Pin 1 and Pin 2 of sensor is about 5V. No Next step.
Check whether respective loops between Pin 17 &40 of ECU and the connection Pin 1 &2 of Yes
5 harness.
sensor are broken loops, or short circuit to power supply.
No Next step.
Start the engine and have it running at idle-speed. Observe the change of value at item inlet-air Yes Diagnosis help.
6 temperature”displayed on diagnosis instrument, and whether the value is increased accordingly
when the engine inlet-air temperature is being increased. No Change the sensor.

Fault code：P0113 The temperature indicated by inlet-air temperature sensor is too high”
Check
result
Observe whether the value of item inlet-air temperature”in data stream is fit for the
Yes Continue to proceed until step 5.
2 temperature inside the air-inlet pipe (specific value depends on the existing pressure). Note: If
the displayed value is always -40℃, it indicates a possible failure caused by a broken loop. No Next step.
Pull out the plug of inlet-air temperature sensor from wiring harness, and a multimeter may be Yes Next step.
3 used to check whether the resistance between Pin 1 and Pin 2 of sensor is fit for the
temperature.
4
Check whether respective loops between Pin 17 &40 of ECU and Pin 1 &2 of sensor are Yes
5 harness.
broken loops or short circuit to ground.
No Next step.
Start the engine and have it running at idle-speed. Observe the change of value at item inlet-air Yes Diagnosis help.
6 temperature”displayed on diagnosis instrument, and whether the value is increased accordingly
when the engine inlet-air temperature is being increased. No Change the sensor.
Fault code：P0117 The temperature indicated by engine cooling-fluid temperature sensor is too
low.”
S.N. Operation steps Check Follow-up steps
result
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Observe whether the value at item “cooling-fluid temperature ” in data stream is fit for engine
2 temperature (specific data depends on the existing pressure). Note: If the displayed value is
always -40℃, it indicates a possible failure caused by the broken loop. No Next step.
Pull out the plug of cooling-fluid temperature sensor from wiring harness, and a multimeter Yes Next step.
3 may be used to check whether the resistance between Pin 1 and Pin 2 of sensor is fit for the
temperature. .
4
5 harness.
No Next step.
Start the engine and have it running at idle-speed. Observe whether the value of item Yes Diagnosis help.
6 cooling-fluid temperature” displayed on diagnosis instrument is increased accordingly
when the temperature of engine cooling-fluid is being increased. No Change the sensor.
Fault code：P0118 The temperature indicated by the engine cooling-fluid temperature sensor
is too high”
Check
result
Observe whether the value at item “cooling-fluid temperature ” in data stream is fit for engine
2 temperature (specific data depends on the existing pressure). Note: If the displayed value is
always -40℃, it indicates a possible failure caused by the broken loop. No Next step.
Pull out the plug of cooling-fluid temperature sensor from wiring harness, and a multimeter Yes Next step.
3 may be used to check whether the resistance between Pin 1 and Pin 2 of sensor is fit for the
temperature. .
4
5 harness.
No Next step.
Start the engine and have it running at idle-speed. Observe whether the value of item Yes Diagnosis help.
6 cooling-fluid temperature” displayed on diagnosis instrument is increased accordingly
when the temperature of engine cooling-fluid is being increased. No Change the sensor.

Fault code：P0122 The signal voltage in the loop of throttle position sensor is too low.”
Check
result
Observe whether the value of item absolute opening degree of throttle valve”in data stream Yes Next step.
2
is within 4%-10%. No Continue to proceed until step 5.
Step on the gas slowly until it’s full opened, and observe whether the value of item absolute Yes Next step.
3 opening degree of throttle valve”in data stream is increased to a degree of 85%-95% when the
No Continue to proceed until step 5.
opening degree of throttle valve is being increased.
Repeat step 3 to observe the item absolute opening degree of throttle valve”in data stream, Yes Change the sensor.
4
and whether any abrupt change exists during the change of value. No Next step.
Pull out the plug of throttle valve sensor from wiring harness, and check whether respective Repair or change the wiring
Yes
5 loops between Pin 32/17/16 of ECU and the connection Pin 1/2/3 of sensor are broken loops, harness.
or short circuit to ground. No Next step.
A multimeter may be used to check whether the voltage between Pin 1 and Pin 2 of the plug is Yes Diagnosis help.
6
about 5V. No Continue to proceed until step 5.
Fault code：P0123 The signal voltage in the loop of throttle position sensor is too high”
Check
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result
Observe whether the value of item absolute opening degree of throttle valve”in data stream is Yes Next step.
2
within 4%-10%. No Continue to proceed until step 5.
Step on the gas slowly until it’s full opened, and observe whether the value of item absolute Yes Next step.
3 opening degree of throttle valve”in data stream is increased to a degree of 85%-95% when the
opening degree of throttle valve is being increased.
Repeat step 3 to observe the item absolute opening degree of throttle valve”in data stream, Yes Change the sensor.
4
and whether any abrupt change exists during the change of value. No Next step.
Pull out the plug of throttle valve sensor from wiring harness, and check whether respective Repair or change the wiring
Yes
5 loops between Pin 32/17/16 of ECU and the connection Pin 1/2/3 of sensor are broken loops, harness.
or short circuit to ground. No Next step.
A multimeter may be used to check whether the voltage between Pin 1 and Pin 2 of the plug is Yes Diagnosis help.
6
about 5V. No Continue to proceed until step 5.
Fault code：P0130“Failure caused by inappropriate signal for upstream sensor”
Note: The diagnosis flow process below is applicable to cases excluding that P0135 is not produced simultaneously; if P0135 is
produced simultaneously, you need to settle the failure with P0135 first before performing a check and repair as per the flow process
below.
Check
result
Start the engine and have it running at idle-speed until the cooling-fluid temperature reaches its
Yes Diagnosis help.
2 normal value. Observe the change of value at the item oxygen sensor voltage”on diagnosis
instrument, and whether the displayed value makes a rapid change within 100mV~900mV. No Next step.
Check whether respective loops between Pin 36 &18 of ECU and the connection Pin A Repair or change the wiring
Yes
3 (corresponding to the grey connection line of oxygen sensor) and B(corresponding to the black harness.
connection line of oxygen sensor) of sensor are broken loops. No Change the sensor.

Fault code：P0132 the signal voltage in the loop of upstream sensor is too high”
produced simultaneously, you need to settle the failure with P0135 first before performing a check and repair as per the flow process
below.
Check
result
Yes Diagnosis help.
Yes
3 (corresponding to the grey connection line of oxygen sensor) and B (corresponding to the harness.
black connection line of oxygen sensor) of sensor are broken loops. No Change the sensor.
A、Whether the exhaust system is leaking air or has been blocked;
Check and repair it based on
B、Whether the oil injector has any leakage; Yes
diagnosis.
4 C、Whether the fuel pressure is too big;
D、Whether the clearance of air valve is too small
So on and so forth.
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Fault code：P0134 Failure with the signal of upstream sensor”

produced simultaneously, you need to settle the failure with P0135 first before performing a check and repair as per the flow
process below.
Check
result
1 Connect with the diagnosis instrument, and place the ignition switch to the ON”position. Yes Next step.
Yes Diagnosis help.
Yes
3 (corresponding to the grey connection line of oxygen sensor) and B (corresponding to the harness.
black connection line of oxygen sensor) of sensor are broken loops. No Change the sensor.
Fault code：P0135 Failure with heating loop of upstream oxygen sensor.”
Check
result
Pull out the plug of oxygen sensor from wiring harness, and a multimeter may be used to check
Yes Next step.
whether the voltage between Pin C corresponding to the white connection line of oxygen
2
sensor and Pin D corresponding to the white connection line of oxygen sensor of the plug
is about 12V.
A multimeter may be used to check whether the resistance between Pin C (white) and Pin Yes Next step.
3
D(white) of oxygen sensor is within 1-6 Ω when at 20℃. No Change the sensor.
Yes Change the fuse
4 Check whether the 8A fuse in the heating loop of oxygen sensor has been blown and broken.
No Next step.
Check whether respective loops between Pin 1 of ECU / Pin 87 of main relay and the Repair or change the wiring
Yes
connection Pin C (corresponding to the while connection line of oxygen sensor) and Pin D harness.
5
(corresponding to the while connection line of oxygen sensor) of sensor are broken loops, or
No Diagnosis help.
short circuit to ground or power supply.

Fault code：P0171 The self-adaptive value for a closed-loop control of air /fuel ratio is beyond the upper limit. ”
Note: The diagnosis flow process below is applicable to cases excluding that fault codes are produced simultaneously on
inlet-air pressure sensor, carbon-canister control valve, oxygen sensor, etc. If fault codes are produced simultaneously, settle
other failures first before performing a check and repair as per the flow process below.
Check
result
Connect with the diagnosis instrument, and place the ignition switch to the
1 Next step.
ON”position.
Start the engine and have it running at idle-speed until the cooling-fluid
Yes Next step.
temperature reaches its normal value. When under a full working condition,
observe the change of value at the item oxygen sensor voltage”on diagnosis
2
instrument, and whether the displayed value remains at about 100mV(yet
No Diagnosis help.
with less changes) for a long-term period when under some working
conditions.
end of fuel inlet pipe included in the fuel distributing pipe assembly), check
3 whether the fuel pressure keeps at about 260 kpa while engine is running at Check and repair the fuel
No
idle-speed; and whether the fuel pressure keeps at about 300kpa after vacuum system.
Check whether respective loops between Pin 36 &18 of ECU and the Repair or change the wiring
Yes
connection pin A (corresponding to the grey connection line of oxygen sensor) harness.
4
&B (corresponding to the black connection line of oxygen sensor) of sensor
No Next step.
are short circuit to ground.
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A、 Check whether severe air leakage exists in the air inlet system;
B、 Whether fuel injector has been blocked; Check and repair it based
Yes
C、 Whether the clearance of spark plug is too big; on diagnosis.
5
D、 Whether the resistance of fire division line is too big;
E、 Whether the clearance of air valve is too big;
No Diagnosis help.
So on and so forth.
Fault code: P0172 The self-adaptive value for a closed-loop control of air /fuel ratio is beyond
the lower limit”
Note: The diagnosis flow process below is applicable to cases excluding that fault codes are produced simultaneously on
inlet-air pressure sensor, carbon-canister control valve, oxygen sensor, etc. If fault codes are produced simultaneously, settle other
failures first before performing a check and repair as per the flow process below.
Check
result
1 Next step.
ON”position.
Start the engine and have it running at idle-speed until the cooling-fluid
Yes Next step.
temperature reaches its normal value. When under a full working condition,
observe the change of value at the item oxygen sensor voltage”on diagnosis
2
instrument, and whether the displayed value remains at about 900mV(yet
No Diagnosis help.
with less changes) for a long-term period when under some working
conditions.
end of fuel inlet pipe included in the fuel distributing pipe assembly), check
3 whether the fuel pressure keeps at about 260 kpa while engine is running at Check and repair the fuel
No
idle-speed; and whether the fuel pressure keeps at about 300kpa after vacuum system.
Check whether respective loops between Pin 36 &18 of ECU and the Repair or change the wiring
Yes
connection pin A (corresponding to the grey connection line of oxygen sensor) harness.
4
&B (corresponding to the black connection line of oxygen sensor) of sensor
No Next step.
are short circuit to power supply.
A、 Whether the injector is leaking; Check and repair it based
Yes
B、 Whether the exhaust pipe has been blocked; on diagnosis.
C、 Whether the clearance of air valve is too small;
No Diagnosis help.
So on and so forth.

Fault code：P0201 Failure with the loop of fuel injector inside cylinder 1”
Check
result
1 Next step.
ON”position.
Pull out the plug of fuel injector for cylinder 1 from wiring harness, and a Continue to proceed until
Yes
2 multimeter may be used to verify whether the voltage between the connection step 4.
Pin 1 and the negative electrode of power supply is about 12V. No Next step.
Check whether the loop between the connection Pin 1 of fuel injector for Yes
3 harness.
cylinder 1 and main relay is a broken loop, or short circuit to ground.
No Next step.
A multimeter may be used to check whether the resistance between Pin 1 and Yes Next step.
4
Pin 2 of fuel injector for cylinder 1 is within 11-17 Ω when at 20℃. No Change the fuel injector
A multimeter may be used to check whether the voltage between Pin 2 of fuel Yes Diagnosis help.
5 injector for cylinder 1 and the negative electrode of power supply is about
3.7V. No Next step.
Check
result
1 Next step.
ON”position.
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Yes
3 harness.
No Next step.
4
3.7V. No Next step.
Check whether the loop between Pin 2 of fuel injector for cylinder 2 and the Yes
6 harness.
Pin 6 of ECU is a broken loop, or short circuit to ground or power supply.
No Diagnosis help.
Check
result
1 Next step.
ON”position.
Yes
3 harness.
No Next step.
4
3.7V. No Next step.
6 harness.
No Diagnosis help.

Check
result
1 Next step.
ON”position.
Yes
3 harness.
No Next step.
4
3.7V. No Next step.
6 harness.
No Diagnosis help.
Fault code：P0230 Failure with the control loop of fuel pump”
Check
result
1 Next step.
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ON”position.
Pull out the fuel pump relay, place the ignition switch to the “ON” position, Continue to proceed until
Yes
and check whether respective voltage between the negative electrode of power step 4.
2
supply and the power supply end (ie. Pin 30 &86) of fuel pump relay is about
No Next step.
12V.
Check whether the loop on the power supply end of relay is a broken loop or Yes
3 harness.
short circuit to ground.
No Next step.
Change the fuel pump
A multimeter may be used to check whether the resistance between Pin 1 and Yes
4 relay.
Pin 2 of fuel injector for cylinder 1 is within 11-17 Ω when at 20℃.
No Next step.
A multimeter may be used to check whether the voltage between the control Yes Diagnosis help.
5 end (ie.Pin 85) of fuel pump relay and the negative electrode of power supply
is about 3.7V. No Next step.
Fault code P0324 Failure with the processing chip of knock signal, and its loops.”
Check
result
1 Next step.
ON”position.
Yes Next step.
2 Eliminate any fault code, and re-check whether the failure is a stable failure.
No System is normal.
3 Change the ECU.
Fault code：P0325 Failure with the loop of knock sensor.”
Check
result
1 Next step.
ON”position.
Pull out the plug of knock sensor from wiring harness, and a multimeter may Yes Next step.
2 be used to verify whether resistance between Pin 1 and Pin 2 of knock sensor is
greater than 1MΩ. No Change the sensor.
Check whether respective loops between the connection pin 1 &2 of knock Repair or change the wiring
Yes
3 sensor and Pin 19 &20 of ECU are broken loops, or short circuit to ground or harness.
power supply. No Next step.
Change the knock sensor as per installation specification. Have a loop test and Yes Diagnosis help.
4 make the rotating-speed of engine greater than 2200 revolutions per minute. Continue to proceed until
No
And re-check whether the fault code P0325 will be shown. step 3.

Fault code：P0335 Failure with the signal of crankshaft position sensor.”

Check
result
1 Next step.
ON”position.
Pull out the plug of rotating speed sensor from wiring harness, and a Yes Next step.
2 multimeter may be used to verify whether the resistance between Pin 1 and Pin
2 of rotating speed sensor is within 770-950 Ω when at 20℃. No Change the sensor.
Check whether respective loops between the connection Pin 1 &2 of rotating Repair or change the wiring
Yes
3 speed sensor and Pin 15 &34 of ECU are broken loops, or short circuit to harness.
ground or power supply. No Next step.
Yes Change the sensor.
Check whether the installation position of sensor satisfies relevant
4 Check and repair it based
requirements, and whether the signal panel of flywheel is intact. No
on diagnosis.
Fault code：P0336 The failure is caused by an inappropriate signal of crankshaft position sensor.”
Check
result
1 Next step.
ON”position.
Pull out the plug of rotating speed sensor from wiring harness, and a Yes Next step.
2 multimeter may be used to verify whether the resistance between Pin 1 and Pin
2 of rotating speed sensor is within 770-950 Ω when at 20℃. No Change the sensor.
Check whether respective loops between the connection Pin 1 &2 of rotating Repair or change the wiring
Yes
3 speed sensor and Pin 15 &34 of ECU are broken loops, or short circuit to harness.
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ground or power supply. No Next step.

Check whether the installation position of sensor satisfies relevant
4 Check and repair it based
requirements, and whether the signal panel of flywheel is intact. No
on diagnosis.
Fault code：P0340 Failure with the signal of phase sensor.”
Check
result
1 Next step.
ON”position.
Pull out the plug of phase sensor from wiring harness, and a multimeter may be Continue to proceed until
Yes
2 used to verify whether the voltage between Pin 1 and Pin 3 of phase sensor is step 4.
about 12V. No Next step.
Check whether the loop between the connection pin 1 of phase sensor and Pin Repair or change the wiring
Yes
3 87 of main relay is a broken loop, or short circuit to ground. And check harness.
whether the pin 3 of phase sensor has been well grounded. No Next step.
Continue to proceed until
Check whether the voltage between the connection Pin 2 of phase sensor and Yes
4 step 6.
the negative electrode of power supply is about 9.9V.
No Next step.
Check whether the loop between the connection pin 2 of phase sensor and Pin Yes
5 harness.
79 of ECU is a broken loop, or short circuit to power supply or ground.
No Next step.
6 Check whether the signal panel of camshaft is intact.
No Change the signal panel
Fault code：P0443 Failure with the control loop of driving stage for carbon-canister control valve.”
Check
result
1 Next step.
ON”position.
Pull out the plug of carbon-canister control valve from wiring harness, and a Continue to proceed until
Yes
2 multimeter may be used to verify the voltage between Pin 1 of the plug and the step 4.
negative electrode of power supply is about 12V. No Next step.
Yes
Check whether the loop (on power supply end) of carbon-canister control valve harness.
3
is a broken circuit or short circuit to ground. Continue to proceed until
No
step 2.

Check
result
A multimeter may be used to verify whether the resistance between Pin 1 and Yes Next step.
4
Pin 2 of carbon-canister control valve is within 22-30 Ω when at 20℃. No Change the control valve.
A multimeter may be used to verify whether the voltage between the Yes Diagnosis help.
5 connection Pin 1 of carbon-canister control valve and the negative electrode of
power supply is about 3.7V. No Next step.
Check whether the loop between the connection Pin 2 of carbon-canister Yes
6 harness.
control valve and Pin 46 of ECU is a broken loop.
No Diagnosis help.
Fault code：P0444 The voltage in the control loop of driving stage for carbon-canister control
valve is too low.”
Check
result
1 Next step.
ON”position.
Yes
Yes
3
is in a broken circuit or is short circuit to ground. Continue to proceed until
No
step 2.
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4
6 harness.
control valve and the Pin 46 of ECU is short circuit to ground.
No Diagnosis help.
Fault code：P0445 The voltage in the control loop of driving stage for carbon-canister control
valve is too high.”
Check
result
1 Next step.
ON”position.
Yes
Yes
3
is in a broken circuit or is short circuit to ground. Continue to proceed until
No
step 2.
4
6 harness.
control valve and Pin 46 of ECU is a broken loop.
No Diagnosis help.
Fault code：P0480 failure with the control loop of cooling-fan relay”
Check
result
Connect with a diagnosis instrument, and place the ignition switch to the
1 Next step.
OFF”position.
Pull out the relay from the cooling-fan, place the ignition switch to the ON” Continue to proceed until
Yes
2 position, and verify the voltage between the power supply end (ie. Pin 30 &85) step 4.
of relay and the negative electrode of power supply is about 12V. No Next step.

Check
result
Yes
Check whether the loop on the power supply end of cooling-fan relay is a harness.
3
broken loop or short circuit to ground. Continue to proceed until
No
step 2.
A multimeter may be used to check whether the voltage between the control Yes Change the relay.
4 end (i.e. Pin 86) of cooling-fan relay and the negative electrode of power
No Next step.
supply is about 3.7V.
Check whether the loop between the control end (i.e. Pin 86) of relay and Pin Yes
5 harness.
No Next step.
Yes Diagnosis help.
6 Check whether the cooling-fan is working under a normal condition.
No Change the fan.
Fault code： P0500 The failure is caused by an inappropriate signal of vehicle speed.”
Check
result
1 Next step.
OFF” position.
Check and repair ABS
For vehicles having been equipped with ABS system, check ABS system for Yes
2 system.
any fault code.
No Next step.
Yes Next step.
3 Check whether the needle of tachometer is working under a normal condition. Check and repair the
No
instrumentation loop.
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Yes Next step.

4 Check whether the vehicle speed sensor is working under a normal condition. Change the vehicle speed
No
sensor.
Check whether the loop between the signal line of vehicle speed sensor and Pin Yes
5 harness.
No Diagnosis help.
Fault code P0506 The rotating-speed under an idle-speed control is lower than the desired
idle-speed value.”
Check
result
1 Next step.
OFF” position.
Yes Next step.
Check whether adjusting screws of throttle valve, pulling line of gas pedal, and
2 Perform necessary
throttle valve are working under a good condition. No
maintenance and service.
Yes Next step.
3 Check whether the idle-speed adjustor is working under a good condition. Perform necessary
No
A、 Check whether the pressure of fuel supply system is too low; Perform necessary
B、 Check whether the fuel injector has been blocked Yes
4 maintenance.
C、 Check whether the inlet /exhaust gas within the system is free
So on and so forth. No Diagnosis help.
Fault code： P0507 The rotating-speed under an idle-speed control is higher than the desired
idle-speed value.”
Check
result
1 Next step.
OFF” position.
Yes Next step.
Check whether adjusting screws of throttle valve, the pulling line of gas pedal,
2 Perform necessary
and throttle valve are working under a good condition. No
Yes Next step.
3 Check whether the idle-speed adjustor is working under a good condition. Perform necessary
No
D、 Check the fuel supply system for air leakage; Perform necessary
E、 Check the fuel injector for fuel leakage; Yes
4 maintenance.
F. Check whether the inlet /exhaust gas within the system is too high, so on
and so forth. No Diagnosis help.

Fault code：P0508 The voltage in the control loop of idle-speed adjustor is too low.”
Check
result
1 Next step.
ON”position.
Pull out the plug from idle-speed adjustor, and a multimeter may be used to Yes Next step.
2 verify whether the resistance values between Pin A and D, and between Pin B
and C are about 53±5.3 Ω when at 20℃. No Change the step motor.
Check whether respective loops between the connection Pin A /B /C /D of Repair or change the wiring
Yes
3 idle-speed adjustor and the Pin 65 /66 /67/ 64 of ECU are short circuit to harness.
ground. No Diagnosis help.
Fault code：P0509 The voltage in the control loop of idle-speed adjustor is too high.”
Check
result
1 Next step.
ON”position.
Check whether respective loops between the connection Pin A /B /C /D of Repair or change the wiring
Yes
3 idle-speed adjustor and the Pin 65 /66 /67/ 64 of ECU are short circuit to harness.
ground. No Diagnosis help.
Fault code：P0511 Failure with the control loop of idle-speed adjustor.”
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Check
result
1 Next step.
ON”position.
Check whether respective loops between the connection Pin A /B /C /D of Yes
3 harness.
idle-speed adjustor and the Pin 65 /66 /67/ 64 of ECU are a broken loop
No Diagnosis help.
Fault code：P0560 Inappropriate signal of system voltage.”
Check
result
1 Next step.
OFF”position.
A multimeter may be used to verify whether the voltage of accumulator jar is Yes Next step.
2
about 12V.
No Change the accumulator jar.
Check whether the respective loop between Pin 87 of main relay and Pin 44 Yes
3 harness.
/45 /63 of ECU is a broken loop or short circuit to ground.
No Next step.
Check whether the charge voltage of generator is always within a scope of Yes Next step.
4
9-16 V while engine is starting at various rotating-speed. No Change the generator
Yes Diagnosis help.
Check whether the ground point of engine wiring harness is under a good
5 Repair or change the wiring
condition. No
harness.
Fault code：P0562 The signal of system voltage is too low.”
Check
result
1 Next step.
OFF”position.
2
about 12V.

Check
result
Check whether the resistance in the respective loop between Pin 87 of main Yes
3 harness.
relay and Pin 44 /45 /63 of ECU is too large.
No Next step.
4
Yes Diagnosis help.
5
condition. Repair or change the wiring
No
harness.
Fault code：P0563 The voltage signal of system is too high.”
Check
result
1 Next step.
OFF”position.
2
about 12V.
3
Yes Diagnosis help.
4
condition. Repair or change the wiring
No
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harness.
Fault code：P0601 The verification code for electronic controller has not been programmed yet”
Check
result
1 Next step.
ON”position.
Clear away any fault code, and re-verify whether the failure is of a stable Yes Next step.
2
failure. No System is normal.
3 Change ECU. END
Fault code：P0602 The diagnosis data ID code of electronic controller has not been programmed
yet.”
Check
result
Connect with the diagnosis instrument, and place the ignition switch to the Next step.
1
ON”position.
Clear away any fault code, and re-verify whether the failure is of a stable Yes Next step.
2
failure. No System is normal.
3 Change ECU. END
Fault code：P0645 Failure with the control loop of air-conditioner compressor relay.”
Check
result
1 Next step.
OFF”position.
Pull out the relay from the air-conditioner compressor, place the ignition Continue to proceed until
Yes
switch to the ON”position, and verify the voltage between the power supply step 4.
2
end (i.e. Pin 30 &85) of relay and the negative electrode of power supply is
No Next step.
about 12V.
Yes
Check whether the loop on the power supply end of relay is a broken loop or harness.
3
short circuit to ground. Continue to proceed until
No
step 2.
A multimeter may be used to verify the voltage between the control end (i.e. Yes Change the relay.
4 Pin 86 of relay) of air-conditioner compressor relay and the negative electrode
of power supply is about 3.7V. No Next step.

Check
result
Check whether the loop between the control end (i.e. Pin 86 ) of Yes
5 harness.
air-conditioner compressor relay and Pin 70 of ECU is a broken loop.
No Next step.
Yes Diagnosis help.
Check whether the electromagnetic clutch for air-conditioner compressor is
working in a normal way. No
electromagnetic clutch.
Fault code：P0646 The voltage in the control loop of air-conditioner compressor relay is too low.”
Check
result
1 Next step.
OFF”position.
Yes
2
end (ie. Pin 30 &85 ) of relay and the negative electrode of power supply is
No Next step.
about 12V.
Yes
3
No
step 2.
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No Next step.
of power supply is about 3.7V.
Check whether the loop between the control end (ie. Pin 86) of air-conditioner Yes
5 harness.
compressor relay and Pin 70 of ECU is a broken loop.
No Next step.
Yes Diagnosis help.
Fault code：P0647 The voltage in the control loop of air-conditioner compressor relay is too high.”
Check
result
1 Next step.
OFF”position.
Yes
2
end (ie. Pin 30 &85 ) of relay and the negative electrode of power supply is
No Next step.
about 12V.
Yes
3
No
step 2.
No Next step.
of power supply is about 3.7V.
Check whether the loop between the control end (i.e. Pin 86 of relay) of Repair or change the wiring
Yes
5 air-conditioner compressor relay and Pin 70 of ECU is short circuit to power harness.
supply. No Next step.
Yes Diagnosis help.

Fault code：P1530 “Failure with the loop of temperature sensor for air-conditioner evaporator”
Check
result
1 Next step.
OFF” position.
Observe whether the item temperature of evaporator”in data stream is suitable Yes Continue to proceed until
2 6
to the existing temperature of evaporator. No Next step.
Pull out the plug to the temperature sensor of air-conditioner evaporator, use a Yes Next step.
3 multimeter to verify the resistance value between Pin 1 and Pin 2 of the sensor
is corresponding to its temperature value.
Pull out the plug to the temperature sensor of air-conditioner evaporator from Continue to proceed until
Yes
4 the wiring harness, use a multimeter to verify the voltage value between Pin 1 step 6.
and Pin 2 is about 5V. No Next step.
Check whether the loop between pin 35 &42 of ECU and Pin 1 &2 of sensor is Yes
5 harness.
a broken loop, or short circuit to power supply or ground.
No Next step.
When the engine is running at idle-speed and the air-conditioner is opened,
Yes Diagnosis help.
observe the change of value corresponding to the item "temperature of
6
evaporator" on a diagnosis instrument, and the displayed value shall be
decreased accordingly when the temperature of evaporator is reduced.
Fault code：P1651 Failure with the control loop of engine fault indicator lamp SVS .”
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Check
result
1 Next step.
OFF” position.
The item “actuator action test” displayed on diagnosis instrument may be used Continue to proceed until
Yes
2 to test the action of engine fault indicator lamp to observe it’s within a step 6.
flameout status or a lighting status. No Next step.
Check whether the loop (on power supply end) of engine fault indicator lamp Yes Next step.
3
is a broken circuit or short circuit to ground. No Change the sensor
Check whether the loop between the connector pin (on control end) of engine Continue to proceed until
Yes
4 fault indicator lamp and Pin 29 of ECU is a broken loop, or short circuit to step 6.
power supply or ground. No Next step.
Check whether the bulb of engine fault indicator lamp is able to work under a Yes
5 harness.
normal condition.
No Next step.

EF.2-1
Delphi฀engine฀management฀system
ProCarManuals.com
Page
Description฀of฀system......................................................................................EF.2-2
MT20U฀system฀control...................................................................................EF.2-4
Determination฀on฀the฀principal฀/utility฀/failure฀of฀key฀system฀parts......................EF.2-9
Methods฀for฀failure฀diagnosis฀/fault฀codetospareparts......................................EF.2-23
Precautions฀to฀the฀use฀/service฀/troubleshooting฀of฀electrical฀injection฀system...EF.2-26
Troubleshooting.............................................................................................EF.2-27

EF.2-2 Delphi฀engine฀management฀system-Description฀of฀system
Description฀of฀system
Model฀GW491QE฀petrol฀engine฀has฀been฀installed฀with฀Delphi฀ITMS-6฀and฀MT20U฀engine฀management
system฀for฀electric-injection:฀the฀exhaust฀from฀ITMS-6฀is฀in฀compliance฀with฀European฀Class-II฀standard,฀and
the฀exhaust฀from฀MT20U฀is฀in฀compliance฀with฀European฀Class- standard;฀The฀engine฀management฀system
for฀electric-injection฀adopts฀a฀multi-point฀fuel฀injection฀controllable฀by฀a฀closed-loop฀of฀electronic฀control฀module
(ECU),฀and฀is฀subject฀to฀a฀direct฀ignition฀(without฀ignition฀distributor),฀and฀a฀post-processing฀technique฀by฀a
three-way฀catalytic฀converter.฀Generally฀speaking,฀each฀function฀of฀engine,฀eg.฀oil฀injection,฀ignition,฀idle฀speed,
etc.฀may฀be฀effected฀by฀a฀control฀over฀respective฀actuating฀mechanism,฀such฀as฀fuel฀injector ignition฀coil,
etc.,฀as฀supported฀by฀an฀electronic฀control฀module฀(ECU)฀which฀receives฀appropriate฀signals฀from฀each฀sensor
(eg.฀intake฀pressure฀&temperature฀sensor,฀crankshaft฀position฀sensor,฀throttle฀position฀sensor,฀etc.)฀and฀by฀an
ECU฀internal฀control฀program฀which฀calculates฀the฀best
The฀engine฀management฀system฀for฀electric-injection฀is฀mainly฀composed฀of฀three฀parts:฀sensor,฀electronic
control฀module฀(ECU),฀and฀actuator.
The฀basic฀structure฀of฀ITMS-6฀system฀is฀as฀shown฀in฀the฀figure฀below:
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Signal฀input Control฀output System฀control
absolute-pressure sensor for inlet

manifold fuel pump relay
IT M S-6
crankshaft position sensor
injector
throttle position sensor
E ngine ignition timing
coolant temperature sensor

control carbon-canister evaporator
inlet air temperature sensor

module air conditioner
compressor
fuel pressure
oxygen sensor
air conditioner fan fuel filter
system voltage signal
E CU engine fault indicator ignition energy
air conditioner request switch light
signal conversion of
system communication waste gas by
air conditioner pressure switch
interface three-way
l
vehicle speed sensor idle-speed & starting air-control valve

Delphi฀engine฀management฀system-Description฀of฀system EF.2-3
The฀basic฀structure฀of฀MT20U฀system฀is฀as฀shown฀in฀the฀figure฀below:
12V accumulator jar power supply
12V ignition-switch power supply

system ignition coil A ignition
system power-supply ground wire
power-supply ignition coil B systemcontrol
ignition &oil-injection ground
management
5V reference voltage MT20U fuel pump relay
fuel injector A
5V reference voltage feedback fuel supply
fuel injector B
speed & crankshaft position sensor system
fuel injector C
engine cylinder No. identification signal control
absolute-pressure sensor for inlet manifold Engine fuel injector D
idle-speed control valve A/Hi

system throttle position sensor idle-speed
power-supply coolant temperature sensor control idle-speed control valve A/Lo
idle-speed control valve B/Hi

system
input inlet air temperature sensor control
oxygen sensor module idle-speed control valve B/Lo
carbon-canister wash solenoid valve

evaporating
vehicle speed sensor &exhausting

electrical cooling (high-speed)fan relay
dynamic steering signal cooling-system
electrical cooling (low-speed)fan relay
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air conditioner air conditioner request signal control
system signal air conditioner load signal ECU air conditioner clutch relay
air conditioner
air conditioner fan relay
temperature signal for 1st evaporator system control
Diagnostic & theft- engine rotating-speed signal
nd
temperature signal for 2 evaporator
prevention signal engine fault indicator light communication
diagnosis request signal
Serial communication K W2000 &theft-prevention
theft-detector control signal
theft-detector control system control
standby EGR feedback signal
linear EGR control valve
European-III signal for 2nd oxygen sensor standby
signal signal for fuel level sensor European-III
system control
System฀characteristics:
I ts฀fuel฀supply฀to฀engine฀and฀the฀idle-speed฀is฀subject฀to฀a฀closed-loop฀control฀system,฀which฀may฀eliminate฀the฀manufacturing
difference฀between฀the฀system฀and฀other฀relevant฀mechanical฀parts฀&components,฀increase฀the฀integrity฀of฀whole฀vehicle,฀and
reduce฀the฀possibility฀of฀tolerance฀produced฀on฀vehicle฀due฀to฀abrasion฀in฀practical฀use;฀The฀system฀has฀divided฀four฀engine
cylinders฀into฀two฀groups:฀group1-4,฀and฀group฀2-3,฀usable฀for฀a฀control฀over฀fuel฀supply฀and฀ignition฀respectively,฀which฀may฀have
the฀structure฀of฀system฀best฀optimized฀and฀simplified,฀reducing฀the฀cost฀of฀parts฀&components฀in฀manufacturing฀and฀fabrication;
The฀system฀has฀been฀provided฀with฀a฀three-way฀catalytic฀converter,฀usable฀for฀a฀post-processing฀on฀gas฀having฀combusted฀inside
the฀engine,฀which฀will฀be฀conversed฀into฀nonharmful฀gas฀and฀exhausted฀to฀the฀atmosphere.
Function฀of฀ITMS-6฀system:
-Measure฀the฀position฀reference฀of฀crankshaft฀and฀the฀rotating฀speed;
-Air฀velocity฀&density฀computation;
-Multi-point฀fuel฀injection฀by฀group฀when฀under฀a฀closed-loop฀control,฀a฀simplified฀system฀structure,฀and฀a฀decreased฀processing
cost.
-A฀direct฀high-capacity฀ignition฀(without฀ignition฀distributor),฀assures฀an฀accurate฀and฀valid฀ignition,฀with฀less฀interference ,฀and
without฀adjustment฀required.
-Self-learning฀function฀is฀provided฀for฀the฀closed-loop฀control฀to฀effectively฀eliminate฀the฀tolerance฀resulting฀from฀the฀manufacturing
and฀abrasion฀of฀mechanical฀parts,฀and฀to฀enhance฀the฀integrity฀&consistency฀of฀whole฀vehicle.
-Step฀motor฀is฀with฀a฀closed-loop฀control฀over฀idle-speed;
-Play฀&plug฀control฀applied฀to฀the฀air฀conditioner฀system฀and฀the฀cooling฀system.
-Fuel฀cut฀/overflow฀control:฀when฀a฀‘flooded฀engine’฀is฀produced,฀step฀on฀the฀gas฀to฀a฀Max.฀extent฀to฀stop฀fuel฀injection฀based฀on
a฀computer฀control.
-The฀fuel-cut฀control฀when฀decelerating฀saves฀fuel฀and฀decreases฀the฀exhaust.

EF.2-4 Delphi฀engine฀management฀system-MT20U฀system฀control
-Evaporating฀/exhaust฀/pollution฀control.
- Waste-gas฀exhaust฀control;฀post-processing฀by฀a฀three-way฀catalytic฀converter;฀and฀closed-loop฀fuel฀control฀by฀signal฀from
oxygen฀sensor.
-Protection฀function฀offered฀by฀three-way฀catalytic฀converter;
-When฀the฀electronic฀theft-prevention฀system฀has฀not฀received฀a฀correct฀password฀from฀the฀key,฀the฀computer฀control฀system฀will
not฀make฀fuel-injection฀or฀ignition,฀which฀prevents฀the฀engine฀from฀starting.
-Waste-gas฀exhaust฀control;฀post-processing฀by฀a฀three-way฀catalytic฀converter;฀and฀closed-loop฀fuel฀control฀by฀signal฀from฀oxygen
sensor.
-Protection฀function฀offered฀by฀three-way฀catalytic฀converter;
-Evaporating฀/exhaust฀/pollution฀control.
-Whereby฀the฀computer฀self-diagnosis฀function฀works฀abnormally฀on฀system฀parts฀&components,฀a฀fault฀indicator฀light฀may฀remind
user฀of฀inspection฀and฀repair,฀meanwhile,฀a฀bypass฀control฀program฀under฀emergency฀will฀be฀used฀to฀control฀the฀working฀of฀engine.
-Fault฀indication฀/communication฀function฀may฀be฀used฀for฀a฀two-way฀communication฀after฀the฀connection฀with฀the฀Fault฀Diagnosis
Instrument,฀and฀with฀PC฀computer.
Function฀of฀MT20U฀system:
-Starting฀control฀logic
-Ignition฀control฀logic
-Idle-speed฀control฀logic
-Knock฀control฀logic
-Accelerating฀/฀decelerating฀/฀fuel฀cut฀&overflow฀control฀logic
-Play฀&plug฀air฀conditioner฀control฀logic
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-฀Carbon-canister฀solenoid฀valve฀control฀logic
-฀Temperature฀control฀logic฀for฀three-way฀catalytic฀converter
-Cooling฀fan฀control฀logic
-Mileage฀accumulation฀control฀logic
-Theft-detector฀control฀logic
-Whole-vehicle฀exhaust฀control฀logic
MT20U฀system฀control
1.฀Starting฀control
After฀the฀ignition฀switch฀is฀opened,฀fuel฀pump฀will฀run฀for฀1.5฀seconds,฀then฀stop.
Following฀the฀rotation฀of฀engine,฀the฀fuel฀pump฀will฀start฀to฀run฀when฀ECU฀detects฀tw o
valid฀58X฀signals
If฀the฀rotating-speed฀signal฀has฀been฀off฀for฀0.8฀second,฀or฀when฀fuel฀pump฀needs฀to฀be฀closed฀as฀required฀by฀the฀theft฀detector,฀the
fuel฀pump฀will฀stop฀running.
Start฀pre-injection the฀start฀pre-injection฀only฀acts฀once฀during฀a฀normal฀starting฀process.
Initial฀stage฀of฀starting฀process The฀inner฀pressure฀of฀inlet฀manifold฀is฀shown฀as฀ambient฀atmospheric฀pressure.฀When฀throttle
is฀closed,฀the฀idle-speed฀adjustor฀will฀have฀a฀fixed฀parameter฀changeable฀by฀the฀starting฀temperature.
During฀the฀starting:฀The฀fuel฀injection฀amount฀will฀vary฀depending฀on฀the฀change฀of฀engine฀temperature,฀and฀the฀ignition฀angle฀will
be฀adjusted฀respectively,฀and฀will฀vary฀depending฀on฀the฀change฀of฀engine฀temperature฀/฀inlet฀temperature฀/engine฀rotating฀speed.
Completion฀of฀starting The฀starting฀status฀will฀be฀ended฀when฀the฀engine฀rotating฀speed฀exceeds฀600r/min.
฀2.฀Ignition฀control฀logic
Coil฀magnetization฀control The฀magnetization฀time฀of฀ignition฀coil฀determines฀the฀ignition฀energy฀of฀spark฀plug.฀A฀much฀longer
magnetization฀will฀damage฀the฀coil฀or฀coil฀driver,฀while฀a฀much฀shorter฀magnetization฀will฀cause฀a฀fire.
Main฀ignition฀lead-angle When฀the฀engine฀water฀temperature฀is฀normal,฀the฀main฀ignition฀angle฀when฀throttle฀is฀open฀is฀usually
Min.฀ignition฀angle฀at฀best฀torque฀point฀(MBT),฀or฀knock฀critical฀point฀(KBL) When฀throttle฀is฀closed,฀the฀ignition฀angle฀shall฀be
less฀than฀MBT฀point฀to฀acquire฀a฀stable฀idle฀speed.
Modification฀to฀ignition฀lead-angle Modification฀to฀water฀temperature,฀modification฀to฀inlet฀temperature,฀modification฀to
altitude฀compensation,฀idle-speed฀modification,฀accelerating฀modification,฀modification฀to฀dense฀dynamical฀force,฀modification฀to฀oil-
cut฀when฀decelerating,฀modification฀to฀air฀conditioner฀control,฀and฀modification฀to฀waste฀gas฀re-circulation.
I dle-speed฀contr ol฀logic
Idle-speed฀control฀refers฀to฀a฀closed-loop฀control฀of฀system฀over฀the฀engine฀rotating฀speed฀when฀throttle฀valve฀is฀closed.฀T he฀idle
speed฀may฀be฀controlled฀by฀system฀through฀the฀adjustment฀of฀following฀parameters฀so฀that฀the฀actual฀rotating฀speed฀is฀consistent฀to
the฀desired฀idle฀ speed
฀-I dle-speed฀air฀amount฀control
฀-Fuel-injection฀amount฀control
฀-Ignition฀timing฀control.

Delphi฀engine฀management฀system-MT20U฀system฀control EF.2-5
The฀desired฀idle฀speed฀is฀determined฀by฀various฀elements:
When฀the฀engine฀water฀temperature฀is฀lower,฀system฀will฀give฀a฀greater฀desired฀idle฀speed฀1200r/min฀to฀accelerate฀the฀warming
฀฀of฀vehicle;฀For฀engine฀using฀mechanical฀fan£¬when฀the฀temperature฀of฀engine฀coolant฀is฀much฀higher,฀system฀will฀give฀a฀greater
฀฀idle฀speed฀1300r/min฀as฀well฀to฀increase฀air฀inflow฀amount฀inside฀the฀cooling฀water฀tank.
Applied฀load:If฀the฀air฀conditioner฀changes,฀system฀will฀increase฀the฀idle฀speed฀150r/min.
To฀compensate฀the฀electrical฀power฀consumption฀when฀the฀dipped฀headlight฀is฀opened,฀the฀desired฀idle฀speed฀will฀increase฀by
฀50฀r/min.
System฀voltage฀compensation:When฀system฀voltage<12V,฀system฀will฀auto.฀increase฀the฀desired฀idle฀speed฀150r/min.
Vehicle฀speed฀compensation:฀The฀desired฀idle฀speed฀while฀vehicle฀is฀traveling฀will฀be฀increase฀by฀50r/min฀when฀compared฀to
฀฀that฀while฀vehicle฀is฀parking.
Decelerating฀adjustment:฀when฀the฀vehicle฀is฀decelerating฀or฀being฀stopped,฀the฀speed฀will฀decreased฀gradually฀and฀degressively
฀to฀the฀desired฀idle฀speed฀for฀vehicle฀parking.
4.฀Oil-injection฀pulse฀width฀contro
air /fuel ratio
absolute-pressure of inlet manifold Oil-injection pulse width
modification to closed-loop
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constant of injector
modification to supply voltage

A mathematic model for
air-inflation temperature
velocity-density is used to
air flow determine the basic
Fuel
oil-injection amount
air-inflation efficiency
self-learning modification
thicker when accelerating
thinner when decelerating
oil-cut when decelerating
waste-gas circulation
5 K nock ฀contr ol฀logic

K nock฀control฀function฀is฀applied฀to฀eliminate฀possible฀knock฀which฀may฀happen฀when฀engine฀is฀under฀a฀combustion฀condition,
and฀to฀optimize฀the฀dynamic฀performance฀of฀engine,฀and฀the฀cost-effectiveness฀of฀fuel.
MT 20U฀system฀is฀competent฀to฀provide฀a฀separate฀knock฀control฀over฀various฀cylinders฀inside฀engine.
Work฀condition฀ for฀ knock฀ control
-E ngine฀shall฀be฀running,฀and฀the฀running฀time฀must฀exceed฀two฀seconds;
-E ngine฀rotating฀speed฀>800r/min
-A bsolute-pressure฀of฀inlet฀manifold40฀kPa
K nock฀ control฀ mode
-Stable฀knock฀control Once฀a฀knock฀occurs,฀the฀system฀will฀quickly฀delay฀the฀ignition฀lead-angle฀to฀remove฀the฀knock.
-Instantaneous฀knock฀control A ฀knock฀is฀easy฀to฀occur฀when฀making฀a฀sharp฀acceleration.฀When฀a฀knock฀is฀predicted฀to occur,
the฀system฀will฀auto.฀delay฀the฀ignition฀lead-angle฀to฀avoid฀the฀occurrence฀of฀any฀out-of-limit฀(strong)฀knock.
-Adaptive฀knock฀control If฀an฀abraded฀engine฀is฀running,฀the฀system฀will฀auto.฀make฀an฀adaptive฀adjustment฀over฀the฀฀ignition฀lead-
angle฀to฀prevent฀the฀occurrence฀of฀strong฀knock.

EF.2-6 Delphi฀engine฀management฀systm-MT20U฀system฀control
6.฀฀Accelerating฀/decelerating฀/fuel฀cut฀&overflow฀control
Whenever฀฀the฀฀engine฀rotating฀speed฀is฀greater฀than฀the฀set฀highest฀rotating฀speed,฀system฀will฀cut฀off฀fuel฀suppy,฀protect฀the฀engine
by฀stopping฀its฀rotating฀speed฀from฀rising฀unlimitedly,฀and฀prevent฀vehicle฀from flying And฀system฀will฀immediately฀resume
the฀fuel฀supply฀when฀the฀rotating฀speed฀returns฀to฀a฀level฀lower฀than฀Max.฀rotating฀speed฀specified฀by฀the฀system.
During฀the฀normal฀running฀of฀engine,฀driver฀may฀release฀the฀gas฀pedal฀to฀make฀vehicle฀enter฀a฀sliding฀mode,฀and฀counter-pull฀the฀engine
and฀vehicle฀does฀not฀need฀any฀dynamic฀force฀provided฀by฀the฀engine;฀And฀as฀a฀smaller฀air฀inlet฀amount฀after฀throttle฀valve฀has฀been
completely฀closed฀will฀cause฀an฀insufficient฀combustion฀inside฀engine,฀which฀results฀in฀an฀increment฀of฀exhausted฀harmful฀matters,
therefore,฀system฀will฀cut฀off฀fuel฀supply฀accordingly฀to฀dramatically฀decrease฀the฀generation฀of฀harmful฀matters฀exhausted,฀from฀engine,
and฀improve฀the฀cost-effectiveness฀of฀fuel.
After฀repeatedly฀unsuccessful฀startings฀of฀engine,฀petrol฀residuals฀without฀sufficient฀combustion฀will฀remain฀inside฀the฀cylind er,฀that
is฀the฀so-called฀ flooded฀engine .฀In฀such฀case,฀driver฀may฀step฀on฀the฀gas฀to฀the฀end฀to฀start฀the฀engine and฀system฀will฀auto.฀adopt
a฀very฀lean฀air฀/fuel฀ratio฀to฀have฀excessive฀petrol฀inside฀cylinder฀to฀be฀exhausted฀while฀the฀engine฀is฀rotating.
7.฀฀Play฀&plug฀air฀conditioner฀control
ECU฀will฀monitor฀A/C฀request฀input฀and฀A/C฀evaporator฀temperature฀sensor฀input and฀control฀the฀clutch฀for฀air฀conditioner
compressor฀via฀an฀air฀conditioner฀relay.฀And฀system฀may฀auto.฀identify฀the฀air฀conditioner฀system฀based฀on฀a฀play฀&plug฀basis.
Working฀conditions฀of฀air฀conditioner
The฀engine฀has฀been฀starting฀longer฀than฀five฀seconds.
The฀air฀conditioner฀may฀be฀started฀when฀the฀engine฀rotating฀speed฀is฀higher฀than฀600r/min฀and฀less฀than฀6200r/min.
After฀the฀air฀conditioner฀and฀evaporator฀are฀started,฀the฀desired฀engine฀idle-speed฀will฀increase฀by฀150฀revolutions.
The฀air฀inlet฀temperature฀is฀greater฀than฀3.75 .
he฀cooling-water฀temperature฀is฀greater฀than฀3.75 .
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The฀compressor฀will฀be฀started฀when฀the฀cooling-water฀temperature฀is฀less฀than฀105 .
The฀air฀conditioner฀compressor฀will฀be฀stopped฀when฀the฀cooling-water฀temperature฀is฀greater฀than฀108 .
The฀air฀conditioner฀compressor฀will฀be฀stopped฀when฀the฀temperature฀for฀front฀air฀conditioner฀evaporator฀is฀less฀than฀1. 5 .
The฀compressor฀will฀be฀started฀when฀the฀temperature฀for฀front฀air฀conditioner฀evaporator฀is฀greater฀than฀3.75 .
To฀ensure฀the฀dynamic฀performance,฀air฀conditioner฀will฀be฀cut฀off฀when฀TPS฀is฀greater฀than฀90%,฀or฀the฀engine฀is฀with฀heavy฀load.
C ar bon-canister ฀solenoid฀valve฀contr ol฀logic
Fuel฀tank฀is฀with฀exterior฀heat฀radiation฀and฀fuel-return฀heat฀transfer;฀fuel฀inside฀fuel฀tank฀shall฀be฀heated฀to฀form฀a฀fuel฀evaporation,
which฀will฀be฀collected฀into฀an฀activated฀carbon฀canister.฀A nd฀the฀carbon-canister฀solenoid฀valve฀may฀be฀used฀to฀control฀the฀time฀as
to฀open฀or฀close฀the฀passage฀between฀the฀activated฀carbon฀canister฀and฀the฀inlet฀manifold.
฀Working฀condition฀for฀carbon-canister฀solenoid฀valve
System฀voltage฀less฀than฀17V .
65.25 ฀<฀engine฀water฀temperature฀<฀110.25 .
T he฀opening฀degree฀of฀throttle฀shall฀be฀greater฀than฀1.2%฀and฀less฀than฀100%.
T he฀engine฀has฀been฀in฀a฀closed-loop฀work฀mode,฀or฀the฀oil-cut฀time฀has฀been฀longer฀than฀two฀seconds.
Work฀mode฀of฀carbon-canister฀solenoid฀valve;฀Its฀opening฀degree฀may฀be฀determined฀by฀E CU฀in฀accordance฀with฀the฀occupation
ratio฀(PWM)฀signal฀based฀on฀the฀engine฀status.฀When฀under฀a฀non-idle-speed฀condition,฀Max.฀opening฀degree฀฀of฀carbon-canister
solenoid฀valve฀will฀be฀determined฀by฀closed-loop฀air฀flow฀amount,฀and฀Max.฀value฀is฀100%.
9.฀Temper atur e฀contr ol฀logic฀for ฀three-way฀catalytic฀conver ter
A t฀the฀initial฀stage฀of฀starting,฀the฀three-way฀catalytic฀converter฀needs฀a฀rapid฀heating฀process฀to฀start฀work฀and฀decrease฀the
exhaust฀ of฀ waste฀ gas.฀ Normally,฀ the฀ heating฀ progress฀ may฀ be฀ quickened฀by฀ appropriately฀ delaying฀ the฀ ignition฀ lead-angle.
Protection฀control฀for฀three-way฀catalytic฀converter:฀System฀will฀predict฀the฀working฀temperature฀of฀three-way฀catalytic฀converter
while฀the฀engine฀is฀running:฀when฀the฀predicted฀temperature฀is฀higher฀than฀the฀protection฀temperature,฀the฀time฀starts฀to฀count;฀If฀the
working฀temperature฀of฀catalytic฀converter฀is฀always฀higher฀than฀the฀protection฀temperature฀within฀a฀specific฀time system฀will
decrease฀the฀working฀temperature฀by฀controlling฀the฀fuel฀supply฀amount฀and฀increasing฀the฀air฀/fuel฀ratio A fter฀some฀time฀that฀the
predicted฀temperature฀for฀catalytic฀converter฀has฀been฀decreased,฀resume฀the฀original฀air฀/fuel฀ratio,฀and฀continue฀to฀predicate฀the
working฀temperature฀of฀catalytic฀converter฀to฀prepare฀for฀an฀actual฀protection.
10.฀C ooling฀fan฀contr ol
Whether฀to฀open฀each฀cooling฀fan฀provided฀for฀system฀control฀engine฀and฀air฀conditioner฀may฀be฀determined฀by฀E CU฀depending
on฀ the฀temperature฀value฀of฀engine฀coolant,฀and฀whether฀it’ s฀in฀compliance฀with฀appropriate฀requirements฀for฀opening฀the฀air
conditioner.
-When฀water฀temperature฀is฀greater฀than฀92.25 the฀low-speed฀fan฀will฀run.
-W hen฀water฀temperature฀is฀less฀than฀87 the฀low-speed฀fan฀will฀stop฀running.
-When฀water฀temperature฀is฀greater฀than฀98.25 the฀high-speed฀fan฀will฀run.
-W hen฀water฀temperature฀is฀less฀than฀93 the฀low-speed฀fan฀will฀stop฀running.

Delphi฀engine฀management฀systm-MT20U฀system฀control EF.2-7
accumulator
high-speed฀fan฀for฀engine
dual-speed฀fan฀for
engine
low-speed฀fan฀for฀engine
11.฀Mileage฀accumulation฀function฀control
The฀mileage฀accumulation฀function฀of฀MT20U฀is฀specially฀designed฀for฀mileage฀statistics฀within฀after-sale฀warranty฀period,฀an d
will฀not฀supercede฀the฀existing฀vehicle฀speed฀meter฀or฀odometer.
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฀System฀will฀receive฀vehicle฀speed฀signal฀from฀the฀vehicle฀speed฀sensor,฀accumulate฀the฀mileages,฀and฀stop฀accumulating฀the฀mileage
when฀it฀reaches฀80,000km.
฀System฀will฀have฀the฀mileage฀accumulation฀function฀applied฀to฀two฀aspects:
-During฀running฀in฀period,฀system฀will฀limit฀the฀speed฀of฀vehicle.
-During฀quality฀warranty฀period,฀system฀will฀activate฀the฀accumulative฀mileage฀protection฀logic.฀No฀matter฀for฀goodness฀or฀badness,
when฀there’s฀any฀failure฀with฀vehicle฀speed฀sensor฀or฀its฀connection฀loop,system
will฀cut฀fuel฀supply฀to฀protect฀the฀engine,฀and฀the฀engine฀rotating฀speed฀is฀unallowable฀to฀exceed฀2500฀r/min฀to฀limit฀thevehicle฀driving
speed,฀and฀vehicle฀users฀will฀be฀urged฀to฀clear฀the฀failure฀away.
-The฀speed฀limiting฀function฀will฀fail฀when฀the฀overall฀accumulative฀mileage฀is฀greater฀than฀70,000km.
12.฀Theft-detector฀control
System฀offers฀an฀electronic฀theft฀detector฀for฀selection฀or฀installation:฀ECU฀will฀control฀the฀engine฀management฀system฀not฀to฀make
fuel-injection฀or฀ignition and฀not฀to฀start฀the฀engine฀before฀the฀electronic฀theft-detector฀receives฀correct฀identification฀password.
Password฀repeater It’s฀installed฀inside฀the฀start฀key,฀with฀password฀to฀be฀updated฀on฀real-time฀basis฀with฀the฀change฀of฀electric-
control฀system฀plus฀the฀theft-prevention฀system.
theft-prevention
indicator light
ignition fuse 2
theft
rrequest line accumulator fuse 4
Data line
detector
key having installed
password repeater

EF.2-8 Delphi฀engine฀management฀systm-MT20U฀system฀control
13.฀Whole-vehicle฀exhaust฀control
¡¤Whole-vehicle฀exhaust฀control฀means฀to฀precisely฀adjust฀the฀initial฀rating฀data฀of฀open-loop฀fuel฀within฀the฀vehicle฀traveling฀scope
allowed฀by฀exhaust฀laws฀and฀regulations,฀using฀a฀closed-loop฀control.฀In฀such฀way,฀the฀exhaust฀characteristics฀of฀vehicle฀may฀be
optimized.
¡¤ The฀closed-loop฀control฀system฀will฀play฀its฀role฀when฀oxygen฀sensor฀has฀been฀installed฀between฀the฀exhaust฀manifold฀and฀the
three-way฀catalytic฀converter฀to฀monitor฀the฀oxygen฀content฀in฀waste฀gas;฀The฀exhausted฀gas฀mixture฀containing฀thin฀oxygen฀content
may฀produce฀about฀100mV฀sensor฀voltage,฀while฀that฀containing฀thick฀oxygen฀content฀may฀produce฀about฀800mV฀sensor฀voltage.
When฀the฀air฀/fuel฀ratio฀is฀(14.6£º1),฀the฀sensor฀voltage฀may฀have฀an฀abrupt฀change.฀And฀the฀computer฀closed-loop฀control฀will
respond฀to฀the฀oxygen฀sensor฀signal฀to฀modify฀and฀control฀the฀variant฀so฀that฀the฀voltage฀of฀oxygen฀sensor฀could฀change฀within฀(100-
800)฀mV.฀In฀such฀way,฀an฀optimum฀air฀/fuel฀ratio฀may฀be฀controlled.
14.฀EOBD฀failure฀diagnosis฀&control
¡¤EOBD฀is฀one฀much฀complicated฀self-diagnosis฀system฀used฀to฀check฀and฀test฀the฀failure฀on฀parts฀&components฀and฀systems฀which
will฀influence฀the฀vehicle฀exhaust.฀The฀OBD฀system฀does฀not฀take฀the฀place฀of฀regular฀exhaust฀test,฀and฀act฀as฀a฀monitor฀monitoring
the฀exhaust฀from฀vehicle฀on฀real฀time฀basis.
¡¤ Classification฀of฀EOBD฀diagnosis฀&test£º
-฀Parts฀&components฀test£ºapplicable฀to฀parts฀&components฀having฀input฀or฀output฀function฀on฀diagnosis฀instrument฀and฀controller;
The฀test฀is฀mainly฀performed฀in฀the฀electrical฀loop฀of฀parts฀&components,฀and฀it฀also฀includes฀determination฀on฀the฀reasonableness
of฀sensor฀input฀value
-฀System฀test£ºapplicable฀to฀diagnosis฀on฀system฀failures,฀eg.฀misfire,฀deterioration฀of฀catalytic฀converter,฀failure฀with฀EGR฀control
system฀/cooling฀system,฀etc.฀The฀failure฀might฀result฀from฀mechanical฀parts฀or฀electrical฀loop.
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-฀Controller฀(ECU)฀test£ºapplicable฀to฀communication฀failure,฀hardware฀failure,฀RAM฀memory฀change,฀which฀correlates฀the
controller฀and฀the฀diagnosis฀instrument.
-฀Failure฀detection£ºFlash฀code฀function฀isn’t฀provided฀on฀the฀vehicle¡£ The฀EOBD฀failure฀detection฀must฀pass฀a฀decoder฀and฀a
universal฀diagnosis฀interface.฀Any฀diagnosis฀instrument฀having฀EOBD฀function฀may฀be฀applied฀to฀any฀EOBD฀vehicle฀model.
¡¤ Missed฀fire฀diagnosis£ºEOBD฀will฀detect฀any฀missed฀fire฀(on฀single฀cylinder฀or฀multiple฀cylinders)฀causing฀the฀abrupt฀change฀of
HC.
-Diagnostic฀method฀by฀the฀speed฀change฀of฀crankshaft£ºAny฀missed฀fire฀may฀be฀diagnosed฀by฀the฀speed฀change฀of฀crankshaft.
-Ionic-current฀diagnostic฀method£ºAny฀missed฀fire฀may฀be฀diagnosed฀by฀observing฀the฀ionic฀current฀inside฀cylinder.
¡¤ Deterioration฀diagnosis฀on฀catalytic฀converter£ºAs฀required฀by฀EOBD,฀the฀indicator฀light฀shall฀be฀lighted฀and฀the฀faul t
code฀must be฀recorded฀when฀the฀deterioration฀of฀catalytic฀converter฀makes฀HC฀exceed฀the฀exhaust฀limit฀value
¡¤ Deterioration฀diagnosis฀on฀oxygen฀sensor£ºThe฀diagnosis฀on฀deterioration฀is฀only฀for฀upstream฀oxygen฀sensors.฀When฀oxygen
sensor฀becomes฀poisonous฀or฀is฀degraded฀in฀performance,฀the฀output฀will฀become฀slow.฀If฀so,฀the฀fault฀indicator฀light฀shall฀be฀lighted
and฀the฀fault฀code฀must฀be฀recorded.
¡¤ Deterioration฀diagnosis฀on฀waste-gas฀recycling฀system£ºThe฀waste-gas฀recycling฀system,฀when฀blocked฀by฀the฀carbide฀in฀waste
gas,฀loses฀its฀recycling฀function,฀which฀will฀result฀in฀an฀increment฀of฀Nox฀content.฀And฀the฀fault฀indicator฀light฀will฀be฀lighted,฀and฀the
fault฀code฀needs฀to฀be฀recorded฀accordingly.
¡¤ Failure฀diagnosis฀on฀idle-speed฀control฀system£ºThe฀failure฀on฀idle-speed฀control฀system฀will฀affect฀the฀performance฀and฀exhaust
of฀engine;฀The฀diagnosis฀may฀be฀performed฀by฀testing฀the฀actual฀rotating฀speed,฀and฀controlling฀its฀difference฀from฀the฀desired฀rotating
speed.
¡¤ ฀Deterioration฀diagnosis฀on฀fuel฀supply฀system£ºThe฀fuel฀supply฀system฀will฀gradually฀deviate฀from฀its฀original฀status฀due฀to฀the
aging฀and฀deterioration฀of฀hardware:฀A฀slight฀amount฀of฀deviation฀may฀be฀compensated฀by฀EMS฀control฀system;฀But฀when฀the฀extent
of฀deterioration฀is฀out฀of฀the฀self-adjustment฀limit฀by฀control฀system,฀the฀exhaust฀will฀be฀influenced.฀When฀the฀exhaust฀exceed s฀the
EOBD฀limit฀value,฀fault฀indicator฀light฀shall฀be฀lighted,฀and฀fault฀code฀must฀be฀recorded.
¡¤ Failure฀diagnosis฀on฀cooling-system£ºOwing฀to฀the฀failure฀with฀water฀temperature฀sensor฀or฀temperature-saving฀valve,฀the
cooling฀system฀might฀make฀control฀system฀unable฀to฀enter฀the฀closed-loop฀control฀or฀have฀it฀postponed,฀which฀will฀affect฀the฀exhaust.
The฀diagnostic฀method฀is฀to฀forecast฀the฀change฀of฀water฀temperature฀by฀simulating฀the฀course฀of฀engine฀as฀to฀heat฀devices.
¡¤ Controller฀test£ºCommunication฀failure;฀RAM฀memory฀test;฀hardware฀failure,฀etc.
15.฀Program฀update฀function
ECU฀is฀available฀with฀such฀function฀as฀to฀online฀update฀the฀programs฀rapidly,฀and฀is฀able฀to฀update฀system฀control฀software฀directly
on฀vehicle฀yet฀without฀change฀of฀program฀chips.฀This฀function฀may฀be฀effected฀via฀serial฀input฀/output฀interface,฀and฀is฀easy฀to
operate.
The฀online฀updating฀of฀programs฀needs฀special฀software฀and฀shall฀be฀operated฀by฀Delphi฀specialist.

Delphi฀engine฀management฀systm-Determination฀on฀the
principal฀/utility฀/failure฀of฀key฀system฀parts EF.2-9
Determination฀on฀the
principal฀/utility฀/failure฀of฀key฀system฀parts
.฀System฀power฀supply฀and฀wire-harness
FUSE฀4 B AT T฀ FUSE4 B AT T
฀฀ignition FUSE฀3
IGN฀FUSE3 B AT T
switch
FUSE฀2 IGN฀FUSE2 IG N
FUSE฀1 IGN฀FUSE1 CD฀GND

CD฀GND
PWR฀ GND
Battery
PWR฀ GND
PWR฀ GND
PWR฀ GND
(a)Function฀&principal System฀adopts฀a฀12V ฀DC฀power฀supply one฀current฀loop฀coming฀from฀accumulator฀jar฀and฀going฀into

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system฀and฀E CU฀via฀ignition-key฀switch,฀is฀used฀as฀main฀power฀supply฀for฀system฀working,฀and฀transmits฀the฀system฀voltage฀signal
to฀E CU,฀which฀will฀modify฀the฀actuation฀from฀actuating฀mechanism;฀T he฀other฀current฀loop฀goes฀directly฀into฀E CU฀via฀fuse,฀the
uninterrupted฀power฀supply฀makes฀E CU฀retain฀the฀parameters฀after฀a฀system฀self-learning,฀and฀prepare฀for฀the฀next฀starting฀process
at฀the฀moment฀for฀switching฀off฀the฀device.
(b)F ailur e฀deter mination I mportant฀ note E ither฀ of฀ following฀determinations฀may฀ be฀concluded฀ based฀on฀that฀ the฀ whole
vehicle฀and฀other฀system฀parts฀& components฀are฀normal฀in฀function:฀Permanent฀electric฀wire฀& loop฀have฀been฀connected฀to฀ignition
switch฀by฀mistake E rror฀No.฀matching฀between฀wire-harness฀and฀terminal Steel฀part฀overlapping฀on฀E CU฀exterior฀cover฀might
cause฀signal฀deviation T he฀connection฀line฀of฀engine฀rotating-speed฀sensor฀/crankshaft฀position฀sensor฀/฀knock฀sensor฀is฀not
shielded฀ wire
2.฀E ngine฀contr ol฀module฀(E C U)
IT MS-6฀engine฀control฀module฀(E CU)
(a)฀F unction฀& pr incipal E ngine฀control฀module฀is฀one฀ microprocessor฀based฀on฀a฀single-chip฀device.฀A nd฀its฀function฀is฀to
process฀ sensor฀ data฀ coming฀ from฀ different฀ positions฀ of฀ vehicle,฀ to฀ determine฀ the฀ working฀ status฀ of฀ engine,฀ and฀ to฀ exactly
control฀ the฀ engine฀ via฀ an฀ actuator.฀A uxiliary฀ system฀ control฀ function theft-prevention฀ system;฀ fan฀ cooling฀ system air
conditioner฀system,฀etc.
Installation It฀shall฀be฀installed฀inside฀the฀driving฀cab;฀and฀better฀not฀have฀steel฀part฀overlapping฀on฀exterior฀cover.
(b)฀Per for mance฀par ameter E CU฀ has฀ passed฀vibration฀ test drop฀test impact฀test high฀/low฀temperature฀ test,฀etc.,฀and
may฀work฀in฀a฀normal฀way฀under฀various฀circumstances.
Storage฀ temperature฀ (-40 90)
Moisture฀sensitivity T he฀design฀of฀E CU฀is฀able฀to฀ensure฀the฀normal฀working฀of฀unit฀when฀moisture฀content฀condenses฀on฀internal
components.
(c)W or k ฀humidity T he฀unit฀ is฀able฀to฀ work฀normally฀ when฀ a฀power฀ connection฀ is฀made฀ at฀ambient฀temperature฀65 ,and
relative฀humidity฀95%.
(d)฀Characteristics฀of฀product
8-bit฀single-chip฀microprocessor฀with฀high฀performance
10-bit฀module฀converter
R ewritable฀128K b฀memory
8K b฀R A M฀memory
Installation฀in฀driving฀cab
Working฀temperature฀ (-40 85)
Normal฀working฀voltage (9 16)V
A bnormal฀working฀voltage (6.3 9)V
(16฀ 24)V
Over-voltage฀protection (-12V 24)V

EF.2-10 principal฀/utility฀/failure฀of฀key฀system฀parts
(e)Engine฀ control-module฀ fail฀ mode:The฀ failure฀ of฀ generator฀ voltage-adjustor฀ will฀ burn฀ and฀ damage฀ the฀ computer.
When฀ the฀ computer฀ is฀ changed,฀ measure฀ first฀ the฀ supply฀ voltage฀ at฀ idle฀ speed฀ and฀ ensure฀ it’s฀ less฀ than฀ 15฀ volts.
When฀ the฀ engine฀ rotating฀ speed฀ has฀ been฀ increased฀ to฀ a฀ value฀ greater฀ than฀ 2,000฀ revolutions,the฀ supply
voltage฀shall฀be฀less฀than฀15฀volts.
(f)Function฀&principal The฀function฀of฀signal฀collecting฀system฀is฀to฀tell฀ECU฀the฀working฀status฀of฀engine฀and฀whole฀vehicle,฀and
to฀meet฀relevant฀requirements฀on฀dynamic฀&auxiliary฀function฀imposed฀by฀the฀driver.฀Sofar,฀signals฀from฀following฀articles฀has฀been
covered฀in฀system฀configuration:
-฀Engine฀rotating-speed฀sensor฀/crankshaft฀position฀sensor
-฀Oxygen฀sensor
-฀Throttle฀position฀sensor
-฀Pressure฀sensor฀for฀inlet฀manifold
-฀Inlet฀temperature฀sensor
-฀Temperature฀sensor฀for฀engine฀coolant
-฀Vehicle฀speed฀sensor
-฀Air฀conditioner฀/evaporating฀temperature฀sensor
-฀Electrical฀load฀signal
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฀฀฀฀฀MT20U฀engine฀control฀module฀(ECU)
(a)Function฀&principal
Engine฀control฀module฀is฀one฀microprocessor฀based฀on฀a฀single-chip
device.฀And฀its฀function฀is฀to฀process฀sensor฀data฀coming฀from฀different
positions฀of฀vehicle,฀to฀determine฀the฀working฀status฀of฀engine,฀and฀to
exactly฀control฀the฀engine฀via฀an฀actuator.
Auxiliary฀ system฀ control฀ function theft-prevention฀ system;฀ fan
cooling฀system air฀conditioner฀system,฀etc. Installation It฀shall
be฀installed฀inside฀the฀engine฀chamber;฀and฀better฀not฀have฀steel฀part
overlapping฀on฀exterior฀cover.
(b)Failure฀determination
Important฀ note Either฀ of฀ following฀ determinations฀ may฀ be
concluded฀based฀on฀that฀the฀whole฀vehicle,฀its฀wire-harness,฀and฀other
system฀ parts฀ &components฀ are฀ normal฀ in฀ function
ECU฀fault System฀is฀unable฀to฀communicate฀with฀the฀outside฀world;
-Theft-prevention฀locked It฀has฀been฀connected฀with฀the฀theft฀detector,฀and฀may฀be฀used฀again฀after฀a฀decoding฀process.
-Failure฀with฀the฀signal฀input฀system Unable฀to฀receive฀the฀signal฀from฀sensor.
-Failure฀with฀the฀generator฀adjustor฀might฀cause฀a฀much฀higher฀output฀voltage,฀and฀damage฀the฀ECU.
-Failure฀with฀the฀output฀control฀system When฀the฀driver฀inside฀ECU฀is฀damaged,฀the฀driving฀&actuating฀mechanism฀will฀not
work฀any฀more.
(c)Characteristics฀of฀product
16-bit฀single-chip฀processor฀with฀high฀performance
10-bit฀module฀converter
Rewritable฀128Kb฀memory
8Kb฀RAM฀memory
working฀temperature฀ (-40 85)
normal฀working฀voltage (9 16)V
abnormal฀working฀voltage (6.3 ฀ 9)V (16 24)V
over-voltage฀protection (-12฀V 24)V

3.฀ Absolute-pressure฀ sensor฀ for฀ inlet฀ manifold฀ (MAP

(ITMS-6)
(a)Function฀ &principal
The฀absolute-pressure฀sensor฀for฀inlet฀manifold฀(MAP)฀is฀used฀to฀measure฀the
pressue฀of฀inlet฀manifold,฀and฀ECU฀may฀use฀this฀signal฀to฀determined฀the฀air
amount฀inside฀engine฀and฀the฀load฀of฀engine.฀MAPsensor฀is฀composed฀of฀one
sealed฀flexible฀silicon฀chip,฀and฀relevant฀bridge-type฀electrical฀loops,฀with฀one
typical฀5V฀voltage฀applied฀to฀one฀end฀of฀electrical฀bridge;฀Whereby฀the฀change
of฀pressure฀results฀in฀a฀deformation฀of฀silicon฀chip,฀the฀resistance฀value฀will
change฀accordingly;฀On฀the฀other฀end฀of฀electrical฀bridge฀is฀0 5฀V฀output
signal,฀making฀direct฀proportion฀with฀input฀pressure.
Wiring฀terminal฀ A--signalground,B--pressuresignal,C--+5V.
Installation:฀It’s฀usually฀installed฀on฀the฀pressure฀stabilization฀cavity฀of
inlet฀manifold.
(b)Failure฀ determination
I mpor tant฀note E ither฀of฀following฀determinations฀may฀be฀concluded
based฀on฀that฀the฀whole฀vehicle,฀its฀wire-harness,฀and฀other฀system฀parts
& components฀are฀normal฀in฀function.
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(c)Characteristics฀of฀product -Pressure฀value฀read฀from฀a฀Diagnosis฀Instrument฀shall฀be฀consistent฀to฀the
Pressure฀range (15 102)฀kPa actual฀value.
Working฀temperature (-40 105) -When฀exterior฀cover฀is฀damaged฀or฀there’ s฀air฀leakage,฀the฀pressure฀will฀be
Working฀voltage (5.0฀ ฀0.1)฀V a฀fixed฀value
Working฀current 12฀mA฀(M ax.)
Output฀ impedance <฀ 10฀
DC฀load 30฀k ฀(Min.) 51฀k ฀(recommended)
Output฀function E o=E r฀(0.01059P฀-฀0.10941)
(whereby T he฀unit฀of฀P฀is฀kPa)
4.฀Inlet฀temperature฀sensor฀ ( M AT ) ( I T M S - 6 )
T he฀inlet฀temperature฀sensor฀is฀used฀to฀test฀and฀measure฀the฀temperature฀of
air฀inside฀the฀engine฀cylinder;฀As฀any฀change฀of฀air฀temperature฀will฀directly
influence฀the฀density,฀it’ s฀regarded฀as฀one฀of฀significant฀parameters฀usable
to฀calculate฀the฀actual฀air฀amount฀inside฀the฀cylinder
(b)F ailur e฀ deter mination
Important฀note T he฀temperature฀value฀read฀from฀a฀Diagnosis฀Instrument
shall฀be฀consistent฀to฀the฀actual฀value.฀T he฀temperature฀value฀has฀a฀large
deviation.฀When฀at฀normal฀temperature฀(20 30) ,฀its฀resistance฀value
will฀be฀(3510 2240) .
(c)C har acter istics฀of฀ pr oduct
working฀voltage 5V DC
working฀ temperature฀ (-40 135)
T he฀schematic฀diagram฀of฀electric฀circuit:฀refer฀to฀the฀left฀figure
Sensor
Converter
GND

5.฀Manifold฀pressure฀/temperature฀sensor M A P/M AT
฀ ฀ ฀ (a)Function฀ &principal
฀฀฀฀T he฀pressure฀sensor฀for฀inlet฀manifold฀shall฀be฀installed฀together฀with฀the
฀฀฀฀฀inlet฀temperature฀sensor฀for฀an฀easy฀use฀and฀installation.฀And฀the฀function
฀ ฀ ฀ of฀ the฀ integrated฀ unit฀ is฀ thesame฀ as฀ that฀ of฀ each฀ separated฀ unit.
-W iring฀terminal A -pressure฀signal,฀B -+5V ,฀C-฀temperature฀signal,
฀฀฀฀D-signal฀ground
-I nstallation T hey฀shall฀be฀installed฀on฀the฀gas฀duct฀of฀four฀cylinders
฀฀฀฀for฀inlet฀manifold,฀and฀may฀be฀used฀to฀determine฀specific฀cylinder฀by
฀฀฀฀manifold฀pressure.
฀฀ ฀ -Technique฀ “cylinder฀ determination฀ by฀pressure” W hen฀the฀ engine
฀฀฀cylinder฀is฀working฀on฀an฀inlet฀stroke,฀a฀sudden฀opening฀of฀inlet฀door
(c)Characteristics฀of฀product: ฀฀฀will฀make฀the฀manifold฀pressurenearby฀air฀valve฀decreased฀sharply฀by
Characteristics฀of฀pressure฀sensor ฀฀ ฀approx฀ 1kPa,฀whichwill฀be฀ detected฀by฀the฀ inlet฀pressure฀ sensor;and
฀฀฀฀฀฀฀฀฀฀฀฀฀Pressure฀(kPa)฀฀฀฀฀฀฀Output฀voltage฀(V) ฀ ฀ ฀ this฀ signal(highpass฀ filtering)฀ shall฀ be฀ separated฀ and฀ processed฀ by
฀฀฀E CUthrough฀software.฀In฀such฀way,฀the฀determination฀on฀cylindermay
฀฀฀฀be฀effected.
฀ ฀ (b)F ailur e฀ deter mination
฀฀฀I mpor tant฀note E ither฀of฀following฀determinations฀may฀be฀concluded
Characteristics฀of฀temperature฀sensor ฀ ฀ ฀ based฀ on฀ that฀ the฀ whole฀ vehicle,฀ its฀ wire฀ harness,฀ and฀ other฀ system
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Working฀voltage 5 V฀ DC ฀฀฀parts฀& components฀are฀normal฀in฀function.

Working฀temperature฀ (-40 135) ฀฀฀-T he฀pressure฀/temperature฀value฀may฀be฀read฀out฀using฀฀a฀Diagnosis
฀฀฀Instrument,฀and฀shall฀be฀consistent฀to฀the฀actual฀value
฀฀฀-Damageoncomponentswithregardtoitsinternalperformance;
6.฀Engine฀rotating-speedsensorcrankshaftpositionsensor
B eing฀ one฀ type฀ of฀ magnetoelectric฀ sensor,฀ the฀ engine฀ rotating-speed
sensor฀ /crankshaft฀ position฀ sensor฀ shall฀ be฀ installed฀ nearby฀ the
crankshaft,฀ and฀ shall฀ work฀ with฀ 58x฀ gear฀ ring฀ on฀ crankshaft.฀ W hen
crankshaft฀ is฀ rotating,฀ 58X ฀ gear฀ top฀ /groove฀ will฀ pass฀ the฀ sensor
successively฀yet฀with฀different฀distance฀to฀sensor,฀and฀the฀sensor฀may
feel฀ the฀A C฀ changes฀ of฀ magnetic฀ reluctance,฀ which฀ results฀ in฀ an฀A C
changed฀output฀signal.฀Using฀this฀signal,฀E CU฀is฀able฀to฀determine฀the
rotati ng฀ posi ti on฀ & speed฀ of ฀ crank shaf t. ฀ W i ri ng฀ termi nal :
A ฀-฀signal฀+,฀B -signal฀-,฀C-shielded฀layer.฀I nstallation T hey฀shall฀be
installed฀nearby฀the฀crankshaft.
I mpor tant฀note E ither฀of฀following฀determinations฀may฀be฀concluded฀based฀on฀that฀the฀whole฀vehicle,฀its฀wire-harness,฀and
other฀system฀parts฀& components฀are฀normal฀in฀function.
-Failures฀having฀been฀diagnosed฀by฀system฀will฀be฀read฀out฀through฀a฀Diagnosis฀Instrument.
-Shielded฀ wire฀ has฀ not฀been฀applied฀to฀ the฀ signal฀in฀ wire-harness,฀or฀the฀ shielding฀ layer฀ of฀shielded฀wire฀ has฀not฀ been฀well
connected฀to฀ ground
-T he฀magnetic฀core฀has฀absorbed฀a฀larger฀quantity฀of฀metal฀dusts;
-T he฀distance฀between฀sensor฀and฀gear฀ring฀is฀beyond฀limit;
-T he฀relative฀position฀of฀gear฀ring฀to฀the฀crankshaft฀is฀incorrect฀or฀a฀displacement฀is฀produced
-฀Working฀temperature฀ (-40 165)
-฀Working฀clearance (0.25 1.75)mm
-฀ Output 400฀mV @ 60฀ r/min
-฀Coil฀resistance -฀Coil฀inductance

7.฀฀Coolant฀temperature฀sensor฀(CTS)
-The฀coolant฀temperature฀sensor฀is฀used฀to฀check฀the฀working฀temperature
of฀engine Depending฀on฀various฀temperatures,฀ECM฀will฀provide฀the
engine฀with฀an฀optimum฀control฀scheme.฀And฀the฀coolant฀temperature
sensor฀adopts฀thermal฀resistor฀with฀negative฀temperature฀coefficient฀as
induction฀component
-Wiring฀terminal A-signal฀ground,฀B-฀temperature฀signal
-Installation The฀coolant฀temperature฀sensor฀shall฀be฀installed฀on฀a
coolant฀minor฀cycle฀passage฀of฀engine.
Important฀note Either฀of฀following฀determinations฀may฀be฀concluded
&components฀are฀normal฀in฀function.
-The฀temperature฀value฀read฀from฀a฀Diagnosis฀Instrument฀shall฀be฀consistent
to฀the฀actual฀value
-฀The฀temperature฀value฀has฀a฀large฀deviation
-At฀normal฀temperature฀(20฀~฀30) its฀resistance฀value฀is฀(3510฀~
2240) .
Sensor (c)Characteristics฀of฀product
- Working฀voltage 5 V฀ DC
฀฀฀-Working฀temperature฀ (-40 135)
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฀ ฀ ฀ ฀8.฀Oxygen฀sensor฀(O )
2
-The฀oxygen฀sensor฀is฀regarded฀as฀a฀significant฀component฀within฀the
closed-loop฀fuel฀control฀system,฀usable฀to฀adjust฀or฀retain฀an฀ideal฀air฀/fuel
ratio,฀so฀that฀the฀three-way฀catalytic฀converter฀could฀reach฀an฀optimum
conversion฀efficiency.฀When฀the฀air฀/fuel฀ratio฀involved฀in฀engine฀combustion
becomes฀thin,฀the฀accumulative฀oxygen฀content฀in฀exhaust฀gas฀will฀be
increased,฀while฀the฀output฀voltage฀of฀oxygen฀sensor฀will฀be฀decreased;
On฀the฀contrary,฀the฀output฀voltage฀value฀will฀be฀increased.฀In฀such฀way,
information฀concerning฀the฀air฀/fuel฀ratio฀may฀be฀feedbacked฀to฀ECM.฀The
main฀sensitive฀material฀of฀oxygen฀sensor฀is฀zirconia.฀When฀zirconia฀is
activated฀by฀the฀heat฀exhaust฀gas฀(300 ),฀the฀oxygen฀ion฀will฀pass฀through
the฀zirconia฀component,฀and฀reach฀its฀outside฀electrode.฀The฀zirconia
component฀will฀induce฀the฀oxygen฀content฀in฀exhausted฀gas฀from฀engine,
and฀change฀its฀output฀voltage฀value.฀The฀oxygen฀sensor฀is฀made฀from
shaped฀stainless-steel฀component฀and฀Teflon฀insulation฀lead฀wire;฀And
the฀reference฀air฀is฀input฀from฀lead฀wire;
-Wiring฀terminal฀ A-signal฀low,฀B-signal฀high C฀and฀D-฀connect฀to฀a
heat฀power฀supply
-Installation The฀oxygen฀sensor฀shall฀be฀installed฀between฀the฀exhaust
valve฀and฀the฀three-way฀catalytic฀converter.
฀฀฀฀฀฀฀(b)Failure฀determination
Important฀note E ither฀of฀following฀determinations฀may฀be฀concluded
฀฀฀฀฀฀based฀on฀that฀the฀whole฀vehicle,฀its฀wire-harness,฀and฀other฀system฀parts
฀฀฀฀฀฀& components฀are฀normal฀in฀function.
-T he฀voltage฀value฀of฀oxygen฀sensor฀may฀be฀read฀out฀from฀a฀Diagnosis
฀฀฀฀฀I nstrument;฀when฀not฀on฀ground,฀non-heat฀type
-T he฀voltage฀is฀450mV ;฀Heat-type the฀voltage฀is฀less฀than฀450mV
-T he฀thick-thin฀abrupt฀change฀time฀is฀too฀small;฀Heavy฀metal฀(eg. lead,
฀฀฀฀฀฀manganese,฀etc.),฀phosphorus฀and฀sulphur฀poison,฀or฀damaged฀due฀to฀high
฀฀฀฀฀฀temperature.
฀฀฀฀฀(c)฀Characteristics฀of฀product
-Working฀temperature฀ (260 850)
-Max.฀over-heat฀temperature฀ ฀930
-Heating฀resistance(23 )฀ 13

Delphi฀engine฀management฀systm Determination฀on฀the
9.฀Camshaft฀position฀sensor฀(CAM)(MT20U)
-Tnearby฀the฀camshaft,฀and฀works฀with฀signal฀wheel฀on฀camshaft.฀The
may฀measure฀the฀digital฀voltage฀signal฀via฀its฀sensor฀so฀as฀to฀determine฀the
cylinder฀on฀which฀engine฀is฀working,฀and฀to฀perform฀an฀one-to-one฀control;
-Wiring฀terminal A--signal,฀B--signal฀ground,฀C--+5V
-฀Installation:฀It’s฀installed฀nearby฀the฀camshaft.
(b)฀Failure฀determination (c)Characteristics฀of฀product
Important฀note Either฀of฀following฀determinations฀may ฀ ฀ ฀Working฀temperature฀ (-40 150)
be฀concluded฀based฀on฀that฀the฀whole฀vehicle,฀its฀wire- ฀ ฀ ฀Working฀voltage (4.3 13)V
harness,฀and฀other฀system฀parts฀&components฀are฀normal ฀฀฀Working฀clearance (0.3 2)mm
in฀function.
฀-฀฀Failure฀diagnosed฀by฀the฀system฀may฀be฀read฀out฀from฀a
Diagnosis฀Instrument
-Damage฀when฀over-voltage;฀the฀distance฀between฀sensor
and฀signal฀wheel฀is฀out฀of฀limit;
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-The฀relative฀position฀of฀signal฀wheel฀to฀camshaft฀is฀incorrect,
or฀a฀displacement฀is฀produced.
10.฀Vehicle฀speed฀sensor฀ ( VS S )
Driving฀performance.
Important฀note Either฀of฀following฀determinations฀may฀be฀concluded฀based฀on฀that฀the฀whole฀vehicle,฀its฀wire-harness,฀and
other฀systemparts&componentsarenormalinfunction.
-Failure฀diagnosed฀by฀the฀system฀may฀be฀read฀out฀from฀a฀Diagnosis฀Instrument;
-The฀form฀of฀fault฀signal฀includes:฀sensor฀damaged,฀looseness฀&disconnection฀of฀plug฀connectors,฀normal฀or฀artifical฀failure฀with฀wire-
harness
-The฀system฀will฀limit฀the฀driving฀performance฀of฀vehicle฀in฀an฀appropriate฀way,฀ie:฀worse฀Vehicle฀speed฀signal฀is฀provided฀by
instrumentations฀on฀vehicle;฀And฀ECU฀is฀able฀to฀receive฀digital฀square฀wave,฀whose฀amplitude฀value฀is฀within฀5 14฀volt;฀The฀number
of฀square฀wave฀per฀kilometer฀for฀vehicle฀may฀be฀determined฀when฀developing฀the฀system.฀And฀system฀has฀been฀designated฀to
improve฀the฀driving฀performance฀of฀whole฀vehicle฀via฀the฀signal.฀Besides,฀the฀driving฀mileage฀needs฀to฀be฀recorded.
Accumulative฀mileage 80,000฀kilometers;
Limitation฀of฀engine฀rotating฀speed฀when฀sensor฀fails 2500r/min
Expiration฀for฀engine฀rotating-speed฀limit When฀exceeding฀70,000฀kilometer
11.฀Knock฀sensor฀(KS)(MT20U)
-The฀knock฀sensor฀is฀a฀piezoelectric฀type฀of฀vibrating฀sensor฀installed฀at฀a
sensitive฀position฀on฀engine฀unit,฀and฀is฀used฀to฀induce฀the฀knock฀produced฀by
engine.฀ECM฀will฀detect฀the฀intensity฀of฀knock฀via฀knock฀sensor฀so฀as฀to
modify฀the฀ignition฀lead-angle,฀effectively฀control฀the฀knock,฀and฀optimize฀the
dynamical฀performance฀of฀engine,฀the฀cost-effectivenss฀of฀fuel,฀and฀the฀exhaust
level.฀The฀system฀adopts฀a฀frequency-response฀typed฀knock฀sensor,฀and
ECM฀will฀filter฀its฀received฀signal;฀Due฀to฀a฀relatively฀weak฀sensor฀signal,฀the
leadin฀shall฀be฀of฀shielded฀wire
-Wiring฀terminal฀ A-signal,฀B-ground฀via฀shielded฀layer
-Installation The฀knock฀sensor฀is฀installed฀at฀a฀position฀sensitive฀to฀the
engine฀knock.

Delphi฀engine฀management฀systm Determination฀on฀the
(b)Failure฀determination ฀฀฀฀฀(c)Characteristics฀of฀product Output฀signal

฀฀฀฀฀Frequency฀฀฀฀฀฀฀Output฀signal
Importantnote:Either฀of฀following฀determinations฀may฀beconcluded
฀฀฀฀5kHz฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀(17~37)mV/g
based฀on฀that฀the฀whole฀vehicle,฀its฀wire-harness,฀and฀other฀system
฀฀฀฀8kHz฀฀฀฀฀฀฀+15 5kHz
parts฀&components฀are฀normal฀in฀function.Failure฀diagnosed฀by฀the
฀฀฀13kHz฀฀฀฀฀+30 ฀when฀at฀5kHz
system฀may฀be฀read฀out฀from฀a฀Diagnosis฀Instrument
฀฀฀18kHz฀฀฀฀Two฀times฀of฀that฀when฀at฀13kHz
The฀signal฀in฀wire-harness฀has฀not฀adopted฀shielded฀฀wire,฀or฀its
฀฀฀฀It’s฀always฀>17mV/g฀under฀no฀circumstance.
shielded฀layer฀has฀not฀been฀well฀grounded.
Range฀of฀frequency฀response (3~18)kHz
Capacitor 1480~2220pf when฀at25 1000Hz
Resistance >1M ฀ when฀at฀25
Working฀temperature ~
12.฀A i r฀inlet฀system
Function฀ &principal
T he฀function฀of฀air฀inlet฀control฀system฀is฀to฀supply฀an฀appropriate฀amount฀of฀air฀based฀on฀the฀requirement฀for฀engine฀dynamical
output.฀T he฀air฀inlet฀control฀is฀divided฀into฀active฀control฀and฀system฀auto.฀control:฀the฀former฀means฀to฀control฀the฀enginedynamical
output฀by฀actively฀adjusting฀the฀opening฀degree฀of฀throttle฀valve฀in฀accordance฀with฀various฀demands฀of฀driver฀on฀engine฀dynamic
force;฀฀A nd฀the฀latter฀means฀to฀stabilize฀the฀work฀of฀engine฀฀(eg closed-loop฀control฀for฀engine฀idle-speed)฀by฀systemauto.฀adjusting
the฀air฀inlet฀amount฀in฀accordance฀with฀information฀feedbacked฀from฀the฀closed-loop฀control฀monitor.
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air inlet control system

throttle valve unit
valve unit throttle sensor idle-speed control valve
13.฀Throttle฀valve฀assembly
(a)Function฀&principal:
-The฀function฀of฀throttle฀valve฀is฀to฀control฀the฀air฀inlet฀amount฀while
engine฀is฀working,฀and฀may฀be฀regarded฀as฀the฀most฀fundamental฀channel฀for
a฀“talk”฀across฀the฀electrical-injection฀system฀and฀the฀driver;
-Throttle฀ valve฀ is฀ composed฀ of฀ valve฀ unit,฀ valve,฀ acceleratorrod
mechanism,฀throttle฀position฀sensor,฀idle-speed฀control฀valve,฀etc.
-฀Some฀throttle฀valves฀have฀one฀coolant฀pipeline฀installed฀on฀the฀bottom,
which฀may฀be฀used฀to฀prevent฀icing฀within฀valve฀plate฀area฀when฀engine฀is
working฀at฀a฀cold฀temperature฀as฀hot฀coolant฀heat฀by฀engine฀will฀pass
through฀this฀pipeline;
-Installation Throttle฀valve฀is฀installed฀in฀front฀of฀the฀inlet฀manifold.
(b)Failure฀determination:
Important฀note E ither฀of฀following฀determinations฀may฀be฀concluded
& component฀are฀normal฀in฀function.฀A฀regular฀wash฀is฀needed฀as฀the฀valve
and฀its฀idle-speed฀hole฀might฀be฀blocked฀by฀oil฀sludge.
-Diameter฀of฀throat฀opening ฀ 38฀mm
-Diameter฀of฀idle-speed฀valve฀hole ฀ 10฀mm

14.฀Idle฀speed฀control฀valve
The฀function฀of฀idle-speed฀control฀valve฀is฀to฀control฀theflow฀area฀of
bypass฀air฀duct฀on฀throttle฀valve,฀adjust฀the฀air฀inlet฀amount฀inside฀engine,
and฀control฀the฀engine฀idle฀speed.฀The฀main฀body฀of฀idle-speed฀control
valve฀is฀one฀step฀motor;฀The฀head฀forward฀/backward฀movement฀and฀its
extent฀of฀idle-speed฀control฀valve฀may฀be฀controlled฀by฀ECM฀via฀digital
square-wavesignal;
-Wiring฀terminal฀:A฀--฀coilB-,฀B฀--฀coil฀B+,฀C฀--฀coil฀A-,฀D฀--coil฀A+;
-Installation:฀Two฀Delphi฀designated฀screws฀shall฀be฀used฀to฀fix฀฀฀the฀idle-
speed฀control฀valve฀onto฀a฀throttle฀valve฀unit.
Important฀note:฀Either฀of฀following฀determinations฀may฀be฀concluded
idle฀control฀valve
based฀on฀that฀the฀whole฀vehicle,its฀wire-harness,฀and฀other฀system฀parts
&฀compnentsare฀normal฀in฀function;
-The฀action฀of฀idle-speed฀valve฀maybe฀controlled฀by฀a฀Diagnosis฀Instrument;
Observe฀the฀response฀of฀idle-speed฀control฀valve฀,฀and฀the฀status฀of฀engine;
-Read฀out฀the฀failure฀diagnosed฀by฀system;
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throttle฀body -A฀regular฀wash฀is฀needed฀as฀the฀idlespeed฀valve฀hole฀might฀be฀blocked฀by
fuel฀sludge;
-An฀error฀connection฀between฀the฀wiring฀terminal฀of฀idlespeed฀valve฀and
ECM฀wiring฀terminal฀via฀wire-harness.
-Coil฀resistance 53 ฀ 10
-Coil฀inductance:฀33mH฀ 20
-Working฀voltage (7.5 12)V
-L imit฀voltage (3.5 14)V
฀฀฀฀฀฀15.฀Throttle฀position฀sensor฀(TPS)(MT20U)
T hrottle฀position฀sensor฀has฀the฀same฀structure฀as฀linearly฀variable฀resistor,
and฀its฀sliding฀terminals฀are฀driven฀by฀throttle฀shaft;฀A฀different฀opening฀degree
of฀throttle฀will฀result฀in฀a฀different฀response฀of฀resistance฀signal฀from฀its฀sensor
to฀E CU.฀Depending฀on฀the฀output฀signal฀value฀and฀its฀change฀rate,฀system฀may
determine฀the฀real฀load฀on฀engine,฀and฀the฀dynamical฀change฀status:฀wiring
terminal:฀A -+5V,฀B -signal฀ground,฀C-฀throttle฀position฀signal.฀I nstallation
T hrottle฀position฀sensor฀is฀installed฀on฀the฀throttle฀valve฀assembly,฀and฀shares
one฀same฀shaft฀with฀accelerator฀rod฀and฀throttle฀valve.
(b)F ailur e฀ deter mination
T he฀opening฀degree฀of฀throttle฀valve฀read฀from฀a฀Diagnosis฀Instrument฀shall
vary฀within฀0%-99.6%;฀A nd฀the฀impedance฀between฀terminal฀A and฀C฀shall฀be
within฀(3-12)k ;฀Measure฀the฀change฀of฀resistance฀for฀A - C ฀ or฀ C -B ,฀ and฀ it
shall฀be฀smooth฀andfree฀from฀stagnancy.

-R ange ฀A n฀opening฀degree฀within฀7% 93%
5V -฀Working฀voltage (5 0.1)V
-T hrottle฀valve฀close ฀12%฀of฀reference฀voltage฀ 5%
-T hrottle฀full฀ opened 83% 93%
ECU -A B ฀impedance ฀12k
-Working฀temperature฀ (-40 150)
16.฀Ignition฀coil
Ground (a)Function฀&principal:
The฀ignition฀coil฀assembly฀includes฀two฀groups฀of฀coil,฀each฀is฀able฀to
provide฀ignition฀energy฀to฀two฀cylinder฀spark฀plugs฀which฀have฀360฀degree
difference฀in฀rotating฀angle฀on฀crankshaft.฀When฀piston฀moves฀to฀the฀upper
compression฀/exhaust฀stop฀point,฀the฀ignition฀will฀be฀made฀simultaneously;
Cylinder฀nearby฀the฀upper฀exhaust฀stop฀point฀has฀a฀lower฀internal฀air
pressure฀yet฀a฀higher฀temperature,฀a฀small฀amount฀of฀energy฀could฀make฀the
electrode฀of฀spark฀plug฀through฀an฀ignition,฀that’s฀so฀called฀excessive฀ignition;
Cylinder฀nearby฀the฀upper฀compression฀stop฀point฀has฀gas฀mixture฀which
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is฀with฀higher฀density฀and฀pressure,฀and฀a฀greater฀amount฀of฀energy฀is
needed฀for฀the฀ignition฀of฀cylinder฀spark฀plug,฀and฀the฀gas฀mixture฀will฀be
rapidly฀ignited฀to฀do฀work,฀the฀ignition฀for฀this฀cylinder฀is฀called฀valid
ignition
-Wiring฀terminal(ITMS6฀drive฀the฀cylinder฀A-2-3;B+12V฀drive฀the฀cylinder
C-1-4.
wiring฀terminal(MT20U฀drive฀the฀cylinder฀A-2-3;B+12V฀drive฀the฀cylinder
C-1-4.
-฀Installation,฀It’s฀installed฀inside฀the฀engine฀chamber฀and฀remember฀to฀make
shielding฀against฀radio฀interference.
Important฀note Either฀of฀following฀determinations฀may฀beconcluded
based฀on฀that฀the฀whole฀vehicle,฀its฀wire-harness,฀andother฀system฀parts
&components฀are฀normal฀in฀function.
-Any฀failure฀on฀ingnition฀coil฀and฀loops฀maybo฀determined฀by฀cheking฀the
฀ITMS-6฀฀ ฀฀MT20U
Primary฀resistance
Secondary฀resistance
Range฀of฀voltage฀use
(c)Characteristics฀of฀product Primary฀charge฀time ms฀ mS
Peak฀value฀of฀primary฀power-cut฀current฀฀฀฀฀
Secondary฀output฀voltage
Min.฀zener฀energy mJ mJ
Min.฀ignition฀lasting฀time mS mS
Tightening฀moment ฀฀฀฀฀฀฀฀฀฀฀฀฀

17.฀฀Spark฀plug฀and฀high-tension฀wiring
(a)Spark฀plug
-The฀function฀of฀spark฀plug฀is฀to฀ignite฀inflammable฀gas฀inside฀engine฀cyliner;
-The฀spark฀plug฀used฀shall฀be฀of฀resistor฀type฀so฀as฀to฀protect฀the฀driver฀of฀ignition฀coil,฀and฀to฀reduce฀radio฀interference฀wave฀released
during฀ignition;
To฀assure฀energy฀release฀on฀ignition฀coil,฀the฀clearance฀between฀spark฀plugs฀shall฀be฀adjusted฀within฀(1.0 1.2)mm;
- To฀assure฀consistent฀ignition฀energy฀for฀each฀cylinder,฀the฀clearance฀between฀electrodes฀of฀spark฀plug฀on฀each฀cylinder฀shall฀be
consistent฀as฀we
฀(b)High-tension฀wiring
As฀system฀will฀be฀supported฀by฀a฀high฀energy฀/voltage฀ignition,฀and฀the฀high-tension฀wiring฀shall฀have฀appropriate฀impedance,฀able
to฀withstand฀sufficient฀voltage฀and฀constrain฀the฀radio฀interference฀wave฀released฀by฀ignition฀system฀during฀a฀high-energy฀igni tion
process.
18 I gnition฀system
Function฀&principal
The฀function฀of฀ignition฀system฀is฀to฀ignite฀the฀gas฀mixture฀of฀air฀and฀fuel
inside฀engine฀at฀appropriate฀time฀in฀accordance฀with฀ignition฀command
given฀by฀the฀engine฀control฀module.฀Using฀magnetize฀&ignite฀technique,
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the฀ignition฀system฀decreases฀energy฀loss฀in฀the฀whole฀system,฀increases
the฀output฀for฀energy฀/secondary฀voltage฀of฀ignition฀coil,฀and฀makes฀the
engine฀combusting฀and฀working฀more฀stably.
ignition฀system
ignition฀coil spark฀plug฀leading spark฀plug
connection฀via฀engine
19.฀Fuel฀supply฀system
Composition฀and฀principal฀of฀fuel฀supply฀system

fuel฀supply
system
fuel฀ pump fuel฀rail฀as-

line
assembly sembly
fuel fuel฀level fuel fuel฀ pressure injec

fuel฀inlet fuel฀filter fuel฀trail
pump ฀sensor returnpipe adjustor -tor
Fuel฀pump฀assembly
฀(a)Function฀&principal:
-The฀fuel฀pump฀assembly,฀whose฀main฀function฀is฀to฀provide฀system
with฀appropriate฀fuel฀amount฀to฀produce฀sufficient฀pressure,฀is฀composed
of฀fuel฀pump,฀support,฀fuel฀level฀sensor,฀and฀oil฀storage฀tank.฀And฀a
flexible฀installation฀method฀may฀be฀adopted฀to฀reduce฀direct฀influence฀on
fuel฀pump฀due฀to฀vibration;฀The฀fuel฀pump฀is฀a฀turbine฀single-step฀electrical
fuel฀pump,฀whose฀work฀will฀be฀controlled฀by฀ECM฀via฀fuel฀pump฀relay.
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And฀an฀one-way฀valve฀design฀provided฀at฀the฀outlet฀of฀fuel฀pump฀is฀used
to฀ensure฀the฀re-starting฀performance฀by฀preventing฀oil฀residue฀inside
pipe฀from฀returning฀to฀oil฀tank฀while฀the฀engine฀is฀not฀working.฀And฀the
fuel฀level฀sensor฀is฀of฀a฀sliding-blade฀variable฀resistor;
-฀Wiring฀terminal฀(MT20U)฀ A-fuel฀pump฀positive,฀B-sensor฀positive,
฀฀C-sensor฀negative,฀D-fuel฀pump฀negative.
฀Wiring฀terminal฀(ITMS-6)฀ A-fuel฀pump฀positive,฀B-fuel฀pump฀฀negative.
฀-Installation:฀It฀shall฀be฀installed฀inside฀the฀fuel฀tank.
-฀Any฀failure฀on฀fuel฀pump฀and฀its฀related฀loops฀may฀be฀determined฀by฀driving฀the฀fuel฀pump฀relay฀to฀act฀with฀a฀Diagnosis฀Instrument
(when฀not฀driving);
-Failure฀diagnosed฀by฀the฀system฀may฀be฀read฀out฀from฀a฀Diagnosis฀Instrument;
-The฀primary฀filter฀screen฀has฀been฀blocked
-Fuel฀pump฀damaged;
-The฀sensing฀piece฀on฀fuel฀level฀sensor฀is฀broken,฀or฀the฀armed฀rod฀is฀deformed.
฀(c)Characteristics฀of฀product
Items
Fuel฀level฀sensor
Resistance฀value
Maximum฀Operating฀current
Fuel฀pump:
Output฀flow
Output฀pressure
Safe฀ decompression ฀
Operating฀voltage
over฀voltage฀protection
Operating฀without฀fue

work฀schematic฀diagram฀for฀fuel-rail฀assembly 21.฀Fuel-rail฀assembly
fuel฀return ฀Function฀&principal
fuel฀inlet -฀Fuel-rail฀is฀composed฀of฀fuel฀guide฀pipe,฀pressure฀stabilization
fuel-pressure฀adjustor chamber,฀pressure฀adjustor,฀injector,฀and฀some฀components฀used
fuel-rail for฀fixing฀purpose;
-฀Fuel-rail฀has฀provided฀a฀pressure-adjustment฀capacity฀for฀high-
injection
pressure฀fuel,฀a฀pipeline฀for฀flowing฀to฀each฀injection฀nozzle,฀and
nozzle
a฀fixed฀support฀for฀each฀injection฀nozzle;
-Installation It฀shall฀be฀installed฀on฀the฀inlet฀manifold.
inlet฀manifold pressure฀balance฀pipe
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22.฀Oil฀pressure฀adjustor
฀-The฀function฀of฀fuel฀pressure฀adjustor฀is฀to฀adjust฀the฀pressure
of฀fuel฀inside฀fuel-rail,฀and
to฀reduce฀the฀fuel-injection฀interference฀from฀following฀aspects:
change฀of฀fuel฀supply฀velocity,฀change฀of฀fuel฀supply฀from฀fuel
pump,฀change฀of฀vacuum฀degree฀inside฀engine฀inlet฀manifold.
And฀the฀fuel฀pressure฀adjustor฀will฀be฀controlled฀by฀an฀interaction
of฀internal฀adjustment฀spring฀against฀the฀vacuum฀degree฀of฀exterior
inlet฀manifold;฀and฀will฀always฀keep฀a฀constant฀oil-pressure
difference฀across฀fuel-rail฀and฀inlet฀manifold.฀Excessive฀fuel฀having
been฀adjusted฀by฀adjustor฀will฀return฀to฀oil฀tank฀via฀fuel฀return
pipe;
-Installation:฀the฀fuel-pressure฀adjustor฀is฀installed฀on฀oneend
pressure-adjustment฀hole฀on฀manifold connect฀with฀inlet
manifold offuel-rail.
฀(b)Failure฀determination
Important฀note Either฀of฀following฀determinations฀may฀be
pressure-adjustment฀spring
pressure-adjustment฀membrane concluded฀based฀on฀that฀the฀whole฀vehicle,฀its฀wire-harness,฀and
other฀system฀parts฀&components฀are฀normal฀in฀function.
- Vacuum-pressure฀adjustment฀pipe฀loosened;
pressure฀fuel
-Sealing฀ring฀damaged;
-Adjustor฀damaged.
Setting฀of฀pressure:฀฀300฀kPa
fuel฀return

23.฀I nj ector
-The฀injection฀nozzle฀structure฀is฀an฀electromagnetic฀switch฀unit.฀The
coil฀pulled฀out฀from฀two฀electrodes฀will฀connect฀with฀ECM฀and฀power
supply฀respectively฀via฀engine฀wire-harness;฀And฀the฀coil฀is฀controlled฀by
ECM,฀and฀after฀connection฀with฀system฀ground,฀will฀produce฀magnetic
force฀against฀spring฀force,฀fuel฀pressure,฀and฀vacuum฀suction฀force฀of
manifold.฀When฀steel฀core฀is฀lift฀up฀by฀suction฀force,฀fuel฀will฀spray฀from
guiding฀hole฀into฀(in฀a฀form฀of฀fog)฀air฀inlet฀gate฀after฀passing฀through฀the
valve-hole฀sealing฀surface฀on฀a฀same฀structure฀as฀steel฀core;฀After฀a฀power
cut,฀the฀magnetic฀force฀will฀disappear,฀and฀the฀injection฀nozzle฀will฀be
closed.฀Rubber฀sealing฀ring฀installed฀on฀the฀top฀of฀fuel฀injector฀will฀work
with฀fuel-rail฀interface฀to฀form฀a฀secure฀pressure฀oiltightness;฀And
rubbersealing฀ring฀installed฀on฀the฀bottom฀will฀work฀with฀engine฀inlet
manifold฀for฀an฀airtightness
-Wiring฀terminal A฀ -฀ +12V,฀ B฀ -฀ ECM -Installation:฀It฀is฀fixed฀on
the฀inlet฀manifold฀via฀fuel-rail.
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-Any฀failure฀on฀injector฀and฀its฀related฀loops฀may฀be฀determined฀by
driving฀the฀injector฀to฀act฀via฀Diagnosis฀Instrument฀(when฀not฀driving);
-Failure฀diagnosed฀by฀the฀system฀may฀be฀read฀out฀from฀aDiagnosis
Instrument
-Blocked฀by฀foreign฀materials;
-฀A฀glue฀film฀is฀formed฀after฀fuel฀evaporation;
-Damaged฀sealing฀ring฀cause฀an฀air฀or฀oil฀leakage;
-Connectors฀loosened,฀and฀wire-harness฀damaged;
-Broken฀coil฀loop฀leads฀to฀a฀non฀oil-injection.
-Working฀temperature฀ -30฀ 125฀
-Min.฀working฀voltage <6฀V
-Coil฀resistance (12.0 0.6)
24.฀Fuel฀filter฀and฀pipe
Fuel฀ filter
-฀฀The฀function฀of฀fuel฀filter฀is฀to฀separate฀foreign฀solid฀materials฀from
fuel;
-฀฀To฀keep฀a฀better฀filtration฀effect,฀and฀prevent฀the฀injection฀nozzle฀from
blocking฀by฀foreign฀materials฀while฀working,฀A฀special฀fuel฀filter฀for
electrical-injection฀shall฀installed฀in฀the฀system;
-฀฀The฀cover฀of฀filter฀must฀be฀with฀sufficient฀strength,฀and฀will฀not
rupture฀due฀to฀fuel฀pressure;
Fuel฀ pipe:
As฀the฀fuel฀working฀pressure฀within฀system฀is฀about฀(250 350)฀kPa,
for฀safety฀purpose,฀the฀selected฀fuel฀pipe฀must฀be฀corrosion฀proof฀against
fuel,฀and฀have฀sufficient฀pressure-withstand฀safe฀coefficient;
Installation
The฀fuel฀filter฀is฀serially฀connected฀to฀an฀oil฀loop฀between฀the฀electrical
fuel฀pump฀and฀the฀fuel-rail฀via฀fuel฀pipe
T he฀filter฀has฀been฀blocked,฀or฀it฀has฀insufficient฀fuel฀pressure

25.฀Carbon-canister฀wash฀solenoid฀valve
-The฀ petrol฀ evaporation฀ amount฀ from฀ carbon-canister฀ into฀ inlet
manifold฀ may฀ be฀ controlled฀ by฀ ECM฀ via฀ carbon-canister฀ wash
&control฀solenoid฀valve;฀The฀occupation฀ratio฀between฀ECM฀output
pulse฀ square฀ wave฀ and฀ air฀ amount฀ shows฀ a฀ linear฀ correlation.
Depending฀ on฀ the฀ load฀ and฀ the฀ engine฀ rotating฀ speed,฀ ECM฀ may
change฀ the฀ washing฀ time฀ and฀ velocity฀ of฀ carbon-canister;
-Wiringterminal A - E C M B-+12V;
-Installation:฀it’s฀installed฀on฀engine,฀and฀between฀fuel฀evaporation
carbon-canister฀and฀inlet฀manifold;
-Any฀failure฀on฀carbon-canister฀solenoid฀valve฀and฀its฀related฀loopsmaybe
determined฀by฀driving฀the฀carbon-canister฀solenoid฀valve฀to฀act฀via฀Diagnosis
Instrument฀(when฀not฀driving)
-Failure฀ diagnosed฀ by฀ the฀ system฀ may฀ be฀ read฀ out฀ from฀ a
DiagnosisInstrument
- Working฀voltage (8 16)฀V
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-Limit฀voltage 25฀V฀(<60S)
- Working฀temperature฀ (-40 120)
-Impedance ฀(19 22)฀
-Inductance:฀(12 15)฀mH
26.฀Three-way฀catalytic฀converter
-The฀function฀of฀three-way฀catalytic฀converter฀is฀to฀converse฀harmful฀gas
exhaust฀having฀combusted฀in฀engine฀into฀nonharmful฀gas฀discharge฀to
atmosphere;
-฀The฀internal฀structure฀of฀three-way฀catalytic฀converter฀is฀of฀honeycomb
pipe฀design,฀whose฀pipe฀wall฀is฀with฀noble฀metal฀elements฀like฀Pt,฀rhodium,
Pd฀coated฀layer฀used฀as฀catalytic฀reaction฀medium;
-฀The฀power฀loss฀of฀three-way฀catalytic฀converter฀is฀about฀(3 4)%;
-฀Installation:฀three-way฀catalytic฀converter฀is฀serially฀connected฀between
and฀exhaust฀manifold฀and฀muffler,฀and฀behind฀the฀oxygen฀sensor;
-The฀catalyzer฀inside฀three-way฀catalytic฀converter฀is฀able฀to฀facilitate฀the
oxidation฀reaction฀between฀hydrocarbon฀(HC)฀and฀carbon฀monoxide฀(CO)
by฀conversing฀them฀into฀water฀steam฀(H O)฀and฀carbon฀dioxide฀(CO )
2 2
respectively,฀and฀deoxidizing฀the฀nitrogen฀oxides฀(NO )฀into฀nitrogen฀gas
x
(N );
2
-Three-way฀catalytic฀function:
three-way฀catalytic฀converter HC,฀CO฀and฀NO three-way฀catalytic฀converter฀ H O,฀฀CO

X 2 2
and฀N2
฀฀฀-฀Oxidation฀reaction
efficiency ฀฀-฀Deoxidization฀reaction
air฀/fuel฀ratio

The฀oxidation฀reaction฀of฀HC฀and฀CO฀made฀by฀catalytic฀converter฀will
keep฀an฀optimum฀status฀when฀the฀air฀/fuel฀ratio฀is฀greater฀than฀14.5,฀while
the฀deoxidation฀reaction฀of฀Nox฀will฀keep฀an฀optimum฀status฀when฀the฀air
/fuel฀ratio฀is฀less฀than฀14.8.฀Under฀the฀consideration฀of฀above฀two฀aspects,
the฀general฀conversion฀efficiency฀of฀three-way฀catalytic฀converter฀shall฀be
within฀the฀air฀/fuel฀ratio฀as฀14.6 14.7;฀Based฀on฀appropriate฀signal฀feeback
from฀oxygen฀sensor,฀ECU฀will฀have฀the฀engine฀combustion฀air฀/fuel฀ratio
controlled฀beyond฀the฀optimum฀air฀/fuel฀ratio฀of฀three-way฀catalytic
converter.
-Heavy฀metal฀(eg.฀lead,฀manganese,฀etc.฀),฀phosphorus฀or฀sulphur
poison฀&failure;
-Burning-out฀failure฀(eg.฀engine฀single-cylinder฀causes฀fire)฀at฀high
temperature;
-The฀carrier฀is฀broken฀due฀to฀exterior฀impact฀or฀shock฀chilling฀impact;
-Blockage฀by฀foreign฀materials฀(eg.฀machine-oil฀burning฀inside฀engine);
-Blockage฀of฀three-way฀catalytic฀converter,฀which฀makes฀engine฀unable฀to
drive฀vehicle;฀slack฀acceleration;฀and฀an฀abnormally฀high฀pressure฀value฀for
inlet฀manifold.
฀(c)Characteristics฀of฀product
B est฀working฀temperature:฀(375 800) ฀(instantaneous฀ withstanded
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฀฀฀฀฀฀฀temperature฀950 )
Optimum฀work฀air฀/fuel฀ratio:฀14.6 14.7
Methods฀for฀failure฀diagnosis฀/fault฀code฀to฀spare฀parts
1.฀Common฀repair฀devices฀applicable฀to฀electrical-injection฀system
(a)Installation฀&dismantle฀of฀parts฀&components฀within฀electrical-control฀system-Common฀tools฀used฀to฀dismantle฀mechanical
parts฀&components฀from฀vehicle;
(b)Electrical-control฀system฀loop฀/฀system฀current฀signal฀-digital฀multimeter฀(with฀buzzer);
(c)System฀square-wave฀/pulse-wave฀signal฀–฀oscillograph;
(d)Fuel฀pressue-pressure฀meter฀whose฀measuring฀range฀is฀(0 1)Mpa;
(e)Exhaust฀test฀meter;฀used฀to฀diagnose฀the฀quality฀of฀oxygen฀sensor฀and฀three-way฀catalytic฀converter;
(f)Ultrasonic฀washing฀machine฀for฀injector;฀used฀to฀wash฀injector;
(g)Electrical-control฀system฀failure฀diagnosis฀plus฀engine฀work฀status฀detection-฀Fault฀Diagnosis฀Instrument฀applicable฀to฀vehicle
electrical-control฀system,฀or฀Delphi฀PCHUD฀computer฀test฀&control฀software.
2.฀Engine฀fault฀indicator฀light
(a)If฀there’s฀any฀failure฀with฀system฀or฀parts฀&components฀while฀engine฀is฀running,฀engine฀fault฀indicator฀light฀will฀auto.฀light฀up฀to
remind฀vehicle฀driver฀of฀check฀and฀maintenance฀in฀time.
(b)When฀under฀an฀emergency,฀some฀special฀operations฀may฀be฀performed฀to฀activate฀the฀stroboflash฀of฀engine฀fault฀indicator฀light฀so
as฀to฀read฀engine฀fault฀code.฀And฀this฀is฀most฀cost-effective฀way฀to฀acquire฀fault฀code.
3.฀Code฀reading฀method฀by฀the฀stroboflash฀of฀engine฀fault฀indicator฀light
(a)That฀the฀fault฀indicator฀light฀is฀on฀while฀engine฀is฀running฀indicatesan฀availability
Definition฀of฀diagnosis฀plugs฀&interfaces of฀fault฀code;
null (b)Diagnosis฀request฀terminal฀1฀among฀fault฀diagnosis฀plugs฀shallbe฀short-circuit
connected
Communication null with฀ground฀wire฀terminal฀4฀or฀5฀via฀lead฀wire;
null null (c)If฀there’s฀any฀failure฀(or฀any฀history฀fault฀code฀not฀having฀been฀cleared฀after
ground฀wire ฀null fault฀is฀solved)฀with฀system฀when฀engine฀is฀not฀started,฀engine฀fault฀indicator
light฀will฀be฀flashing฀as฀per฀some฀rule,฀and฀the฀output฀system฀will฀detect฀the฀fault
ground฀wire ฀฀฀null code;฀(when฀fault฀code฀is฀being฀read,฀the฀idle-speed฀control฀valve฀will฀make
null null action฀for฀return฀to฀original฀position).
null null (d)฀Any฀failure฀will฀be฀reported฀in฀accordance฀with฀the฀sequence฀memorized฀by
fault฀code;฀It฀will฀stop฀for฀3.2฀seconds฀between฀fault฀codes,฀and฀the฀digits฀will฀be
diagnosis฀request null flashing฀as฀per฀the฀frequency฀“lighting for฀0.4฀second,฀then฀stop฀for฀0.4฀second”
;฀and฀it฀will฀stop฀for฀1.2฀seconds฀between฀numeric฀positions;

EF.2-24 Methods฀for฀failure฀diagnosis฀/fault฀code฀to฀spare฀parts
Digit฀0฀will฀flash฀for฀ten฀times,฀other฀digits฀will฀correspond฀to฀their฀literal฀flashing฀times฀accordingly;
(e)After฀failure฀is฀cleared฀away,฀a฀Fault฀Diagnosis฀Instrument฀shall฀be฀used฀to฀clear฀away฀fault฀code฀to฀avoid฀any฀influence฀on ฀the
determination฀of฀next฀maintenance.
4.฀Code฀reading฀card฀(fault฀code฀reader)
(a) The฀code฀reading฀card฀may฀provide฀a฀fast฀way฀to฀read฀fault฀codes.
(b) The฀code฀reading฀card฀shall฀be฀inserted฀to฀a฀fault฀diagnosis฀plug;
(c) The฀code฀reading฀card฀will฀have฀fault฀code฀cycling฀as฀per฀the฀sequence฀remembered฀by฀fault฀code£»
(d) Whereby฀any฀abnormality฀is฀found฀by฀vehicle฀owner,฀or฀when฀the฀fault฀indicator฀light฀is฀lighting,฀contact฀by฀phone฀with฀the
franchised฀service฀station฀to฀tell฀the฀displayed฀fault฀code,฀and฀the฀service฀station฀will฀determine฀the฀failure฀degree฀based฀on฀fault฀code
reported฀by฀user,฀and฀provide฀with฀relevant฀services.฀If฀the฀failure฀does฀not฀do฀harm฀to฀the฀driving฀safety฀and฀other฀parts
&components,฀user฀may฀be฀suggested฀to฀drive฀the฀vehicle฀to฀service฀station฀for฀repair;฀If฀the฀failure฀might฀cause฀a฀more฀severe
consequence,฀user฀may฀be฀suggested฀to฀wait฀for฀a฀field฀rescue฀from฀service฀station,฀so฀as฀to฀avoid฀any฀safety฀accident,฀or฀any฀loss
resulting฀from฀other฀parts฀&components.
5.฀Fault฀Diagnosis฀Instrument
The฀main฀function฀of฀Diagnosis฀Instrument฀is฀to฀read฀system฀information฀and฀system฀work฀data฀stream,฀to฀temporarily
control,฀check฀and฀test฀system฀parts฀&components,฀and฀read฀or฀clear฀away฀fault฀code.฀Being฀easy฀to฀operate,฀it฀is฀used฀as฀key฀tool
at฀present฀to฀determine฀any฀failure฀on฀vehicle,฀and฀to฀test฀and฀check฀the฀system฀status.
6.฀Fault฀code฀checklist฀for฀fault฀code฀reader
(a)฀Fault฀code฀checklist฀for฀ITMS-6฀fault฀code฀reader
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F ault code check list for fault code reader

F ault F ault
D escription of f ailure D escription of failure
code code
F ailure wi th the loop of inlet manif ol d F ailure w ith the loop of carbon-canister
0105 0443
pressure sensor solenoid valve
F ailure w ith the loop of inlet temperature F ailure w ith the loop of f an in water tank
0110 0481
sensor only f or electrical f an
F ailure w ith the loop of w ater F ailure w ith the loop of idle-speed
0115 0505
temperature sensor control v alv e
F ailure with the loop of throttle position M uch high system v oltage
0120 0560
sensor
0130 F ailure wi th the loop of ox ygen sensor 1362 F ailure wi th the theft detector
A n abnormal read v alue of ox ygen sensor F ailure w ith the loop of air conditioner
0170 1530
clutch
0200 F ailure wi th the loop of injector 1532 A n abnormal read value of temperature
0230 F ailure wi th the loop of fuel pump 1533 sensor on air conditioner evaporator
F ailure w ith the loop of crank shaf t F ailure wi th control computer
0335 1604
position sensor
F ailure w ith the loop of ignition coil1 on
0351 1605
f our cylinders
F ailure w ith the loop of ignition coil1 on
0352 1640
f our cylinders
1 A s code reader is able to read out any history fault code stored yet not being cleared inside the
computer.,
C odes read out by code reader shall be v alid onl y w hen any failure is indicated by f ault indicator
light.
N ote
2 T he display of -------- on code reader indicates the system is work ing normally ; and the
display of E indicates the k ey sw itch has not been opened yet.
3 I t’ s recommended to clear aw ay any f ault code at serv ice station af ter f ailure has been solv ed
each time.

Methods฀for฀failure฀diagnosis฀/fault฀code฀to฀spare฀parts EF.2-25
(b) Fault code checklist for MT20U fault code reader

Fault Fault Fault
Description of failure Description of failure Description of failure
code code code
The pressure of inlet manifold too K nock sensor has no
The voltage of accumulator is too high.
high signal.
The pressure of inlet manifold too 58x crankshaft sensor
The knock control system has an error.
low has no signal.
The temperature of inlet manifold 58x crankshaft sensor The fault indicator light is short circuit to
too high signal has an error. accumulator.
The temperature of inlet manifold Camshaft sensor signal The fault indicator light is short circuit to ground or
too low is long and low. in an open circuit.
Coolant temperature too low short Camshaft sensor signal The air conditioner relay is short circuit to
/broken circuit with accumulator is long and high. accumulator.
Coolant temperature too high short Line diagram 1-4 is
The air conditioner relay is short circuit to ground or
circuit to ground short circuit to
in an open circuit..
accumulator.
Throttle position too high short Line diagram 1-4 is
/broken circuit with accumulator short circuit to ground EEPR OM memory has an error.
or in an open circuit.
Throttle position too low short Line diagram 2-3 is
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circuit to ground short circuit to FL ASH memory has an error.

accumulator.
Oxygen sensor has no signal Line diagram 2-3 is
The theft-prevention controller memory has an
short circuit to ground
error.
or in an open circuit.
The ‘ thick’ time of oxygen sensor is The carbon-canister
The communication between ECM and theft
too long. solenoid valve is short
detector has an error.
circuit to accumulator.
The ‘thin’ time of oxygen sensor is The carbon-canister
too long. solenoid valve is short
The temperature of front evaporator is too high.
circuit to ground or in
an open circuit.
The loop of fuel injector A cylinder Fan 1 is short circuit to
1 has accumulator. The temperature of front evaporator is too low.
an error.
The loop of fuel injector B cylinder Fan 1 is short circuit to
3 has ground or in an open The temperature of rear evaporator is too high.
an error. circuit.
The loop of fuel injector C cylinder Fan 2 is short circuit to
4 has accumulator. The temperature of rear evaporator is too low.
an error.
The loop of fuel injector D cylinder Fan 2 is short circuit to
The air conditioner after-cycle trip valve
2 has an error. ground or in an open
is short circuit to accumulator.
circuit.
The fuel pump relay is short circuit The vehicle speed The air conditioner after-cycle trip valve
to accumulator. sensor has no signal. is short circuit to ground or in an open circuit.
The fuel pump relay is short circuit Error idle-speed
to ground or in an open circuit. control
Explanatory฀note
1.฀As฀code฀reader฀is฀able฀to฀read฀out฀any฀history฀fault฀code฀stored฀yet฀not฀being฀cleared฀inside฀the
computer,฀codes฀read฀out฀by฀code฀reader฀shall฀be฀valid฀only฀when฀any฀failure฀is฀indicated฀by฀fault
indicator฀light.
2.฀The฀display฀of฀ ———— on฀code฀reader฀indicates฀the฀system฀is฀working฀normally;฀and฀the
฀฀฀฀display฀of E indicates฀the฀key฀switch฀has฀not฀been฀opened฀yet.
3.฀It’s฀recommended฀to฀clear฀away฀any฀fault฀code฀at฀service฀station฀after฀failure฀has฀been฀solved฀each
฀฀฀฀time.

EF.2-26 Precautions฀to฀the฀use฀/service฀/troubleshooting฀of฀electrical฀injection฀system
9.฀Key฀points฀to฀failure฀elimination฀when฀fault฀indicator฀light฀is฀lighting
(a)A฀Fault฀Diagnosis฀Instrument฀may฀be฀used฀to฀read฀out฀fault฀code฀and฀to฀find฀out฀its฀appropriate฀content ;
(b)Most฀failures฀displayed฀and฀indicated฀by฀fault฀code฀are฀caused฀by฀loop฀failure฀or฀bad฀connection฀of฀plug฀connectors;
(c)Check฀at฀top฀priority฀the฀sensor฀or฀actuator฀or฀its฀relevant฀loops฀as฀indicated฀by฀fault฀code;
(d)Relevant฀loops฀may฀be฀checked฀by฀measuring฀the฀resistance฀or฀voltage;
(e)Results฀of฀failure฀elimination฀may฀be฀determined฀using฀a฀Fault฀Diagnosis฀Instrument฀to฀observe฀whether฀the฀read฀value฀of฀sensor
satisfies฀requirements;
(f)Results฀of฀failure฀elimination฀may฀also฀be฀determined฀using฀a฀Fault฀Diagnosis฀Instrument฀to฀operate฀and฀control฀the฀action฀of
actuator;
(g)Drive฀vehicle฀once฀for฀verification฀on฀failure฀elimination.
Precautions฀to฀the฀use฀/service฀/troubleshooting฀of฀electrical฀injection฀system
1.฀Routine฀use฀and฀service
(a)The฀petrol฀to฀be฀used฀shall฀be฀quality฀lead-free฀vehicle฀petrol฀which฀is฀ 93#฀(GB17930-1999).฀It’s฀specially฀noted฀here฀that฀filling
oil฀tank฀with฀petrol฀containing฀lead฀for฀one฀time฀will฀make฀three-way฀catalytic฀converter฀lose฀its฀function฀completely;
(b)Any฀abnormal฀oil฀consumption฀shall฀be฀settled฀timely,฀as฀phosphorus฀content฀in฀machine-oil฀will฀make฀the฀oxygen฀sensor฀and
three-way฀catalytic฀converter฀lose฀their฀function;
(c)An฀immediate฀troubleshooting฀shall฀be฀performed฀if฀the฀fault฀indicator฀light฀is฀lighting฀while฀engine฀is฀running;
(d)Do฀not฀operate฀any฀mechanism฀on฀engine฀(including฀gas฀pedal)฀when฀starting฀engine;฀and฀the฀clutch฀shall฀be฀disconnected฀when฀it’s
cold;
(e)Vehicle฀shall฀be฀running฀at฀high฀speed฀from฀time฀to฀time฀to฀clear฀away฀any฀possible฀carbon฀deposit฀remained฀in฀engine฀and฀air
exhaust฀system,฀and฀to฀prevent฀three-way฀catalytic฀converter฀from฀damage฀due฀to฀temporary฀poison;
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(f)If฀fire฀occurs฀on฀some฀cylinder,฀stop฀the฀vehicle฀immediately฀to฀check฀and฀settle฀it,฀as฀gas฀mixture฀without฀sufficient฀com bustion
will฀continue฀to฀re-combust฀inside฀exhaust฀manifold,฀which฀results฀in฀a฀fast฀damage฀on฀oxygen฀sensor฀and฀three-way฀catalytic
converter;฀If฀ignition฀failure฀can฀not฀be฀eliminated฀at฀one฀time,฀It’s฀required฀to฀remove฀the฀plug฀to฀fuel฀supply฀injection฀nozzle฀on฀the
cylinder฀having฀a฀fire฀on฀a฀temporary฀basis,฀and฀to฀drive฀the฀vehicle฀at฀low฀or฀medium฀speed฀to฀service฀station฀for฀repair.
(g)During฀a฀long-term฀storage฀period,฀the฀vehicle฀or฀engine฀needs฀a฀running฀once฀every฀one฀month฀to฀prevent฀glue฀film฀from฀forming
on฀injection฀nozzle฀or฀fuel฀pump.
(h)Petrol฀filter฀shall฀be฀changed฀once฀every฀(7,000 10,000)฀km;฀When฀under฀a฀normal฀use฀condition,฀throttle฀valve฀and฀injection
nozzle฀shall฀be฀washed฀annually฀or฀every฀20,000฀kilometers;฀When฀a฀dismantle-free฀method฀is฀applied฀to฀wash฀injector,฀ensure฀that
additive฀to฀be฀used฀contains฀no฀materials฀harmful฀to฀oxygen฀sensor฀and฀three-way฀catalytic฀converter;
(i)฀When฀performing฀an฀inspection฀on฀dual฀idle-speed฀exhaust,฀remember฀to฀sufficiently฀preheat฀the฀engine฀and฀three-way
catalytic฀converter,฀and฀to฀measure฀the฀high฀idle-speed฀first฀before฀the฀low฀idle-speed;
2.฀Precautions฀during฀installation฀of฀accessories฀for฀electrical-injection฀system
(a)When฀air฀conditionerer฀is฀installed฀on฀vehicle฀not฀having฀been฀equipped฀with฀air฀conditionerer฀in฀the฀plant,฀(The฀interface฀for฀air
conditioner฀signal฀control฀has฀already฀been฀provided฀for฀system฀wire-harness฀in฀most฀cases),฀be฀familiar฀with฀the฀working฀principal
of฀loops,฀and฀do฀not฀have฀the฀installed฀air฀conditionerer฀out฀of฀control฀by฀computer,฀otherwise,฀auxiliary฀functions฀under฀the฀control
of฀system฀air฀conditionerer฀may฀not฀be฀effected,฀which฀will฀influence฀the฀normal฀working฀of฀engine;
(b)In฀cold฀areas,฀increase฀or฀enlarge฀auxiliary฀water฀tank฀(s)฀for฀warming฀purpose;฀Excessive฀use฀of฀engine฀for฀warming฀purpose฀might
lead฀to฀a฀much฀lower฀coolant฀฀temperature,฀thus,฀it฀will฀worsen฀the฀engine฀abrasion,฀increase฀fuel฀consumption,฀and฀produce฀carbon
deposits฀inside฀the฀engine฀and฀air฀exhaust฀system;
(c)When฀theft฀detector฀out฀of฀control฀by฀computer฀is฀increased฀to฀original฀device,฀do฀not฀cut฀off฀ECU฀permanent฀power฀supply,฀ or
the฀normal฀working฀of฀electrical-injection฀system฀will฀be฀influenced;฀The฀increment฀of฀ECU฀theft฀detector฀to฀original฀device฀shall฀be
subject฀to฀an฀approval฀by฀Delphi฀company.
(d)The฀carbon-canister฀solenoid฀valve฀is฀subject฀to฀ECU฀control฀and฀adjustment;฀The฀function฀of฀fuel฀evaporation฀fromcarbon-
canister฀into฀engine฀is฀to฀ensure฀the฀normal฀working฀of฀engine฀when฀carbon-canister฀is฀with฀desorption.฀The฀evaporation/exhaust
control฀effect฀of฀fuel฀tank฀will฀be฀directly฀affected฀by฀the฀size฀of฀capacity฀for฀activated฀carbon฀canister:฀if฀the฀capacityis฀too฀small,฀fuel
evaporated฀gas฀might฀get฀out฀of฀the฀canister฀when฀at฀high฀temperature฀or฀at฀idle฀speed฀for฀long฀time.฀If฀there’sany฀smell฀like฀fuel
evaporated฀gas฀nearby฀the฀carbon-canister,฀replace฀with฀a฀carbon-canister฀having฀a฀large฀capacity฀to฀settle฀it.
3.฀Precautions฀when฀clearing฀failure
(a)As฀parts฀&components฀within฀the฀electrical-injection฀system฀are฀with฀high฀reliability,฀relevant฀mechanical฀parts฀&components ,
system฀plug฀connectors,฀and฀wire-harness฀shall฀be฀checked฀at฀top฀priority฀whereby฀any฀abnormality฀is฀found฀on฀vehicle฀or฀engine ;
Prior฀to฀a฀determination฀on฀the฀damage฀of฀some฀part฀&component,฀an฀alternative฀test฀must฀be฀made฀repeatedly฀for฀inspection
purpose;
(b)When฀฀fuel฀system฀parts฀&components฀are฀dismantled฀(eg.฀change฀of฀filter,฀dismantle฀of฀fuel฀pump,฀dismantle฀of฀oil฀inlet฀/return
pipeline฀on฀fuel-rail),฀duster฀cloth฀may฀be฀used฀to฀cover฀the฀connection฀point฀on฀oil฀pipe฀before฀connector฀is฀loosened฀to฀relieve฀oil
pressure฀in฀pipeline.฀During฀operation,฀always฀prevent฀fuel฀from฀splashing฀onto฀engine฀or฀its฀high-temperature฀exhaust฀pipeline;

Precautions฀to฀the฀use฀/service฀/troubleshooting฀of฀electrical฀injection฀system EF.2-27
(c)The฀leadin฀of฀spark฀plug฀shall฀not฀be฀pulled฀out฀when฀checking฀whether฀the฀ignition฀system฀is฀working,฀as฀the฀injection฀nozzle฀is
still฀working,฀and฀some฀petrol฀spraying฀out฀yet฀not฀being฀used฀will฀be฀combusting฀rapidly฀inside฀three-way฀catalytic฀converter฀ and
cause฀damages;
(d)Do฀not฀dismantle฀system฀electrical฀parts฀&components฀when฀ignition฀switch฀is฀connected฀to฀avoid฀damages;
(e)When฀checking฀the฀replacement฀of฀ECU,฀please฀be฀noted฀that฀the฀vehicle฀shall฀be฀equipped฀with฀computer-based฀theft฀detector;฀If
so,฀ECU฀may฀be฀replaced฀after฀a฀power฀cut฀made฀to฀theft฀detector,฀otherwise,฀new฀ECU฀will฀be฀locked฀by฀theft-prevention฀function,
and฀can฀not฀work฀on฀other฀vehicles;
(f)Anti-interference฀spark฀plug฀plus฀high-tension฀wiring฀shall฀be฀used฀within฀system,฀if฀not,฀negative฀effect฀may฀be฀brought฀to ฀the
ignition-coil฀drive฀mode฀inside฀ECU,฀and฀ECU฀may฀even฀be฀damaged.
(g)When฀changing฀fuel฀inlet฀/return฀pipe,฀use฀petrol฀pipe฀which฀can฀withstand฀a฀bursting฀pressure฀greater฀than฀2Mpa;
(h)Method฀like฀‘use฀needle฀to฀punch฀wire-harness’฀shall฀not฀be฀used฀to฀check฀the฀system฀current฀signal;
(i)Always฀remember฀to฀disconnect฀accumulator฀jar฀from฀ECU฀connector฀when฀exterior฀electrical฀system฀tools฀are฀applied฀for฀welding
purpose
(j)During฀installation฀or฀dismantling฀of฀components฀within฀the฀electrical-injection฀system,฀severe฀knocks฀or฀strikes฀against฀components
are฀prohibited;
(k)Any฀check฀or฀test฀shall฀not฀proceed฀when฀ECU฀cover฀is฀opened฀to฀avoid฀greater฀damage.
Any฀loss฀produced฀after฀ECU฀is฀opened฀will฀not฀be฀compensated;
(l)When฀changing฀or฀dismantling฀the฀oxygen฀sensor,฀it’s฀unallowable฀to฀apply฀any฀sealant฀to฀the฀threaded฀part฀of฀oxygen฀sensor฀to
avoid฀burning฀and฀damage;
(m)It’s฀unallowable฀for฀fuel฀pump฀to฀run฀for฀a฀long฀term฀period฀when฀it฀contains฀no฀petrol,฀neither฀to฀run฀in฀air฀even฀when฀its฀contains
petrol;
(n)If฀any฀breakage฀is฀found฀in฀loop,฀quality฀insulation฀tape฀shall฀be฀used฀for฀wrapping฀purpose฀during฀maintenance฀to฀avoid฀greater
loss.
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(o)Upon฀the฀confirmation฀on฀damage฀on฀electrical-injection฀components,฀they฀shall฀be฀changed฀accordingly฀in฀normal฀case฀as฀most฀of
them฀are฀unable฀to฀be฀restored.
T r oubleshooting
1.฀Solutions฀to฀failure
(a)Query฀diagnostic฀method
-When฀query,฀you฀shall฀be฀earnest,฀conscientious,฀amiable,฀and฀attentive฀in฀listening.
-The฀query฀shall฀be฀made฀from฀an฀integral฀view฀and฀focus฀on฀key฀points;฀and฀you฀need฀to฀further฀understand฀the฀history฀and฀the
frequency฀of฀symptom.
-Based฀on฀the฀symptom฀known฀from฀vehicle฀owner฀when฀some฀failure฀is฀produced,฀an฀analysis,฀judge,฀and฀initial฀determination฀may
be฀concluded.
(b)Observe฀diagnostic฀method
-The฀observation฀shall฀be฀based฀on฀the฀symptom,฀and฀consider฀the฀whole฀system฀and฀some฀focus,฀and฀proceed฀as฀per฀a฀certain
sequence
-An฀exterior฀inspection฀is฀needed฀to฀check฀the฀water฀/฀air/fuel/฀electrical฀loop฀of฀vehicle฀which฀has฀failure
- To฀find฀the฀cause฀of฀failure,฀some฀instruments฀or฀instrumentations฀applicable฀to฀vehicle฀may฀be฀used฀during฀the฀inspection.
฀-฀A฀judge฀shall฀also฀be฀made฀based฀on฀a฀careful฀observation฀on฀the฀symptom,฀fault฀code,฀sound,฀etc.฀when฀some฀failure฀is฀฀produced.
(c)฀฀Component฀displacement฀method
-New฀component฀will฀be฀used฀to฀take฀the฀place฀of฀original฀component฀which฀may฀have฀possible฀failures;
-The฀original฀component฀which฀may฀have฀possible฀failures฀will฀be฀installed฀on฀another฀good฀vehicle฀for฀a฀further฀verification;
-The฀displacement฀of฀some฀component฀shall฀be฀supported฀by฀appropriate฀reasons,฀and฀can฀฀not฀be฀made฀on฀blindness.
(d)฀฀Case฀application฀method
-Based฀on฀results฀concluded฀from฀typical฀cases,฀direct฀search฀the฀cause,฀remove฀the฀failure,฀and฀reduce฀unnecessary฀inspections
-This฀method฀is฀only฀applicable฀to฀the฀same฀failure฀produced฀on฀the฀same฀model฀of฀vehicle฀or฀the฀same฀type฀of฀system
-This฀method฀is฀not฀applicable฀to฀common฀failures,฀which฀have฀a฀similar฀symptom฀yet฀caused฀by฀various฀causes.
(e)฀฀Experience฀method
-Based฀on฀previous฀results฀gained฀from฀the฀settlement฀of฀various฀failures,฀experiences฀may฀be฀accumulated฀gradually,฀and฀the
capability฀to฀solve฀the฀trouble฀may฀be฀increased฀as฀well
-Depending฀on฀the฀similarity฀and฀difference฀of฀symptoms,฀a฀determination฀may฀be฀concluded฀accordingly฀by฀applying฀previous
experiences฀in฀a฀flexible฀way
-Existing฀experiences฀may฀be฀optimized฀by฀make฀a฀conclusion฀from฀the฀settlement฀of฀special฀or฀typical฀failures,฀and฀recording฀ the
successes฀and฀mistakes฀in฀the฀course฀of฀settlement.
(f)฀Logic฀thinking฀method
-A ฀logic฀thinking฀method฀may฀be฀adopted฀to฀analyze฀the฀failure฀and฀find฀out฀the฀failure฀points฀in฀accordance฀with฀the฀working
principal฀of฀testing฀data฀and฀system
-It’ s฀required฀to฀be฀familiar฀with฀the฀working฀principal฀and฀function฀of฀engine,฀the฀electrical-injection฀system,฀and฀system฀components
-For฀some฀failures,฀a฀logic฀thinking฀& analysis฀is฀much฀compulsory.

EF.2-28 Precautions฀to฀the฀use฀/service฀/troubleshooting฀of฀electrical฀injection฀system
(g)Reversed฀logic฀thinking฀method
-Think฀in฀a฀reversed฀way฀what฀symptom฀might฀be฀against฀a฀certain฀failure฀with฀component;
-Accumulate฀and฀make฀a฀conclusion฀from฀symptoms฀which฀are฀produced฀when฀components฀are฀damaged฀or฀fail฀to฀help฀quickly
find฀out฀the฀failure฀point.
(h)Flow฀diagram฀analysis฀method
-Applicable฀to฀complicated฀failures
-Perform฀operations฀as฀per฀the฀given฀flow฀diagram฀to฀find฀out฀the฀failure฀point;
-Other฀methods฀may฀be฀applicable฀during฀operation฀to฀assist฀in฀the฀analysis฀and฀determination.
2.฀Module-like฀solutions฀to฀failure
Module-like฀solutions฀to฀failure฀is฀one฀kind฀of฀method฀to฀check฀the฀failures฀by฀optimum฀priority,฀which฀is฀divided฀into:฀whole฀vehicle
inspection฀module,฀fuel฀supply฀system฀module,฀ignition฀system฀module,฀air฀inlet฀system฀module air฀exhaust฀system฀module,฀and
component฀diagnostic฀module.฀And฀the฀inspection฀on฀these฀modules฀may฀help฀to฀basically฀fix฀the฀failure฀point฀caused฀by฀the
electrical-injection฀system.
(a)Whole฀vehicle฀inspection฀module
฀฀฀฀Step฀I cooling฀vehicle
The฀engine฀keeps฀still฀(for฀about฀30฀seconds)฀when฀the฀key฀switch฀is฀turned฀to฀a฀position ON ;
Test฀item฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀System฀status฀and฀Limit฀value
1)฀฀Display฀of฀fault฀code None
2)฀฀Engine฀fault฀indicator฀light On
3)฀฀Accumulator฀jar฀voltage (11.5฀~฀13)V
4)฀฀Coolant฀temperature฀sensor normal฀temperature
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5)฀฀Inlet฀temperature฀sensor ambient฀temperature
6)฀Absolute-pressure฀sensor฀for฀inlet฀manifold ambient฀atmosphere฀(For฀plain฀area:฀about฀100kPa)
7)฀฀Work฀range฀of฀throttle฀position฀sensor (0฀~฀99.6)%
8)฀฀Oxygen฀sensor <฀200฀mV฀(heating฀type) (฀450฀ ฀10)฀mV(non-heating฀type)
9)฀฀Idle-speed฀control฀valve (40฀~฀159)฀steps฀(step)
Step฀II Idle-speed฀check฀(Preheat฀the฀engine฀to฀a฀normal฀water฀temperature฀after฀it’s฀starting฀)—at฀low฀idle฀speed
Test฀item ฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀System฀status฀and฀Limit฀value
1)฀฀Engine฀fault฀indicator฀light Off
2)฀฀Display฀of฀fault฀code ฀None
3)฀฀Coolant฀temperature (80฀~฀94)
4)฀฀Accumulator฀jar฀voltage (13.5฀~฀14.5)฀V
5)฀฀Rotating฀speed Typical฀idle฀speed฀ 30฀r/min
฀฀(when฀fan,฀headlight,฀and฀air฀blow฀unit฀are฀starting) Typical฀idle฀speed+50฀ ฀30฀r/min
6)฀฀Ignition฀lead-angle (5฀~฀13)
7)฀฀Pressure฀of฀inlet฀manifold (35฀~฀55฀)kPa
8)฀฀Actual฀position฀of฀idle-speed฀motor (15฀~฀30)฀steps
9)฀฀Oil-injection฀pulse฀width (2฀~฀4)฀mS
10)฀฀Jump฀of฀oxygen฀sensor/ten฀seconds ฀6฀times
Step฀III Idle-speed฀check฀(Preheat฀the฀engine฀to฀a฀normal฀water฀temperature฀after฀it’s฀starting฀)฀—at฀high฀idle฀speed
Test฀item฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀System฀status฀and฀Limit฀valu e
1)฀฀Engine฀fault฀indicator฀light Off
5)฀฀Rotating฀speed actual฀value
[controlled฀within฀(2000฀ ฀50)฀r/min]
6)฀฀Ignition฀lead-angle (20฀~฀30)
7)฀฀Oil-injection฀pulse฀width (2฀~฀4)฀mS
8)฀฀Jumps฀of฀oxygen฀sensor฀/10฀seconds 10฀times
Step฀IV:฀฀Driving฀inspection
Driving฀inspection฀includes:฀an฀inspection฀on฀the฀failure฀of฀oxygen฀sensor฀when฀the฀opening฀degree฀of฀throttle฀is฀above฀10 ฀and
lasting฀for฀at฀least฀15฀seconds;฀and฀an฀inspection฀on฀the฀failure฀of฀the฀vehicle฀speed฀sensor฀when฀the฀vehicle฀speed฀reaches฀80฀km/
h฀at฀a฀direct฀gear฀shift,฀and฀when฀it฀slides฀for฀at฀least฀5฀seconds฀after฀the฀throttle฀valve฀is฀closed.
Test฀item฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀System฀status฀and฀Limit฀value

Precautions฀to฀the฀use฀/service฀/troubleshooting฀of฀electrical฀injection฀system EF.2-29
1)฀฀Engine฀fault฀indicator฀light ฀Off
5)฀฀Absolute-pressure฀sensor฀for฀inlet฀manifold 20฀kPa฀~฀atmospheric฀pressure
6)฀฀Work฀range฀of฀throttle฀position฀sensor (0฀~฀99.6)%
7)฀฀Oxygen฀sensor (50฀~฀950)฀mV
(b)฀Fuel฀supply฀system฀module
-฀A฀Diagnosis฀Instrument฀may฀be฀used฀to฀drive฀the฀fuel฀pump—observe฀the฀status฀of฀fuel฀pump฀relay฀and฀fuel฀pump.
-฀Disconnection฀of฀hose฀from฀the฀oil฀entrance฀of฀fuel-rail฀—฀drive฀the฀fuel฀pump—observe฀the฀oil฀going฀out฀of฀pump.
-฀Connection฀with฀the฀fuel฀manometer—drive฀the฀fuel฀pump—observe฀whether฀the฀pressure฀value฀is฀300KPa—The฀pressure
฀฀adjustor฀shall฀be฀changed฀when฀the฀pressure฀is฀higher฀than฀300KPa—And฀the฀fuel฀pump฀or฀pressure฀adjustor฀shall฀be฀changed
฀฀when฀the฀pressure฀is฀lower฀than฀300KP.
-฀Observe฀whether฀the฀pressure฀value฀on฀vehicle฀is฀250kPa฀(idle฀speed)—฀when฀it’s฀higher฀than฀250KP,฀check฀the฀injector.Subject฀to
above฀inspections,฀a฀basic฀determination฀may฀be฀made฀to฀judge฀whether฀each฀relevant฀component฀within฀the฀fuel฀system฀is฀working
in฀a฀normal฀way.
(c)฀Ignition฀system฀module
-฀Subject฀to฀above฀inspections,฀a฀basic฀determination฀may฀be฀made฀to฀judge฀whether฀each฀relevant฀component฀within฀the฀fuel฀฀฀system
is฀working฀in฀a฀normal฀way.฀Remove฀the฀high-tension฀wiring฀on฀cylinder฀1฀or฀4—
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-฀Install฀a฀spark฀plug฀at฀the฀same฀time—drive฀the฀ignition-coil฀for฀ignition—observe฀the฀status฀of฀spark—Remove฀the฀high-฀฀tension
wiring฀on฀cylinder฀2฀or฀3—operate฀in฀the฀same฀way฀above—
-฀Make฀a฀determination฀on฀ignition-coil฀and฀relevant฀loops
-฀Subject฀to฀above฀inspections,฀a฀basic฀determination฀may฀be฀made฀to฀judge฀whether฀each฀relevant฀component฀within฀the฀fuel฀฀฀system
is฀working฀in฀a฀normal฀way.฀Take฀out฀four฀spark฀plugs—observe฀the฀status฀of฀spark-plug฀electrode—determine฀the฀฀฀working฀status
of฀each฀cylinder.
฀-฀Subject฀to฀above฀inspections,฀a฀basic฀determination฀may฀be฀made฀to฀judge฀whether฀each฀relevant฀component฀within฀the฀fuel฀฀฀system
is฀working฀in฀a฀normal฀way.฀Place฀a฀group฀of฀new฀spark฀plugs—After฀starting,฀observe฀the฀engine฀running฀at฀an฀idle฀฀฀speed—Take฀out
spark฀plug฀again฀and฀determine฀the฀working฀status฀of฀each฀cylinder.฀Subject฀to฀above฀inspections,฀a฀basic฀฀฀determination฀may฀be฀made
to฀judge฀whether฀each฀relevant฀component฀within฀the฀ignition฀system฀is฀working฀in฀a฀normal฀way.
(d)฀Air฀inlet฀system฀module
Removal฀of฀air฀filter฀on฀the฀front฀side฀of฀throttle฀valve—to฀ensure฀the฀smooth฀going฀of฀inlet฀air—observe฀the฀change฀of฀engine.
(e)฀Air฀exhaust฀system฀module
Removal฀of฀three-way฀catalytic฀converter฀—to฀ensure฀a฀smooth฀going฀of฀air฀exhaust฀system—฀observe฀the฀change฀ofengine
Based฀on฀above฀inspection,฀a฀basic฀determination฀may฀be฀made฀to฀judge฀whether฀the฀air฀exhaust฀system฀is฀working฀in฀a฀normal฀way.
(f)฀Parts฀&components฀diagnosis฀module
-฀Signal฀input฀components฀determination฀on฀each฀sensor฀may฀be฀made฀based฀on฀whether฀the฀reading฀data฀is฀in฀compliance฀with฀the
status฀of฀such฀sensor(refer฀to฀“Delphi฀engine฀management฀system-฀Delphi฀Determination฀on฀the฀principal฀/utility฀/failure฀of฀key
system฀parts”฀PEF.2-09).
-฀฀Signal฀actuator฀component—a฀Fault฀Diagnosis฀Instrument฀may฀be฀used฀to฀control฀the฀action฀of฀actuator—฀observe฀the฀action฀of
actuator.
Subject฀to฀above฀inspections,฀a฀basic฀determination฀may฀be฀made฀to฀judge฀whether฀the฀parts฀&components฀are฀working฀in฀a฀normal
way.
3.฀Solutions฀to฀common฀failures
(a)฀฀Flame-out฀when฀decelerating
฀-฀Check฀whether฀ECU฀permanent฀power฀supply฀will฀be฀cut฀off฀when฀the฀ignition฀switch฀is฀closed฀(Special฀care฀shall฀be฀given฀to
vehicles฀which฀have฀been฀installed฀with฀theft฀detector฀by฀users฀themselves.);฀and฀this฀terminal฀is฀supposed฀to฀maintain฀a฀permanent
power฀ supply
-฀Wash฀the฀throttle฀valve,฀and฀the฀step฀motor
-฀Check฀valve฀mechanism฀system฀on฀engineAttached฀figure฀I฀and฀II฀are฀Electric-Control฀Schematic฀Diagram฀for
ITMS-฀฀6฀System.

EF.2-30 Delphi฀engine฀management฀system-troubleshooting฀and฀common฀failure
Attached฀figure฀III฀and฀IV฀are฀Electric-Control฀Schematic฀diagram฀for฀MT20U฀SystemAttached฀figure฀V,฀V I , ฀VII,฀and฀VIII฀are฀Typical
Failure฀Diagnosis฀Flow฀Diagram.
(b)฀Slack฀accelerating
- Check฀oil฀amount฀and฀the฀fuel฀filter฀inside฀oil฀tank
-฀฀฀Check฀the฀air฀exhaust฀system฀for฀blockage eg. whether฀three-way฀catalytic฀converter฀has฀been฀blocked฀due฀to฀฀breakage฀or฀the
burning฀of฀machine-oil;฀when฀at฀a฀normal฀idle฀speed,฀the฀pressure฀value฀of฀inlet฀manifold฀shall฀be฀greater฀฀than฀60KPa
฀-฀฀Verify฀whether฀the฀pressure฀within฀fuel฀supply฀loop฀is฀300kPa,฀and฀clean฀the฀oil฀nuzzle .
(c)฀Oil฀consumption฀is฀abnormally฀high
-฀฀After฀a฀verification฀that฀the฀mechanical฀components฀of฀engine฀and฀the฀oxygen฀sensor฀are฀under฀a฀normal฀condition,฀start฀the฀engine
and฀observe฀the฀read฀value฀of฀oxygen฀sensor:฀the฀read฀value฀shall฀be฀always฀greater฀than฀500mV฀when฀at฀a฀normal฀water฀temperature.
And฀check฀whether฀the฀injector฀is฀leaking฀oil,฀and฀whether฀the฀water฀temperature฀sensor,฀and฀the฀฀฀manifold฀pressure฀sensor฀are
working฀in฀a฀normal฀way.
(d)฀Indicating฀a฀failure฀with฀the฀air฀conditioner฀system฀is฀produced฀on฀vehicles฀without฀air฀conditioner.
-฀฀Check฀whether฀the฀pre-installed฀air฀conditioner฀plug฀has฀been฀contaminated,฀if฀so,฀clean฀it฀and฀provide฀it฀with฀a฀dustproof
protection,฀then฀ECU฀power฀supply฀will฀be฀disconnected,฀and฀resumed฀in฀ten฀minutes.
-฀฀Fault฀code฀must฀be฀cleared฀away฀from฀MT20฀system฀using฀a฀Fault฀Diagnosis฀Instrument
(e)฀Removal฀of฀common฀failures฀on฀theft-prevention฀controller
-฀฀The฀theft-prevention฀indicator฀light฀is฀not฀on Check฀the฀power฀supply฀and฀the฀ground฀wire฀for฀theft-prevention฀controller;฀As
฀the฀failure฀of฀control฀computer฀results฀from฀a฀current฀impact฀which฀is฀produced฀at฀the฀time฀when฀inductive฀load฀on฀฀accumulator฀jar
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฀line฀is฀cut฀off,฀the฀electrical-injection฀system฀and฀the฀theft฀detector฀fuse฀shall฀be฀pulled฀out,฀and฀re-inserted฀after฀ten฀seconds.
-฀฀฀Subject฀to฀a฀mating฀between฀electrical-injection฀control฀and฀theft฀detector,฀the฀engine฀fault฀indicator฀light,฀after฀an฀ignition,฀will฀be
flashing฀(at฀2Hz)฀for฀30฀seconds,฀and฀then฀be฀off;฀The฀electrical-injection฀unable฀to฀start฀(the฀electrical-injection฀indicator฀light฀will
be฀flashing฀at฀1H) the฀theft-prevention฀indicator฀light฀will฀be฀on฀for฀2฀seconds฀after฀a฀normal฀ignition,฀and฀then฀be฀off;฀Try฀to
replace฀the฀password฀key;฀when฀PCHUB฀is฀used฀to฀measure฀the฀electrical-injection฀controller,฀the฀unselected฀<no฀key>may฀be
seen,฀which฀indicates฀that฀the฀password฀key฀does฀not฀have฀a฀valid฀password฀repeater That฀the฀selected฀<฀theft฀detector฀no
response>฀is฀seen฀indicates฀that฀the฀communication฀between฀the฀electrical-injection฀controller฀and฀the฀theft฀detector฀has฀not฀been
฀connected.
-฀฀฀When฀the฀electrical-injection฀control฀has฀mated฀with฀the฀theft฀detector,฀it฀will฀be฀flashing฀at฀2Hz฀for฀30฀seconds฀after฀an฀ignition,
then฀be฀off,฀and฀the฀electrical-injection฀is฀starting฀(the฀electrical-injection฀indicator฀light฀is฀permanently฀on฀or฀off),฀the฀theft฀prevention
indicator฀light฀will฀be฀on฀for฀2฀seconds฀after฀a฀normal฀ignition,฀and฀then฀be฀off;฀Such฀failure฀is฀caused฀by฀coils฀having฀not฀be฀fastened
onto฀the฀ignition฀lock฀nut,฀or฀ignition฀nuts฀having฀troubles฀with฀the฀raw฀material;฀Watch฀and฀see฀if฀it฀returns฀to฀a฀normal฀condition฀after
coils฀have฀been฀re-fastened฀onto฀the฀ignition฀lock฀nut฀(unscrewing฀the฀nuts฀may฀be฀needed฀before฀coils฀arere-fastened)฀;฀A฀large฀hole
in฀supporting฀bracket฀for฀ignition฀lock฀might฀make฀coils฀unable฀to฀be฀installed฀onto฀the฀ignition฀lock฀nut;฀if฀it฀is฀still฀unable฀back฀to฀a
normal฀condition,฀the฀ignition฀lock฀nut฀or฀coils฀may฀be฀changed.
(f)฀฀The฀key฀to฀the฀theft-prevention฀controller฀is฀lost฀or฀damaged:
Normally,฀the฀theft฀detector฀within฀electrical-injection฀system฀has฀been฀provided฀with฀two฀types฀of฀key:฀one฀in฀red,฀others฀in฀black.
And฀only฀black฀keys฀are฀for฀routine฀use.
-฀฀฀Black฀key฀lost Provide฀with฀one฀new฀black฀key,฀and฀a฀code฀operation฀study฀for฀black฀key฀is฀needed.
-฀฀฀Red฀key฀lost Provide฀with฀new฀red฀&black฀keys
Change฀the฀original฀theft-detection฀computer,฀as฀the฀theft-detector฀computer฀provided฀for฀original฀vehicle฀only฀accepts฀original
฀red฀key,฀which฀is฀a฀mark฀to฀start฀the฀key฀study฀flow฀process.฀And฀computer฀ECU฀for฀engine฀needs฀to฀be฀posted฀to฀Delphi฀company
for฀a฀decoding฀process,฀as฀computer฀ECU฀for฀engine฀only฀accepts฀an฀original฀mark฀provided฀for฀original฀vehicle฀to฀start฀฀the฀theft-
detector฀computer฀flow฀process.
A฀study฀on฀red฀key฀and฀black฀key฀is฀needed,฀and฀shall฀be฀performed฀successively฀in฀accordance฀with฀the฀code฀operation฀study฀steps
corresponding฀to฀theft-detector฀key.
(The฀code฀operation฀study฀steps฀corresponding฀to฀theft-detector฀key฀may฀be฀claimed฀from฀Delphi฀Company).
Figure฀1฀and฀2฀are฀the฀Electronic฀Principle฀Diagram฀for฀ITMS-6฀system.
Figure฀3฀and฀4฀are฀the฀Electronic฀Principle฀Diagram฀for฀MT20U฀system.
Figure฀5,6,7฀and฀8฀are฀the฀Diagnosis฀Process฀of฀Typical฀Failures.

Delphi฀engine฀management฀system-troubleshooting฀and฀common฀failure EF.2-31
A ttached฀figure฀I
electronic฀ignition฀timing฀3
Note:฀J1-Cxx฀and฀J1-Dxx฀are฀white฀plug฀terminals
electronic฀ignition฀timing฀A J2-Axx฀and฀J2-Bxx฀are฀red฀plug฀terminals
high-voltage
electronic฀ignition฀timing฀B coil฀driver
idle฀valve฀drive฀A(high) spark฀plug
idle-speed฀&air
idle฀valve฀drive฀A(low)
control฀valve
injection฀nozzle
idle฀valve฀drive฀B(high)
idle฀valve฀drive฀B(low)
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injection฀nozzle฀drive฀A
injection฀nozzle฀drive฀B
1ignition฀fuse1 fuel฀pump฀relay
fuel฀pump฀relay
carbon-canister฀wash
solenoid฀valve
฀ignitionfuse2
fault฀diagnosis฀socket
serial฀data battery฀fuse4
diagnosis฀request
engine฀fault฀indicator฀light
engine฀ fault
indicator฀light ignition fuse฀checklist
fuel฀pump injection฀nozzle
fuse1(15A)
ECU฀ignition
carbon-canister฀wash฀solenoid฀valve
fuse2(10A)
theft฀detector฀ignition
fuse3(10A) electronic฀ignition฀control฀module฀-4
ECU฀power฀supply
engine฀rotating-speed฀signal fuse4(10A) theft-detector฀power฀supply
diagnosis-instrument฀power฀supply

A ttached฀figure฀II
fuse4 ฀battery฀fuse4 battery
fuse3 ignitionfuse3 battery
ignition฀switch fuse2 ignition฀fuse2 ignition฀switch
fuse1 ignition฀fuse1
power฀ground
engine฀ fault power฀ground
battery
indicator฀light injection฀nozzle฀(low)A
injection฀nozzle฀(low)B
58gear฀signal฀(high)
58-gear฀ring
58-gear฀signal฀(low)
air฀conditioner฀request฀switch
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air฀conditioner
air-blow฀motor฀switch request฀signal
battery air฀conditioner
airconditioner ฀load฀signal
high฀temperature฀switch฀for฀air clutchrelay
air฀ conditioner air฀ conditioner
compressor
pressure฀switch clutch
oxygen฀ sensor high
oxygen฀sensor oxygen฀sensor(low)
5V฀reference฀voltage
throttle฀position
throttle฀position฀signal
sensor 5 V฀ground฀A
5V฀ground฀B
manifold
absolute-
pressure฀sensor manifold฀absolute-pressure฀signal
coolant฀temperature฀signal
coolant
temperature
sensor
manifold฀air-temperature฀signal
manifold฀air-tem-
perature฀sensor
vehicle฀speed฀signal
vehicle฀speed฀sensor

A ttached฀figure฀III
fuel฀pump accumulator
yellow
purple฀&black
front฀oxygen฀sensor
red
green฀&yellow
pink฀&brown
red฀&yellow
main฀relay
green฀&red
black฀&blue
red฀&yellow
red
black฀&yellow
connected฀to฀ignition฀switch
fuel฀pump฀relay
black&฀yellow
black฀&green
black฀&green
fuel฀injector1
red฀&blue
crankshaft฀position฀sensor
fuel฀injector2 fuel฀injector3 fuel฀injector4
black&฀yellow
brown฀&blue
blue฀&grey
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purple฀&red
coolant฀temperature฀sensor
green฀&red blue฀&red
sensor฀ground1
spark฀plug
green฀&yellow
green฀&red
green฀&yellow blue฀&white
green฀&yellow
knock฀sensor
green
electromagnetic฀switch฀฀for฀carbon-canister฀wash฀control
red
green
red red฀&green
power฀supply/฀generator฀excitation
white฀&black connected฀to฀instrumentation
grey
throttle-valve฀position฀sensor
red฀&yellow black฀&white
blue฀&red fault฀indicator฀light
blue฀&white
blue฀&yellow black฀&yellow
red
connected฀to฀the฀center-control฀door฀&lock฀and฀the฀motorized฀seat
grey฀&black
electromagnetic฀clutch
connected฀to฀the฀center-control฀door฀&lock
connected฀to฀the฀sensor฀for฀vehicle฀speed฀odometer
฀for฀compressor idle-speed฀control฀valve
green฀&purple
connected฀to฀the฀sensor฀for฀speed฀indicator
sensore฀ground2
switch฀(permanently฀closed)
connected฀to฀the฀three-air฀conditioner-status
black฀&yellow blue฀&white
yellow
green
green฀&white
black฀&red
black฀&white
brown฀&red
grey&white
air฀conditioner
connected฀to
grey&white
red red

Delphi฀engine฀management฀system-troubleshooting฀and฀common฀failure
connected฀to฀the฀wire-harness฀inside฀engine฀chamber
connected฀to฀the฀water฀temperature฀sensor
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connected฀ to connected฀ to connected฀to฀the฀sensor฀for connected฀ to฀ the฀ front

connected฀ to connected฀to฀the฀ignition฀coil
injection฀nozzle injection฀nozzle connected฀ to water฀temperature฀gauge
injection฀nozzle oxygen฀sensor
No.1 No.2 injection฀nozzle
No.4
No.3
shielding฀ground
A ttached฀figure฀IV
connected฀ to฀ the

machine-oil฀pressure
switch connected฀ to฀ the
knock฀sensor connected฀ to฀ the฀ idle-speed connected฀ to฀ the connected฀ to฀ the
EF.2-34
control฀valve throttle฀ position carbon-canister฀control

connected฀ to฀ the฀ air฀ inlet connected฀ to฀ the฀ air crankshaft฀position฀sensor
sensor valve
temperature฀/pressure฀sensor conditioner฀clutch

attached฀figure฀V
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Attached฀figure฀VI
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A ttached฀figure฀VII
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A ttached฀figure฀VIII
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EM.1-1
Engine฀body
Page
Disassembly฀figure฀of฀engine฀body .................................. .....................................EM.1-2

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Preparations฀before฀and฀key฀points฀to฀the฀disassembly฀of฀engine฀body...................EM.1-3
Disassembly฀of฀engine฀body ................................................................................EM.1-4
Inspection฀on฀engine฀body ...................................................................................EM.1-9
Inspection฀on฀camshaft฀components ............................... ...................................EM.1-10
Disassembly฀of฀piston฀and฀connection-rod฀components .. ...................................EM.1-12
Inspection฀on฀piston฀and฀connection-rod฀components ..... ...................................EM.1-13
Assembly฀of฀piston฀and฀connection-rod฀components...........................................EM.1-18
Installation฀of฀engine฀body..................................................................................EM.1-20
Assembly฀of฀engine฀body...................................................................................EM.1-22

EM.1-2 Disassembly฀figure฀of฀engine฀body
Disassembly฀figure฀of฀engine฀body
piston฀ring
piston
timing฀chainwheel
chamber฀cover connection-rod
timing฀chain฀and฀chainwheel connection-rod
bearing฀bush
timing฀ chainwheel
chamber
sealing฀gasket
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rear฀oil-seal฀cover
sealing฀gasket sealing฀gasket
crankshaft฀pulley crankshaft
crankshaft฀main฀bearing
crankshaft฀thrust฀washer
main฀bearing฀cover
oil฀pump
crankcase฀oil฀tray

Preparations฀before฀and฀key฀points฀to฀the฀disassembly฀of฀engine฀body EM.1-3
Preparations฀before฀and฀key฀points฀to฀the
disassembly฀of฀engine฀body
1.฀Preparations฀before฀the฀disassembly฀of฀engine฀body
(a)
-Removal฀of฀flywheel.
-The฀flywheel฀may฀be฀removed฀by฀unscrewing฀six฀bolts.
(b)Removal฀of฀rear฀end฀cover฀plate
The฀rear฀end฀cover฀plate฀may฀be฀removed฀by฀unscrewing฀two฀bolts.
(c)Installation฀of฀engine฀support฀for฀an฀easy฀disassembly.
(d)Remove฀the฀cylinder฀cover.
(e)Removal฀of฀brackets฀connecting฀the฀oil฀filter
Bolts฀&nuts,฀and฀brackets฀connecting฀the฀oil฀filter฀shall฀be฀dismantled.
(f)The฀engine฀installation฀bracket฀on฀the฀left฀&right฀side฀shall฀be
removed.
(g)Remove฀ the฀ cooling-fluid฀ release฀ valve namely฀ water฀ drain
switch from฀engine.
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(h)Dismantle฀the฀oil฀pressure฀switch
(i)Removal฀of฀cooling-water฀bypass฀pipe.
The฀cooling-water฀bypass฀pipe฀may฀be฀removed฀by฀unscrewing฀bolts.
(j)Dismantle฀the฀AC฀generator฀bracket.
(k)Remove฀the฀sealing฀ring฀from฀oil฀seat฀on฀the฀rear฀end.
The฀sealing฀ring฀may฀be฀removed฀from฀oil฀seat฀on฀the฀rear฀end฀by฀฀unscrewing
five฀bolts.

EM.1-4 Preparations฀before฀and฀key฀points฀to฀the฀disassembly฀of฀engine฀body
2.฀Key฀points฀to฀the฀disassembly฀of฀engine฀body
(a)As฀oil฀dish฀is฀sealed฀by฀joint฀strip฀and฀sealing฀gum,฀S S T฀shall฀be฀inserted
to฀a฀place฀between฀the฀engine฀body฀and฀the฀crankcase฀oil฀tray฀to฀thoroughly
cut฀off฀the฀sealing฀material฀after฀the฀fixing฀bolts฀have฀been฀unscrewed.
(b)During฀the฀disassembly฀of฀bearing฀cover฀from฀the฀connection-rod,฀match
marks฀must฀be฀made฀to฀assure฀a฀correct฀re-assembly฀at฀a฀later฀stage.฀During
the฀removal฀of฀the฀piston฀connection-rod฀assembly฀from฀the฀engine฀body,
steps฀on฀cylinder฀shall฀be฀scraped฀away฀at฀top฀priority£¬and฀the฀threaded
part฀of฀connection-rod฀bolt฀must฀be฀installed฀with฀plastic฀pipe฀to฀avoid฀any
strike฀or฀damage฀on฀the฀crankshaft.
(c)The฀removed฀components,฀particularly฀main฀bearing฀cover฀of฀crankshaft,
bearing,฀thrust฀washer,฀shall฀be฀placed฀in฀order฀as฀per฀the฀sequence฀for฀a
correct฀&easy฀re-assembly&฀restoration฀to฀place.
front
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Disassembly฀of฀the฀cylinder฀unit
1.฀Measure฀the฀axial฀clearance฀of฀connection-rod
(a)The฀axial฀clearance฀of฀connection-rod฀may฀be฀measured฀using฀a฀micrometer
while฀the฀connection-rod฀is฀moving฀back฀and฀forth.
Standard฀ clearance (0.16 0.31)mm
M ax.฀ clear ance 0.35฀ mm
(b)If฀the฀actual฀clearance฀is฀greater฀than฀Max.฀value,฀the฀connection-rod฀and
/or฀crankshaft฀shall฀be฀changed.
2.฀Measure฀the฀oil฀clearance฀of฀connection-rod
(a)A฀punch฀head฀or฀number฀punch฀head฀may฀be฀used฀to฀make฀match
marks฀on฀the฀connection-rod฀and฀its฀cover฀to฀assure฀acorrectreassembly.
(b)A฀twelve-edge฀socket฀spanner฀may฀be฀used฀to฀unscrew฀the฀fixing฀nuts฀on
the฀connection-rod฀cover.

(c)฀A฀plastic฀hammer฀may฀be฀used฀to฀remove฀the฀connection-rod฀cover฀by฀gently
striking฀against฀the฀connection-rod฀bolt.
Remark฀ Have฀the฀lower฀bearing฀bush฀retained฀inside฀the฀connection-rod
cover.
(d)To฀prevent฀crankshaft฀from฀damage,฀the฀connection-rod฀bolt฀shall฀be฀installed
with฀short฀hose฀sleeve.
(e)Clean฀the฀connection-rod฀bush,฀and฀the฀connection-rod฀neck-journal.
(f)Check฀whether฀each฀bearing฀bush฀has฀any฀exfoliation฀or฀scratch.฀If฀the
connection-rod฀neck-journal,฀or฀the฀main-bearing฀bush฀of฀crankshaft฀has฀some
damages,฀the฀crankshaft,฀and฀the฀main-bearing฀bush฀shall฀be฀changed.
(g)Remove฀the฀short฀hose.
(h)Put฀one฀piece฀of฀plastic฀feeler฀gaugeonto฀the฀connection-rod฀neck-journal.
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(i)฀The฀installation฀of฀connection-rod฀cover฀shall฀be฀subject฀to฀marks฀made฀on
the฀connection-rod฀and฀its฀cover.฀Nuts฀on฀the฀connection-rod฀cover฀shall฀be
tightened฀as฀per฀specified฀tightening฀moment฀and฀steps.
Remark Do฀not฀rotate฀the฀crankshaft.
Prior฀to฀the฀installation,฀a฀thin฀layer฀of฀oil฀must฀be฀applied฀to฀the฀threaded฀part
of฀nut,฀and฀to฀the฀lower฀part฀of฀nuts฀as฀well.
(j)฀Removal฀of฀the฀connection-rod฀cover
(k)A฀measurement฀shall฀proceed฀at฀the฀widest฀point฀of฀plastic฀feelergage.
Standard฀clearance (0.021 0.051)mm
(l)Thoroughly฀clear฀away฀plastic฀feeler฀gauge฀strips฀and฀pieces.
Remark When฀a฀standard฀bearing฀bush฀is฀used,฀it฀shall฀have฀the฀same฀No.฀as
that฀on฀the฀bearing฀cover.฀Standard฀bearing฀bush฀is฀available฀with฀three฀sizes,
which฀may฀be฀indicated฀respectively฀by฀relevant฀marks฀including:฀6,฀7,฀8.

491QE฀connection-rod฀bearing฀bush฀hole฀and฀connection-rod฀neck-journal mm
H ole diameter
D iameter of
of M ax . abrasion
S .N connection-rod C learance
connection-rod cl earance
neck -journal
bearing bush
+ 0 . 037 0
+ 0 . 022 − 0 . 015
+ 0 . 036 0
+ 0 . 0211 − 0 . 015
+ 0 . 035 0
+ 0 . 0201 − 0 . 015
3.฀Remove฀piston฀and฀the฀connection-rod฀component
(a) All฀carbon฀deposits฀shall฀be฀cleared฀away฀from฀the฀top฀of฀the฀cylinder.
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(b)To฀prevent฀the฀crankshaft฀neck-journal฀from฀damage,฀the฀connection-rod
bolt฀shall฀be฀installed฀with฀a฀short฀hose฀sleeve.
(c)Remove฀piston,฀the฀connection-rod,฀and฀the฀upper฀bearing฀bush฀from฀the
top฀of฀the฀engine฀body฀by฀pushing.
Remark
front - Always฀keep฀the฀connection-rod฀bush฀and฀the฀connection-rod฀cover฀as฀an
integral฀part.
-฀Piston฀and฀the฀connection-rod฀cover฀shall฀be฀put฀in฀order฀as฀per฀a฀correct
฀฀฀sequence.
4.฀Measure฀the฀axial฀clearance฀of฀crankshaft
Its฀axial฀clearance฀may฀be฀measured฀by฀a฀micrometer฀when฀prizing฀the฀crankshaft
with฀a฀screwdriver฀on฀front฀and฀back฀side.
Standard฀axial฀clearance (0.02 0.22)mm
M ax.฀ axial฀ clear ance 0.30฀ mm
I f฀the฀ actual฀axial฀clearance฀is฀greater฀than฀M ax฀value฀a฀whole฀seto฀fthrus
twashers฀hallbe฀changed.
T he฀increased฀size฀applicable฀to฀the฀repair฀of฀thrust฀washer฀shall฀be0.125฀and
0.250mm.

5.฀Measure฀the฀oil฀clearance฀of฀main฀neck-journa r adial
cl ear ance
(a) A฀twelve-edge฀socket฀spanner฀may฀be฀used฀to฀unscrew฀and฀remove฀bolts฀on
main฀bearing฀cover฀progressively฀in฀three฀steps฀in฀accordance฀with฀numeric
sequence฀indicated฀in฀the฀figure.
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(b)Theremovedboltmaybeusedtoprizethebearingcoverbackandforthtoremove
the฀bearing฀cover฀which฀has฀connected฀with฀the฀lower฀bearing฀bush฀and฀the
thrust฀washer only฀ for฀ No.฀ 3฀ main฀ neck-journal at฀the฀same฀time.
Remark
-Keep฀the฀lower฀bearing฀bush฀and฀the฀bearing฀cover฀as฀an฀integral฀part,฀and฀do
not฀keep฀them฀apart.
-Place฀the฀lower฀thrust฀washer฀of฀bearing฀cover฀in฀order฀as฀per฀a฀฀correct
sequence.
(c)Dismantle฀of฀crankshaft
Remark Keep฀the฀upper฀bearing฀bush,฀and฀the฀upper฀thrust฀฀washer฀ only
for฀No.3฀main฀neck-journal with฀the฀engine฀body฀as฀an฀integral฀part.฀Do฀not
keep฀them฀apart.
(d)Clean฀the฀main฀neck-journal฀and฀the฀bearing฀bush.
(e)Check฀whether฀the฀main฀neck-journal฀and฀the฀main-bearing฀bush฀has฀any
scratch฀or฀exfoliation.
If฀the฀main฀neck-journal฀and฀the฀main-bearing฀bush฀has฀some฀damages,฀the
crankshaft฀shall฀be฀abraded,฀repaired,฀or฀changed,฀and฀the฀main-bearing฀bush
shall฀be฀changed.
(f)Place฀the฀crankshaft฀onto฀the฀engine฀body.
(g)Place฀a฀piece฀of฀plastic฀feeler฀gauge฀horizontally฀onto฀each฀main฀neck
journal.
(h)Install฀the฀crankshaft฀main฀bearing฀cover฀which฀connects฀with฀the฀lower
bearing฀bush฀and฀the฀lower฀thrust฀washer;฀And฀install฀and tighten฀bolts฀on
the฀main฀bearing฀cover do฀not฀rotate฀crankshaft฀then
(i)Remove฀main฀bearing฀cover฀from฀the฀crankshaft.
(j)A฀measurement฀shall฀proceed฀at฀the฀widest฀point฀of฀plastic฀feeler฀gage.
Standard฀clearance (0.020 0.049)mm
If฀the฀actual฀clearance฀is฀greater฀than฀Max.฀value,฀the฀main-bearing฀bush฀shall฀be
changed,฀or฀/and฀the฀main฀neck-journal฀shall฀be฀abraded฀and฀repaired.
B ear ing฀bush฀with฀a฀r educed฀size ฀0.25฀mm

(k)Plastic฀feeler฀gauge฀shall฀be฀scraped฀thoroughly฀away฀from฀the฀main-bearing
bush฀and฀the฀main฀neck-journal.
Remark If฀a฀standard฀bearing฀bush฀is฀to฀be฀used replace฀with฀a฀bearing
bush฀having฀the฀same฀mark฀as฀that฀made฀on฀the฀engine฀body at฀a฀place฀close
to฀cylinder฀hole฀and฀on฀the฀contacting฀surface฀between฀the฀cylinder฀and฀the
cylinder฀cover .฀And฀standard฀bearing฀bush฀is฀available฀with฀three฀size฀which
may฀be฀indicated฀by฀relevant฀marks฀including:฀1,฀2,฀or฀3.
Main฀bearing฀hole฀and฀main฀neck-journal฀ mm on฀crankshaft
front D iameter of
D iameter
main M ax .
of main
S .N -journal abrasion
6.฀Dismantle฀of฀main-bearing฀bush bearing on C learance
on clearance
(a) Remove฀the฀crankshaft. crank shaf t
crank shaf t
(b)The฀upper฀bearing฀bush฀and฀the฀upper฀thrust
0.022
washeroncrankshaft฀may฀be฀removed฀from฀the฀engine 1 58 ++ 00..03 6
0 22 58 0− 0 . 01 5
0.053
body.
(c)฀฀Put฀the฀main฀bearing฀cover,฀the฀main-bearing฀bush + 0 . 03 7 0 0.022
2 58 + 0 . 0 22 58 − 0 . 01 5 0.10
and฀ thethrust฀ washer฀ in฀ order฀ as฀ per฀ a฀ correct 0.052
sequence. 0.021
3 58 ++ 00..03 6
0 21 58 0− 0 . 01 5
0.051
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7.฀Removal฀of฀camshaft
(a) Take฀out฀the฀hydraulic฀tappet.
As฀shown฀in฀the฀figure,฀a฀thin฀steel฀wire฀ may฀be฀used฀to฀take฀outthe
hydraulic฀tappet.
(b)Remove฀the฀chain฀shock-absorber.
(c)Remove฀the฀thrust฀collar฀from฀camshaft.

(d)Remove฀the฀camshaft.
Inspection฀on฀engine฀body
1.฀W ash฀the฀engine฀body.
A฀spacer฀scraper฀may฀be฀used฀to฀clear฀all฀spacer฀materials฀away฀from฀the฀surface฀of
the฀engine฀body.
2.฀W ash฀the฀engine฀body
The฀engine฀body฀may฀be฀washed฀using฀soft฀brush฀and฀solvent.
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3.฀Check฀the฀cylinder
(a) Verify฀by฀visual฀check฀whether฀any฀longitudinal฀scratched฀traceremains฀on฀the
wall฀of฀the฀cylinder.
(b)If฀there’s฀any฀deep฀scratched฀trace,฀four฀cylinders฀must฀be฀re-bored.
4.฀Check฀the฀flexural฀deflection฀of฀the฀engine฀body
(a)Precise฀ruler฀and฀feeler฀gauge฀may฀be฀used฀to฀check฀whether฀anyflexural
deflection฀exists฀on฀the฀surface฀where฀the฀spacer฀of฀cylindercoveris฀installed.
Max.฀flexural฀deflection 0.05฀ mm
(b)If฀the฀actual฀flexural฀deflection฀is฀greater฀than฀Max.฀value,฀the฀enginebodyshall
be฀changed.
5.฀Measure฀the฀diameter฀of฀cylinder
1.pushing฀direction (a) A฀bore฀gauge฀may฀be฀used฀to฀measure฀the฀diameter฀of฀cylinder฀at฀axial฀point฀A ,
front
2.axial฀direction B฀and฀C฀of฀push฀force.
Standard฀diameter฀ (91 91.03)mm
M ax.฀ diameter ฀ 91.24฀ mm
If฀the฀actual฀diameter฀is฀greater฀than฀Max.฀value,฀four฀cylinders฀must฀be฀re฀bored;
A nd฀the฀engine฀body฀shall฀be฀changed฀when฀necessary.
middle (b)T he฀difference฀of฀values฀measured฀at฀point฀A ,฀B ฀and฀C฀respectively฀shall
be฀less฀than฀the฀limit฀of฀cylindricity.
limit฀ of฀ cylindr icity 0.01฀ mm

EM.1-10
(c)฀The฀difference฀of฀values฀measured฀from฀pushing฀direction฀and฀axial฀direction
respectively฀shall฀be฀less฀than฀the฀limit฀of฀roundness.
Limit฀of฀roundness 0.02฀ mm
Inspection฀on฀camshaft฀components
ProCarManuals.com
1.฀Check฀the฀tension฀degree฀of฀timing฀chain
When฀a฀98N฀force฀is฀applied฀to฀pull฀the฀timing฀chain฀at฀a฀position฀as฀indicated
in฀the฀figure,฀a฀spring฀balance฀may฀be฀used฀to฀measure฀Max.฀clearance฀between
the฀plunger฀piston฀and฀the฀support฀seat฀of฀chain฀tensioner,฀which฀shall฀not
exceed฀13.5mm.฀If฀the฀actual฀clearance฀exceeds฀Max.฀clearance,฀the฀timing
chain฀or฀chainwheel฀shall฀be฀changed.
2.฀Check฀the฀length฀of฀timing฀chain
Using฀measurement฀methods฀given฀in฀the฀figure,฀a฀spring฀balance฀may฀be฀used
to฀verify฀the฀Max.฀length฀of฀chain฀(291.4mm)฀when฀a฀49N฀pulling฀force฀is
applied.฀And฀two฀or฀three฀points฀may฀be฀selected฀anddeterminedasmeasure
ment฀point.฀If฀Max.฀length฀of฀chain฀exceeds฀the฀limit฀value,฀the฀chainshall฀be
changed.
C heck ฀the฀diameter ฀of฀timing฀chainwheel

(a)Using฀measurement฀methods฀given฀in฀the฀figure,฀a฀vernier฀caliper฀may
be฀ used฀ to฀ measure฀ the฀ diameter฀ of฀ timing฀ chainwheel฀ (with฀ chain).
Min.฀diameter฀of฀timing฀chainwheel฀ with฀chain฀
T iming฀ chainwheel฀ on฀ cr ank shaft฀ 580-0.2฀ mm
T iming฀ chainwheel฀ on฀ camshaft฀ 1130-0.23฀ mm
I f ฀ the฀ actual ฀ di ameter฀ of ฀ chai nwheel ฀ i s฀ l ess฀ than฀ M i n. ฀ val ue,
twochainwheelsand฀chainsshall฀be฀changed.

(b)฀฀Check฀the฀abrasion฀situation฀of฀plunger฀piston฀on฀chain฀tensioner.฀If฀a
vernier฀caliper฀is฀used฀to฀measure฀Min.฀thickness฀on฀the฀head฀of฀plunger
piston,฀it฀shall฀not฀be฀less฀than฀12.5mm.฀If฀the฀actual฀of฀thickness฀is฀less฀than
Min.฀value,฀the฀plunger฀piston฀shall฀be฀changed,฀otherwise,฀the฀tension฀of
timing฀chain฀may฀be฀affected฀adversely.
(c)฀฀Check฀the฀chain฀tensioner
Callipers฀may฀be฀used฀to฀measure฀the฀thickness฀of฀chain฀tensioner.
Standard฀thickness 15.0฀ mm
M in.฀ thick ness 12.5฀ mm
If฀the฀actual฀thickness฀is฀less฀than฀Min.฀value,฀the฀chain฀tensioner฀shall฀be
changed.
4.฀Check฀the฀bending฀of฀camshaft
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Place฀the฀front฀&back฀neck-journal฀of฀camshaft฀onto฀a฀V-shaped฀steel;฀And฀a
dial฀gauge dial฀indicator may฀be฀used฀to฀measure฀the฀bending฀on฀the
middle฀neck-journal.฀If฀the฀actual฀bending฀exceeds฀the฀limit฀value,฀which฀is฀0
06mm,฀the฀camshaft฀shall฀be฀changed.
฀5.฀Check฀the฀height฀of฀convexity฀on฀camshaft
(a)฀Check฀if฀there’s฀any฀pockmark,฀damaged฀mark,฀or฀abnormal฀abrasion
on฀the฀whole฀surface฀of฀cam,฀and฀the฀camshaft฀shall฀be฀changed฀when฀necessary.
If฀there’s฀slight฀amount฀of฀pockmark฀or฀damaged฀mark,฀which฀will฀not฀affect
the฀work฀of฀camshaft,฀the฀surface฀shall฀be฀abraded฀and฀repaired฀using฀oilstone.
And฀a฀micrometer฀shall฀be฀used฀to฀measure฀the฀height฀of฀convexity฀on฀camshaft,
and฀Min.฀height฀of฀convexity฀may฀be฀measured฀at฀the฀big฀end฀on฀the฀slope฀of
cam.฀ If฀ the฀ height฀ of฀ convexity฀ is฀ less฀ than฀ Min.฀ value,฀ the฀ camshaft
+ 0 . 720
A ir inlet cam: 38 mm
+ 0 . 620
+ 0 . 729
A ir ex haust cam:38 mm
+ 0 . 629
(b) Check฀the฀mating฀clearance฀between฀the฀camshaft฀neck-journal฀and฀the
camshaft฀bearing.฀The฀standard฀value฀shall฀be฀(0.025 0.081)mm,฀and฀the฀limit
value฀shall฀be฀0.1mm.฀If฀the฀actual฀clearance฀value฀exceeds฀the฀limit฀value,฀the
bearing฀or฀camshaft฀shall฀be฀changed.

6.฀Check฀the฀axial฀clearance฀of฀camshaft
The฀thrust฀collar,฀and฀the฀timing฀chainwheel฀shall฀be฀installed฀onto฀the
camshaft;฀and฀fixing฀bolts฀shall฀be฀tightened฀to฀the฀specified฀tightening
moment.฀And฀a฀thickness฀gauge฀may฀be฀used฀to฀measure฀the฀axial฀clearan
as฀shown฀in฀figure on฀thrust฀surface฀between฀the฀thrust฀collar฀and฀the
front฀neck-journal฀of฀camshaft;฀The฀standard฀value฀shall฀be฀(0.07 0.22)
mm,฀and฀the฀limit฀value฀shall฀be฀0.3mm.฀If฀the฀actual฀clearance฀exceeds฀the
limit฀ value,฀ the฀ thrust฀ collar฀ or฀ camshaft฀ shall฀ be฀ changed.
Disassembly฀of฀piston฀and฀connection-rod
components
1.฀Check฀the฀mating฀situation฀between฀the฀piston฀and฀the
piston฀pin
Pull฀the฀piston฀installed฀on฀piston฀pin฀back฀and฀forth;฀If฀it฀feelsloose,฀the
piston฀and฀the
piston฀pin฀shall฀be฀changed.
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2.฀Removal฀of฀piston฀ring
(a) The฀first฀and฀second฀piston฀ring฀may฀be฀removed฀using฀a฀expander.
(b)Manually฀ remove฀ the฀ retaining฀ ring฀ and฀ the฀ oil฀ piston฀ ring฀ on
two฀sides฀of฀oil฀ring.
Remark The฀ piston฀ ring฀ shall฀ be฀ placed฀ in฀ order฀ as฀ per฀ acorrect
sequence.
R emove฀the฀connection-r od฀fr om฀the฀piston

A ฀special฀tool฀SST ฀may฀be฀used฀to฀take฀out฀the฀piston฀pin.
SST ฀09221-00020฀฀09221-00030฀฀09221-00040
09221-00071฀฀09221-00081
piston฀pin

Remark
Piston฀and฀piston฀pin฀are฀mating฀members;฀And฀the฀installation฀of฀piston,
piston฀pin,฀piston฀ring,฀connection-rod,฀and฀bearing฀bush฀shall฀be฀subject
to฀a฀correct฀sequence.
Inspection฀on฀piston฀and฀connection-rod
components
1.฀Clean฀the฀piston
(a) Gasket฀scraper฀may฀be฀used฀to฀clear฀carbon฀deposit฀away฀from฀the฀top
of฀piston.
ProCarManuals.com
(b)Cleaning฀tools฀applicable฀to฀piston฀ring-groove,฀or฀broken฀piston฀ring
may฀be฀used฀to฀clear฀all฀contaminants฀away฀from฀the฀ring-groove.
(c)฀Piston฀may฀be฀thoroughly฀washed฀using฀solvent฀and฀soft฀brush.
Note:฀Do฀not฀use฀steel-wire฀brush.
2.฀Measure฀the฀clearance฀of฀piston
(a) A฀micrometer฀may฀be฀used฀to฀measure฀the฀diameter฀of฀long฀piston
shaft฀at฀a฀place฀24mm฀away฀from฀the฀top฀of฀piston.
Standard฀piston฀diameter฀ (90.938 90.968)mm
(b) T he฀diameter฀of฀cylinder฀may฀be฀measured฀from฀a฀pushing฀direction.

(c)The฀measured฀value฀of฀diameter฀for฀piston฀shall฀be฀reduced฀by฀that฀for
the฀engine฀body.
Standard฀piston฀clearance (0.065 0.085)mm
Oper ation฀limit: 0.085฀mm
If฀the฀actual฀piston฀clearance฀is฀greater฀than฀Max.฀value,฀all฀pistons฀for฀four
cylinders฀must฀be฀changed,฀and฀/or฀four฀cylinders฀must฀be฀re-bored.
3.฀Measure฀the฀clearance฀between฀the฀piston฀ring-groove฀and
the฀piston฀ring
(a)Aclearancegaugemaybeusedtomeasuretheclearancebetweennew฀piston฀ring฀and
ring-groove.
฀ ฀Standard฀ring-groove฀clea(0.03~0.075)mm
Max฀ring฀grooveclearance0.2mm
(b)The฀piston฀shall฀be฀changed฀if฀the฀actual฀clearance฀is฀greater฀than฀Max.฀value.
4.฀Check฀the฀clearance฀of฀opening฀for฀piston฀ring
(a) Install฀the฀piston฀ring฀into฀cylinder.
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(b) The฀ piston฀ =ring฀ may฀ be฀ pushed฀ to฀ the฀ end฀ of฀ stroke฀ by฀ piston,
then฀a฀measurement฀may฀proceed฀using฀chock฀gauge.
(c) A฀feeler฀gauge฀may฀be฀used฀to฀measure฀the฀clearance฀ofopening.
-If฀the฀actual฀opening฀clearance฀is฀greater฀than฀Max.฀value,฀thepiston฀ring฀shall
be฀changed.
-If฀the฀actual฀opening฀clearance฀is฀still฀greater฀than฀Max.฀valueafter฀a฀replacement
with฀new฀piston฀ring,฀the฀cylinder฀shall฀be฀rebored,฀and฀piston฀ring฀with฀an
increased฀size฀shall฀be฀used.฀It’sstrictly฀prohibited฀to฀file฀the฀end฀of฀pistonring.
The฀ opening฀ clearance฀ of฀ piston฀ ring mm

R ing
1st ring 2nd ring Oil ring
value
Standard
value
Max.
value
฀5.฀Inspection฀on฀connection-rod
(a)A฀straightener฀may฀be฀used฀to฀check฀the฀linearity฀of฀connection-rod฀in฀follo
wing฀aspects:
-฀Check฀the฀bending฀deformation.
Max.฀bending฀deformation 0.05฀mm/100฀mm
T he฀ connection-rod฀ component฀ shall฀ be฀ changed฀ if฀ the฀ actual฀ bending
deformation฀is฀greater฀than฀Max.฀value.

-Check฀the฀torsional฀deformation
Max.฀torsional฀deformation 0.15฀mm/100฀mm
T he฀connection-rod฀component฀shall฀be฀changed฀if฀the฀actual฀torsional
deformation฀is฀greater฀than฀Max.฀value.
R emark I f฀ the฀ connection-rod฀ needs฀ to฀ be฀ changed,฀ the฀ No.฀ for
connection-rod฀bearing฀bush฀shall฀be฀the฀same฀that฀fornewconnection-rod
bearing฀cover
(b)Check฀the฀connection-rod฀bolt฀using฀following฀method:
-One฀nut฀may฀be฀screwed฀into฀each฀connection-rod฀bolt,฀and฀check฀whether
nut฀may฀be฀manually฀screwed฀to฀the฀end฀of฀thread.
-If฀nut฀can฀not฀be฀dismantled฀after฀being฀screwed฀to฀the฀lower฀part฀of
thread,฀a฀measuring฀tool฀shall฀be฀used฀to฀measure฀the฀diameter฀of฀small
excircle.
-If฀the฀position฀of฀small฀excircle฀can฀not฀be฀determined฀visually,฀the
diameter฀of฀small฀excircle฀may฀be฀measured฀at฀the฀position฀as฀indicated฀in
ProCarManuals.com
the฀figure.
฀฀฀฀฀฀Standard฀diameter฀ (7.4 7.6)mm
฀฀฀฀฀฀M in.฀diameter ฀ 7.2฀mm
If฀the฀measured฀value฀is฀less฀than฀Min.฀value,฀nuts฀on฀bearing฀cover฀for
connection-rod฀and฀connection-rod฀bolt฀shall฀be฀changed.
(c)Measure฀the฀oil฀clearance฀between฀the฀lining฀on฀small฀end฀of฀connection-
rod฀and฀the฀piston฀pin.
฀-A฀caliper฀gauge฀shall฀be฀used฀to฀measure฀the฀inner฀diameter฀of฀lining฀on
small฀end฀of฀the฀connection-rod.
฀Standard฀diameter฀ (24.008 24.009)mm
-A ฀micrometer฀is฀used฀to฀measure฀the฀external฀diameter฀of฀piston฀pin.
฀Standar d฀ diameter ฀ (24.000 24.009)mm
-T he฀diameter฀of฀piston฀pin฀will฀be฀reduced฀by฀the฀measured฀value฀of
diameter฀for฀small฀end฀lining฀on฀the฀connection-rod.
Standar d฀ oil฀ clear ance (0.005 0.011)mm
M ax.฀ oil฀ clear ance 0.015฀ mm
If฀the฀actual฀oil฀clearance฀is฀greater฀that฀Max.฀value,฀the฀lining฀on฀small฀end
Piston฀pin฀and฀piston฀pin฀hole(mm)
S Diameter Diameter
Mating
. of piston of R emark
clearance
N pin hole piston pin
+0. 016 0
+ 0. 012 − 0. 003
Match-
+0. 012 −0. 003 making
+ 0. 009 − 0. 006
by three
groups
+0. 009 −0. 006
+ 0. 006 − 0. 010

6.฀Change฀of฀lining฀on฀small฀end฀of฀the฀connection-rod
(a)Remove฀lining฀from฀small฀end฀of฀the฀connection-rod฀Using฀SST,฀lining
may฀be฀removed฀from฀the฀small฀end฀of฀connection-rod.
SST฀09207-76010
(b)Installation฀of฀new฀lining
Using฀SST,฀lining฀may฀be฀re-installed฀into฀the฀small฀end฀of฀connectionrod.
Remark Make฀the฀oil฀hole฀of฀lining฀facing฀exactly฀the฀oil฀hole฀on฀the
small฀end฀of฀connection-rod.
oil฀hole
ProCarManuals.com
SST
(c)New฀lining฀will฀be฀honed,฀and฀check฀the฀mating฀of฀piston฀pin฀with฀the
lining฀on฀small฀end฀of฀the฀connection-rod.
-New฀lining฀will฀be฀honed,฀and฀check฀whether฀the฀oil฀clearance฀is฀within
a฀standard฀scope.
Standard฀oil฀clearance (0.005 0.011)mm
-Check฀the฀mating฀of฀piston฀pin฀under฀a฀normal฀room฀temperature.Piston
pin฀will฀be฀applied฀with฀appropriate฀amount฀of฀oil,฀and฀be฀pushed฀by
thumb฀into฀lining฀on฀small฀end฀of฀the฀connection-rod.
7.฀Inspection฀on฀crankshaft
(a)Measure฀the฀radial฀runout฀of฀crankshaft
-Place฀the฀crankshaft฀on฀a฀V-shaped฀piece.
-A฀micrometer฀may฀be฀used฀to฀measure฀the฀circumferential฀radial฀runout
atthe฀center฀of฀the฀neck-journal.
Max.฀circumferential฀radial฀runout 0.06฀ mm
If฀the฀actual฀runout฀is฀greater฀than฀Max.฀value,฀the฀crankshaft฀shall฀be
changed.
R emark A ฀long฀mandrel฀shall฀be฀applied฀to฀the฀micrometer.

(b)Inspection฀on฀main฀neck-journal฀and฀the฀connection-rod฀neck-journal
A฀micrometer฀may฀be฀used฀to฀measure฀the฀diameter฀of฀main฀neck-journal
and฀that฀of฀the฀connection-rod฀neck-journal.
Diameter฀of฀main฀neck-journal (57.985 58.000)mm

Diameter ฀of฀the฀connection-r od฀neck -j our nal฀ (47.985 48.000)
mm
ProCarManuals.com
Measure฀the฀roundness฀and฀cylindrictiy฀of฀neck-journal฀as฀indicated฀in
the฀figure.
Max.฀ cylindrictiy 0.02฀ mm
M ax.฀ r oundness 0.02฀ mm
T he฀crankshaft฀may฀be฀abraded,฀repaired฀and฀/or฀changed฀if฀the฀actual
roundness฀and฀cylindrictiy฀is฀greater฀than฀Max.฀value.
(c)Main฀neck-journal฀or฀/and฀the฀connection-rod฀neck-journal฀may฀be
abraded฀and฀repaired฀when฀necessary.
-Main฀neck-journal฀or฀/and฀the฀connection-rod฀neck-journal฀may฀be฀abraded
and฀repaired฀to฀a฀reduced฀diameter.
R educed฀size฀of฀the฀bear ing฀bush฀hole ฀U/S฀0.25฀mm
F inal฀ diameter ฀ of฀main฀ neck -j our nal (57.485 57.500)mm
F inal฀diameter ฀of฀connection-r od฀ neck -j our nal (47.485 47.500)
mm
-New฀bearing฀bush฀with฀a฀reduced฀size฀may฀be฀installed฀onto฀main฀neck-
journal฀or฀/and฀the฀connection-rod฀neck-journal.
8.฀Change฀of฀oil-seal
(a)Oil-seal฀shall฀be฀removed฀using฀screwdriver฀and฀hammer.

(b)MP฀multi-purpose฀grease฀may฀be฀applied฀to฀the฀lip฀of฀new฀oil-seal.
(c)New฀oil-seal฀will฀be฀installed฀using฀SST.
SST฀09223-56010
Remark The฀oil-seal฀shall฀not฀be฀installed฀to฀an฀inclined฀shape.
9.฀Bored฀cylinder
Remark
Four฀cylinders฀will฀be฀bored฀depending฀on฀the฀external฀diameter฀of฀piston฀with
an฀increased฀size.
Respective฀piston฀ring฀shall฀be฀replaced฀to฀place฀as฀per฀the฀matching฀pistons.
(a)Selection฀of฀piston฀with฀an฀increased฀size
Diameter฀of฀piston฀with฀an฀increased฀size฀ ฀0.50฀mm
(b)Calculation฀of฀size฀for฀cylinder฀to฀be฀bored
ProCarManuals.com
-A฀micrometer฀may฀be฀used฀to฀measure฀the฀diameter฀of฀piston฀at฀a฀position
which฀form฀a฀right฀angle฀with฀the฀center฀line฀of฀piston฀pin,฀and฀is฀24mm฀away
from฀the฀top฀of฀piston.
-The฀size฀of฀each฀cylinder฀to฀be฀re-bored฀may฀be฀calculated฀as฀per฀the฀formula
given฀below:
Size฀to฀be฀re-bored฀=P+C-H
Whereby:฀P=฀diameter฀of฀piston;฀C=฀Clearance฀of฀piston 0.03-005mm
H=the฀surplus฀of฀honing less฀than฀0.02mm
(c)The฀cylinder฀shall฀be฀bored฀and฀honed฀to฀the฀calculated฀size.
Max.฀honing฀amount:฀฀0.02฀mm
Note:฀Excessive฀honing฀will฀damage฀the฀precisely-made฀roundness.
Assembly฀of฀piston฀and฀connection-rod
components
1.฀Assembly฀of฀piston฀and฀connection-rod฀component
(a)Pre-matching฀between฀piston฀and฀cylinder฀Four฀pistons฀having฀the฀same
No.฀as฀cylinder฀holes฀must฀be฀kept฀into฀a฀special฀work฀place฀tool฀chest฀in
accordance฀with฀the฀sequence฀for฀cylinder.
(b)Selection฀and฀match-making฀of฀piston฀pin฀Piston฀pins฀having฀been฀installed
into฀respective฀installation฀holes฀shall฀rotate฀in฀a฀flexible฀way฀without฀any
loose,฀and฀will฀then฀be฀pushed฀down฀to฀be฀kept฀together฀with฀respective
pistons฀into฀a฀work฀place฀tool฀chest.
(c)Heating฀the฀connection-rod,฀and฀freezing฀the฀piston฀pin
-฀After฀the฀heating฀temperature฀for฀oven฀has฀been฀set฀to฀140¡æ,฀the฀connection-
rod฀component฀may฀be฀put฀by฀group฀into฀the฀oven,and฀the฀heating฀lasts฀for
(20~30)min.
-฀After฀piston฀pins฀have฀been฀put฀sequentially฀into฀a฀special฀piston฀pin
container,฀have฀them฀freezing฀inside฀a฀liquid฀nitrogen฀bottle฀for฀(20~30)min.
Note:฀The฀sequence฀shall฀not฀be฀wrong฀during฀the฀operation฀as฀the
฀฀฀฀฀฀selected฀piston฀and฀piston฀pin฀are฀matching฀with฀each฀other.

(d)Pressed฀installation฀of฀piston฀pin
-฀Set฀the฀pressure฀of฀a฀hydraulic฀machine฀to฀6Mpa.฀When฀the฀piston฀is฀placed
to฀the฀clamping฀fixture฀(used฀for฀pressed฀installation)฀on฀a฀universal฀single-
column฀hydraulic฀machine,฀take฀out฀the฀connection-rod฀components฀sequentially
from฀oven,฀and฀the฀piston฀pin฀from฀the฀liquid฀nitrogen฀pot;฀The฀small฀head฀of
piston฀pin connection-rod฀will฀be฀inserted฀into฀the฀฀inner฀chamber฀of฀piston,฀with฀the
small-head฀hole฀facing฀exactly฀the฀installation฀hole฀of฀piston฀pin;฀Hold฀the฀bid
head฀of฀the฀connection-rod฀by฀left฀hand฀to฀keep฀the฀rod฀level,฀and฀insert฀the
piston฀pin฀into฀the฀installation฀hole฀of฀piston฀pin฀by฀right฀hand,฀then฀the
piston฀pin฀may฀be฀pressed฀and฀installed฀into฀place฀using฀hydraulic฀machine
to฀be฀effected฀by฀a฀clamping฀fixture฀used฀for฀pressed฀installation .
-Check฀whether฀the฀piston฀pin฀has฀been฀pressed฀and฀installed฀to฀place;฀Hold฀the฀piston฀by฀left฀hand,฀and฀pull฀the฀connection-rod฀by
right฀hand,฀and฀rotate฀the฀connection-rod,฀and฀the฀rotation฀of฀piston฀pin฀shall฀be฀made฀in฀a฀flexible฀฀way.
SST฀09221-00020฀฀09221-00030฀฀09221-00040
09221-00071฀฀09221-00081
Remark
The฀mark฀“forward”฀of฀piston฀shall฀be฀consistent฀to฀that฀of฀the฀connection- rod฀component.
Groups฀of฀the฀connection-rod฀divided฀by฀weight฀shall฀consistent฀to฀each฀other.
2.฀Installation฀of฀piston฀ring
(a)Manually฀install฀the฀oil-ring฀gasket฀spring฀into฀the฀ring-groove฀of฀combined
oil฀rings฀at฀the฀apron฀of฀piston;฀And฀do฀not฀overlay฀at฀the฀opening฀point.
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(b)Special฀piston-ring฀installation฀pliers฀may฀be฀used฀to฀install฀the฀scrapin g
blades฀of฀oil฀ring two฀blades ,฀the฀second฀gas฀ring,฀and฀the฀first฀gas฀ring
first into฀place฀sequentially.
Remark Two฀gas฀rings฀vary฀from฀each฀other:฀The฀first฀gas฀ring฀has฀a฀mark
AT G on฀end฀surface,฀the฀second฀one฀has฀a฀mark A 2 on฀end฀surface.
And฀the฀side฀of฀gas฀ring฀having฀marks฀shall฀face฀upward.
second
(c)The฀adjustment฀of฀the฀opening฀position฀of฀piston฀ring฀is฀as฀shown฀in฀the
symbol฀mark
figure:
Note:
1.On฀the฀top฀of฀European- ฀piston,฀two฀gr ooves฀have฀been฀installed฀to
second฀compression฀ring pr event฀air-valve฀fr om฀striking,฀and฀an฀anodic฀oxidation฀may฀be฀performed
upper฀ring on฀the฀top฀of฀piston฀as฀well.
2.E ur opean- ฀piston฀and฀piston฀r ing฀may฀be฀installed฀onto฀E ur opean-
device,฀ but฀ these฀ two฀ par ts฀ must฀ be฀ inter changed฀ simultaneously;
front E ur opean- piston฀and฀piston฀r ing฀may฀not฀be฀installed฀onto฀E ur opean-
฀device,฀or ฀air ฀valve฀will฀str ike฀against฀the฀piston; ฀E ur opean- ฀piston
r ing฀may฀not฀be฀installed฀onto฀E ur opean- piston,฀or ฀it฀will฀lead฀to฀a
lower฀ring ser ies฀of฀tr ouble,฀eg.฀bur ning฀of฀oil,฀abnor mal฀sound฀pr oduced฀on฀engine,
first฀ compression etc.
ring฀and฀piston฀ring
3.Assembly฀of฀the฀connection-rod฀bush
(a) After฀ the฀ installation฀ of฀ piston฀ ring,฀ the฀ piston฀ &connection-rod
component฀may฀be฀transferred฀by฀group฀to฀a฀position฀where฀the฀connection-
rod฀bush฀will฀be฀installed.
(b)The฀connection-rod฀bushes฀may฀be฀selected฀in฀accordance฀with฀the฀group
No.(group฀ No.฀ for฀ big-head฀ hole฀ to฀ be:6,฀ 7,฀ 8)marked฀ on฀ the฀ big-
head฀hole฀side฀of฀the฀connection-rod.
(c) After฀nuts฀on฀connection-rod฀have฀been฀removed,฀a฀special฀bench฀vice
may฀ be฀ used฀ to฀ dismantle฀ bush฀ cover฀ from฀ the฀ connection-rod.
oil฀control
(d)฀Clean฀up฀the฀inner฀surface฀of฀the฀hole฀of฀connecting฀rod฀big฀end,then
mount฀the฀connecting฀rod฀bearing฀to฀the฀connecting฀rod฀and฀cover฀of฀the
connecting฀rod฀bearing฀respectively,the฀convex฀key฀of฀the฀connecting฀rod
bearing฀should฀be฀inserted฀into฀the฀locating฀notch฀of฀connecting฀rod.

(e)To฀avoid฀confusion,฀one฀end฀of฀bush฀covers฀(having฀been฀installed฀with฀connection-rod฀bush)฀,฀plus฀relevant฀nuts,฀shall฀be
installed฀onto฀the฀connection-rod฀unit.
General฀precautions฀during฀the฀assembly
(a)A ll฀parts฀to฀be฀installed฀must฀be฀washed฀thoroughly;฀Prior฀to฀installation,฀clean฀oil฀shall฀be฀applied฀to฀all฀sliding฀or฀rotating
surfaces.
(b)Pistons฀within฀the฀same฀group฀shall฀be฀included฀in฀the฀same฀group฀divided฀by฀mass.
(c)Connection-rod฀components฀within฀the฀same฀group฀shall฀be฀included฀in฀the฀same฀group฀divided฀by฀mass.
(d)T he฀mark฀“forward”฀on฀the฀top฀of฀piston฀shall฀be฀consistent฀to฀that฀on฀the฀connection-rod.
(e)A lways฀keep฀clean฀during฀the฀assembly.
Installation฀of฀engine฀body
1.฀Installation฀of฀bearing฀bush฀onto฀crankshaft
In฀accordance฀with฀size฀No.฀for฀main฀bearing฀hole฀as฀printed฀on฀the฀lower฀plane
of฀engine฀body,฀main฀bearing฀bush฀and฀the฀upper฀/lower฀bushes฀may฀be฀selected,
and฀installed฀onto฀the฀bush฀cover฀on฀engine฀body,฀after฀which฀appropriate
amount฀of฀clean฀oil฀may฀be฀applied฀to฀the฀inner฀surface฀of฀main-bearing฀bush.
oil฀hole
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2.฀Installation฀of฀thrust฀washer
Appropriate฀amount฀of฀oil฀may฀be฀applied฀to฀the฀surface฀where฀the฀thrust
washer฀is฀connected฀on฀two฀sides฀of฀main฀bearing฀hole฀in฀the฀middle฀of฀engine
body,฀followed฀by฀an฀installation฀of฀two฀upper฀thrust฀washers฀onto฀the฀engine
body.฀During฀installation,฀the฀oil-groove฀surface฀shall฀face฀outward.
3.฀Put฀the฀crankshaft฀into฀engine฀body
Note:฀During฀the฀installation,฀the฀crankshaft฀shall฀be฀handled฀with฀care
฀฀฀to฀avoid฀strike฀or฀damage฀on฀bearing฀bush,฀or฀prevent฀the฀thrust
฀฀฀฀฀฀฀฀฀฀washer฀from฀escape฀due฀to฀strike.
฀4.฀Installation฀of฀main฀bearing฀cover
(a)No.฀1 2 4 5฀main฀bearing฀cover,฀which฀have฀been฀installed฀with
bush,฀ may฀ be฀ installed฀ onto฀ each฀ main฀ neck-journal฀ sequentially.
(b)Two฀lower฀thrust฀washers,฀whose฀friction฀surfaces฀have฀been฀applied฀with
slight฀amount฀of฀clean฀oil,฀may฀be฀installed฀onto฀the฀main฀bearing฀cover฀in฀the
middle,฀which฀will฀be฀installed฀onto฀main฀neck-journal฀in฀the฀middle฀while฀two
thrust฀washers฀are฀being฀pinched฀by฀hand.
(c)Appropriate฀bolts฀must฀be฀manually฀screwed฀into฀each฀main฀bearing฀cover
by฀3 4฀threads,฀and฀a฀steel฀hammer฀may฀be฀used฀to฀gently฀strike฀the฀top฀of
each฀main฀bearing฀cover฀so฀that฀it฀will฀be฀well฀connected฀with฀the฀main฀neck
journal,฀and฀the฀engine฀body.

5.฀Tighten฀bolts฀on฀crankshaft
Bolts฀on฀the฀main฀bearing฀cover฀shall฀be฀tightened฀progressively฀in฀three฀steps฀as
indicated฀in฀the฀figure.
Tightening฀ moment ( 80 3) N m
6.฀C heck฀whether ฀the฀r otation฀of฀cr ankshaft฀is฀under ฀a฀balance.
A ppropriate฀amount฀of฀clean฀oil฀will฀be฀applied฀into฀oil฀hole฀of฀each฀connection-
rod฀฀ neck-journal฀on฀ crankshaft,฀and฀to฀ the฀surface฀ where฀two฀ lower฀thrust
washers฀are฀connected฀with฀the฀crankshaft,฀and฀crank฀handle฀may฀be฀used฀to
drive฀the฀crankshaft฀rotating฀by฀3 4฀rounds฀back฀and฀forth,฀and฀the฀rotation
shall฀be฀easy,฀fast฀and฀smooth.
7.฀Check฀the฀axial฀clearance฀of฀crankshaft
A฀dial฀indicator฀may฀be฀used฀to฀check฀the฀axial฀clearance฀of฀crankshaft,฀and฀the
clearance฀should฀be฀within฀0.02-0.22mm.
Note:
(a)The฀size฀group฀of฀mainbearingbushtobeinstalledshallbeconsistentto
No.฀marked฀on฀the฀lower฀plane฀of฀air฀cylinder.
(b)The฀surface฀of฀main-bearing฀bush฀shall฀be฀clean฀and฀without
any฀struck,scratched฀or฀damaged฀trace.
(c)During฀installation,฀always฀keep฀each฀part฀clean,฀particularly฀it’s
unallowable฀to฀have฀any฀foreign฀material฀used฀as฀gasket฀material
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between฀bush฀back฀and฀bush฀seat.
(d)Each฀main฀bearing฀cover฀shall฀be฀subject฀to฀a฀correct฀installation
sequenceand฀direction.
8.฀Installation฀of฀piston฀and฀connection-rod
(a)To฀prevent฀crankshaft฀from฀damage,฀the฀connection-rod฀bolt฀shall฀be฀installed
with฀a฀short฀hose฀sleeve.
(b)Clean฀oil฀may฀be฀used฀to฀lubricate฀the฀inner฀wall฀of฀cylinder,฀and฀the฀neck
journal฀of฀connection-rod.
(c)Appropriate฀amount฀of฀clean฀oil฀shall฀be฀applied฀to฀the฀piston฀ring,฀and฀to฀the
connection-rod฀bush.
front฀ sign (d)After฀the฀piston฀compressor฀has฀been฀tightened฀stably฀(rather฀than฀striking
closely฀against฀the฀piston),฀the฀wood฀handle฀of฀hammer฀or฀similar฀tools฀may฀be
used฀to฀gently฀strike฀the฀piston฀and฀connection-rod฀having฀correct฀number฀into
front respective฀cylinder.
Remark:Die฀hole฀on฀the฀piston,฀and฀the฀convexity฀on฀the฀connection-rod฀shall
face฀the฀front฀side฀of฀engine.
9.฀Installation฀of฀connection-rod
front (a)Make฀the฀numbered฀bearing฀cover฀matching฀with฀the฀numbered฀connection-
rod,฀and฀have฀them฀included฀in฀the฀group.
front฀mark (b)฀During฀the฀installation฀of฀bearing฀cover,฀its฀front฀mark฀shall฀face฀frontward.

10.฀Screw฀up฀nuts฀on฀the฀bearing฀cover฀of฀connection-rod.
Nuts฀shall฀be฀tightened฀progressively฀in฀two฀or฀three฀steps฀using฀a฀torque
spanner.
11.฀C heck ฀whether ฀the฀r otation฀of฀cr ank shaft฀is฀level฀and
stable.
Manually฀rotate฀the฀crankshaft,฀and฀its฀rotation฀shall฀be฀flexible฀and฀without
any฀jamming.
Assembly฀of฀engine฀body
1.฀Installation฀of฀rear฀oil-seal฀guard฀ring
(a)Apply฀sealant฀to฀the฀oil-seal฀guard฀ring
Sealant Pr oduct฀No.฀08826-00080฀or ฀ similar ฀type.
(b)Using฀a฀small฀fur฀brush,฀a฀layer฀of฀varnish฀may฀be฀applied฀evenly฀to
two฀sides฀of฀rear฀oil-seal฀seat฀gasket,฀which฀will฀be฀adhered฀to฀a฀place฀where
rear฀oil-seal฀seat฀is฀installed฀on฀rear฀end฀surface฀of฀the฀engine฀body;฀After฀oil-
seal฀has฀been฀pressed฀into฀rear฀oil-seal฀seat,฀a฀layer฀of฀albany฀grease฀may฀be
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applied฀evenly฀to฀the฀oil-seal฀lip,฀which฀will฀be฀installed฀onto฀rear฀oil-seal
seat฀฀gasket.฀During฀installation,฀the฀pushing฀shall฀be฀made฀on฀a฀parallel฀basis
to฀prevent฀the฀rear-end฀surface฀of฀crankshaft฀from฀striking฀and฀damaging฀the
oil-seal฀lip.฀A nd฀it฀may฀be฀fixed฀onto฀the฀rear฀end฀of฀฀engine฀body฀using฀five
M8 22฀bolts with฀flat฀washer฀and฀standard฀spring฀฀washer ,฀and
bolts฀shall฀be฀tightened฀to฀a฀specified฀moment฀using฀a฀fixed-torque฀wrench.
฀ T ightening฀ moment ( 12 2) N m
฀฀฀฀฀฀฀฀SST ฀฀09223-61010
฀2.฀I nstallation฀of฀A C ฀gener ator ฀br ack et

T he฀generator฀bracket฀may฀be฀fixed฀onto฀the฀cylinder฀using฀two
M10 1.2 35฀bolts.
฀ ฀ T ightening฀ moment (25 2) N m
฀3.฀Installation฀of฀oil฀filter฀bracket
(a)A฀layer฀of฀varnish฀may฀be฀applied฀evenly฀to฀two฀sides฀of฀oil฀filter฀gasket,
which฀will฀be฀adhered฀to฀the฀surface฀where฀the฀oil฀filter฀seat฀is฀connected
with฀the฀engine฀body.
(b)The฀oil฀filter฀seat฀may฀be฀fixed฀on฀the฀engine฀body฀using฀three฀M8 35
bolts with฀flat฀washer฀and฀standard฀spring฀washer .
฀ Tightening฀ moment ( 18 3) N m
4.฀Installation฀of฀rear฀partition฀plate
(a)Installation฀of฀gland฀strip฀onto฀rear฀oil-seal฀seat
Note T he฀jut฀of฀gland฀str ip฀shall฀be฀embedded฀into฀the฀pit฀of฀r ear
฀฀oil-seal฀seat.
(b)R ear฀partition฀plate฀for฀clutch฀cover฀shall฀be฀installed฀onto฀two฀M10
22฀positioning฀pins฀behind฀the฀engine฀body,฀and฀be฀fixed
using฀two฀M 8 14฀ bolts with฀ standard฀ spring฀ washer .
T ightening฀ moment: ฀ (18 3)N m

5.฀Installation฀of฀flywheel
When฀flywheel฀has฀been฀installed฀to฀a฀place฀behind฀the฀crankshaft,฀manually
rotate฀the฀flywheel฀to฀make฀it฀facing฀exactly฀the฀assembly฀mark฀made฀on฀the
rear฀end฀surface฀of฀crankshaft,฀then฀six฀flywheel฀bolts฀will฀be฀used฀to฀fix฀the
flywheel฀onto฀the฀rear฀end฀of฀crankshaft:฀the฀bolts฀shall฀be฀subject฀to฀a฀pre-
tightening฀made฀by฀a฀pneumatic฀wrench,฀and฀a฀re-tightening฀diagonally฀to฀the
specified฀moment฀made฀by฀a฀stud฀bolt฀tightener.
฀ Tightening฀ moment ( 85 3) N m
6.฀Installation฀of฀camshaft฀component
(a)Installation฀of฀camshaft
-Appropriate฀amount฀of฀clean฀oil฀shall฀be฀applied฀to฀five฀main฀neck-journal s
on฀camshaft,฀and฀to฀gears฀which฀connects฀with฀the฀transmission฀shaft฀of฀oil
pump.
-Hold฀the฀front฀side฀of฀camshaft฀by฀right฀hand,฀and฀hold฀the฀middle฀position
of฀camshaft฀by฀left฀hand,฀and฀slowly฀install฀camshaft฀into฀its฀installation฀hole.
During฀installation,฀the฀camshaft฀may฀be฀drawn฀manually฀via฀original฀installation
hole฀for฀petrol฀pump฀on฀the฀engine฀body,฀and฀will฀be฀pushed฀to฀the฀end฀afte r
each฀neck-journal฀is฀installed฀onto฀respective฀camshaft฀lining.
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-The฀ thrust฀ collar฀ of฀ camshaft฀ shall฀ be฀ fixed฀ onto฀ engine฀ body฀ at฀ the
camshaft฀ hole฀ using฀ two฀ M8 16฀ bolts with฀ flat฀ washer฀ and
standardspring฀washer .
R emark T he฀thrust฀collar฀of฀camshaft฀shall฀make฀the฀side฀having฀‘ pit’ mark
face฀outward.
(b)Manually฀rotate฀the฀camshaft,฀and฀its฀rotation฀shall฀be฀flexible.฀T henthe
woodruff฀key฀of฀camshaft฀must฀be฀turned฀to฀an฀upward฀position.
(c)Assembly฀of฀chain฀shock-absorber Using฀brush,฀a฀layer฀of฀clean฀oil฀may
be฀applied฀to฀the฀rubber฀surface฀of฀chain฀shock-absorber,฀which฀will฀be฀fixed฀to
an฀appropriate฀position฀inside฀chainwheel฀chamber฀using฀two฀M8 16฀bolt
with฀standard฀spring฀washer and฀be฀tightened฀to฀the฀specified฀moment
using฀a฀fixed-torque฀wrench.
(d)Installation฀ of฀ tappet฀ component Prior฀ to฀ the฀ assembly,฀ tappet

component฀shall฀be฀soaked฀in฀clean฀oil฀to฀provide฀a฀preliminary฀lubrication
between฀tappet฀and฀tappet฀hole฀or฀between฀tappet฀and฀the฀cam฀of฀camshaft,
followed฀by฀an฀manual฀installation฀of฀eight฀hydraulic฀tappets฀successively
into฀tappet฀holes.
฀ ฀ ฀ ฀฀Precautions
฀฀฀฀฀฀-A lways฀keep฀it฀clean฀and฀avoid฀pollution฀dur ing฀the฀whole฀cour se฀of
฀฀฀฀฀฀฀assembly.
฀฀฀฀฀-Pr event฀camshaft฀fr om฀touching฀or ฀str iking฀its฀lining฀dur ing฀the
฀฀฀฀฀฀installation.
฀฀฀฀฀-W oodr uff฀key฀shall฀be฀installed฀to฀place฀to฀have฀its฀upper ฀plane฀par allel
฀฀฀฀฀฀to฀the฀neck-jour nal฀of฀camshaft.

EM.1-24 Assembly฀of฀engine฀body
7.฀Installation฀of฀oil฀dish฀component oil฀dish,฀namely฀the
฀ ฀ ฀ cr ank case฀ oil฀ tr ay
The฀oil-seal฀is฀3mm฀wide (a)Check฀the฀oil฀dish฀to฀assure฀its฀internal฀cleanness:฀E xisting฀sealing฀materials
must฀be฀cleared฀away฀from฀the฀oil฀dish,฀and฀it’ s฀unallowable฀for฀oil฀to฀drop
onto฀the฀installation฀interconnection฀surface.
(b)Sealing฀material฀will฀be฀filled฀into฀the฀oil฀dish฀as฀indicated฀in฀the฀figure.
W hen฀ oil฀sump฀on฀ the฀oil฀dish฀is฀facing฀ downward,฀and฀when฀ eighteen
installation฀holes฀on฀the฀oil฀dish฀are฀facing฀exactly฀the฀installation฀holes฀of
dish฀gasket,฀and฀the฀installation฀holes฀on฀the฀lower฀surface฀of฀the฀engine
body,฀the฀oil฀dish฀may฀be฀fixed฀using฀eighteen฀M8 16฀bolts with฀flat
washer฀and฀standard฀spring฀washer .
T ightening฀ tor que (7 2) N m
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EM.2-1
Cylinder฀head
page
Disassembly฀figures฀for฀cylinder฀head...........................................EM.2-2
Dismantle฀of฀cylinder฀head...........................................................EM.2-3
Disassembly฀of฀cylinder฀head ......................................... .............EM.2-4
Clean฀up฀/inspection฀on฀each฀spare฀part ......................... .............EM.2-5
Assembly฀of฀cylinder฀head.........................................................EM.2-12
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Installation฀of฀cylinder฀head........................................................EM.2-15

EM.2-2 Disassembly฀figures฀for฀cylinder฀head
To฀prevent฀the฀cylinder฀gasket฀from฀leaking฀air฀or฀water,฀the฀tightening฀torque฀of฀bolts฀on฀cylinder฀head฀shall
be฀checked฀using฀a฀torque฀wrench฀before฀new฀vehicles฀travel฀for฀500฀or1000฀kilometers,฀and฀will฀be฀90N.m฀for
ten฀M12฀bolts,฀or฀20N.m฀for฀three฀M8฀bolts.฀And฀a฀tightening฀may฀not฀proceed฀until฀the฀engine฀cools฀down.฀ To
perform฀a฀correct฀maintenance฀and฀adjustment,฀a฀general฀description฀is฀provided฀as฀below฀for฀dismantle฀/
inspection฀/maintenance฀of฀cylinder฀head.
Disassembly฀figures฀for฀cylinder฀head
valve฀locker
clamp
valve฀spring
valve฀chamber฀cover valve฀spring฀upper seat฀ (air
seat air฀ exhaust inlet)
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valve฀spring
rocker฀shaft฀and฀spring
valve฀oil฀seal
rocker฀shaft valve฀spring
lower฀seat
valve
spark฀plug
push฀rod
engine
spark฀plug฀sleeve
valve฀guide
engine฀rear฀fender
cylinder฀head
water฀outlet฀pipe
front฀ warm-air cylinder฀gasket

water฀pipe
hydraulic฀tappet
engine฀ front
engine฀hook fender

Dismantle฀of฀cylinder฀head EM.2-3
Dismantle฀of฀cylinder฀head
1. Dismantle฀of฀high-tension฀damping฀wiring฀andignition
coil฀components
(a)High-tension฀damping฀wiring฀shall฀be฀removed.
(b)Ignition฀coil฀components฀shall฀be฀removed.
2. Dismantle฀of฀wiring฀harness฀and฀the฀fuel฀distributor
assembly
(a)Wiring฀harness฀must฀be฀removed.
(b)Unscrew฀the฀contact฀nut.
(c)Take฀out฀the฀fuel฀distributor฀assembly.
3.฀Piston฀for฀cylinder฀No.฀1฀will฀be฀placed฀to฀thetopdead
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center฀of฀compression฀stroke.
Rotate฀the฀crankshaft฀pulley฀to฀have฀its฀groove฀facing฀exactly฀to฀mark
0 ฀made฀on฀the฀timing฀chaincover.
4. Dismantle฀of฀inlet฀&outlet฀manifold
(a)Have฀the฀cooling-water฀bypass฀hose฀removed฀from฀theinlet฀manifold.
(b)A฀torque฀wrench฀will฀be฀used฀to฀unscrew฀eight฀fixing฀nutson฀inlet
&outlet฀manifold,฀based฀on฀which฀the฀inlet฀&outlet฀manifold฀plus฀the
sealing฀ring฀may฀be฀taken฀out.

EM.2-4 Disassembly฀of฀cylinder฀head
5.฀Dismantle฀of฀cylinder฀head
The฀cylinder฀head฀may฀be฀removed฀by฀unscrewing฀the฀bolts฀and฀nuts฀on
cylinder฀head.
6.฀Dismantle฀of฀rocker-shaft
Subject฀to฀the฀numbering฀sequence฀indicated฀in฀the฀figure,฀bolts฀and฀nuts
on฀rocker-shaft฀may฀be฀removed฀progressively฀in฀three฀steps.
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7. Dismantle฀of฀cylinder฀head
(a)Based฀on฀the฀bolt฀numbering฀sequence฀indicated฀inthe฀figure,฀a฀12-edge
socket฀ spanner฀ shall฀ be฀ used฀ tounscrew฀ bolts฀ on฀ cylinder฀ head
progressively฀in฀threesteps.฀Any฀dismantle฀in฀nonconformance฀with
theindicated฀sequence฀might฀cause฀a฀deformation฀or฀bendon฀cylinder
head.
(b)The฀cylinder฀head฀may฀be฀lift฀up฀from฀the฀connection฀surface฀of
device฀unit,฀and฀put฀onto฀a฀wood฀block฀onsaddle฀piece฀which฀has฀been
provided฀in฀advance.
Note Do฀not฀damage฀cylinder ฀head,฀and฀the฀sur face฀of
device฀unit฀on฀one฀side฀having฀cylinder-cover ฀spacer.
R emark If฀the฀cylinder฀head฀is฀hard฀to฀be฀lifted฀up,฀a฀screwdriver฀may
be฀used฀to฀prize฀the฀middle฀of฀convexity฀on฀cylinder฀head.
(c)฀Sealing฀ring฀will฀be฀removed฀from฀the฀cylinder฀head.
Disassembly฀of฀cylinder฀head
1. Dismantle฀of฀rear฀fender฀from฀cylinder฀head
Rear฀fender฀and฀sealing฀ring฀may฀be฀removed฀from฀the฀cylinderhead฀by
unscrewing฀four฀bolts.
engine฀rear฀fender
2.฀Dismantle฀of฀cooling-water฀outlet฀pipe
Cooling-water฀outlet฀pipe฀and฀sealing฀ring฀may฀be฀removed฀by฀unscrewing
two฀bolts.

Cleanup฀/inspection฀on฀each฀spare฀part EM.2-5
3.฀Dismantle฀of฀the฀rocker-shaft฀assembly
Based฀on฀the฀numbering฀sequence฀indicated฀in฀the฀figure,฀bolts฀and฀nuts
on฀rocker฀shaft฀maybe฀unscrewed฀progressively฀in฀two฀or฀three฀steps฀to
prevent฀the฀rocker-shaft฀from฀bending฀or฀prevent฀bolts฀from฀damage.
4. Dismantle฀of฀valve
(a)Valve฀spring฀seat฀will฀be฀compressed฀using฀SST฀until฀two฀valve฀locker
clamps฀have฀been฀removed.
SST฀09202-43013
(b)SST฀and฀two฀valve฀locker฀clamps฀shall฀be฀removed.
(c) Take฀out฀valve฀spring฀seat,฀valve฀spring,฀and฀spring฀shim฀successively.
(d) Remove฀the฀oil-seal.
(e) Disassembly฀the฀valve.
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(f) Disassembly฀other฀valves฀in฀a฀similar฀way.
(g) Place฀all฀removed฀parts฀in฀a฀good฀order.
IN
EX
Cleanup฀/inspection฀on฀each฀spare฀part
1. Clean฀the฀top฀of฀piston฀and฀device฀unit
(a)Carbon฀deposits฀on฀the฀top฀of฀piston฀may฀be฀scraped฀awaywhen฀the
piston฀inside฀each฀cylinder฀has฀been฀lifted฀respectively฀to฀the฀upper฀stop
point฀while฀the฀crankshaft฀isrotating.
(b)All฀spacer฀materials฀must฀be฀cleared฀away฀from฀the฀top฀of฀device฀unit,
and฀carbon฀deposits฀and฀oil฀contaminants฀shall฀beblown฀off฀as฀well฀from
bolt฀holes.
Note Tak e฀car e฀of฀your ฀eyes฀when฀compr essiveair ฀is
applied.
2.฀C lear ฀away฀sealing฀r ing฀mater ials
When฀a฀scraper฀is฀used฀to฀remove฀cylinder฀gasket฀materials฀adhered฀to
cylinder฀head,฀device฀unit,฀and฀the฀contact฀surface฀of฀cylinder฀gasket,
avoid฀any฀damage฀on฀the฀contact฀surface฀when฀scraping,฀and฀prevent
cylinder฀gasket฀materials฀from฀entering฀tappet฀holes,฀cooling-water฀sleeves,
and฀bolt฀holes.
Note Do฀not฀damage฀each฀sur face฀when฀ scr aping.
3. C lean฀the฀combustion฀chamber
A฀steel฀wire฀brush฀will฀be฀used฀to฀clear฀all฀carbon฀deposits฀away฀from฀the
combustion฀chamber.

EM.2-6 Cleanup฀/inspection฀on฀each฀spare฀part
4.฀Clean฀the฀valve฀guide
All฀valve฀guides฀may฀be฀cleaned฀using฀brush฀and฀solvent.
5.฀Clean฀the฀cylinder฀head
The฀cylinder฀head฀maybe฀cleaned฀using฀soft฀brush฀and฀solvent.
Note Do฀not฀wash฀the฀cylinder ฀head฀with฀br ush฀inside
a฀hot฀container ,฀or ฀it฀will฀be฀ser iously฀damaged.
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6.฀Check฀the฀planeness฀of฀cylinder฀head
(a)Using฀precise฀ruler฀and฀feeler฀gage,฀measure฀the฀planeness฀on฀the
bottom฀surface฀of฀cylinder฀head,฀and฀check฀for฀flexuralde฀flection฀on฀the
contact฀surface฀between฀cylinder฀head฀and฀inlet฀/outlet฀manifold.
(b)The฀planeness฀on฀the฀bottom฀surface฀of฀cylinder฀head฀shall฀be
0.05mm.
(c)The฀planeness฀on฀the฀contact฀surface฀between฀cylinder฀head฀and฀inlet
/outlet฀manifold฀shall฀be฀0.10mm.
(d)The฀cylinder฀head฀shall฀be฀changed฀if฀the฀measured฀planeness฀is฀greater
than฀the฀foresaid฀value.
7.฀Check฀for฀cracks฀on฀the฀cylinder฀head
(a)Using฀color฀penetrating฀fluid,฀check฀whether฀there’s฀anycrack฀on
combustion฀chamber,฀at฀air฀inlet/outlet฀hole,฀and฀atthe฀surface฀or฀on฀the
top฀of฀the฀cylinder฀head.
(b)The฀cylinder฀head฀needs฀to฀be฀changed฀if฀any฀crack฀isfound.
8.฀Clean฀the฀valve
(a)A฀spacer฀scraper฀may฀be฀used฀to฀clear฀away฀all฀carbondeposits฀from
the฀valve.
(b)A฀steel฀wire฀brush฀may฀be฀used฀to฀thoroughly฀clean฀thevalve.
Note B e฀ car eful฀ enough฀ to฀ avoid฀ any฀ damage฀ on
the฀sur face฀of฀valve฀seat.

9.฀Inspection฀on฀the฀abrasion฀degree฀of฀valve฀rod฀and
guide.
(a)An฀amesdial฀may฀be฀used฀to฀measure฀the฀inner฀diameter฀of฀guide.
Standard฀inner฀diameter (8.01-8.03)฀ mm
(b)A฀micrometer฀may฀be฀used฀to฀measure฀the฀external฀diameter฀of฀valve
rod.
External฀diameter฀of฀valve฀rod,฀and฀standard฀clearance(mm)
External diameter of
Standard clearance Max. clearance
standard valve rod
Engine
Air Air Air
model Air inlet Air inlet
exhaust inlet exhaust
valve valve
valve valve valve
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10.฀The฀valve฀guide฀shall฀be฀changed฀when฀necessary.
(a)Heat฀the฀cylinder฀head฀to฀approx.฀90 .
(b)The฀valve฀guide฀may฀be฀struck฀out฀using฀SST฀and฀hammer.
฀฀฀฀฀SST฀09201-60011
(c)A฀caliper฀gauge฀may฀be฀used฀to฀measure฀the฀diameter฀of฀installation
hole฀for฀valve฀guide฀on฀cylinder฀head.
Diameter฀of฀installation฀hole฀for฀standard฀valve฀guide
(13.000 13.018)฀mm

(d)Selection฀of฀new฀valve฀guide
If฀the฀diameter฀of฀installation฀hole฀for฀valve฀guide฀on฀cylinder฀head฀is
greater฀than฀13.027mm,฀the฀installation฀hole฀needs฀a฀re-boring฀to฀ensure
the฀diameter฀is฀within฀(13.050 13.077)฀mm,฀and฀the฀external฀diameter
for฀0.05mm฀valve฀guide฀(an฀increased฀size฀for฀repair฀purpose)฀will฀be
applicable. the฀external฀diameter฀for฀standard฀valve฀guide฀shall฀be฀within
(13.045 13.060mm .
(e)Using฀copper฀rod฀and฀hand฀hammer,฀the฀valve฀guide฀shall฀be฀struck฀to
a฀degree฀that฀the฀opening฀snap฀ring฀is฀able฀to฀contact฀cylinder฀head.
(f)To฀make฀the฀clearance฀between฀valve฀guide฀and฀new฀valve฀rod฀meet
relevant฀standard฀&requirement,฀a 8mm฀sharp฀reamer฀shall฀be฀used฀to
ream฀the฀inner฀diameter฀of฀valve฀guide.
Standard฀clearance:
Air฀inlet฀valve฀฀(0.025 0.060)mm
A ir ฀exhaust฀valve฀฀(0.030 0.065)mm
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11.฀Check฀and฀abrade฀the฀valve
(a)An฀abrading฀method฀will฀be฀applied฀to฀clear฀away฀any฀indent
or฀carbon฀deposit฀from฀the฀valve.
(b)Check฀ whether฀ the฀ cone฀ angle฀ on฀ valve฀ surface฀ has฀ been
abraded฀to฀a฀correct฀angle.
Cone฀angle฀on฀valve฀surface 44.5
Note:฀The฀abraded฀amount฀shall฀be฀decreased฀to฀a฀Min.
degreewhen฀possible฀yet฀sufficient฀to฀remove฀any฀damage
remainedon฀the฀surface.
(c)Inspection฀on฀edge฀thickness฀for฀valve
Min.฀edge฀thickness฀specified฀as฀below
A ir ฀inlet฀valve฀0.5mm
A ir ฀exhaust฀valve฀฀0.8mm
T he฀valve฀shall฀be฀changed฀whereby฀edge฀thickness฀on฀the฀head฀of฀valve
is฀less฀than฀Min.฀value.
edge฀thickness
(d)Inspection฀on฀the฀whole฀length฀of฀valve
Standard฀whole฀length฀of฀valve฀ mm
Standard whole length
M in. length
of valve
E ngine
A ir
model A ir inlet A ir exhaust A ir inlet
whole฀length inlet
valve valve valve
valve
The฀valve฀shall฀be฀changed฀whereby฀the฀whole฀length฀of฀valve฀is฀less฀than
Min.฀value.

(e)Check฀whether฀the฀valve฀rod฀has฀been฀abraded฀too฀much฀on฀endsurface.
If฀it฀does฀occur,฀a฀grinding฀machine฀may฀be฀used฀to฀repair฀the฀end฀surface,
or฀the฀valve฀shall฀be฀changed.
Note Do฀not฀mak e฀an฀over-abr asion฀to฀avoid฀thewhole
length฀of฀valve฀is฀less฀than฀M in.฀value.
12.฀Check฀and฀clean฀the฀valve฀seat
(a)A฀45 carbide฀tool฀will฀be฀used฀to฀repair฀or฀modify฀the฀valve฀seat.
Extra฀metals฀need฀to฀be฀cut฀off฀when฀cleaning฀the฀valve฀seat.
(b)The฀valve฀may฀be฀installed฀after฀a฀thin฀layer฀of฀ or฀white฀lead
film฀has฀been฀applied฀to฀the฀sealing฀surface฀of฀valve.฀When฀the฀valve฀seat
is฀being฀pressed฀naturally,฀make฀the฀valve฀rotating฀against฀the฀valve฀seat.
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(c)The฀valve฀surface฀and฀the฀valve฀seat฀shall฀be฀checked฀as฀per฀the฀following:
-If฀the฀valve฀surface฀shows฀blue฀on฀the฀360 circumference,฀it฀indicates
that฀the฀valve฀is฀homocentric,฀if฀not,฀the฀valve฀needs฀to฀be฀changed.
-If฀the฀valve฀seat฀shows฀blue฀on฀the฀360 circumference,฀it฀indicates฀that
width the฀valve฀guide฀and฀the฀valve฀seat฀are฀homocentric,฀if฀not,฀the฀valve฀seat
needs฀to฀be฀abraded฀and฀repaired.
-Check฀whether฀the฀contacting฀width฀between฀valve฀seat฀and฀the฀middle
of฀valve฀surface฀is฀within฀฀(1.2 1.6)฀mm;฀If฀not,฀a฀modification฀to฀the
valve฀seat฀shall฀be฀made฀as฀per฀methods฀stated฀below:
-If฀the฀valve฀seat฀is฀much฀higher฀than฀the฀valve฀surface,฀30 and฀45
carbide฀tools฀shall฀be฀used฀to฀modify฀the฀valve฀seat.
-฀If฀the฀valve฀seat฀is฀much฀lower฀than฀the฀valvesurface,฀60 and฀45
carbide฀tools฀shall฀be฀used฀฀to฀modify฀the฀valve฀seat.

(d)The฀valve฀and฀the฀valve฀seat฀may฀be฀manually฀abraded฀using
carborundum.
(e)Following฀a฀manual฀abrasion,฀the฀valve฀and฀the฀valve฀seat฀shall฀be
cleaned.
13. Check฀the฀valve฀spring
(a)A฀steel฀square฀will฀be฀used฀to฀check฀theperpendicularity฀of฀valve
spring.
Max.฀allowable฀value 2.0฀ mm
T he฀spring฀needs฀to฀be฀changed฀if฀the฀perpendicularity฀is฀greater฀than
Max.฀allowable฀value.
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(b)A฀vernier฀caliper฀will฀be฀used฀to฀check฀the฀freelength฀of฀valvespring.
Free฀ length 47 0.5฀ mm
T he฀valve฀springshallbechangedifitcannotsatisfyspecifiedrequirements.
(c)A฀spring฀tester฀will฀be฀used฀to฀check฀the฀tensile฀force฀for฀each฀spring
having฀specified฀installation฀length.
Installation฀length:40.6฀mm
Standard฀installation฀tensile฀force 345฀ N
M in.฀ installation฀ tensile฀ for ce 282฀ N
T he฀spring฀shall฀be฀changed฀if฀the฀installation฀tensile฀force฀is฀less฀than
Min.฀installation฀tensile฀force.
14.฀Inspection฀on฀rocker฀and฀rocker-shaft
(a)Inspection฀on฀rocker-shaft
Verify฀by฀visual฀check฀the฀contact฀surface฀betweenrocker-shaft฀and฀the
push฀rod.฀If฀the฀contacting฀ballsurface฀or฀circular฀arc฀surface฀between
rocker-shaftand฀the฀push฀rod฀has฀been฀abraded฀much฀or฀even฀damaged,
the฀two฀contacting฀surfaces฀must฀be฀repaired,฀or฀the฀rocker-shaft฀shall฀be
changed.

(b)Measure฀the฀clearance฀between฀rocker฀and฀rocker-shaft
Standard฀value (0.018 0.046)mm
M ax.฀ value 0.08฀ mm
R ocker฀and฀rocker-shaft฀shall฀be฀changed฀if฀the฀clearance฀is฀greater฀than
Max.฀value.
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(c)฀฀Check฀whether฀the฀direction฀on฀the฀rear฀end฀of฀air฀valve฀rocker-shaft
is฀correct.฀And฀the฀valve฀spring฀and฀the฀rocker-shaft฀may฀be฀assembled฀as
indicated฀in฀the฀figure.฀During฀assembly,฀special฀maintenance฀tools฀may
be฀used฀for฀an฀installation฀of฀clamps.฀If฀the฀contact฀surface฀between฀valve
and.rocker฀shaft฀as฀been฀much฀abraded฀oil฀stone฀provided฀฀for฀valve
refacer฀may฀be฀used฀for฀abrading,฀or฀they฀may฀be฀changed.
SST฀฀09207-71010
upward
front
convexity
convexity฀position
15 I nspection฀on฀hydr aulic฀tappet฀and฀push฀r od
(a)Inspection฀on฀hydraulic฀tappet
-A฀micrometer฀will฀be฀used฀to฀measure฀the฀external฀diameter฀of฀hydraulic
tappet,฀then฀an฀inner-diameter฀amesdial฀will฀ be฀used฀to฀ measure฀the
diameter฀ of฀ installation฀ hole฀ for฀ hydraulic฀ tappet฀ on฀ device฀ unit.
Standar d฀clear ance฀ value (0.012 0.056)mm
M ax.฀ value 0.100฀ mm
Hydraulic฀tappet฀shall฀be฀changed฀if฀the฀actual clearance฀exceeds฀Max.
value.

EM.2-12 Assembly฀of฀cylinder฀head
-When฀hydraulic฀tappet฀is฀submerged฀in฀light฀oil,฀push฀the฀plunger฀piston
for฀several฀times฀to฀discharge฀air฀insidethe฀hydraulic฀tappet.
SST฀฀09276-71010
-During฀a฀settlement฀test฀aimed฀at฀an฀inspection฀on฀the฀hydraulic฀tappet,
a฀sealing฀settlement฀tester฀may฀be฀used฀to฀apply฀a฀196N฀force฀onto฀the
plunger฀piston.฀And฀measure฀the฀time฀it฀takes฀to฀drop฀for฀1mm฀after฀it
has฀dropped฀for฀about฀2mm.
-Sealing฀&settlement฀time when฀at฀20 if฀the฀timeto฀drop฀for
1mm฀can฀not฀reach฀(7 50)seconds,฀the฀hydraulic฀tappet฀shall฀be฀changed.
(b)Inspection฀on฀push฀rod
-Max.฀radial฀runout฀at฀the฀middle฀of฀push฀rod shall฀ be฀ checked฀ as
indicated฀in฀the฀figure,฀and฀the฀push฀rod฀shall฀be฀changed฀if฀the฀actual
runout฀is฀greater฀than฀030mm.
-Check฀whether฀the฀oil฀hole฀on฀push฀rod฀has฀been฀blocked,if฀so,
compressive฀air฀may฀be฀applied฀to฀blow฀off฀any฀blocked฀material.
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16.฀Inspection฀on฀inlet฀/outlet฀manifold
(a) Precise฀ruler฀and฀feeler฀gage฀may฀be฀used฀to฀check฀whether฀the฀surface
contacting฀cylinder฀head฀has฀any฀flexual฀deformation.
Max.฀flexure฀ 0.2฀mm฀for฀inlet฀manifold;฀0.7mm฀for฀outlet฀manifoldThe
manifold฀shall฀be฀changed฀if฀the฀flexure฀is฀greater฀than฀Max.฀value.
(b)฀The฀planeness฀on฀the฀surface฀where฀the฀inlet฀&outletmanifold฀are
connected฀with฀cylinder฀head฀shall฀not฀be฀greater฀than฀0.4mm.฀If฀the
actual฀planeness฀is฀greater฀than฀04mm,inlet฀&outlet฀manifold฀shall฀be
changed,฀or฀the฀connection฀surface฀shall฀be฀cut฀by฀milling฀machine฀to฀a
smooth฀degree,with฀Max฀milling฀amount฀as฀0.5mm.
Assembly฀of฀cylinder฀head
1.฀Check After฀a฀washing,฀the฀cylinder฀head,฀air฀inlet฀/outlet฀duct
and฀the฀combustion฀chamber฀shall฀be฀clean,฀and฀without฀any฀scratched,
knocked,฀or฀damaged฀trace฀on฀fabricated฀surface;฀and฀without฀any฀casting
defect฀on฀the฀surface฀of฀cylinder฀head.
Note:
1.฀The฀thickness฀of฀cylinder฀head฀conforming฀to฀Class฀ ฀E ur opean
standar d฀shall฀be฀0.5mm฀smaller ฀than฀that฀confor ming฀to฀C lass
E ur opean฀standar d; ฀A nd฀there’ s฀a฀mar k E 3 ฀made฀on฀the฀r ight
side฀of฀cylinder ฀head฀confor ming฀to฀C lass฀ ฀E ur opean฀standar d,
and฀the฀other ฀one฀does฀not฀have฀this฀mar k.
2.฀A ny฀mis-installation฀across฀the฀E uropean- ฀cylinder฀head฀and
the฀E ur opean- cylinder ฀ head฀is฀ unallowable.฀ I f฀ E ur opean-
cylinder ฀head฀was฀installed฀onto฀E ur opean-I I ฀device฀by฀mistake,฀it
might฀make฀the฀valve฀touch฀the฀piston I f฀E ur opean- cylinder
head฀ was฀ installed฀ onto฀ E ur opean- ฀ device฀ by฀ mistak e,฀ the
per for mance฀of฀engine฀might฀be฀degr aded,฀and฀other ฀failur es฀might
occur฀accor dingly.

Assembly฀of฀cylinder฀head EM.2-13
2.฀Matching฀air฀inlet฀valve฀with฀air฀exhaust฀valve
After฀the฀bottom฀surface฀of฀cylinder฀head฀has฀been฀put฀level฀on฀work
bench฀and฀is฀facing฀upward,฀air฀inlet฀&exhaust฀valves฀will฀be฀installed
onto฀the฀cylinder฀head฀as฀per฀the฀sequence฀“exhaust-inlet-inlet-exhaust-
exhaust-inlet-inlet-exhaust”,฀and฀could฀be฀inserted฀into฀the฀valve฀guides
IN smoothly฀after฀installation฀without฀any฀loose.
Note Pr ior ฀to฀the฀matching,฀check฀the฀valve฀guide฀r od,
and฀ensure฀ther e’ s฀no฀any฀knocked฀,฀scratched฀or฀damaged
EX tr ace฀on฀the฀coned฀sealing฀sur face฀of฀valve.
3.฀L eakage฀test฀on฀sealed฀parts฀of฀valve฀and฀its฀seat฀hole
T he฀cylinder฀head฀having฀been฀installed฀with฀air฀inlet฀/exhaust฀valve฀will
be฀put฀to฀a฀position฀for฀leakage฀test,฀and฀the฀side฀of฀cylinder฀head฀having
air฀inlet฀/exhaust฀duct฀must฀face฀upward.฀When฀the฀tail฀end฀of฀valve฀rod
is฀being฀pulled฀by฀hand,฀fill฀relevant฀air฀inlet฀/exhaust฀ducts฀with฀clean
kerosene฀and฀wait฀for฀(5~6)฀seconds,฀if฀kerosene฀from฀the฀sealing฀band฀of
valve฀does฀not฀flow฀into฀the฀combustion฀chamber,฀it฀indicates฀that฀cylinder
head฀has฀no฀any฀leakage;฀In฀case฀of฀leakage,฀the฀valve฀and฀its฀seat฀hole
shall฀be฀abraded฀accordingly.
4.฀A br ading฀on฀valve฀ and฀valve฀seat฀hole
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(a)A fter฀ air฀inlet฀(exhaust)฀valve฀is฀removed,฀appropriate฀amount฀ of

abrasive฀sands฀must฀be฀applied฀evenly฀to฀the฀coned฀sealing฀surface฀of฀air
valve฀and฀to฀the฀valve฀seat฀hole,฀then฀be฀installed฀into฀valve฀guide฀for฀an
abrasion฀by฀special฀abrading฀tool฀for฀(7~10)฀minutes.
(b)A fter฀air฀inlet฀(exhaust)฀valve฀is฀removed,฀kerosene฀will฀be฀used฀to
wash฀residual฀abrasive฀sands฀on฀valve,฀in฀the฀valve฀seat฀hole,฀inside฀the
combustion฀chamber,฀or฀inside฀the฀air฀inlet฀/exhaust฀duct.
R emark:Valves฀after฀an฀abrasion฀are฀not฀interchangeablewhen฀washing฀the
removed฀valves,฀they฀shall฀be฀placed฀in฀order฀by฀sequence฀to฀avoid฀any
mis-installation฀and฀misdetermination฀at฀a฀later฀stage.
marked฀with฀green฀color 5.฀Pressed฀installation฀of฀air฀inlet฀/exhaust฀valve
upward (a)A ppropriate฀amount฀of฀clean฀machine฀oil฀shall฀be฀taken฀out฀from
machine฀oil฀pot฀and฀be฀applied฀to฀the฀rod฀of฀eight฀air฀inlet฀/฀exhaust
valves฀respectively,฀then,฀have฀the฀cylinder฀head฀fixed฀onto฀a฀clamping
fixture฀applicable฀to฀the฀pressed฀installation฀of฀valves.
(b)I nstall฀eight฀valve฀spring฀seat฀gaskets฀successively฀into฀place.A nd
the฀number฀of฀gaskets฀must฀be฀correct.
(c)A ฀special฀press฀tool฀shall฀be฀used฀during฀the฀pressed฀installation฀of
eight฀valve฀oil-seals.
Note F or ce฀applied฀to฀the฀oil-seal฀could฀not฀be฀too฀big,if฀the฀pr essed฀oil฀seal฀deviates฀fr om฀the

฀฀฀installation฀position,฀it฀shall฀be฀taken฀out฀and฀discar ded฀accor dingly,and฀may฀not฀be฀r e-
฀฀฀used฀any฀longer .
(d)Put฀the฀valve฀spring฀and฀the฀valve฀spring฀seat฀into฀place฀successively.
R emark
-T he฀smaller฀pitch฀end฀(viz฀colored฀end฀)of฀valve฀spring฀฀must฀be฀put฀to฀the฀downside.
-Different฀from฀air฀inlet฀valve,฀the฀spring฀seat฀on฀air฀฀exhaust฀valve฀has฀a฀rotatable฀mechanism,฀which฀can฀฀not฀be฀mis-installed.
SST ฀09202-43013
(e)Using฀a฀special฀press฀tool฀applicable฀to฀valve,฀each฀locker฀clamp฀of฀valve฀may฀be฀pressed฀into฀the฀cone฀hole฀on฀the฀cap฀of฀air฀inlet
/exhaust฀valve.

EM.2-14 Assembly฀of฀cylinder฀head
(f)To฀have฀the฀locker฀clamp฀of฀valve฀well฀connected฀with฀the฀spring฀seat
and฀the฀valve฀rod,฀a฀copper฀hammer฀may฀be฀used฀to฀strike฀gently฀against
the฀tail฀end฀of฀each฀valve฀rod.
6.฀Installation฀of฀spark฀plug฀component
(a)R espective฀sealing฀gasket฀shall฀be฀installed฀onto฀the฀spark฀plug฀sheath,
and฀the฀level฀end฀of฀sealing฀ring฀must฀be฀connected฀with฀the฀flanged
surface฀of฀socket.
(b)Insert฀the฀spark฀plug฀into฀the฀sleeve฀of฀spark฀plug.
(c)Four฀sets฀of฀spark฀plug฀and฀sleeve฀component฀shall฀be฀manually฀installed
into฀(by฀3 4฀threads)฀the฀installation฀hole฀on฀the฀right฀side฀of฀cylinder
head,฀and฀be฀tightened฀with฀a฀spark฀plug฀wrench.
฀ ฀ ฀ ฀ ฀ ฀ T ightening฀ tor que (20 3)N m
7.฀Installation฀of฀front฀water-tight฀cover฀plate
(a)A ฀ layer฀ of฀ varnish฀ shall฀ be฀ applied฀ evenly฀ onto฀ both฀ sides฀ of
spacers฀ used฀for฀ the฀ front฀ water-tight฀ cover฀ plate฀ of฀ cylinder฀ head,
which฀will฀be฀adhered฀to฀the฀inner฀surface฀of฀front฀water-tightcover฀plate.
A nd฀make฀it฀facing฀the฀bolt฀hole฀exactly.
( b)T wo฀ M 8 20฀ bolts with฀ standard฀ spring฀ washer may฀ be
used฀to฀fix฀the฀front฀water฀tight฀cover฀plate฀as฀well฀as฀spacer฀component
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onto฀the฀front฀side฀of฀cylinder฀head.
฀ ฀ T ightening฀ tor que (12 2)N m
8.฀Installation฀of฀rear฀fender฀onto฀cylinder฀head
(a)A ฀layer฀of฀varnish฀shall฀be฀applied฀evenly฀onto฀both฀sides฀of฀sealing
spacer฀for฀rear฀fender,฀which฀will฀be฀adhered฀to฀the฀surface฀where฀the฀rear
fender฀is฀linked฀with฀cylinder฀head.฀And฀make฀them฀facing฀four฀installation
holes฀exactly.
(b) F our฀ M 8 14฀ bolts with฀ standard฀ spring฀ washer may฀ be
used฀to฀fix฀the฀rear฀fender฀onto฀the฀rear฀end฀surface฀of฀cylinder฀head.
T ightening฀ tor que ( 12 2)N m
9.฀ I nstallation฀ of฀cooling฀ liquid฀ temper atur e฀ sensor
(a)A fter฀an฀appropriate฀amount฀of฀L e฀tai฀branded฀anaerobicglue฀243
has฀been฀applied฀to฀the฀threaded฀part฀of฀cooling฀liquid฀tempe฀raturesensor,
manual฀screw฀it฀into฀the฀installation฀hole฀in฀front฀of฀cylinder฀head฀by
3 4฀thread.
(b)T ighten฀it฀with฀a฀wrench.
10. I nstallation฀of฀connector ฀component฀onto฀water ฀outlet

pi p
(a)R ubber฀plug฀shall฀be฀installed฀onto฀the฀connector.
(b)A฀layer฀of฀varnish฀shall฀be฀applied฀evenly฀onto฀both฀sides฀of฀connector
spacers,฀which฀will฀be฀adhered฀to฀the฀=surface฀where฀the฀connector฀is
linked฀with฀cylinder฀head.Make฀it฀facing฀the฀installation฀hole฀exactly.
( c) T wo฀ M 8 25฀ bolts with฀ flat฀ washer฀ and฀ standard฀ spring
washer may฀ be฀ used฀ to฀fix฀ the฀ connector฀ at฀ water฀ discharge฀ hole.

Reinstallation฀/restoration฀of฀cylinder฀head EM.2-15
Reinstallation฀/restoration฀of฀cylinder฀head
1. Installation฀of฀cylinder฀gasket
Cylinder฀gasket฀will฀be฀installed฀onto฀the฀device฀plane,฀and฀be฀fixed
using฀positioning฀pin.
2. Installation฀of฀cylinder฀head
The฀cylinder฀head฀component฀may฀be฀installed฀onto฀the฀cylinder฀gasket
on฀device฀unit,฀be฀positioned฀by฀two฀positioning฀pin฀sleeves,฀and฀befixed
using฀ten฀M12฀cylinder-cover฀bolts฀plus฀three฀M8฀cylinder-cover฀bolt
with฀cylinder-cover฀bolts฀&washers .฀Based฀on฀the฀sequence฀indicated
in฀the฀figure,฀a฀wrench฀will฀be฀used฀to฀screw฀ten฀M12฀bolts฀to฀an฀extent
as฀90N m,฀followed฀by฀a฀complete฀unscrewing,฀then฀a฀re-screwing฀to
90N m The฀tightening฀torque฀for฀three฀M8฀bolts฀shall฀be฀20฀N.m.
Finally,฀an฀100%฀verification฀needs฀to฀be฀performed฀using฀a฀fixed฀torque
wrench.
3. Rocker-shaft฀assembly
upward (a)Two฀rocker-shafts฀inside฀each฀cylinder฀may฀be฀fixed฀together฀via฀one
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special฀clamping฀plate.
(b)The฀rocker-shaft฀assembly฀shall฀be฀installed฀onto฀two฀studbolts฀on
front
convexity the฀cylinder฀head฀in฀such฀a฀way฀that฀one฀endofrocker-shaft฀having฀dummy
club฀(its฀surface฀facing฀upward)฀will฀be฀backward.
SST฀฀09207-71010
convexity฀position (c)Two฀M8฀nut with฀flat฀washer may฀be฀manually฀screwed฀onto

stud฀bolt;฀Screw฀the฀short฀threaded฀end฀ofthree฀bolts฀(fixing฀the฀rocker-
shaft฀)฀into฀the฀fixed฀seat฀for฀rocker-shaft,฀followed฀by฀a฀tightening฀made
push฀rod progressively฀in฀two฀steps฀as฀from฀the฀middle฀to฀two฀sides as฀shown
in฀the฀figure .
push฀rod Tightening฀ torque ( 18 3)N m
(d)A fter฀a฀layer฀of฀clean฀machine฀oil฀has฀been฀applied฀to฀the฀ball฀surface
on฀two฀ends฀of฀the฀push฀rod,฀the฀lower฀end฀will฀be฀installed฀into฀a฀ball
socket฀on฀the฀tappet฀cap,฀while฀the฀upper฀end฀will฀be฀pressed฀by฀a฀special
press฀ rod฀ into฀ the฀ ball฀ socket฀of฀rocker-shaft฀while฀the฀ crankshaft฀is
rotating.
4.฀Installation฀of฀valve฀chamber฀cover
Cotton฀cloth฀may฀be฀used฀to฀clean฀sealing฀band฀on฀the฀plane฀of฀cylinder
head,฀after฀which฀valve฀chamber฀cover฀will฀be฀installed฀onto฀three฀bolts
used฀to฀fix฀rocker-shaft฀for฀cylinder฀head;฀when฀the฀rubber฀sealing฀ring฀on
the฀bottom฀of฀valve฀chamber฀cover฀is฀facing฀exactly฀to฀sealing฀band฀on
theplane฀of฀cylinder฀head,components฀like฀bolt&washer฀used฀to฀fix฀three
valve฀chamber฀covers฀will฀be฀installed฀onto฀the฀fixing฀bolt฀of฀rocker-shaft,
followed฀by฀a฀fixing฀with฀three฀cap฀nuts,฀plus฀a฀tightening฀made฀from฀the
middletotwoends.
Tightening฀ torque ( 5 1) N m

EM.2-16 Reinstallation฀/restoration฀of฀cylinder฀head
5.฀Installation฀of฀inlet฀&outlet฀manifold
(a)Install฀air-inlet฀manifold฀components฀onto฀eight฀stud฀boltson฀the฀left฀side
of฀cylinder฀head,฀and฀have฀the฀positioning฀pinfacing฀exactly฀to฀its฀installation
hole.
(b)Install฀the฀lower฀part฀of฀air฀inlet฀/exhaust฀manifold฀onto฀eight฀stud
bolts฀on฀the฀left฀side฀of฀cylinder฀head,฀followed฀by฀a฀fixing฀using฀relevant
components฀like฀nut,฀washer,฀etc.฀plus฀a฀tightening฀made฀from฀the฀middle
to฀two฀sides.
Tightening฀ torque ( 50 5)N m
(c)I nstall฀ dust-cover฀ provided฀ for฀ the฀ lower฀ part฀ of฀ air-inlet฀ manifold
onto฀ the฀ surface฀ where฀ the฀ lower฀ part฀ and฀ the฀ upper฀ part฀ of฀ air-inlet
manifold฀are฀connected,฀so฀as฀to฀prevent฀any฀foreign฀material฀from฀entering
air฀inlet฀duct฀prior฀to฀the฀assembly฀of฀upper฀part.
(d)Installation฀of฀thermal฀baffle฀for฀wiring฀harness.
(e)Two฀ M6 18฀ bolts with฀flat฀ washer฀ and฀ light-typespring฀washer
will฀be฀used฀to฀have
the฀thermal฀baffle฀for฀wiring฀harness฀fixed฀onto฀the฀lowerpart฀of฀air-inlet
manifold.
T ightening฀ tor que ( 7 2) N m
(f)Installation฀of฀the฀upper฀part฀of฀air-inlet฀manifold
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-Following฀a฀dismantle฀of฀dust-cover฀from฀the฀lower-part฀of฀air-inlet฀manifold,
connection฀spacers฀shall฀be฀installed฀onto฀a฀plane฀where฀the฀lower฀part฀and
the฀upper฀part฀of฀ air-inlet฀ manifold฀ are฀ connected,฀ and฀ shall฀ face฀to฀ six
installation฀holes฀exactly.
-T he฀upper฀part฀of฀air-inlet฀manifold฀shall฀be฀installed฀onto฀gaskets฀where฀the
lower฀part฀and฀the฀upper฀part฀of฀air-inlet฀manifold฀are฀connected,฀and฀have฀six฀installation฀holes฀facing฀exactly฀to฀relevant฀spacers,฀and
to฀six฀holes฀on฀the฀low฀part.
-Six฀M8 30฀hexagonal฀socket฀head฀bolts with฀flat฀washer฀and฀standard฀spring฀washer will฀be฀used฀for฀fixing฀purpose,฀and
shall฀be฀tightened฀as฀per฀the฀sequence฀“from฀the฀middle฀to฀two฀ends”:฀a฀pre-tightening฀may฀be฀made฀using฀a฀pneumatic฀wrench฀before
a฀re-tightening฀to฀specified฀torque฀using฀a฀fixed-torque฀wrench.
(g)Installation฀of฀dead฀plate฀and฀the฀manifold฀supporting฀frame
-Using฀two฀M8 16฀bolts with฀flat฀washer฀and฀standard฀spring฀washer ,฀dead฀plate฀may฀be฀installed฀onto฀front฀end฀surface฀at
the฀lower฀/upper฀part฀of฀inlet฀manifold฀to฀link฀the฀lower฀part฀with฀the฀upper฀part.฀T ightening฀torque (16 3)N m
-One฀M8 16฀bolt with฀flat฀washer฀and฀standard฀spring฀washer will฀be฀used฀to฀have฀the฀upper฀part฀of฀manifold฀supporting
frame฀on฀the฀rear฀side฀of฀cylinder฀head฀fixed฀onto฀the฀upper฀part฀of฀inlet฀manifold.฀And฀two฀bolts฀on฀manifold฀supporting฀frame฀may
be฀tightened฀using฀a฀fixed-torque฀wrench.
6.฀Installation฀of฀the฀fuel฀distributor฀assembly
(a)A฀layer฀of฀clean฀machine฀oil฀shall฀be฀applied฀evenly฀to฀the฀external฀edge฀of
sealing฀ringwhere฀four฀fuel฀injectors฀of฀the฀fuel฀distributor฀assemblywill฀be
linked฀with฀the฀air฀inlet฀manifold.
(b)When฀four฀fuel฀injectors฀are฀facing฀exactly฀to฀respective฀installation฀hole฀at
the฀lower฀part฀of฀air-inlet฀manifold,฀and฀when฀one฀side฀having฀fuel฀pressure
adjustor฀is฀towards฀the฀front฀side฀of฀engine,฀press฀and฀install฀four฀fuel฀injectors
to฀the฀lower฀part฀of฀inlet฀manifold.
(c)The฀fuel฀distributor฀assembly฀will฀be฀fixed฀using฀two฀M8 25฀bolts
with฀flat฀washer฀and฀standard฀spring฀washer applied฀to฀the฀lower฀part
of฀inlet฀manifold.

Reinstallation฀/restoration฀of฀cylinder฀head EM.2-17
7.฀Installation฀of฀wiring฀harness฀on฀engine
(a)Using฀fixing฀clips,฀the฀rear฀end฀of฀wiring฀harness฀may฀be฀fixed฀to฀the
rear฀end฀surface฀of฀cylinder฀head,฀and฀one฀M8 20฀bolt with฀flat
washer฀and฀standard฀spring฀washer is฀ usable฀ to฀ fix฀ a฀ manifold
supporting฀frame.฀And฀the฀tightening฀shall฀be฀performed฀at฀a฀later฀stage.
(b)At฀the฀place฀adjacent฀to฀fuel฀guide฀rail,฀wiring฀harness฀needs฀to฀be฀fixed
onto฀fuel฀guide฀rail฀using฀two฀nylon฀strips,and฀extra฀part฀on฀the฀tip฀of
nylon฀strip฀shall฀be฀cut฀off฀using฀scissors.
(c)Four฀plugs฀provided฀for฀four฀fuel฀injectors฀on฀the฀wiring฀harness฀will
be฀inserted฀into฀relevant฀sockets฀provided฀for฀four฀fuel฀injectors.
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8.฀Installation฀of฀ignition฀coil฀components
Using฀ three฀M 6 35฀bolts with฀ flat฀ washer฀ and฀light฀type฀ spring
washer ,฀ignition฀coil฀may฀be฀fixed฀on฀relevant฀supporting฀frame:฀flat
washer฀shall฀be฀applied฀to฀one฀side฀close฀to฀the฀ignition฀coil,฀and฀light-
type฀spring฀washer฀shallbe฀applied฀to฀one฀side฀close฀to฀the฀supporting
frame฀provided฀for฀ignition฀coil,฀followed฀by฀a฀tightening฀of฀M6nuts.
T ightening฀ tor que ( 7 2) ฀ N m
9.฀ I nstallation฀ of฀ high-tension฀ damping฀wir ing
Two฀ends฀of฀high-tension฀damping฀wiring฀shall฀be฀connected฀to฀ignition
coil฀and฀spark฀plug฀respectively฀as฀indicated฀by฀relevant฀marks฀made฀on
high-voltage฀line฀and฀ignition฀coil.

EM.3-1
Valve฀mechanism
Page
Disassembly฀diagram฀for฀valve฀mechanism...................................EM.3-2
Disassembly฀of฀timing฀chain/camshaft...........................................EM.3-3
Inspection฀&repair฀for฀timing฀chain/camshaft฀components.............EM.3-5
Replacement฀of฀front฀oil฀seal฀on฀crankshaft..................................EM.3-8
Installation฀of฀timing฀chain/camshaft..............................................EM.3-9
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EM.3-2 Valve฀mechanism Disassembly฀figure฀for฀valve฀mechanism
Disassembly฀figure฀for฀valve฀mechanism
sealing฀ring
valve-box฀cover
rocker฀shaft
฀assembly
push฀rod
tappet
camshaft
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thrust฀disk
vibration฀absorber
tensioner
cam฀chainwheel
timing฀chain฀cover
cam฀chainwheel
bolt
timing฀chain
crankshaft
chainwheel
crankshaft
sealing฀ring
pulley฀bolt
front฀oil฀seal฀of฀crankshaft
crankshaft฀pulley
Those฀with฀mark฀*฀refer฀to฀spare฀parts฀which฀have฀been฀used฀and฀can฀not฀be฀re-used.

Valve฀mechanism Disassembly฀of฀timing฀chain/camshaft EM.3-3
Disassembly฀of฀timing฀chain/camshaft
Preparation฀for฀disassembly
(a)Dismantle฀of฀driving฀belt.
(b)Dismantle฀of฀fan฀&water฀pump฀pulley.
(c)Dismantle฀of฀rocker฀arm฀shaft฀assembly฀and฀push฀rod.
1.฀Removal฀of฀valve฀tappet
Eight฀tappets฀will฀be฀removed฀using฀a฀steel฀wire฀or฀magnet.
Note A lways฀k eep฀tappets฀in฀an฀upr ight฀ar r ay฀as

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฀฀฀฀per ฀a฀cor r ect฀sequence.
2.฀Removal฀of฀crankshaft฀pulley
(a)Removal฀of฀pulley฀bolt฀using฀SST
SST฀฀09213-70010฀and฀09330-00021
(b)Even฀removal฀of฀crankshaft฀pulleys฀using฀SST

EM.3-4 Valve฀mechanism Disassembly฀of฀timing฀chain/camshaft
3.฀Removal฀the฀cover฀of฀timing฀chainwheel฀chamber
The฀cover฀of฀chain฀wheel฀cham฀ber฀may฀be฀removed฀by฀unscrewing
eleven฀bolts฀on฀the฀cover฀of฀chainwheel฀chamber฀using฀a฀torque
spanner.
4.฀Inspection฀on฀the฀tension฀degree฀of฀timing฀chain
Subject฀to฀a฀removal฀of฀crankshaft฀front฀belt฀/timing chain฀ cover,฀ the
tension฀degree฀of฀timing฀chain฀may฀be฀checked฀in฀accordance฀with฀Max.
allowable฀tension฀degree฀13.5mm฀when฀applied฀with฀a฀98N฀pulling฀force.
If฀it฀exceeds฀Max.฀allowable฀value,฀the฀timing฀chainwheel฀shall฀be฀changed.
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5.฀Removal฀of฀chair฀tensioner
6.฀Removal฀of฀timing฀chainwheel
(a)To฀loosen฀the฀fixing฀bolts฀on฀camshaft฀chainwheel,฀crankshaft฀pulley
needs฀to฀be฀installed.
(b)After฀unscrewing฀the฀fixing฀bolt,฀SST฀may฀be฀used฀to฀have฀camshaft
chainwheel,฀crankshaft chainwheel฀and฀chain฀dismantled฀evenly.
SST฀฀09950-20017

Valve฀mechanism Inspection฀&repair฀for฀timing฀chain/camshaft฀components EM.3-5
7.฀Removal฀of฀shock฀absorber
Two฀bolts฀plus฀the฀shock฀absorber฀may฀be฀dismantled.
8.฀Removal฀of฀thrust฀disk฀and฀camshaft
(a)Two฀bolts฀plus฀the฀thrust฀disk฀may฀be฀dismantled.
(b)Take฀out฀the฀camshaft฀carefully.
Note Do฀ not฀ damage฀ the฀ camshaft฀ bear ing.
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I nspection฀and฀r epair ฀of฀timing฀chain฀and฀camshaft

components
1.฀Check฀the฀camshaft
(a)When฀the฀camshaft฀is฀placed฀on฀a฀V-shape฀steel,฀measure฀the฀radial
runout฀at฀neck฀journal฀on฀the฀center฀of฀camshaft.
Max.฀circumferential฀radial฀runout 0.06฀ mm
T he฀camshaft฀needs฀to฀be฀changed฀if฀the฀runout฀exceeds฀Max.value.
(b)Measure฀the฀height฀of฀convexity฀of฀camshaft฀using฀amicrometer
Standard฀height฀of฀convexity
A ir ฀ inlet฀ por t (38.620 38.720)mm
A ir ฀ exhaust฀ por t (38.629 38.729)mm
M in฀ height฀ of฀ convexity
A ir ฀ inlet฀ por t 38.26฀ mm
A ir ฀ exhaust฀ por t 38.27฀ mm
T he฀camshaft฀needs฀to฀be฀changed฀if฀the฀height฀of฀convexity฀is฀less฀than
Min.฀value.
(c)Measure฀the฀diameter฀of฀neck฀journal฀using฀a฀micrometer.
Standard฀diameter from฀front฀side
No.฀ 1 (46.459 46.475)mm
No.฀ 2 (46.209 46.225)mm
No.฀ 3 (45.959 45.975)mm
No.฀ 4 (45.709 45.725)mm
No.฀ 5 (45.459 45.475)mm

EM.3-6 Valve฀mechanism Inspection฀&repair฀for฀timing฀chain/camshaft฀components
(d)Have฀the฀thrust฀disk฀and฀the฀camshaft฀chainwheel฀installed฀on
camshaft.
(e)The฀fixing฀bolts฀for฀camshaft฀chainwheel฀need฀to฀be฀installed฀and
tightened.
Tightening฀ torque 90฀ N M
(f)Axial฀clearance฀between฀the฀thrust฀disk฀and฀the฀camshaft฀may฀be
measured฀using฀a฀feeler฀gage.
Standard฀axial฀clearance (0.07 0.22)mm
M ax.฀ axial฀ clear ance 0.30฀ mm
T he฀thrust฀disk฀needs฀to฀be฀changed฀when฀the฀clearance฀exceeds฀Max.
value,฀and฀the฀camshaft฀needs฀to฀be฀changed฀as฀well฀when฀necessary.
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2. Inspection฀on฀chain฀and฀chainwheel
(a)When฀chain฀is฀thoroughly฀stretched,฀measure฀its฀length.
(b)A฀similar฀measurement฀may฀be฀performed฀on฀three฀pointsormore฀having
been฀random฀selected.
Max.฀stretched฀length฀of฀chain ฀291.4mm฀when฀a49N฀str etching
for ce฀is฀applied.
T he฀chain฀needs฀to฀be฀changed฀if฀the฀read฀value฀of฀stretched฀length฀exceeds
Max.฀value.
(c)Measure฀the฀diameter฀of฀chainwheel฀installed฀with฀chain฀using฀callipers.
Min.฀diameter฀of฀chainwheel with฀chain
Crankshaft฀฀฀฀฀฀59฀mm
Camshaft฀฀฀฀฀฀114฀mm
The฀chain฀needs฀to฀be฀changed฀if฀the฀actual฀diameter฀is฀less฀than฀Min.
value.
3.฀Inspection฀on฀chain฀tensioner
Measure฀the฀thickness฀of฀chain฀tensioner฀using฀callipers.
Standard฀thickness 15.0฀ mm
M in.฀ thick ness 12.5฀ mm
T he฀chain฀tensioner฀needs฀to฀be฀changed฀if฀the฀actual฀thickness฀is฀less
than฀Min.฀value.

Valve฀mechanism Inspection฀&repair฀for฀timing฀chain/camshaft฀components EM.3-7
4.฀Change฀the฀chain฀tensioner฀column฀when฀necessary.
(a)Side฀plate฀may฀be฀removed฀using฀gasket฀scraper฀and฀hammer.
Note:฀do฀not฀bend฀the฀plate.
(b)Dismantle฀the฀chain฀tensioner฀column฀and฀spring.
(c)฀Machine฀oil฀for฀engine฀may฀be฀filled฀to฀the฀chain฀tensioner฀unit,฀or฀to
the฀sliding฀surface฀of฀column.
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(d)Have฀the฀spring฀and฀chain฀tensioner฀column฀installed฀on฀the฀chain
tensioner฀unit.
(e)Install฀the฀side฀plate฀to฀place.
Note I nstallation฀ direction.
(f)Strike฀the฀plate฀into฀place฀using฀hammer฀and฀socket฀spanner.
socket฀spanner
5.฀Inspection฀on฀the฀chain฀shock฀absorber
Measure฀the฀thickness฀of฀shock฀absorber฀using฀callipers:฀Standard
thickness 6.6฀ mm
M in.฀ thick ness 5฀ mm
If฀the฀thickness฀is฀less฀than฀Min.฀value,฀the฀shock฀absorber฀needs฀to฀be
changed.

EM.3-8 Valve฀mechanism Replacement฀of฀front฀oil฀seal฀on฀crankshaft
6.฀Inspection฀on฀valve฀tappet
Measure฀the฀diameter฀of฀tappet฀using฀a฀micrometer.
Diameter฀of฀tappet (21.387 21.404)mm
If฀actual฀diameter฀does฀not฀conform฀to฀relevant฀stipulations,฀oil฀clearance
needs฀to฀be฀checked.
7.฀Take฀out฀the฀tappet฀when฀necessary.
Have฀the฀valve฀tappet฀submerged฀in฀diesel.
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The฀disassembly฀and฀assembly฀of฀tappet฀may฀proceed฀when฀soaking฀in
diesel,฀and฀snap฀ring฀and฀push-rod฀seat฀may฀be฀installed฀using฀a฀presser
applicable฀to฀sealing฀test.
SST฀09276-71010
8.฀Sealing฀drop฀test฀check
Using฀a฀presser฀applicable฀to฀sealing฀test฀(with฀stress฀set฀to196.2N)฀,
measure฀the฀time฀it฀takes฀to฀drop฀for฀1mm฀after฀it฀has฀dropped฀for฀about
2mm.
Sealing฀drop฀time:฀(7-50)s/mm฀when฀at฀20
Replacement฀of฀front฀oil฀seal฀on฀crankshaft
Method฀I ฀ Provided฀that฀the฀ timing฀chain฀cover฀ has฀ been฀ removed
from฀the฀timing฀chain฀box
(a)Strike฀the฀oil฀seal฀out฀using฀screw฀tap฀and฀hammer.

Valve฀mechanism Installation฀of฀timing฀chain/camshaft EM.3-9
(b)Strike฀new฀oil฀seal฀into฀place฀using฀SST฀and฀hammer฀until฀the฀surface
of฀oil฀seal฀reaches
The฀same฀height฀as฀the฀edge฀of฀timing฀chain฀cover.
SST฀09223-22010
(c)MP฀multi-purpose฀grease฀shall฀be฀applied฀to฀the฀jaw฀of฀oil฀seal.
Method฀ II
(a)Dismantle฀the฀oil฀seal฀using฀SST.
SST฀09308-10010
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(b)MP฀multi-purpose฀grease฀shall฀be฀applied฀to฀the฀jaw฀of฀new฀oil฀seal.
(c)Strike฀new฀oil฀seal฀into฀place฀using฀SST฀and฀hammer฀until฀the฀surface
of฀oil฀seal฀reaches
the฀same฀height฀as฀the฀edge฀of฀timing฀chain฀box.
SST฀09223-22010
Installation฀of฀timing฀chain/camshaft
1.฀Installation฀of฀camshaft
(a)Have฀the฀camshaft฀inserted฀carefully฀into฀the฀air฀cylinder฀box.
Note Do฀not฀damage฀the฀camshaft฀bearing.
(b)Thrust฀disk฀will฀be฀fixed฀using฀two฀bolts.
Tightening฀ torque 18.5N m
Note I nstallation฀ direction
front

EM.3-10 Valve฀mechanism Installation฀of฀timing฀chain/camshaft
2.฀Installation฀of฀shock฀absorber
The฀shock฀absorber฀may฀be฀fixed฀using฀two฀bolts.
Tightening฀ torque 18.5฀ N m
3.฀Installation฀of฀timing฀chain฀and฀chainwheel
setting฀of฀camshaft (a)The฀set฀key฀of฀crankshaft฀chainwheel฀must฀be฀installedupward.
(b)Have฀the฀set฀key฀on฀camshaft฀chainwheel฀matching฀well฀with฀the฀mark
made฀on฀the฀thrust฀disk.
mark
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set฀key฀of฀crankshaft
(c)Have฀the฀chainwheel฀installed฀on฀the฀timing฀chain.
Note H ave฀the฀ timing฀chain฀ matching฀well฀with
฀฀฀฀฀฀฀฀the฀mar k ฀made฀on฀the฀chainwheel.
(d)T he฀installation฀of฀timing฀chain฀and฀chainwheel฀may฀proceed฀on฀an
even฀basis.

Valve฀mechanism Installation฀of฀timing฀chain/camshaft EM.3-11
(e)Have฀the฀crankshaft฀pulley฀installed฀on฀crankshaft.
(f)A฀thin฀layer฀of฀engine฀oil฀will฀be฀applied฀to฀the฀top฀/screwed฀parts฀of
camshaft฀chainwheel฀bolts.
(g)The฀camshaft฀chainwheel฀bolts฀may฀be฀installed฀using฀SST฀and
tightened฀as฀well
SST฀09213-70010฀and฀09330-00021
Tightening฀ torque 90N m
Dismantle฀the฀crankshaft฀pulley.
4.฀Installation฀of฀chain฀tensioner
The฀chain฀tensioner฀will฀be฀fixed฀using฀two฀bolts.
Tightening฀ torque:฀ 18.5N m
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5.฀Installation฀of฀timing฀chain฀cover
Using฀eleven฀bolts,฀the฀installation฀of฀new฀sealing฀ring฀and฀timing฀chain
cover฀may฀proceed.
6.฀Installation฀of฀crankshaft฀pulley
(a)A฀plastic฀hammer฀may฀be฀used฀to฀gently฀strike฀the฀crankshaft฀pulley
into฀place.
Plastic฀hammer
(b)A฀layer฀of฀engine฀machine฀oil฀will฀be฀applied฀to฀the฀top/screwed฀parts
of฀pulley฀bolt.
(c)The฀pulley฀bolt฀will฀be฀installed฀using฀SST฀and฀tightened฀as฀well.
SST฀09213-70010฀and฀09330-00021

EM.3-12 Valve฀mechanism Installation฀of฀timing฀chain/camshaft
7.฀Installation฀of฀valve฀tappet
One฀small฀part฀of฀steel฀wire฀or฀magnet฀may฀be฀used฀to฀insert฀the฀valve
tappet฀into฀the฀tappet฀hole฀carefully.
Installation฀at฀a฀later฀stage
(a)Installation฀of฀the฀assembly฀for฀push฀rod฀and฀rocker฀shaft;
(b)Installation฀of฀water-pump฀pulley฀and฀fan;
(c)Installation฀and฀adjustment฀of฀driving฀belt;
(d)Start฀the฀engine฀and฀check฀for฀leakage.
(e)Check฀the฀engine฀oil.
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CO-1
Cooling system
Composition &characteristics of cooling system............................CO-2
Inspection /change of coolant for engine........................................CO-2
Cooling water pump.....................................................................CO-3
Thermostat...................................................................................CO-5
Radiator.......................................................................................CO-6
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Cooling system-Composition &characteristics of cooling system, Inspection /change of
CO-2 coolant for engine
Composition &characteristics of cooling system

The cooling system provided for engine is used to emit an appropriate amount of heat produced by each
part and component of engine in a timely and forcible manner, so that engine may work continuously under a
best temperature condition. For vehicles having air condition, the cooling system may provide heat supply to the
warm-air device as well.
To improve the cooling effect and reduce the dissipation of coolant, Model 491QE petrol engine has been
installed with one closed water cooling system having one automatic valve on the radiator cap: when engine is
under a normal heat condition, the valve will be closed, making the pressure inside the cooling system slightly
higher than atmospheric pressure so as to raise the boiling point of coolant; when the pressure inside the cooling
system is too high or too low, the valve will be opened, making the cooling system ventilated with the atmosphere.
Structure schematic diagram for cooling system as shown below:
water outlet pipe
to the front warm-air device

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from the front

water inlet pipe warm-air device
thermostat installed inside
Inspection /change of coolant inside engine

1. Check the level of coolant inside the standbycoolant
box.
2. Check the quality of engine coolant

(a)Ensure that there’s no any rusted deposit or piece around the cap or
the filling hole of radiator.
And it’s unallowable to have machine oil mixed with coolant.

Cooling system Cooling water pump CO-3
(b)The coolant must be changed if it’s too dirty.

(c)The coolant used shall be of quality ethylene glycolbase coolant
antifreeze liquid .
(d)Capacity 7.9L
3. Change of engine coolant

(a)Dismantle the radiator, or the outlet cover of water tank.
(b)Have the coolant discharged from the radiator and the exhaust valve
of engine. the exhaust valve is onthe left front side ofengine
(c)Screw down the exhaust valve
(d)Fill the system with coolant.
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Cooling water pump Part drawing
fan cooling water pump
sealing ring
cooling water pump pulley

silicone-oil clutch
without silicone-oil clutch
fan
fan transmission shaft
The one with mark refer to spare part which has been used and can not be re-used.

CO-4 Cooling system Cooling water pump
Disassembly of Cooling water pump

1. Discharge the coolant.
2. Dismantle the transmission-belt.
3. Dismantle the fan, and the cooling water-pump pulley.
After removing four nuts on the belt pulley seat used to fix the silicone-
oil clutch, dismantle the fan, the assemblyof silicone-oil clutch, and the
water pump pulley respectively.
4. Dismantle the cooling water pump.

(a)Dismantle the adjustment rod of transmission belt from water pump
after the belt has been dismantled.
(b)Dismantle the nuts, four bolts, water pump, and sealing ring.
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Inspection on components for cooling water pump

1. Inspection on cooling water pump
(a)Rotate the belt pulley seat, and check whether the bearingof water
pump is rotating smoothly and free from noise.
(b)Water pump may be changed when necessary.
2. Inspection on silicone-oil clutch

(a)Check whether the silicone-oil clutch has been damaged,or is leakingoil.
(b)Silicone-oil clutch may be changed when necessary.
Installation of cooling water pump

1. Installation of cooling water pump
Using nuts and five bolts, new sealing ring, water pump and the
adjustment rod for transmission-belt may be installed between the water
pump and the timing chain box.
Tightening torquet Cooling water pump 16.5 N m
Adjusting rod 40 N m

Cooling system Thermostat CO-5
2. Installation of cooling water pump pulley and fan

Using four nuts, the water pump pulley, and the assembly of silicone-oil
clutch and fan may be installed.
3. Check if there’s any leakage after starting the engine.
Thermostat
Dismantle of thermostat
1.Discharge the coolant.
2.Dismantle the outlet hose of radiator from the inlet of water tank.
3.Dismantle the thermostat, and the inlet of water tankTwo nuts, the
inlet of water tank, sealing ring, and the thermostat shall bedismantled
from the timing chain box.
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Inspection on thermostat
Note A constant temperature refers to the starting
temperature of thermostat valve.
1. After the thermostat is submerged in water, add hot
water gradually.
2. Check the starting temperature and the lift range

of thermostat valve.
The thermostat shall be changed if the starting temperature and the lift
range of thermostat valve are not within the limit specified below:
Starting temperature of thermostat valve 80-84 Lifting range of
thermostat valve Equal to or above 8mm when at 95
3. Check whether the spring of valve has been pressed

tightly when thermostat is full closed.
4. If relevant adjustments do not make sense whereby
the starting temperature of thermostat valve is less than
76 or the moving distance of thermostat valve is less
than 8mm when at 95 , the thermostat shall be changed.
Installation of thermostat
1. Installation of thermostat and the inlet of water tank
clamp valve
(a)New sealing ring shall be applied during the installation of thermostat,
and clamp valve shall be placed on the thermostat as indicated in the
figure.

CO-6 Cooling system radiator
(b)Using two nuts, the inlet of water tank may be installed.

Tightening torque 12 N m
2. Connect the outlet hose of radiator to the inlet of water

tank.
3. Refill with coolant.
4. Check whether there’s any leakage after starting
engine.
Radiator
Clean &wash of radiator
Dirts and dusts inside the radiation fin may be cleared away using a
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steam purger.
Note: Do not damage the radiation fin if a high-
pressure purger is used. When the pressure at the
nozzle of purger is (2.944-3.434) Mpa, keep a Min.
distance as (40-50) cm between the nozzle and the
radiation fin.
Inspection on radiator
1. Check the cap or outlet cover for radiator or water
radiator cap tester tank respectively.
(a)Push one radiator cover tester into place until safety valve is opened.
And check whether the valve may beopened when the pressure is between
73.6kPa and103kPa.
(b)Check and ensure the pressure on cover will not go down sharply
when it’s lower than 58.9 kPa.
(c)The cover shall be changed if any failure has been found in either of
above articles.
2. Check the leakage of coolant system

(a)Fill the radiator with coolant, and press the manometer.
(b)Increase the temperature of engine.
(c)After an increment of pressure to 117.72kPa, observe
whether the pressure is going down. If it does occur, check if there’s any
leakage with hose, radiator, or water pump. If no any external leakage is
found, check the radiation fincylinder block, and the cover.
radiator cap tester

LU-1
Lubrication฀system
Page
Composition฀/function฀of฀lubrication฀system..................................LU-2
Inspection฀on฀machine-oil฀pressure.............................................,.LU-2
Change฀of฀engine฀oil฀/oil฀filter฀.......................................................LU-3
Oil฀pump.....................................................................................LU-4
LU
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ST
CH

Lubrilation฀system-Composition฀/function฀of฀lubrication฀system¡¢Inspection฀on฀machine-oil
LU-2 pressure
฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀Composition฀/function฀of฀lubrication฀system
Model฀491QE฀petrol฀engine฀adopts฀a฀compound฀lubrication (the฀combination฀of฀pressure฀lubrication฀and
splash฀lubrication ); ฀And฀the฀lubrication฀system฀mainly฀consists฀of฀oil฀filter,฀oil฀pump,฀oil฀cooler,฀pressure-
limiting฀valve,฀etc.
Lubrication฀system฀has฀key฀functions฀as฀described฀below:฀lubrication,฀sealing,฀cooling,฀cleaning,฀shock
absorption,฀hydraulic฀pressure,฀buffer฀action,฀and฀anti-rust฀function.
Structure฀of฀lubrication฀system฀as฀shown฀in฀the฀figure฀below:
push฀rod
valve
tappet
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camshaft
recommended฀viscosity(SAE) : Inspection฀on฀machine-oil฀pressure
1. Inspection฀on฀the฀quality฀of฀oil฀of฀engine
Check฀whether฀machine-oil฀has฀deteriorated,฀has฀water฀content,changes
color,฀or฀becomes฀thin.
Machine-oil฀shall฀be฀changed฀if฀the฀quality฀is฀too฀bad.
It’s฀allowed฀to฀use฀machine-oil฀stated฀below:฀SG฀grade฀petrol฀machine-
oil,฀with฀viscosity฀coefficient฀API฀10W-40
(GB11121-1995 );฀or฀ better฀ than฀ SG฀ grade;฀ or฀ machine-oil฀ with
recommended฀viscosity.
temperature฀ranges฀before฀oil฀change
2.฀Inspection฀on฀the฀level฀of฀engine฀oil
The฀level฀of฀liquid฀shall฀be฀between฀the฀mark฀฀฀ “L” and฀ the฀ mark
“F”made฀on฀oil฀gauge฀If฀the฀level฀of฀liquid฀is฀too฀low,฀check฀whether
there’ sany฀leakage,฀and฀whether฀machine-oil฀has฀been฀filled฀to฀the฀mark
“F”

Lubrilation฀system-Change฀of฀engine฀oil฀/฀filter LU-3
manometer 3.฀dismantle฀he฀machine-oil฀pressure฀switch฀or฀sensor;
4.฀Install฀the฀oil฀manometer.
5.฀Start฀the฀engine.
Start฀ the฀ engine,฀ and฀ increase฀ the฀ temperature฀ to฀ a
normal฀working฀temperature.
6.฀Check฀the฀oil฀pressure
Machine-oil฀pressure : ฀฀฀>49฀kPa฀฀฀฀when฀at฀idle฀speed
(750± 50)฀revolutions/minute
฀฀฀฀฀245.2-490.3฀kPa฀฀when฀at฀speed฀3000฀revolutions/฀minute
Note£ºF ollowing฀a฀ r e-installation฀of฀ oil฀ pr essur e
฀฀฀฀฀฀฀฀฀฀switch฀or ฀sensor ,฀check฀whether ฀machine-oil฀is
฀฀฀฀฀฀฀฀฀฀leak ing.
Change฀of฀engine฀oil฀/filter
1.฀Discharge฀of฀engine฀machine-oil
SST (a)Dismantle฀the฀cover฀from฀the฀machine-oil฀filter.
(b)Machine-oil฀shall฀be฀discharged฀to฀a฀container฀after฀aremoval฀of฀oil
drain฀plug
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2.฀Change฀of฀oil฀filter
(a)Using฀SST,฀oil฀filter฀may฀be฀dismantled.
SST฀09228-22020
(b)Check฀and฀wash฀the฀installation฀ring฀for฀machine-oil฀filter.
(c)Clean฀engine฀oil฀shall฀be฀applied฀to฀the฀seal฀gasketof฀new
machine-oil฀filter.
(d)Screw฀up฀the฀oil฀filter฀gently฀until฀someresistances฀are฀met.
(e)Screw฀it฀up฀by฀3/4฀round฀using฀SST.
SST฀09228-22020
3.฀Fill฀engine฀with฀machine-oil
(a)After฀a฀washing,฀the฀oil฀drain฀plug฀shall฀be฀installed฀with฀a฀new฀sealing
ring.
(b)Fill฀with฀SG฀or฀better฀oil,฀or฀new฀oil฀having฀recommended฀viscosity.
Capacity
Refill฀after฀discharge
Machine-oil฀(when฀having฀machine-oil฀filter)฀to฀be฀=changed :3.5฀L
Dry฀injection฀amount :฀฀฀4.2฀L
(c)Sealing฀ring฀needs฀to฀install฀฀the฀cover฀of฀machine-oil฀filter.
4.฀Check฀whether฀there’s฀any฀leakage฀after฀starting฀the
engine.
5.฀Check฀the฀level฀of฀engine฀machine-oil.

LU-4 ฀ Oil฀pump
Oil฀pump
Part฀drawing฀for฀oil฀pump
oil฀pump฀body
oil฀pump฀cover
safety฀valve bolt
driving฀rotor * o฀ring
machine-oil฀filter฀screen
spring
safety฀valve฀plug driven฀rotor use฀by฀two฀driving฀vehicles
oil฀pump฀cover
machine-oil฀filter฀screen
use฀by฀four฀driving฀vehicles
The฀one฀with฀mark฀*฀refer฀to฀spare฀part฀which฀has฀been฀used฀and฀can฀not฀be฀re-used
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Disassembly฀of฀oil฀pump
1. Provide฀a฀support฀to฀the฀vehicle.
Note:฀the฀supporting฀to฀the฀vehicle฀shall฀be฀secure฀and
stable.
2.฀Discharge฀the฀engine฀machine-oil.
3.฀Dismantle฀the฀reinforcement฀plate฀on฀left฀&right฀side.
4.฀Removal฀of฀bottom฀oil฀pan.
(a)Unscrew฀eighteen฀bolts.
(b)Subject฀to฀an฀insertion฀of฀SST฀scraper฀between฀the฀device฀unit฀and฀the
SST bottom฀oil฀cover,฀materials฀used฀for฀filling฀&sealing฀purpose฀shall฀be
removed,฀followed฀by฀a฀removal฀of฀bottom฀oil฀cover.
SST
SST฀09032-00100
Note:
-Do฀not฀use฀SST ฀when฀on฀the฀side฀of฀timing-chain฀cover ,
or ฀scr ewdr iver ฀may฀be฀used฀when฀necessar y.
-Do฀not฀damage฀the฀flange฀of฀the฀oil฀pan฀dur ing฀the
dismantle฀of฀oil฀pan.
5.฀Dismantle฀of฀oil฀filter฀screen
Four฀bolts,฀O฀ring,฀and฀screen฀shall฀be฀dismantled฀successively.
6.฀Dismantle฀of฀oil฀pump
Oil฀pump฀may฀be฀pulled฀out฀after฀bolts฀have฀been฀dismantled

฀ Oil฀pump LU-5
Disassembly฀of฀oil฀pump
1.฀Check฀whether฀oil฀pump฀is฀working฀normally.
(a)Have฀the฀filter฀screen฀submerged฀in฀oil฀using฀a฀screwdriver,and฀rotate
the฀shaft฀of฀oil฀pump฀in฀a฀clockwise฀direction,฀and฀machine-oil฀is฀supposed
to฀discharge฀from฀the฀oil฀outlet.
(b)Rotate฀the฀shaft฀of฀oil฀pump฀in฀a฀similar฀way฀stated฀above฀when฀the
machine-oil฀outlet฀has฀been฀blocked฀by฀finger,฀and฀the฀shaft฀of฀oil฀pump
shall฀be฀difficult฀to฀rotate.
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2.฀Removal฀of฀safety฀valve
Remove฀the฀safety฀valve,฀plug,฀and฀spring.
3.฀Removal฀of฀the฀oil฀pump฀cover
safety฀valve
Three฀bolts฀and฀the฀oil฀pump฀cover฀shall฀be฀dismantled฀succe
spring
ssively.
4.฀Take฀out฀the฀driving฀&driven฀rotor
safety฀valve฀plug
Inspection฀on฀oil฀pump
1.฀Check฀whether฀the฀operation฀on฀safety฀valve฀is฀normal
After฀applying฀one฀layer฀of฀engine฀oil฀to฀the฀valve,check฀whether฀machine
oil฀is฀able฀to฀flow฀into฀valve฀hole฀naturally.
Valve฀and/or฀the฀pump฀assembly฀may฀be฀changed฀whennecessary.
2.฀Inspection฀on฀the฀driving฀&driven฀rotor
(a)Check฀the฀clearance฀of฀rotor฀unit.The฀clearance฀between฀rotor฀and
pump฀unit฀may฀be฀measured฀using฀a฀gauge.
Standard฀clearance :(0.10-0.15)mm
M ax.฀ clear ance : 0.20฀ mm
0.10-0.15mm
R otor฀must฀be฀changed฀if฀the฀actual฀clearance฀exceeds฀Max.฀value.฀And
the฀oil-pump฀assembly฀may฀be฀changed฀when฀necessary.

LU-6 ฀ Oil฀pump
(b)Check฀the฀end฀clearance฀of฀rotor฀unit
( 0 . 0 3 - 0 . 0 7 )mm A฀gauge฀may฀be฀used฀to฀measure฀the฀clearance฀as฀indicated฀in฀the฀drawing.
Standard฀clearance :(0.03-0.07)฀ mm
M ax.฀ clear ance : 0.15฀ mm
T he฀rotor฀shall฀be฀changed฀if฀the฀actual฀clearance฀exceeds฀Max.฀value.
A nd฀the฀oil฀pump฀assembly฀may be฀ changed฀ when฀ necessary .
(c)A฀gauge฀may฀be฀used฀to฀check฀the฀clearance฀between฀two฀inner฀rotors,
or฀the฀clearance฀between฀the฀drivin฀grotor฀and฀the฀driven฀rotor.
(0.07-0.12)mm
฀ ฀Standard฀clearance : (0.07-0.12)฀ mm
฀ ฀M ax.฀ clear ance : 0.20฀ mm
R otor฀shall฀be฀changed฀when฀the฀actual฀clearance฀exceeds฀Max฀value฀.
A nd฀the฀oil฀pump฀assembly฀maybe฀changed฀when฀necessary.
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Assembly฀of฀oil฀pump
1.฀Installation฀of฀driving฀&driven฀rotor
Having฀the฀side฀of฀rotor฀with฀punctured฀mark฀facing฀upward,฀the
installation฀of฀pump฀unit฀may฀proceed.
punctured฀mark 2.฀Installation฀of฀oil-pump฀cover
Using฀three฀bolts,฀the฀oil-pump฀cover฀may฀be฀installed,฀followed฀by฀a
tightening฀of฀bolts.
Tightening฀ torque : 8N .m
3.฀Installation฀of฀safety฀valve,฀spring,฀and฀safety฀valve
plug
safety฀valve Following฀an฀insertion฀of฀safety฀valve฀and฀spring,฀the฀safety฀valve฀plug
will฀be฀installed.
spring
฀ ฀ ฀Tightening฀ moment : 37.5N .m
safety฀valve฀plug 4.฀I nspection฀on฀the฀assembly฀of฀oil฀pump
Installation฀of฀oil฀pump
1.฀Installation฀of฀oil฀pump
(a)Align฀the฀convex฀of฀propeller฀shaft฀on฀oil฀pump฀with฀thelocating
slot฀on฀the฀driving฀rotor฀of฀oil-pump.
(b)Oil-pump฀may฀be฀installed฀using฀bolts.
And฀bolt฀shall฀be฀tightened.
Tightening฀ torquet : 18.5N .m

฀ Oil฀pump LU-7
2.฀Installation฀of฀machine-oil฀filter฀screen
(a)New฀O฀ring฀must฀be฀installed฀on฀the฀position฀where฀the฀machine-oil
filter฀screen฀is฀located.
(b)The฀pump฀cover฀may฀be฀fixed฀with฀filter฀screen฀securely฀by฀an
installation฀and฀tightening฀of฀two฀bolts.
Tightening฀ torque : 17.5N . m
(c)Filter฀ screen฀ may฀ be฀ fixed฀ with฀ the฀ device฀ unit฀ securely฀ by฀ an
installation฀and฀tightening฀of฀two฀bolts.
T ightening฀ moment : 12.0N ¡¤ m
3.฀Installation฀of฀bottom฀oil฀cover
(a)Oil฀seal฀materials฀shall฀be฀cleared฀away,฀and฀it’s฀notedthat฀machin e
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oil฀shall฀not฀drop฀on฀the฀installation฀surface฀of฀oil฀pan฀and฀the฀device
unit.
Using฀razor฀and฀scraper฀all฀existing฀materials฀on฀the฀sealing฀surface
and฀groove฀shall฀be฀cleared฀away.
-All฀loose฀parts฀must฀be฀cleared฀away฀thoroughly.
฀The฀oil-seal฀is฀about฀3mm฀wide
-Wash฀the฀sealing฀surface฀using฀non-residual฀solvent.
Note:฀Do฀not฀splash฀solvent฀onto฀the฀painting฀surface.
A B
(b)Fill฀the฀bottom฀oil฀cover฀with฀sealing฀materials฀as฀indicated฀in฀the
figure.
Sealing฀material :Product฀&part฀No.฀08826-00080฀or฀counterparty
A B
product
-Nuzzle฀whose฀opening฀section฀area฀is฀3mm฀must฀beapplied฀during฀the
installation.
Note£ºAvoid฀filling฀ in฀too฀ much฀sealing฀ mater ials
฀฀฀on฀the฀sur face,฀par ticular ly฀at฀r ear ฀oil฀hole.
-T he฀assembly฀of฀spare฀parts฀must฀be฀completed฀within฀fifteen฀minutes,
or฀filled฀materials฀shall฀be฀cleared฀away,฀and฀a฀refilling฀is฀needed฀as฀well.
-Directly฀remove฀the฀ nuzzle฀from฀pipe,฀and฀reinstall฀the฀ installation
cover.
(c)T he฀oil฀pan฀may฀be฀installed฀using฀eighteen฀bolts.
T ightening฀ tor que ( 7±2)N . m
4.฀I nstall฀r einfor cement฀plates฀on฀left฀& r ight฀side.
5.฀Put฀down฀the฀vehicle.
6.฀F ill฀in฀engine฀oil.
7.฀C heck ฀whether ฀ther e’ s฀any฀leak age฀after ฀star ting฀the
engine.
8.฀C heck ฀the฀level฀of฀engine฀machine-oil.

IG-1
Ignition system
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IG-2 Ignition system-preventive measures, Circuit diagram /vehicle inspection of ignition system
Preventive measures
Great Wall automotives are driven by petrol engine, which works after the mixture of petrol and air has been
ignited by the high-voltage electric spark produced by one set of ignition system installed inside the engine. And
the ignition system has such function as to transform the low-voltage provided by battery into a high-voltage
current able to ignite the inflammable gas mixture inside engine cylinder; and to distribute the high-voltage
current on time to the spark plug at each engine cylinder as per engine working procedure. And electric sparks
produced between electrodes of spark plug will ignite the inflammable gas mixture to push the piston for actions,
and to drive the connection rod of crankshaft, and to make the engine working.
The preventive measures are given below
1.If the engine can not be started, do not have the ignition key being connected for over ten minutes;
2.During the connection between system and the tachometer, the test line of tachometer shall be connected to
the negative terminal of ignition coil;
3.To prevent any damage on igniter or ignition coil, do not have the terminal of tachometer contacted withground
4.Do not dismantle the battery while engine is running;
5.Always verify whether the igniter has been connected well with the cover.
Ignition system-Circuit diagram /vehicle inspection of ignition system

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Circuit diagram of ignition system as shown in the figure below
ignition fuse
electronic ignition timing A

high-tension coil
electronic ignition timing B
ignition coil
spark plug
fuse
1-3-4-2 ignition sequence
battery

Ignition system- Circuit diagram /vehicle inspection of ignition system IG-3
Vehicle inspection
Spark plug test check the form of spark plug
1. Remove the high-tension wiring from spark plug
2. Remove the spark plug
3. Spark plug needs to be installed on each high-tension wiring
4. Spark plug will be grounded
5. Check whether the ignition works when engine starts running.
Note Following test may be performed when the
ignition does not work.
Spark test
you can
Check the resistance of high-voltage Change the high voltage resistance line
damping wiring You can’t
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you can
Check the power supply to ignition coil

1. Place the ignition switch to position “ON” Check the line between spark
plug and ignition coil
2. check whether an battery voltage exists on You can’t
the positive connection line of ignition coil
you can
Check the resistance of ignition coil

Delphi
Model ITMS-6 primary grade
secondary grade Change the ignition coil
you can’t
Model MT20U primary grade
secondary grade
United Electronic model 2 2
primary grade
secondary grade
you can
Perform other ignition inspections

IG-4 Ignition system- Inspection on high-tension wiring, inspection on spark plug
Inspection on high-tension wiring

1. Remove the high-tension wiring. Hold the rubber cover with
hand, removing the high tension wiring from the spark plug
carefully.
Note Dragging, pulling or bending the hightension wiring might
cause some damages on internal conductors.
2. Check the resistance of high-tension wiring

Resistance may be measured with an ohmmeter when
the cover is not opened. Unit K
United
Position Delphi
electronic
Cylinder 1 3.80—5.50 2.96—4.72
Cylinder 2 4.00—5.70 2.96—4.72
Cylinder 3 4.50—6.50 2.96—4.72
Cylinder 4 5.30—7.70 5.08—8.30
Specification of high-voltage resistance line:(16 3.2)K /m
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Inspection on spark plug

1. Remove the spark plug.
2. Clean the spark plug.
Clean the spark plug with cleaner or steel wire brush.
3. Check the spark plug visually

Check whether the electrode of spark plug has been abraded, whether
screw thread or insulator has been damaged. Spark plug needs to be
changed whenever there’s any abnormality.
Recommended spark plug F6RTC
4. Adjust the clearance of electrodes.

Following a careful bending of bypass electrode, correct electrode
clearance may be acquired by adjustment.
Correct electrode clearance (1.0 1.2)mm
5. Install the spark plug

Tightening torque 18N m

ST-1
Starting system
Structure /circuit diagram of starter .................................... ST-2
Disassembly of starter ....................................................... ST-3
Inspection on starter ......................................................... ST-4
Assembly of starter ........................................................... ST-7
Testing on starter.................................................................ST-9
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ST-2 Starting system-Structure /circuit diagram of starter
The exterior force of petrol engine comes from one starter, which receives power supply from the battery,
and drives the engine to rotate. The starter is of one special DC electrical motor, which has following features
during operation: with a large starting torque, a large staring current, and subject to an intermittent operation.
Structure /circuit diagram of starter

The structure of starter as shown in the figure below:
felt sealing-gasket
armature
excitation winding(excitation frame)
brush bracket
end cover
rear bearing
front bearing
brush spring bearing
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solenoid switch
idler wheel
steel ball
release spring
starting pinion
starter shell
clutch assembly
The one with mark

Starting system-Disassembly of starter ST-3
Circuit diagram of starter as shown in the figure below:
ignition switch
fuse
terminal 30 terminal 50
battery
starter
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Disassembly of starter
1. Dismantle thearmature assembly inside the excitation
frame.
(a)Remove nuts from the terminal of solenoid switch, and remove
the lead-wire as well.
(b)Two through-bolts need to be taken out.
(c)Take out the excitation frame together with the armature.
(d)Remove the felt sealing-gasket.
2. Removal of starter shell, clutch assembly, and gear

(a)Remove two screws.
(b)Following spare parts shall be removed from the solenoid switch:

a Starter shell
b Idler wheel and bearing
c Clutch assembly
d Release spring

ST-4 Starting system-Inspection on starter
3. Removal of steel ball

A magnetic rod may be used to take steel ball out from the axle hole of
clutch.
magnetic rod
4. Removal of brush frame

Two screws and end cover will be removed from the excitation frame.
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Using screwdriver, spring could be taken out from the brush holder, and
the brush holer could be removed, followed by a removal of four brushes
and brush holders.
Inspection on starter
Armature winding
1. Check whether the rectifier is in an opened loop.
Use an ohmmeter to check whether conduction exists on the
discofrectifier. The armature needs to be changed if the conduction
fails.
conduction
2. Check whether the rectifier has been grounded.

Use an ohmmeter to check whether noncon duction exists between rectifier
and the core of armature windings.
The armature needs to be changed if the conduction works.
non-conduction

Starting system-Inspection on starter ST-5
Rectifier
1. Check whether the surface of rectifier has been
contaminated or damaged by burning.
If it does occur, sand paper (No.400) or lathe may be used for a repair or
correction purpose.
2. Check the circumferential radial runout of rectifier
Max. circumferential radial runout 0.05 mm
Lathe may be used for a repair or correction purpose if the radial runout
exceeds Max. value.
3. Check the diameter of rectifier

Standard diameter 30 mm
Min. diameter 29 mm
The rectifier needs to be changed if the actual diameter is less than Min.
value.
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4. Check the depth of cutting groove

Check whether it’s clean or has foreign materials on the bottom of groove,
and whether the edge of groove is round and smooth.
Standard depth of groove (0.5 0.8)mm
Min. depth of groove 0.2 mm
If the depth of groove is less than Min. value, saw blades may be used
for a repair or correction purpose.
Excitation winding (excitation frame)

1. Check whether the excitation winding is in an opened loop.Use
an ohmmeter to check whethe rconduction exis tsbetween the lead-
wire and the lead-wire of brush on excitation winding.
The excitation frame needs to be changed if the conduction fails.
conduction
2. Check whether the excitation winding has been

grounded.
Use an ohmmeter to check whether non conduction exists between
excitation winding and the excitation frame.
The excitation frame needs to be repaired or changed if the conduction
works.
non-conduction

ST-6 Starting system-Inspection on starter
Brush
Check the length of brush
Standard length 13.5 mm
Min. length 8.50 mm
The brush frame, and the excitation frame must be changed if the length
is less than Min. Value.
Brush spring
Check the load of brush spring using a Pull up balance.
Standard spring load (17.56-23.64) N
Note Read the load produced at the moment when the spring isleaving
the brush while the brushs pring is being pulled up by a Pull-up balance;
If the read value is not within the specified scope, the brush spring shall
be changed.
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Brush holder
Check the insulation of brush holder.
An ohmmeter may be used to check whether nonconduction exists
between positive brush and negative brush.
The brush holder must be repaired or changed if conduction works.
Clutch and gear

rotating 1. Check the gear teeth.
Check whether the teeth of small gear &idler wheel, andthe clutch assembly
have been abraded or damaged.
locked They may be changed if any damage is found. In case of any damage,
check whether the gear ring of flywheel has been abraded or damaged.
2. Check the small gear on clutch
Have the small gear rotating in clockwise direction to check
Bearing
1. Check bearing
Manually push each bearing inward, and have it rotating at the same
time.
The bearing may be changed if any resistance has beenmet, or the rotation
is not flexible.

Starting system-Assembly of starter ST-7
2. The bearing may be changed if necessary.

(a)Use SST to remove the bearing
(b)Use SST and press tool to press new front bearing.

SST 09285-76010
(c)Use a press tool to press into rear bearing

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Solenoid switch
terminal 50 1. Perform a pull-in winding test in an open circuit
An ohmmeter may be used to check whether conduction exists between
terminal 50 and terminal C.The solenoid switch needs to be changed
if non-conduction exists.
terminal C
2. Perform a holding-power winding test in an open circuit

switch unit An ohmmeter may be used to check whether conduction exists between
terminal 50 terminal 50 and the switch unit.
The solenoid switch needs to be changed if non-conduction exists.
Assembly of starter
Note During the assembly of starter, bearings
and gears may be lubricated using high temperature
grease.
1. Installation of armature into the excitation frame
After the armature bearing is applied with greasete ar mature may be
inserted into the excitation frame.

ST-8 Starting system-Assembly of starter
2. Installation of brush holder

(a)Put the brush holder on armature.
(b)To connect armature with the holder, screw tap may be used to press
the brush spring on the back. Beside, four brushes must be connected.
Note: Check and verify that the positive lead-wire
has not been connected with ground.
End cover may be installed using two screws.

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3. Installation of steel ball into the axle hole of clutch

(a)Grease needs to be applied to steel ball.
(b)Steel ball shall be installed into the axle hole of clutch.
4. Installation of clutch assembly

(a)Grease needs to be applied to the release spring.
(b)Release spring shall be installed into the hole of solenoid switch.
(c)Following spare parts shall be installed into the starter shell.

a Clutch assembly
b Idler wheel and bearing

Starting system-Testing on starter ST-9
(d)Using two screws, the starter shell and solenoid switch may be
assembled together.
5. Installation of the excitation frame and the armature

assembly
(a)A new felt sealing-gasket needs to be installed on the armature.
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(b)Have the convexity of excitation frame aligned with the tangent

plane of solenoid switch.
(c)Two through-bolts will be installed.
(d)Install the lead-wire with the terminal of solenoid switch,followed
by an installation of nut.
Testing on starter
Note: to avoid any damage on winding due to burning,
terminal C the test must be completed within (3-5s).
1. Perform a pull-in test
(a)Remove the lead-wire of excitation winding from terminal C.
(b)Connect the battery onto solenoid switch as shown in the figure, and
check while small gear is moving outward.
The solenoid switch assembly needs to be changed if small gear does not
terminal 50 move.
2. Perform a holding-power test

Subject to above wire connection, remove the negative leadwire from
terminal C when small gear is going out, and check whether small gear is
able to keep its status when going out.
The solenoid switch assembly needs to be changed if small gear goes back
to the inside.

ST-10 Starting system-Testing on starter
3. Check the return status of plunger piston

After a removal of negative lead-wire from the switch unit, check whether
small gear is able to go back to the inside.
The solenoid switch assembly needs to be changed if small gear does not
return to the inside.
4. Perform a zero-load performance test

(a)As indicated in the figure, have the battery and armature connected
terminal 50 respectively with the starter
(b)Check whether the rotation of starter is smooth or flexible when small
gear goes out, and whether the current value is within the limit of
specification.
Specified current 90A when at 11.5V
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terminal 30

CH-1
Charging฀device
Page
Structure฀drawing฀/electrical฀schematic฀diagram฀of฀generator.....................CH-2
Inspection฀on฀vehicle .......................................................... .....................CH-5
Disassembly฀of฀AC฀generator...................................................................CH-7
Inspection฀on฀AC฀generator......................................................................CH-9
Assembly฀of฀AC฀generator.....................................................................CH-12
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CH-2 Structure฀drawing฀/electrical฀schematic฀diagram฀of฀generator
Structure฀drawing฀/electrical฀schematic฀diagram฀of฀generator
1.฀Brief฀description฀of฀working฀principle฀for฀generator
That฀the฀stator฀coil฀of฀generator฀goes฀across฀the฀rotating฀magnetic฀field฀produced฀by฀the฀rotor฀makes฀the
statorproduce฀a฀3-phase฀AC฀current,฀which฀will฀be฀transformed฀into฀DC฀current฀by฀rectifier฀bridge฀for฀a
power฀supply฀to฀electrical฀devices฀on฀vehicle.
2.฀Structure฀drawing฀of฀generator
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Name฀of฀spare฀parts฀indicated฀in฀the฀drawing฀is฀given฀below:
1.nut฀฀2.spring฀washer฀3.belt฀pulley฀4.through฀bolt฀5.limiter฀ring฀6.driving฀end฀cover฀7.฀bearing
8.฀bearing฀cove฀฀9.limiter฀ring฀10.rotor฀11.stator฀12.adjustor฀13.insulation฀bush฀14.nut฀15.compensation
bush฀16.brush฀end฀cover฀17.฀rectifier฀bridge฀18.screw฀19.screw฀20.screw

Structure฀drawing฀/electrical฀schematic฀diagram฀of฀generator CH-3
3.฀Electrical฀schematic฀diagram฀of฀generator
(a)฀Circuit฀schematic฀diagram฀for฀90A฀internally-adjusted฀generator
Electrical฀schematic฀diagram
stator฀coil
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excitation฀coil
I·C฀adjustor
(b)฀Circuit฀schematic฀diagram฀for฀90A฀externally-adjusted฀generator
stator฀coil
excitation฀coil
I·C฀adjustor

CH-4 Structure฀drawing฀/electrical฀schematic฀diagram฀of฀generator
(c)฀circuit฀schematic฀diagram฀for฀65A฀internally-adjusted฀generator
stator฀coil
excitation฀coil
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I·C฀adjustor
(d)฀circuit฀schematic฀diagram฀for฀65A฀externally-adjusted฀generator
stator฀coil
฀excitation฀coil

Charge฀device-Inspection฀on฀vehicle CH-5
Inspection฀on฀vehicle
1.฀Check฀the฀specific฀gravity฀of฀accumulator
(a)Check฀the฀specific฀gravity฀for฀each฀accumulator฀unit.฀Standard
upper฀liquid specific฀gravity฀when฀charged฀with฀full฀power฀at฀20 (1.25~1.27)g/cm2
(b)Check฀the฀electrolyte฀amount฀for฀each฀accumulator฀unit.
level
In฀case฀of฀an฀insufficient฀electrolyte฀amount,฀fill฀with฀distilled฀or฀pure
water.
lower฀liquid฀level
2.฀Check฀the฀fuse฀and฀wiring฀terminal฀for฀accumulator
(a)Check฀whether฀the฀wiring฀terminal฀of฀accumulatorhas฀been฀tightened
or฀corroded;
(b)Check฀whether฀the฀fuse฀is฀switched฀into฀conduction.
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3.฀Check฀the฀driving฀belt
(a)Verify฀by฀avisual฀check฀whether฀the฀bonding฀positionbetween฀upper/
lower฀interlayer฀has฀any฀crack฀or฀damage;฀whether฀any฀crack,฀broken
core,฀rupture,฀scratch,฀or฀abrasion฀is฀produced฀on฀the฀edge฀of฀belt;or฀whe
ther฀any฀damage฀is฀produced฀on฀the฀internal฀convexity฀side฀of฀reinforced
rib.
(b)Check฀the฀bending฀deflection฀of฀belt฀by฀applying฀a฀98N฀stress฀to฀the
position฀indicated฀฀in฀“Stressdiagram”.
Bending฀deflection฀of฀driving฀belt
New฀ belt (5 7) mm
U s ed ฀ bel t 7 8 mm
T he฀bending฀deflection฀of฀belt฀may฀be฀adjusted฀when฀necessary.
(c)The฀tension฀of฀driving฀belt฀may฀also฀be฀checked฀using฀SST.
SST฀09216-00020฀and฀09216-00030
T ension฀of฀driving฀belt
N ew฀ belt (686 786)N
U sed฀ belt (294 441)N
T he฀tension฀of฀belt฀may฀be฀adjusted฀when฀necessary.

CH-6 Charge฀device-Inspection฀on฀vehicle
Note
-The฀so฀called฀ new฀belt r efer s฀to฀belt฀having฀wor k ed฀for ฀less
than฀five฀minutes฀on฀the฀r otating฀engine.
-T he฀so฀called฀ used฀belt r efer s฀to฀belt฀having฀wor ked฀for ฀five
minutes฀or ฀above฀on฀the฀r otating฀engine.
-F ollowing฀ the฀ installation฀ of฀ belt,฀ check ฀ whether ฀ the฀ belt฀ is
correct incorrect matching฀with฀wheel฀gr oove฀appr opr iately.
4 . Verify฀ by฀ visual฀ check฀ the฀ connection฀ line฀ of฀A C

generator,฀ and฀ whether฀ there’s฀ any฀ abnormal฀ noise.
(a)Check฀whether฀the฀connection฀line฀is฀under฀a฀normal฀condition.
(b)Check฀whether฀there’s฀any฀abnormal฀noise฀on฀AC฀generator฀while฀the
engine฀is฀running.
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5.฀Check฀the฀loop฀for฀charging฀alarm฀indicator฀lamp.
(a)Heat฀the฀engine,฀then฀stop฀it.
(b)Stop฀all฀auxiliary฀devices.
(c)After฀opening฀the฀ignition฀switch,฀check฀whether฀the฀charging฀indictor
lamp฀has฀been฀lighted฀up.
(d)When฀the฀engine฀is฀starting,฀check฀whether฀the฀charging฀indictor฀lamp
is฀off.
(e)If฀the฀alarm฀lamp฀is฀not฀working฀well,฀try฀to฀eliminate฀any฀failure฀in฀the
Charge฀device.
6.฀Check฀the฀charging฀loop฀when฀under฀zero฀load
remove฀electrical฀wire
ammeter Note
from฀terminal
If฀accumulator/AC฀generator฀test฀meter฀is฀applicable,฀the฀meter฀shall฀be
connected฀into฀the฀charging฀loop฀in฀accordance฀with฀the฀description
provided฀by฀the฀manufacturing฀plant.
(a)If฀the฀meter฀is฀not฀applicable,฀the฀voltmeter฀and฀ammeter฀shall฀be
voltmeter connected฀into฀the฀charging฀loop฀as฀per฀methods฀below:
battery AC฀generator -Remove฀electrical฀wire฀from฀the฀terminal฀B฀on฀AC฀generator,฀and฀connect
the฀negative฀test฀head฀of฀ammeter.
-Connect฀the฀positive฀test฀head฀of฀ammeter฀to฀the฀terminal฀B฀on฀A C
generator.
-Connect฀the฀positive฀test฀head฀of฀voltmeter฀to฀the฀terminal฀B฀on฀A C
generator.
-Connect฀the฀negative฀test฀head฀of฀voltmeter฀to฀ground.

Charge฀device-Inspection฀on฀vehicle CH-7
(b)Check฀the฀charging฀loop฀using฀following฀method
When฀the฀engine฀is฀increased฀from฀idle฀speed฀to฀2000r/min,฀check฀the฀read
value฀on฀ammeter฀and฀voltmeter.
standard฀ current 10A
standar d฀voltage ฀(13.9-15.1)V ฀when฀at฀25
(13.4-14.4)V ฀when฀at฀11.5
If฀the฀voltage฀value฀is฀greater฀than฀standard฀value IC฀adjustor฀needs฀to
be฀changed.
If฀฀the฀voltage฀value฀is฀less฀thanstand฀ardvalue฀IC฀adjustor฀and฀AC฀generat
or฀must฀be฀checked฀using฀followin฀gmethod:
-฀Check฀the฀voltage฀value฀of฀terminal฀B฀when฀terminal฀F฀is฀grounded฀and
the฀engine฀is฀started.
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-If฀the฀voltage฀value฀is฀greater฀than฀standard฀value IC฀adjustor฀needs฀to฀be
changed.
-If฀the฀voltage฀value฀is฀less฀than฀standard฀value฀AC฀generator฀needs฀to฀be
changed.
7.฀Check฀the฀charging฀loop฀when฀under฀load.
(a)Open฀the฀front฀headlight฀when฀engine฀is฀at฀a฀rotatingspeed฀ as฀ 2000
revolutions฀/minute,฀and฀place฀the฀control฀switch฀of฀heater฀fan฀to฀shift
position H I .
(b)Check฀the฀read฀value฀on฀ammeter.
Standard฀ current >30฀A
AC฀generator฀needs฀to฀be฀repaired฀if฀current฀value฀is฀less฀than฀30A.
Note:฀Read฀value฀might฀be฀less฀than฀30A฀when฀the
฀฀accumulator฀is฀charged฀with฀full฀power.

CH-8 Disassembly฀of฀AC฀generator
Disassembly฀of฀AC฀generator
1.฀Dismantle฀the฀assembly฀of฀driving฀end฀shell฀and฀rotor
from฀the฀stator.
(a)Remove฀three฀through-screws.
(b)When฀the฀end฀shell฀is฀prized฀up฀by฀a฀screwdriver,฀have฀it฀removed
simultaneously฀with฀the฀rotor.
Note:฀Don’t฀pry฀the฀wire฀of฀the฀coil.
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2.฀Removal฀of฀belt฀pulley฀and฀fan
(a)Fix฀the฀rotor฀onto฀a฀soft-jaw฀vice.
(b)Remove฀nuts฀and฀spring฀washers.
(c)Remove฀the฀belt฀pulley,฀fan,฀and฀spacer฀bush.
3.฀Removal฀of฀rotor
Use฀a฀press฀tool฀to฀press฀out฀the฀rotor.
4.฀Removal฀of฀rectifier฀shell
(a)Remove฀four฀nuts,฀capacitor,฀and฀two฀terminal฀insulators.
(b)Remove฀the฀rectifier฀shell.
(c)Remove฀two฀insulation฀washers฀from฀the฀stud฀bolt฀on฀rectifier฀support.
(d)Remove฀the฀insulation฀washer฀from฀the฀electrical-brush฀frame.
lead-wire฀grip

Inspection฀on฀AC฀generator CH-9
5.฀Removal฀of฀IC฀adjustor
When฀the฀terminal฀of฀IC฀adjustor฀is฀gripped฀using฀nipper฀pliers,remove฀it฀by
welding.
6.฀Removal฀of฀rectifier฀support
When฀the฀terminal฀of฀IC฀adjustor฀is฀gripped฀using฀nipper฀pliers฀remove฀th e
lead฀wireby฀welding.
Note M easur es฀shall฀be฀taken฀to฀pr event฀the฀r ectifier ฀fr om
damage฀r esulting฀fr om฀bur ning.
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Inspection฀on฀AC฀generator R otor
1.฀C heck ฀whether ฀the฀r otor ฀is฀in฀an฀open฀cir cuit.
Use฀an฀ohmmeter฀to฀check฀the฀conduction฀between฀slip฀rings.
Standard฀ resistance 4
T he฀rotor฀needs฀to฀be฀changed฀if฀non-conduction฀exists.
conduction
2.฀Check฀whether฀the฀rotor฀has฀been฀grounded.
Use฀an฀ohmmeter฀to฀check฀the฀non-conduction฀between฀slip฀ring฀and฀the
rotor.
The฀rotor฀needs฀to฀be฀changed฀if฀conduction฀exists.
non-conduction
3.฀Check฀the฀slip฀ring
(a)Check฀whether฀the฀surface฀of฀slip฀ring฀is฀rough,฀or฀has฀been฀scratched฀or
damaged.
If฀it฀does฀occur,฀the฀rotor฀needs฀to฀be฀changed.
(b)The฀diameter฀of฀slip฀ring shall฀be฀measured฀using฀calipers.
Standard฀diameter (32.3 32.5)mm
Min.฀diameter 32.1฀mm
If฀the฀diameter฀is฀less฀than฀Min.฀value,฀the฀rotor฀needs฀to฀be฀changed.

CH-10 Inspection฀on฀AC฀generator
Stator
1.฀Check฀whether฀the฀stator฀is฀in฀an฀open฀circuit.
Use฀an฀ohmmeter฀to฀check฀conduction฀between฀leading฀of฀the฀coil.
Note I nter sectant฀ lines฀ must฀ be฀ welded฀ well.
T he฀stator฀needs฀to฀be฀changed฀if฀non-conduction฀exists.
conduction
2.฀Check฀whether฀the฀stator฀has฀been฀grounded.
Use฀an฀ohmmeter฀to฀check฀whether฀noncon฀duction฀exists฀between฀the฀coil
leadin฀and฀the฀stator.
If฀conduction฀exists,฀the฀stator฀may฀be฀changed.
non-conduction
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Electrical-brush
1.฀Check฀the฀exposed฀length฀of฀electrical-brush.
Use฀a฀ruler฀to฀measure฀the฀exposed฀length฀of฀electrical฀brush.
Standard฀exposed฀length 12.5฀ mm
M in.฀ exposed฀ length 5.5฀ mm
T he฀electrical-brush฀needs฀to฀be฀changed฀if฀the฀exposed฀length฀is฀less฀than
Min.฀value.
2. The฀electrical-brush฀may฀be฀changed฀when฀necessary.
(a)Remove฀the฀electrical-brush฀and฀spring฀by฀welding.
(b)Have฀the฀electrical-brush฀line฀inserted฀via฀spring.
(c)Connect฀the฀electrical-brush฀onto฀the฀electrical-brush฀frame.
(d)Weld฀the฀electrical-brush฀line฀to฀the฀electrical-brush฀frame฀as฀per฀the฀exposed
length฀specified฀below:
Exposed฀length 12.5฀ mm
(e)Check฀whether฀the฀electrical-brush฀may฀act฀smoothly฀inside฀the฀electrical-
brush฀frame.
(f)Cut฀off฀excessive฀electrical฀wire.

Inspection฀on฀AC฀generator CH-11
Rectifier
1.฀Check฀the฀positive฀rectifier
rectifier฀terminal (a)Using฀ohmmeter,฀connect฀one฀end฀of฀the฀test฀head฀with฀the฀rectifier
terminal,฀and฀connect฀the฀other฀end฀with the฀positive฀terminal.
(b)Exchange฀the฀test฀joint,฀and฀repeat฀the฀above฀step.
ohmmeter (c)Check฀its฀conduction฀or฀non-conduction฀covered฀in฀above฀two฀steps.
(d)The฀rectifier฀support฀shall฀be฀changed฀when฀its฀conduction฀or฀non-conduction
does฀not฀conform฀to฀relevant฀stipulations.
positive฀terminal฀(stud฀bolt฀cap)
2.฀Check฀the฀negative฀rectifier
(a)Using฀ohmmeter,฀connect฀one฀end฀of฀the฀test฀head฀with฀the฀rectifier฀terminal,
rectifier฀terminal and฀connect฀the฀other฀end฀with฀the฀negative฀terminal.
(b)Exchange฀the฀test฀joint,฀and฀repeat฀the฀above฀step.
(c)Check฀its฀conduction฀or฀non-conduction฀covered฀in฀above฀two฀steps.
(d)The฀rectifier฀support฀shall฀be฀changed฀when฀its฀conduction฀or฀non-conduction
ohmmeter
does฀not฀conform฀to฀relevant฀stipulations.
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negative฀terminal stud฀bolt฀cap
Bearing
1.฀Check฀the฀front฀bearing
Check฀whether฀the฀bearing฀is฀smooth฀or฀has฀been฀abraded.
2.฀Change฀the฀front฀bearing฀when฀necessary.
Change฀the฀bearing฀by฀removing฀three฀screws.
3.฀Check฀the฀rear฀bearing.
Check฀whether฀the฀bearing฀is฀smooth฀or฀has฀been฀abraded.

CH-12 Assembly฀of฀AC฀generator
4.฀Change฀the฀bearing฀when฀necessary.
(a)Remove฀the฀bearing฀using฀SST.
฀SST฀฀09286-46011
(b)Use฀a฀press฀tool฀to฀press฀the฀new฀bearing.
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Assembly฀of฀AC฀generator
1.฀Install฀the฀rectifier฀support฀onto฀the฀stator.
Clamp฀the฀rectifier฀terminal฀using฀nipper฀pliers,฀and฀weld฀the฀wiring฀terminal.
Note:฀the฀heat฀shall฀be฀prevented฀from฀transmission฀to
rectifier.
2.฀Installation฀of฀IC฀adjustor
Clamp฀the฀rectifier฀terminal฀using฀nipper฀pliers,฀and฀weld฀the฀wiring฀terminal.
Note:฀the฀heat฀shall฀be฀prevented฀from฀transmission฀to
rectifier.
3. Installation฀of฀the฀rectifier฀end฀shell฀onto฀rectifier฀support
insulation฀washer (a)Put฀the฀insulation฀washer฀on฀the฀positive฀stud฀bolt฀of฀the฀rectifier฀frames
(b)Put฀two฀soft฀cushions฀on฀the฀electrical-brush฀frame฀and฀AC฀generator
terminal฀respectively.
(c)Put฀the฀rectifier฀shell฀onto฀the฀rectifier฀frame.
soft฀cushion

Assembly฀of฀AC฀generator CH-13
(d)Put฀two฀terminal฀insulators฀onto฀the฀positive฀stud฀bolt฀of฀the฀rectifier
frame.
(e)Install฀the฀capacitor฀and฀the฀lead-wire฀grip.
(f)Install฀four฀nuts.
(g)Confirm฀that฀electrical฀wire฀has฀not฀been฀overlapped฀with฀the฀rectifier
shell.
lead-wire฀grip
4.฀Installation฀of฀rotor
(a)Insert฀spacer฀ring฀into฀the฀rotor฀shaft.
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(b)Use฀press฀tool฀to฀press฀rotor฀into฀the฀shaft.
5.฀Installation฀of฀fan฀and฀belt฀pulley
(a) Fix฀the฀rotor฀onto฀soft-jaw฀vice.
(b) Insert฀spacer฀ring฀into฀the฀rotor฀shaft.
(c)Insert฀the฀fan,฀belt฀pulley,฀and฀spring฀washer฀successively฀into฀the฀rotor
shaft.
(d)Install฀and฀tighten฀the฀nut.
Tightening฀ moment 62.5N m

CH-14 Assembly฀of฀AC฀generator
6.฀Assembly฀of฀the฀driving฀end฀shell฀and฀rectifier฀end฀shell
(a)Have฀the฀rotor฀exposed฀by฀bending฀the฀wiring฀head฀of฀rectifier.
(b)Bending฀tools฀may฀be฀used฀to฀push฀the฀electrical-brush฀to฀the฀end,฀then
one฀hard฀steel฀wire฀shall฀go฀through฀the฀manhole฀of฀rectifier฀end฀shell,฀and฀the
electrical-brush฀will฀be฀put฀to฀place.
(c)฀Following฀the฀insertion฀of฀the฀rear฀bearing฀for฀rotorshaft฀into฀the฀rectifier
end฀shell,฀the฀rectifier฀shell฀for฀driving฀end฀shell฀may฀be฀assembled.
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(d)Three฀through-screws฀may฀be฀installed.
(e)Remove฀the฀hard฀steel฀wire฀from฀manhole.
(f)Check฀whether฀the฀rotor฀is฀able฀to฀rotate฀flexibly.
(g)Seal฀the฀manhole.

CL-1
Clutch
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CL-2 Clutch-Dismantle฀of฀clutch฀components,฀and฀inspection฀on฀clutch฀components
Dismantle฀of฀clutch฀components
Dismantle฀of฀clutch฀cover
(a)Remove฀bearing,฀bearing฀sleeve,฀and฀release฀shifting฀fork฀from฀the
transmission.
(b)Bearing฀and฀bearing฀sleeve,฀will฀be฀pulled฀out฀at฀the฀same฀time฀after
removing฀the฀stop฀clamp.
(c)Remove฀the฀release฀shifting฀fork,฀and฀the฀protective฀cover.
(d)Remove฀the฀clutch฀pressure฀plate฀and฀the฀clutch฀friction฀disk.
Inspection฀on฀clutch฀components
1.฀ Check฀ whether฀ the฀ clutch฀ friction฀ disk฀ has฀ been
abraded฀or฀damaged.
Measure฀the฀depth฀of฀rivet฀head฀using฀a฀vernier฀caliper.
Min.฀depth฀of฀rivet฀head 0.3฀mm
The฀clutch฀friction฀disk฀needs฀to฀be฀changed฀if฀any฀failure฀occurs.
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2.฀Check฀the฀radial฀run-out฀tolerance฀on฀end฀surface฀of
the฀clutch฀driven฀disk.
Check฀ the฀ radial฀ run-out฀ tolerance฀ on฀ end฀ surface฀ of฀ the฀ clutch
driven฀disk฀using฀an฀amesdial.
Max.฀radial฀run-out฀tolerance฀ 0.8฀mm
The฀clutch฀driven฀disk฀needs฀to฀be฀changed฀whereby฀the฀radialrun-out
tolerance฀exceeds฀Max.฀value.
3.฀Check฀the฀guide฀bearing
Manually฀rotate฀the฀bearing,฀and฀an฀action฀force฀may฀be฀applied฀along฀the
direction฀of฀axis฀line.
The฀guide฀bearing฀needs฀to฀be฀changed฀if฀it฀can’t฀be฀rotated,฀or฀is฀rotating
with฀great฀resistance.
4.฀Change฀of฀guide฀bearing
(a)฀Use฀SST฀to฀remove฀the฀guide฀bearing.
SST฀฀09303-35011

Clutch-฀assembly฀of฀clutch฀components CL-3
(b)Use฀SST฀to฀install฀a฀new฀guide฀bearing.
SST฀฀09304-30012
5.฀Check฀whether฀the฀diaphragm฀spring฀has฀been฀abraded.
Check฀the฀abraded฀depth฀and฀width฀of฀diaphragm฀spring฀using฀a฀vernier
caliper.
Limit฀value depth฀฀0.6฀mm
฀฀฀฀฀฀฀฀฀฀width฀฀5.0฀mm
The฀clutch฀pressure฀plate฀shall฀be฀changed฀when฀necessary.
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6.฀Check฀the฀release฀bearing
Manually฀rotate฀the฀bearing,฀and฀an฀action฀force฀may฀be฀applied฀along฀the
direction฀of฀axis฀line.
The฀release฀bearing฀needs฀to฀be฀changed฀if฀it฀can’t฀be฀rotated,or฀is฀rotating
with฀great฀resistance.
Note T his฀bear ing฀needs฀no฀lubr ication฀or ฀cleanup
฀฀฀฀฀฀฀as฀it’ s฀฀subj ect฀to฀a฀per manent฀lubr ication.
Installation฀of฀clutch฀components
1.฀Install฀the฀clutch฀driven฀disk฀onto฀flywheel.
flywheel
The฀clutch฀driven฀disk฀may฀be฀installed฀onto฀flywheel฀using฀SST.
side SST฀฀09301-20020
2.฀Installation฀of฀clutch฀pressure฀plate
(a)Have฀the฀clutch฀pressure฀plate฀pointed฀to฀the฀assembly฀mark฀made฀on
flywheel.
(b)Tighten฀the฀bolts฀evenly฀at฀different฀stage฀as฀per฀the฀sequence฀shown฀in
the฀figure฀below.
Tightening฀ moment 30N m
Note B olt฀1฀ & 2฀will฀be฀ tightened฀tempor ar ily.

CL-4 ฀฀Clutch-฀assembly฀of฀clutch฀components
3.฀Check฀the฀alignment฀on฀the฀top฀of฀diaphragm฀spring.
The฀alignment฀on฀the฀top฀of฀diaphragm฀spring฀may฀be฀measured฀using฀an
match฀mark amesdial฀containing฀ball฀bearing.The฀alignment฀on฀the฀top฀of฀diaphragm
spring฀may฀be฀adjusted฀using฀SST฀if฀the฀deviation฀is฀greater฀than฀the
specified฀value.
SST฀฀09333-00013
MAX฀planteress฀tourance฀0.5mm
4.฀Supramoly฀lithium฀base฀grease฀shall฀be฀applied
MP฀multi-purpose฀lubricant
tofollowing฀parts:
(a)Contact฀point฀between฀the฀release฀shifting฀fork฀and฀the฀bearing฀bush;
(b)Contact฀point฀between฀the฀release฀shifting฀fork฀and฀the฀pushrod;
(c)Supporting฀point฀of฀the฀release฀shifting฀fork;
(d)Spline฀of฀clutch฀disk;
(e)Internal฀groove฀of฀the฀release฀bearing฀shell;
(f)MP฀multi-purpose฀lubricant฀shall฀be฀applied฀to฀the฀front฀part฀of฀the
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release฀bearing.

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Engine service &maintenance data...................................................................................... G1

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Engine service /Maintenance data

Key technical parameters for model GW491QE petrol engine.......................

Specification &adjustment parameters for key components ...........................

Technical data for maintenance......................................................................

Tightening torque for fastening elements.........................................................

Engine service /maintenance data..................................................................

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Key technical parameters for Model GW491QE petrol engine

S.N. Item Specification and parameters

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S .N . I tem S pecification and parameters

30 M ax . oil temperature 110

31 C onsumpti on rate of oil 2 g/kw·h

32 F uel consumption ratio of machine oil

33 C ooling method U se forced water circulation for cooling purpose.

34 C omplete mass 150kg

35 P attern of startup E lectrical

39 D ifference between cylinders 98 kpa

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S pecification /adj ustment par ameter s

M aintenance technical data

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Name Test items Standard value Use limit

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Name Test items Standard value Use limit

Name Test items Standard value Use limit

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T ightening torque for fastening elements

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Frequently tightened spare parts N m

2. Standard bolt tightening torque

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Common failures and troubleshooting

not connected well.

2.E ngine can not be accelerated or is slack accelerated.

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C ause of failure Methods of elimination

4 Petrol not conforming to the specification. 4 Make it subject to technical specifications.

4.E ngine is backfired or deflagrated.

C ause of failure Methods of elimination

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5.Unstable idle-speed for engine

C ause of failure Methods of elimination

6.A bnormal sound occurred in engine

C ause of failure Methods of elimination

7.L arge consumption of petrol

C ause of failure Methods of elimination

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E ngine service /maintenance data-T roubleshooting L arge consumption of machine oil

Cause of failure M ethods of elimination

much or even damaged.

C ause of failure M ethods of elimination

10.E ngine too hot

C ause of failure M ethods of elimination