Motor j3 VVT A137 PDF

Maintenance Manual of Tojoy Sedan Contents
Engine Volume
Chapter 1 Mechanical Part of Engine ..................................................... 33

Section 1 Engine Body .............................................................................................. 33
I. General Precautions ..................................................................................................33

III. Preparation ................................................................................................................36
IV. Engine Assembly .......................................................................................................39
V. Drive Belt ...................................................................................................................43
VI. Air Filter and Air Duct .................................................................................................45
VII. Intake Manifold and Exhaust Manifold .......................................................................47
VIII. Exhaust System .........................................................................................................51
IX. Timing sprocket mechanism ......................................................................................53
XI. Cylinder head .............................................................................................................60
XII. Valves ........................................................................................................................65
XIII. Cylinder Body Assembly ............................................................................................70
XIV. Diagnosis of Common Troubles .................................................................................83
XV. Parameters for Maintenance......................................................................................85
Section II Engine Lubrication System ....................................................................... 89
I. Precautions ................................................................................................................89
II. Preparation ................................................................................................................90
III. Lubrication system schematic diagram ......................................................................91
IV. Engine Oil ..................................................................................................................91
V. Oil Pan and Engine Oil Pump ....................................................................................95
Section III Cooling System of Engine ........................................................................ 99
I. Cooling Circuit ...........................................................................................................99

II. Engine Coolant ........................................................................................................100
V. Radiator Cooling Fan ...............................................................................................104
V. Water Pump .............................................................................................................104
VI. Thermostat Sub-assembly .......................................................................................106
VII. Water Piping Sub-assembly.....................................................................................108
VIII. Trouble Analysis ......................................................................................................109
IX. Parameters for Maintenance....................................................................................110
Section IV Fuel Supply System of Engine ............................................................... 111
I. General Precautions ................................................................................................111

II. Preparation ..............................................................................................................112
III. Fuel System .............................................................................................................112

IV. Fuel Injector and Guide Rail ....................................................................................113
V. Fuel Filter .................................................................................................................116
VI. Fuel Pump Assembly ...............................................................................................119
VII. Fuel Tank Assembly ................................................................................................123
Section V Emission Control System of Engine........................................................ 125
I. Fuel Evaporation Control System ............................................................................125

II. Forced Ventilating System of Crankcase .................................................................129
Chapter 2 Electrical Part of Engine....................................................... 132

Section 1 Ignition System........................................................................................ 132
I. Ignition coil ...............................................................................................................132

II. Diagnosis of Common Troubles ...............................................................................134
III. Parameters for Maintenance....................................................................................134
Section 2 Starting and Charging System ................................................................ 135
I. Principle Diagram of Starting and Charging System ................................................135

II. Battery .....................................................................................................................135
III. Starting System .......................................................................................................138
IV. Charging System .....................................................................................................146
Chapter III Electronic Control System of Engine................................. 152

Section I Precautions .............................................................................................. 152
I. Precautions of Supplemental Restraint System (SRS) ............................................152

II. General Precautions ................................................................................................152
III. Precautions in Maintenance.....................................................................................152
IV. Common tools for diagnose .....................................................................................154
V Precautions for On-board diagnose (OBD) system of engine ..................................157
Section II Structural Principle and Inspection of Engine Control System ................. 160
I. System Description ..................................................................................................160

II. Multiple-point Fuel Injection System ........................................................................160
III. On-board Diagnosis System ....................................................................................164
IV. Engine Trouble Diagnosis ........................................................................................170
Section III Structural Principle and Inspection of Engine Electronic Components ... 176
I. Intake Manifold Absolute Pressure (MAP) Sensor ...................................................176

II. Coolant Temperature (ECT) Sensor ........................................................................179
III. Electronic throttle .....................................................................................................181

IV. Hall sensor ...............................................................................................................184
IV. Oxygen sensor .........................................................................................................186
VII. Fuel Injector (INJ) ....................................................................................................189
VIII. Air-conditioning switch and relay .............................................................................192
X. Canister solenoid valve ............................................................................................194
XII. Electric Fuel Pump ...................................................................................................199
XIII. Electronic Control Module (ECM) of Engine ............................................................200
Section IV Trouble Diagnosis Procedures for Engine Control System .................... 205
I. Diagnosis with DTC .................................................................................................205

II. Diagnosis by Trouble Phenomena ...........................................................................222
Mechanical Part of
Maintenance Manual of Tojoy Sedan Engine
Chapter 1 Mechanical Part of Engine

Section 1 Engine Body
I. General Precautions
1. Precautions on Discharging Engine Coolant
Discharge coolant after engine has cooled down.
2. Precautions on Disconnecting Fuel Pipeline
1) Before the operation, ensure that the operating area is free of objects which may cause combustion
or sparks.
2) Disconnect the piping, plug openings to prevent leakage of fuel.
3. Precautions on Dismantlement and Disassembly
1) Use special tools as required in Instruction. Always operate safely; any forcible operations and
operations other than that specified in Instructions are forbidden.
2) Take particular care not to damage the matching face or the sliding face.
3) Use the adhesive tape or equivalent to cover the opening of engine system so as to prevent the
entry of foreign bodies, if necessary.
4) For the purpose of troubleshooting and reassembly, methodically mark and neaten the
disassembled parts.
5) When loosening the bolts and nuts, follow this basic principle: outmost ones first, diagonal ones
second, and so on. Conduct the operation in compliance with the loosening sequence, if specified.
4. Precautions on Check, Repair and Replacement
Thoroughly check the parts before repair or replacement. Check the substitutive parts by the same
means, and then replace as required.
5. Precautions on Assembly and Installation
1) Use the torque spanner to tighten the nuts and bolts.
2) When tightening the nuts and bolts, follow this basic principle: screw up the central nuts and bolts
with the same torque in steps, and then carry out the same operation with the internal and external
diagonal ones. Perform the operation in accordance with the tightening sequence, if it is specified.
3) Replace gaskets, oil seal or O-ring with new ones.
4) Thoroughly rinse, clean and dry every part. Carefully check the engine oil pipeline or engine coolant
pipeline for obstruction.
5) Never damage the sliding face and the matching face. Completely eliminate the foreign bodies such
as cloth scraps or the dust. Before assembly, paste the sliding face with engine oil.
6) When refilling engine coolant after draining completely, release air from the pipes at first.
7) After repair, start the engine and run with high speed to check for any leakage of the engine coolant,
fuel, engine oil and exhaust gas.
33
Mechanical Part of
6. Parts Needed to Be Tightened with Specified Angle
1) Use the angle spanner to finally screw up following engine parts:
- Cylinder head bolt
- Bolt of main bearing cap
- Connecting rod bolt
2) Please follow the specified tightening methods.
3) Make sure that the surfaces of threads and pedestal are clean and coated with engine oil.
II. Precautions on Sealant

Fig.1.1.001
1. Removal of Sealant
JAC-T1F017
After dismounting fixing nuts and bolts, use the
scraper to detach the matching faces and remove
old sealant.
Slide
Knock
Attention:
Do not damage the matching faces.
Insert the scraper, and then knock its side

to slide it as shown in the figure.
For the positions where it is difficult to use

scraper, lightly knock the parts to
dismount them with a plastic hammer. Fig.1.1.002
If you have no choice but to use the tools Scraper
such as a screwdriver, be careful not to

damage the matching faces.
2. Application Steps of Sealant
1) Remove the attached old sealant from the

application and matching faces of liner with
scraper.
Attention:
Thoroughly remove the old sealant from

the groove on surfaces, fixing bolts and
bolt holes where the sealant was applied.
2) Wipe sealant surface and matching surface clean with a special cleaner, remove water drops,
grease and foreign substances.
34
Mechanical Part of
3) Position sealant with the specified size.

Fig.1.1.003
Put the sealant into the groove for it (if any).
Generally, the sealant is put inside the bolt hole; however, it is occasionally put outside the bolt hole.
Install the matching part in a certain period of time after applying sealant.
Eliminate any dirt from the sealant.
Do not re-tighten the bolts or nuts after installation in order to avoid failures of bolts or nuts.
Add engine oil and coolant 30min after the installation has been finished.
Attention:
Conduct the operation in accordance with the instructions specified in this manual.
35
Mechanical Part of
III. Preparation
1. Tools for Maintenance
List of Special Tools

No. Tool Appearance Code Description
Fix camshaft
1 End forked clamp timing
sprocket
JAC-T1D001
Used together
2 Pin with the end
forked clamp
Used to install
Locating tool for
3 and dismantle
piston pin
the piston pin
JAC-T1F005
Used together
with the
4 Guide sleeve
locating tool
for piston pin
Used to fix
5 Flywheel chock JAC-T1F011
the flywheel
Used to
compress the
Valve spring
6 JAC-T1F012 valve spring
compressor
Install valve
cotter
36
Mechanical Part of
Used to install
Oxygen sensor and dismantle
7 JAC-T1F015
socket the oxygen
sensor
Used to
Dismantlement
8 JAC-T1F017 dismantle the
tool for oil pan
oil pan
Used to install
Installer for valve
9 JAC-T3F001 the valve oil
oil seal
seal
Functioning as
Guide for front oil a guide during
11 seal of JAC-T3F003 the installation
crankshaft of front oil seal
of crankshaft
Used to install
Installer for front
the front oil seal
12 oil seal of JAC-T3F004
of engine
crankshaft
crankshaft
Installer for rear Used to install

13 oil seal of JAC-T3F005 the rear oil seal
crankshaft of crankshaft
37
Mechanical Part of
2. List of Auxiliary Materials for Assembling Engine
List of Auxiliary Materials for Assembling Engine
No. Name Application Specification and Grade

Factory filled oil: SAE10W-30
Ambient temperature: -25-35
Engine
1 Used during filling and assembly User must select the appropriate oil
oil
according to the local temperature
Quality level: SJ or above
Silica Engine oil pump, water pump, oil pan
2 LT5699 or equivalent
gel and rear oil seal housing of crankshaft
Oil pressure switch, draining screw plug
3 Sealant LT243 or equivalent
and flywheel bolt
Coolant temperature sensor and water
4 Sealant LT648 or equivalent
temperature alarm switch
5 Petrol 93# unleaded petrol or above
6 Sealant Stud bolt LT271 or equivalent
3. List of Auxiliary Materials for Assembling Cylinder head
List of Auxiliary Materials for Assembling Cylinder head
No. Name Present Material and Model Assembly Position

5W-30 (winter) 15W-40
1 Engine oil (summer),with SJ-class quality Valve head, camshaft and camshaft oil seal
level and above
2 Sealant LT271 or equivalent Stud bolt
Guide sleeve of spark plug, bowl patch of
3 Sealant LT962T or equivalent
cylinder body/cover, connecting pipe nozzle
38
Mechanical Part of
IV. Engine Assembly

1. Precautions on Installation and Dismantlement
Caution:
Operation in violation of the following instructions may incur personal injury!
Park the vehicle on flat and firm ground.
Attention:
Always pay attention to safe operation, and do not conduct any forcible operations or
operations other than that specified in Instructions.
Do not start before the exhaust system and engine coolant have completely cooled down.
If the necessary items or operations are not mentioned in the sections of Engine, see
relevant chapters.
Use the specified lifting points all the time and select appropriate lifters according
conditions.
2. Preparation for Dismounting Engine and Transmission Assembly
1) General
Dismount the engine and transmission assembly from the vehicle, and then detach the engine from
transmission.
2) Preparation
Discharge the engine coolant from the radiator. See Change Engine Coolant.
Discharge the engine oil, transmission oil and clutch oil. See "Engine Oil", Transmission Oil and
Clutch Pipeline.
Collect the refrigerant in AC pipeline.
Discharge power steering fluid.
Attention:
Perform this step after the engine has cooled down.
Do not spill engine cooling fluid or brake fluid to the drive belt.
Dismount the following parts:
Engine trimming cover. See Intake Manifold.
Front wheels and tyres. See Wheels and Tyres.
Engine deflectors (left and right).
Air duct and air filter assembly. See Air Duct.
Battery, battery base and base support. See Battery.
Radiator assembly and radiator fan. See Radiator.
39
Mechanical Part of
3. Dismantlement of Related Elements in Engine Compartment
Disconnect the following pipelines and put them aside.
Attention:
Use plugs to prevent leakage when disconnecting the pipelines.
Inlet pipe of fuel injector. See Fuel Injector.
Vacuum hose of braking vacuum booster on engine side. See Braking Vacuum Booster.
PVC hose. See Fuel Evaporation Control System.
Oil inlet pipe joint of clutch. See Hydraulic Pipeline of Clutch.
Oil inlet pipe and oil return pipe of power steering pump; fixing support of oil pipes. See Power
Steering Pump.
Low and high-pressure pipes of air compressor. See Air Compressor.
Dismount the steering fluid reservoir.
Dismantling of shifting cable.
Disconnect the wire harness connectors and buckles of the following parts and then take them
away:
Oxygen sensor
Engine coolant temperature sensor
Crankshaft position sensor
Camshaft position sensor
Speed sensor
VVT oil control valve harness
Throttle opening sensor
Absolute intake pressure sensor
Ignition coil
Fuel injector
Knock sensor
Generator
Starter
Air conditioner switch
4. Dismantlement of Components of Chassis
Dismount the front drive shaft. See Front Drive Shaft.
Dismount the front exhaust pipe. See Exhaust System.
Dismount the engine supporting beam. See Engine Supporting Beam.
40
Mechanical Part of
5. Dismantlement
Attach the lifting device hook to the hanging lug of the engine
Fig.1.1.004 Fig.1.1.005
Lift the engine and fix it in place.
Use the manual lifting stand or equivalent to firmly support the bottom of engine and transmission
assembly; adjust the lifting tension.
Attention:
A soft pad may be placed on the supporting surface so as to ensure a totally stable state.
Detach left, right, front and rear suspensions of engine. See Engine Suspension.
Carefully lower the engine and transmission assembly. Be aware of following items during
operation:
Make sure that the work will not affect the vehicle.
Make sure that all connecting parts have been disconnected.
In order to avoid falling due to changes of vehicle gravity, use the jack to support the rear lifting
point.
6. Detachment
Dismount the power steering pump assembly and air conditioner compressor assembly from engine
and transmission assembly. See Power Steering Pump.
Dismount starter. See Starter.

Lift engine and transmission assembly with specified lifter, and then detach them.
Attention:
Before lifting, check whether each connection wiring harness has been disconnected.
7. Installation
Be aware of following items to install with steps contrary to dismantlement.
1) Do not damage the soft pad of engine suspension. Meantime, avoid spilling engine oil onto the soft
pad.
2) Make sure that all engine suspensions have been properly fixed. Then, tighten the nuts and bolts.
8. Check after Installation
41
Mechanical Part of
1) Check for any leakage.

The steps for checking oil and fluid leakage, lubricating oil leakage and the exhaust leakage are as
follows:
Before starting engine, check oil and fluid levels (including engine oil and coolant). Refill to specified
level as required..
Check for fuel leakage with following steps
- With ignition switch turned to the ON position, check whether there is fuel leakage at the
connecting positions.
- With engine started, recheck whether there is fuel leakage at the connecting positions during engine
increasing.
During running of engine, check for any abnormal noise and/or vibration.
With engine warmed up, verify that there are no leakage of fuel, exhaust gas or other oil and liquid
(including engine coolant and oil).
Bleed air and replenish by using specified ports and hoses.
After engine cooled down, recheck oil and liquid levels (including engine oil and coolant). If
necessary, refill them to the specified levels.
2) General of Check Items
List of Leakage Check Items
Item Before Startup During Engine After Engine

Operation Stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Transmission oil, brake fluid, power steering Level Leakage Level
fluid and clutch fluid
Fuel Leakage Leakage Leakage
Exhaust Leakage
42
Mechanical Part of
V. Drive Belt
1. Check Drive Belt
Warnings:
Be sure to operate only when engine stopped.
1) Check belt for aging, crack, wear and oil stain. Replace as required.
2) Check the belt tension at the mid-point between pulleys.
Inspection should be conducted with cold state of engine or when it has been stopped for at least
30min.
Tension range - Generator belt: 550 50N; power steering pump belt: 475 50N. Be aware that the
tension of belt reused should be calculated by using the empirical formula: tension of new belt *
1.2/1.5.
Adjust if tension is out of range.
Attention:
When checking belt tension after installation, firstly to adjust tension to specified value.
Then revolve the crankshaft for more than two laps to re-adjust in order to avoid tension
between pulleys changes.
2. Adjustment of Tension
List of Tension Adjustment
Part Method
Generator belt Screw adjusting bolt of generator
Belts of power steering pump Screw adjusting bolt of power steering pump
Attention:
After replacing with the new belt, adjust the tension so as to meet the requirements
When installing the belt, ensure the proper engagement with the belt pulley groove.
Do not splash the engine oil or engine coolant onto the belt.
Do not over wind or bend belt; for worn belt, pay attention to mounting direction.
43
Mechanical Part of
3. Generator Belt
1) Loosen the generator adjusting nuts and supporting nuts. Then adjust the tension by using the
adjusting bolt.
Fig. 1.1.006 Fig. 1.1.007
2) Tighten generator adjusting and supporting nuts.

Tightening torque: Generator adjusting nuts: 22.5 2.5 Nm
Generator supporting nuts: 475 N.m
4. Belt of Power Steering Pump

1) Loosen the power steering pump adjusting and supporting bolts.
Fig. 1.1.008 Fig. 1.1.0009
Tightening torque: Adjusting nuts: 4 - 6N.m

Supporting nuts:20-25N.m
2) Adjust tension with the adjusting bolt.
3) Lock adjusting bolt and power steering pump fixing bolt.
5. Dismantlement of Drive Belt
1) Completely loosen all belts in accordance with the instructions in Tension Adjustment.
2) Dismount the belt of power steering pump, and then the generator belt.
6. Installation of Drive Belt

1) Mount the belt onto the pulley with steps contrary to dismantlement.
Attention:
Make sure that the belt has properly engaged with the groove of pulley.
Make sure that no engine oil or coolant splashed onto any belt or pulley groove.
2) Verify that the tension of every belt is within the standard range. See Inspection of Drive Belt.
44
Mechanical Part of
VI. Air Filter and Air Duct
1. Parts
1 3
Diagram of Positions
1- Front Intake Pipe; 2- PVC Hose; 3- Intake Hose; 4- Air Filter Assembly
2. Intake Pipe Fig.1.1.010

1) Dismantlement
Dismount the fixing bolt of front intake pipe,

take off the front intake pipe assembly.
Tightening torque: 17-19 Nm
Dismount the locking bolt on upper cover of air

filter. Fig.1.1.011
45
Mechanical Part of
Disconnect the locking clamp of intake hose, and then take off upper cover and intake hose.
Fig.1.1.012 Fig. 1.1.013
Dismount the fixing bolt of air filter base, and

then take down the base. Fig. 1.1.014
2) Check after Dismantlement
Check whether there is any crack or wearing on the air duct assembly. If any, replace.
3) Installation
Install with steps contrary to dismantlement.
Attention:
Properly mount every joint and tighten the clamp.
3. Replacement of Air Filter element
1) Dismantlement
Fig.1.1.015
Loosen the locking bolt on upper cover of air
filter and lift the upper cover.
46
Mechanical Part of
Dismount air filter element.

Fig. 1.1.016
Periodically clean or replace the filter element with recommended period. See Periodical
Maintenance.
Blow the filter element from its back side with compressed air, till nothing is blown off.
3) Installation
VII. Intake Manifold and Exhaust Manifold
Decomposition Diagram of Intake and Exhaust Manifolds
1. Intake Manifold
1) Dismantlement
Caution:
Do not discharge the engine coolant when the engine is hot, otherwise you would be scalded.
47
Mechanical Part of
Discharge the engine coolant. See Engine Coolant.
Dismount the engine trimming cover.

Fig.1.1.017
Dismount the air filter assembly. See Air filter Assembly.
Disconnect the wire harness connectors of the following parts:
Absolute intake pressure sensor
Fuel injector
Electronic throttle opening sensor
Carbon canister control solenoid
Disconnect the following hose joints:
Water hose joint (insert a plug to prevent the engine coolant leakage)
PCV hose
Vacuum hose of braking vacuum booster on intake manifold side
Vacuum hose on carbon canister solenoid side
Small circulating water hose for throttle valve body
Dismount fixing bolts and valve body, take off valve Fig.1.1.018
body assembly.
48
Mechanical Part of
Dismount the fuel injector assembly. See Fuel Fig.1.1.019

Injector.
Tightening torque: 18.41.4 Nm
Dismount the supporting bracket of intake manifold Fig.1.1.020

and engine cylinder body.
Dismount the fixing bolt and nut of intake manifold. Fig.1.1.021
Tightening torque: 181.0 Nm
Take off the intake manifold.
Check whether there is any crack or other damage on intake manifold and whether the matching face is
distorted. If this is the case, repair or replace the intake manifold. Check for any abnormal condition of
rubber rings.
3) Installation
Install with steps contrary to the dismantlement.
Attention:
Do not reuse the non-reusable parts.
Before starting the engine, check the level of engine coolant. If the level is lower, refill engine
coolant as specified.
Carry out the following steps to check whether fuel leakage is present.
49
Mechanical Part of
- With ignition switch turned to the ON position, check whether there is fuel leakage at the
connecting positions.
- With engine started, recheck whether there is fuel leakage at the connecting positions during engine
increasing.
With engine warmed up, verify that there is no fuel and/or coolant leakage.
After engine cooled down, recheck the level of engine coolant. Refill to specified level as required.
2. Exhaust Manifold
1) Dismantlement
Caution:
Perform this operation after the exhaust system has completely cooled down.
Disconnect the wire harness connectors of front Fig.1.1.022

oxygen sensor. Special tools should be used if
necessary.
Attention:
Do not damage the oxygen sensor.
It is forbidden to use any oxygen sensor which has dropped to the hard ground from a height
above 0.5m. Such an oxygen sensor should be replaced.
Unscrew the fixing bolt for heat shield of exhaust

Fig.1.1.023
manifold, and then take off heat shield.
Tightening torque: 5-10Nm
50
Mechanical Part of
Unscrew bracket bolt to remove the exhaust manifold

bracket. Fig.1.1.024
Tightening torque: 201.0 Nm
Unscrew fixing bolt to remove the exhaust manifold.
Tightening torque: M8 352 Nm

Fig.1.1.025
Check whether the matching face of exhaust manifold is distorted.
3) Installation
Install with steps contrary to the dismantlement.
Attention:
Do not reuse the non-reusable parts.
Do not excessively tighten oxygen sensor, otherwise it may be damaged.
VIII. Exhaust System
1. Parts
Diagram of Exhaust System
1- Rear muffler; 2- Lug; 3- Front muffler; 4- Front exhaust pipe; 5-Three-element Catalytic Converter; 6-
Bellow; 7-Rear oxygen sensor
51
Mechanical Part of
2. Inspection of Exhaust System
Check whether the exhaust pipe, the three-way catalytic converter, the muffler and the fixing devices are
properly installed and whether there is any leakage, crack, damage or aging.
Repair or replace the damaged part as required.
3. Dismantlement and Installation
Attention:
Do not have you hand cut by the edge of heat shield.
Do use original exhaust system parts or equivalent products.
Perform the operation after the exhaust system has completely cooled down, for the temperature of
exhaust system remains hot when the engine has just stopped.
1) Dismantlement
Disconnect every joint and fixed part.
2) Installation
Replace the exhaust pipe gasket when reassembling the exhaust system each time.
Repair or replace the seriously distorted heat shield. Eliminate the accumulations from the heat
shield.
When install the heat shield, try to avoid wide clearance or blockage and intervention between the
heat shield and each exhaust pipe.
Eliminate the sediments from the sealed face of each joint. Such joints should be firmly connected to
avoid gas leakage.
Pre-tighten the fixing nuts and bolts on exhaust manifold side and those on vehicle side. Check
whether there is any intervention between parts, and then tighten the parts to specified torque.
When install the fixing rubber, avoid excessive upward/downward and leftward/rightward twist or
stretch.
3) Check after Installation
Verify clearance between rear muffler and rear bumper.
WIth engine running, check the connecting position of exhaust pipe for air leakage and abnormal
noise.
Ensure that the fixing support and the fixing rubber have been properly mounted. Do not subject
them to excessive force. Improper installation may result in considerable noise and shake.
52
Mechanical Part of
IX. Timing sprocket mechanism

1. Parts
Timing sprocket mechanism diagram
2. Dismantlement and Installation of Timing

Fig.1.1.026
chain
1) Dismantlement
Dismount the fixing bolt of water pump belt
pulley.
Tightening torque: 7-8.2 Nm
Note: It is permissible to perform the
dismantlement by means of the friction force of
drive belt before drive belt is removed.
b) Dismantle drive belt to check whether the

Fig.1.1.027
drive belt has wearing, aging, cracking, etc.; if
any, replace drive belt.
c) Dismantle oil gauge assembly
Tightening torque: 7-8.2 Nm
53
Mechanical Part of
d) Dismantle damping wheel

Fig.1.1.028
e) Dismantle generators and power steering pump bracket
Fig.1.1.029 Fig.1.1.030
f) Dismantle oil pan and cylinder head cover
Attention: Only when oil pan and cylinder head cover are disassembled can the oil pump
assembly be dismantled.
g) Dismantle oil pump assembly Fig.1.1.031
h) Check timing
Check the timing point shown in the diagram for compliance.
54
Mechanical Part of
Timing mark of sprocket
i) Dismantle tensioner and set/dynamic tracks of the automatic timing chain. Check for any
abnormalities.
Tightening torque: Automatic tensioner: 9 - 11 N m
Set track: 10-12 Nm
Dynamic track: 19-28 Nm
Fig.1.1.032 Fig.1.1.033
j) Dismantle exhaust camshaft sprocket bolt

Fig.1.1.034
55
Mechanical Part of
k) Dismantle intake cam timing controller

Fig.1.1.035
Tightening torque: 64.55.5 Nm
2 Installation
Reverse the above steps for installation. Be aware of timing and tightening torque during installation.
X. Camshaft assembly
1. Parts
Camshaft decomposition diagram
56
Mechanical Part of
2. Disassembly and installation
1 Disassembly
Remove cylinder cover. See "Intake Manifold."
Remove high-voltage ignition coil. See "Ignition Coil."
Disconnect PCV hose and air hose of respirator.
Remove the cylinder head cover from the cylinder head.
Remove camshaft timing sprocket. Seethe "timing sprocket body."
Remove camshaft position sensor from rear end of the cylinder head.
Tightening torque: 9 - 11 N m
Attention:
Handle with care to avoid collision or damage.
Remove the camshaft from cylinder head.
2 Inspection after removal

Fig.1.1.036
Camshaft
Measuring camshaft base circle diameter and

the maximum lifting strokes of intake and
exhaust.
Base circle diameter: 36mm
Maximum lifting stroke of intake8.7054mm
Maximum lifting stroke of exhaust8.2836mm
If specified value is exceeded, replace the

camshaft.
Mechanical tappet Fig.1.1.037
Measure the top thickness of the mechanical

tappet
Measurement should be within: 2.702.30mm
3) Installation
Assembly of camshaft machenism: All parts camshaft assembly should be assembled according to
grouped drawings.
57
Mechanical Part of
The mechanical tappet at the intake side will be grouped and assembled as per the following table
to ensure the intake valve clearance.
Distance between intake camshaft base circle Top end thickness of Mechanical tappet Valve clearance
and valve tappet L1 mechanical tappet label (mm)
2.91L12.93 2.70 270 0.19-0.25
2.93L12.95 2.72 272 0.19-0.25
2.95L12.97 2.74 274 0.19-0.25
2.97L12.99 2.76 276 0.19-0.25
2.99L13.01 2.78 278 0.19-0.25
3.01L13.03 2.80 280 0.19-0.25
3.03L13.05 2.82 282 0.19-0.25
3.05L13.07 2.84 284 0.19-0.25
3.07L13.09 2.86 286 0.19-0.25
3.09L13.11 2.88 288 0.19-0.25
3.11L13.13 2.90 290 0.19-0.25
3.13L13.15 2.92 292 0.19-0.25
3.15L13.17 2.94 294 0.19-0.25
3.17L13.19 2.96 296 0.19-0.25
3.19L13.21 2.98 298 0.19-0.25
3.21L13.23 3.00 300 0.19-0.25
3.23L13.25 3.02 302 0.19-0.25
3.25L13.27 3.04 304 0.19-0.25
3.27L13.29 3.06 306 0.19-0.25
3.29L13.31 3.08 308 0.19-0.25
3.31L13.33 3.10 310 0.19-0.25
3.33L13.35 3.12 312 0.19-0.25
3.35L13.37 3.14 314 0.19-0.25
3.37L13.39 3.16 316 0.19-0.25
3.39L13.41 3.18 318 0.19-0.25
3.41L13.43 3.20 320 0.19-0.25
3.43L13.45 3.22 322 0.19-0.25
3.45L13.47 3.24 324 0.19-0.25
3.47L13.49 3.26 326 0.19-0.25
3.49L13.51 3.28 328 0.19-0.25
3.51L13.53 3.30 330 0.19-0.25
Table: Distance between intake camshaft base circle and top of valve tappet, top end thickness of the
mechanical tappet grouping and assembly
58
Mechanical Part of
The mechanical tappet at the exhaust side will be grouped and assembled as per the following table
to ensure the intake valve clearance.
Distance between exhaust camshaft base circle Top end thickness of Mechanical
Valve clearance (mm)
and valve tappet L2 mechanical tappet tappet label
2.99L23.01 2.70 270 0.27-0.33
3.01L23.03 2.72 272 0.27-0.33
3.03L23.05 2.74 274 0.27-0.33
3.05L23.07 2.76 276 0.27-0.33
3.07L23.09 2.78 278 0.27-0.33
3.09L23.11 2.80 280 0.27-0.33
3.11L23.13 2.82 282 0.27-0.33
3.13L23.15 2.84 284 0.27-0.33
3.15L23.17 2.86 286 0.27-0.33
3.17L23.19 2.88 288 0.27-0.33
3.19L23.21 2.90 290 0.27-0.33
3.21L23.23 2.92 292 0.27-0.33
3.23L23.25 2.94 294 0.27-0.33
3.25L23.27 2.96 296 0.27-0.33
3.27L23.29 2.98 298 0.27-0.33
3.29L23.31 3.00 300 0.27-0.33
3.31L23.33 3.02 302 0.27-0.33
3.33L23.35 3.04 304 0.27-0.33
3.35L23.37 3.06 306 0.27-0.33
3.37L23.39 3.08 308 0.27-0.33
3.39L23.41 3.10 310 0.27-0.33
3.41L23.43 3.12 312 0.27-0.33
3.43L23.45 3.14 314 0.27-0.33
3.45L23.47 3.16 316 0.27-0.33
3.47L23.49 3.18 318 0.27-0.33
3.49L23.51 3.20 320 0.27-0.33
3.51L23.53 3.22 322 0.27-0.33
3.53L23.55 3.24 324 0.27-0.33
3.55L23.57 3.26 326 0.27-0.33
3.57L23.59 3.28 328 0.27-0.33
3.59L23.61 3.30 330 0.27-0.33
Table: Distance between the exhaust camshaft base circle and top of valve tappet, top end thickness of
mechanical tappet assembly grouping and assembling
59
Mechanical Part of
Installation precautions:
Mechanical tappet should be applied with proper amount of oil evenly; after the cylinder
head is assembled, it should turn flexibly without sticking or other abnormalities.
Before assembling camshaft, proper amount of oil should be evenly applied on each contact
surface; after the camshaft bearing bolt is tightened, the camshaft should turn flexibly
without sticking or other abnormalities; axial clearance should be: 0.05 - 0.15mm.
(Measurement location)
Install the camshaft position sensor.

Attention:
Apply a film of sealant to the flange of rear end cover.
Tighten the fixing bolt after the support has been fully mounted.
Install camshaft timing sprocket
Before installing cylinder head cover, clear any sealant on cylinder head.
Make sure that cylinder head cover gasket is put into the installation slot.
Check for proper position of all parts installed.
Check the level of engine oil before starting the engine. If the engine oil is less than the required
volume, replenish to specified level.
With engine running, check for abnormal noise and vibration.
Be sure that there is no oil leakage after engine warmed-up thoroughly.
Recheck the level of engine oil with engine cooled down. Replenish the engine oil to the specified
level as required.
XI. Cylinder head
1. On-vehicle Maintenance
1) Inspect the cylinder pressure:
Thoroughly warm up the engine and then stop it.
Release the fuel pressure. See Release of Fuel Pressure.
Disconnect the fuse of fuel pump, otherwise the fuel may be sprayed out during measurement.
Use special ignition coil and spark plug removal tool. See "Ignition Coil" and the "Spark Plug."
Dismantle engine trimming cover. See Intake manifold.
Install a cylinder pressure gauge (with joint) on the spark plug hole.
Push the accelerator pedal to the end, then turn the ignition switch to the START position to start
the engine. After the instrument finger appears stable, read compression pressure and engine
speed. Perform these steps to check other cylinders.
60
Mechanical Part of
Standard pressure: 1500kPa
Minimum pressure: 1200kPa
Tolerable pressure difference between cylinders: 150kPa
Attention:
It is required to obtain the specified engine speed always by the battery which is fully
charged.
Inspect valve clearance and other relevant parts (such as valve, valve seat, piston, piston
ring, cylinder bore, cylinder head and gasket) if the compression pressure is less than the
minimum value. Repeat measurement of compression pressure after the check.
If the pressures in some cylinders are low, add some engine oil to the spark plug holes of
such cylinders and then inspect again.
The piston ring may be worn or damaged if the cylinder pressure rises after the engine oil is
added. Check the piston ring and replace if necessary.
The valve may have faulty if the compression pressure is still low after the adding of engine
oil. Check whether the valve is damaged. Replace the damaged valve or valve seat.
The cylinder gasket must be leaky if the compression pressures in two neighboring
cylinders are low and even keep low after adding engine oil. Replace cylinder gasket.
After inspection, remount the dismounted parts.
Start engine, confirm that the engine runs smoothly.
2. Parts
Diagram of Cylinder head
1) Dismantlement
61
Mechanical Part of
Discharge engine coolant and oil. See Change Engine Coolant and Change Engine Oil.
Attention:
Perform these steps after engine cooled down.
Do not splash engine coolant or oil onto the drive belt.
Dismount the following elements and the relevant parts:
Engine trimming cover. See Intake Manifold.

Drive belt. See Drive Belt.
Cylinder head cover. See "Camshaft Assembly."
Intake manifold. See Intake Manifold.
Exhaust manifold. See Exhaust Manifold.
Oil gauge tube.
Oil pump body assembly and timing mechanism. See the "Timing Sprocket Mechanism."
Loosen the cylinder head bolts with special tool.
Remove the cylinder gasket.

Cylinder head Bolt
Measure the length of cylinder head bolt.
Limit: 143.50.7mm. Replace the cylinder head bolt if this Limit is exceeded.
Cylinder head
Check whether there are cracks or other damages on the cylinder head.
Check whether there is any blockage in the coolant gallery and oil passage. If any, clean the coolant
gallery and oil passage.
Check planeness of cylinder head.
Note: Check the planeness of cylinder body as well when performing this check.
a. Wipe off the engine oil from the cylinder head, remove any sealant and the carbon deposit.
Attention:
Be careful to prevent impurities from falling into coolant gallery and oil passage of cylinder
head.
62
Mechanical Part of
b. Measure the planeness in six directions at Fig.1.1.38

several positions on bottom surface of cylinder
head.
Standard value: below 0.03mm
Height of cylinder head (new): 1130.1mm
If the the standard value is exceeded, grind or
replace the cylinder head according to the
specification.
Attention:
The total grindable margin of matching surface between cylinder head and cylinder body
should not be greater than 0.2mm.
3) Installation Fig.1.1.039
Install new cylinder gasket.
Follow the numerical order as shown in the
diagram to tighten the cylinder head bolt and
follow the given steps to install cylinder head.
A: Intake side
B: Exhaust side
: Front end of engine
a. Install washer.
b. Apply a film of engine oil onto washer, which is at the threaded portion of bolt.
c. Tighten cylinder head bolts in sequence, until each bolt torque is 24.5 2 N m.
d. Fully unscrew bolts.
e. Tighten the bolts until the torque of each bolt is 24.5 2N m.
f. Paint marks on the bolt head and the cylinder Fig.1.1.040

head (see Fig.1.1.040).
g. Screw each bolt for more 90 with to the

tightening sequence.
h. Re-tighten each bolt by 90.
Attention:
Painting Mark
When the two tightening angles are below
180 , tightening performance can not be
assured; be sure to reach 180 when
tightening.
63
Mechanical Part of
When the two tightening angles are above 184 , completely loosen the bolt and re-tighten
per the initial sequence.
i. If the old cylinder head bolts are replaced during the maintenance, operation should be performed in
sequence from a to h.
j. If the old cylinder head bolts are not replaced during the maintenance, operation should be
performed in sequence a, b, e, f, g and h.
Then, perform the installation steps which are just contrary to dismantlement.
The steps for checking oil leakage, lubricant leakage and tail gas leakage are as following:
Before starting the engine, check the engine oil/coolant level. If the level is lower, replenish the
engine oil/coolant till the specified level is reached.
Perform the following steps to check whether the oil leakage occurs:
- Turn the ignition switch to the ON position (when engine is stopped). With the oil pressure acting
on the oil pipe, check whether there is fuel leakage at the joint.
- Start the engine. With the engine accelerating, recheck whether there is fuel leakage at the joint.
Run the engine to check whether the abnormal noise or vibration appears.
With engine warmed up completely, verify that there is no fuel leakage, tail gas leakage or any
oil/fluid (including engine oil and coolant) leakage.
After engine cooled down, recheck oil/fluid (including engine oil and engine coolant) level. Replenish
the oil/fluid to the specified level as required.
64
Mechanical Part of
XII. Valves
1. Parts
Diagram of Valve parts
1 - cylinder head bolts 2 - cylinder head bolt washer 3 - cylinder head assembly 4 - Cylinder gasket 5
intake valve cotter 6 - intake valve spring upper seat 7 - intake valve spring 8 - intake valve 9 - exhaust
valve cotter 10 - exhaust valve spring upper seat 11 - exhaust valve spring 12 - exhaust valve 13 - intake
valve oil seal 14 - intake valve spring lower seat 15 - exhaust valve seal 16 - exhaust valve spring lower
seat 17 - intake valve guide 18 - exhaust valve guide 19 -intake valve seat 20 - exhaust valve seat 21 -
cylinder head
2. Disassembly and Assembly

Fig.1.1.041 JAC-T1F001
1) Disassembly
Dismount the spark plug with the special

socket.
Dismount the valve cotter, valve spring and

spring seat.
Compress the valve spring with the special

compressor.
Attention:
Pay attention to the position of upper dead

point of piston.
65
Mechanical Part of
Label the dismounted valve, valve spring

Fig.1.1.042 JAC-T1F012
and other parts, and write down their
corresponding cylinder numbers and
positions
Store the parts reliably.
Dismount the valve oil seal.

Fig.1.1.043
See Replacement of Valve Seat to replace
the valve seat, if required.
See Valve Guide to replace the valve guide,

if required.
2) Assembly
Install valve guide if it has been dismounted. See Valve Guide.
Install valve seat, if it has been dismounted. See Valve Seat.
Install valve oil seal.
a. Install the valve spring seat.
b. Install the new valve oil seal with the special Fig1.1.044
tool shown in Fig.1.1.044 JAC-T3F001
Attention:
The valve oil seal should not be reused.
The valve oil seal must be installed with

the proper special tool.
Install valve.
Install valve spring.
Note: The parts with paint mark should be installed upwards.
Install retaining seat for valve spring.
Install valve cotter.
Use the valve spring compressor during the installation.
66
Mechanical Part of
After installation, lightly knock the edge of valve stem with a rubber hammer to check the mounting
condition.
Install spark plug with the spark plug socket.
3) Check after Disassembly Fig.1.1.045

1. Valve
Check whether the contact between valve Good
surfaces is proper. Renew the surface of valve

seat if the contact is uneven or incomplete.
Bad Bad
Inspect thickness of valve edge. Replace the

Fig.1.1.046
valve if the measurement is less than the
specified value. Contact
(required to be
at the center of
For intake valve: 1.35-1.65mm surface)
Thickness of
For exhaust valve: 1.850.15mm edge
Inspect the total length of valve. Replace the valve if the measurement is less than specified value.
For intake valve: 89.51-90.01mm
For exhaust valve: 90.69-91.19mm
2. Valve Spring
Check free height of valve spring. Replace the valve spring if the measurement is less than
specified value.
Check perpendicularity of valve spring. Replace the valve spring if the measurement is out of limit.
Standard value: 2
Limit: 4
67
Mechanical Part of
3. Valve guide
Fig.1.1.047
Check the gap between the valve guide and
the valve stem. Replace the corresponding
parts if the measurement is out of limit. Valve guide
Valve guide
Standard value: 0.020-0.036mm

Outer Diameter of Valve Stem
Limit: 0.10mm Inner Diameter of Valve Conduit
Replacement of Valve guide

a. Push out the valve guide towards the cylinder side by the press.
b. Rebore mounting hole on the valve guide of cylinder head to make it match increased size of valve
guide to be installed.
Attention:
Do not install the valve guides with the same sizes of old ones. Re-boring mounting hole on
the valve guide of cylinder head
Outer diameter of valve guide:

Fig.1.1.048
For the hole with diameter of 10.605-10.615mm,
extend the size of valve guide by 0.05mm.
For the hole with diameter of 10.805-10.815mm,
For the hole with diameter of 11.055-11.065mm, Protrusion
Height
c. Press the valve guide till its protrusion height
reaches the specified value.
Standard value: 23.0mm

Attention:
Use cold pressing method to install valve guide from upper side of cylinder head. Check
whether there are cracks after press fitting.
After valve guide pressed in, insert a new valve to check for smooth sliding of valve.
4. Valve Seat
Check the valve protrusion height between the end face of valve stem and the surface of valve
spring seat. Replace the valve seat if the limit is exceeded.
68
Mechanical Part of
End Face of
Standard values: Fig.1.1.049 Valve Stem
For intake valve: 53.21mm
Valve Protrusion
For exhaust valve: 54.10mm Height
Limits:
Surface of Valve
For intake valve: 53.71mm Spring Seat
For exhaust valve: 54.60mm
Renew valve seat.

a. Before renewing the valve seat, check the clearance between valve guide and valve. Replace the
valve guide if necessary.
b. Resurfacing the valve seat by the proper special tool or the valve seat grinder till specified seat
surface width and angle are met.
c. After renewing the valve seat, grind the valve and the valve seat by the grinding cream. Then, check
the protrusion height of valve stem (refer to the above mentioned check steps of valve seat)
Replacement of Valve Seat Fig.1.1.050

a. Cut away the replaced valve seat from its
inner side in order to decrease the wall
thickness. Then remove the valve seat.
Cut Away
b. Rebore the valve seat hole on cylinder head Fig.1.1.051

till the hole matches the selected valve seat
with a extended diameter. See Parameters
for Maintenance for the detailed size. Valve Seat
Height
c. Do not have the cylinder head hole scratched
by the valve seat cooled by the liquid nitrogen
before it is pressed.
Inner Diameter of Extended Hole
d. Renew the valve seat till its width and angle
meet the specifications (see the operation
instruction of valve seat correction).
e. leak testing must be conducted for

disassembly of valve related components.
69
Mechanical Part of
XIII. Cylinder Body Assembly
1. Parts
Disassembly Diagram of Cylinder Body Assembly
1 - flywheel bolt 2 - signal wheel screw 3 -flywheel 4 - crankshaft oil seal bolt 5 - crankshaft oil seal
housing 6 - bearing cap bolt 7 - bearing caps 8 upper main bearing shell 9 - crankshaft 10 - lower main
bearing shell 11 - crankshaft thrust 12 - crankshaft signal wheel 13 - cylinder block
1) Disassembly
Dismount the engine assembly from the vehicle, and then detach the transmission from engine. See
Engine Assembly for detailed dismantlement steps.
Fix whole engine.
Discharge engine oil. See Change Engine Oil
Dismount following engine accessories. See relevant chapters for detailed dismantlement steps.
Drive belt
70
Mechanical Part of
Generator, power steering pump, compressor and related supports
Intake and exhaust manifolds
Water pump and its components
Ignition coil
Cylinder cover, damping wheel, oil pan
Engine timing sprocket mechanism
Dismount the flywheel assembly. Fix the flywheel by the special tool to dismount the fixing bolt.
Tightening torque: For flywheel: 95-105Nm
Attention:
Fixing bolts should be loosened in the diagonal orders.
Disassemble knock sensor, crankshaft position sensor, oil pressure switch.
Tightening torque: Knock sensor: 16 - 24 N m
Crankshaft position sensor: 7.8 - 9 N m
Oil pressure switch: 8 - 12 N m
Attention:
Do not drop or knock the sensor.
Remove crankshaft rear oil seal bracket
Tightening torque: 7.0-8.2Nm
Insert the screwdriver between the crankshaft and the rear oil seal housing to dismantle.
Attention:
Once dismounted, the rear oil seal must not be reused. It should be replaced by a new one.
Dismount the piston and connecting rod assembly:
Before dismounting the piston and connecting rod assembly, check the gap at the big end of connecting
rod. See Check after Disassembly below.
a. Rotate the crankshaft to place the journal side of crankshaft which is corresponding to the
connecting rod to be dismounted at the center of bottom.
b. Dismount the connecting rod cover.
Tightening torque: 131Nm + 90-94
Be aware that when tightening the "5Nm 10Nm 13Nm +45 +45 " alternate methods should be
followed to tighten.
c. Push out the piston and connecting rod assembly from the cylinder body by the rubber hammer or
equivalent.
71
Mechanical Part of
Attention:
Be careful not to damage the big bonnet and connecting rod fitting surface
Do not damage the cylinder wall and the crankshaft journal with the big end of the connecting
rod.
Maintain the connecting rod big end and the connecting rod body match sequentially and
maintain the connecting rod big end serial number in consistency
Dismount bearing shell from the connecting rod and the connecting rod cover.
Attention:
Identify their mounting positions, and properly place them to avoid confusion.
Dismount ring from the piston.
Check the side clearance of piston ring before dismounting. See Check after Disassembly below.
Attention:
Fig.1.1.052
Use the piston ring expander.
Piston Ring
Dismount the piston ring from the connecting Expander
rod with method below:
a. Insert the push rod (special tool) from the front
side with a arrow mark, and then install the
guide sleeve D.
b. With the front mark of piston face upwards,
install piston and connecting rod assembly on
Push Rod
Fig.1.1.053
the mounting base of piston pin (special tool).
c. Push out the piston ring by the press.
Front Mark
Front
d. Detach the connecting rod from piston. Mark
Attention: Guide Sleeve D
After dismounting piston pin, place it Base

together with the piston pin and the
connecting rod.
It is forbidden to place the pistons, piston

pins and connecting rods of different
cylinders together.
Dismount the crankshaft bearing cap.

Before loosening the crankshaft bearing cap, measure axial clearance of crankshaft. See Check after
Disassembly below.
72
Mechanical Part of
Loosen the bolts of crankshaft bearing cap in the Number of Bearing

Fig.1.1.054 Cap
following sequence.
Tightening torque: 352 Nm6064
Be aware of the number and forward mark of

bearing cap.
In Fig.1.1.065:
For the upper row, 481062
For the lower row, 159 73
During the dismantlement, it is allowable to jiggle Fig.1.1.055

the crankshaft bearing cap forwards and
backwards by the bolts of crankshaft bearing cap.
See Fig.1.1.055.
Dismount the crankshaft.

Fig.1.1.056
2) Check after Disassembly
Axial clearance of Crankshaft
Detection methods are as shown in the figure
If measurement is not within the standard range, replace the thrust washer and repeat measurement. If it
is still over limit, replace the crankshaft.
Big End Clearance of Connecting Rod
Measure the gap between the connecting rod and

Fig.1.1.057
the crankshaft by using feeler gauge.
Limit: 0.4mm
If the limit is exceeded, replace the connecting rod

and measure again. Replace the crankshaft if
measurement is still out of the limit.
73
Mechanical Part of
Side clearance of Piston Ring

Fig.1.1.058
Bad
Measure the side clearance between piston ring
and piston ring groove top land by the feeler
gauge.
Feeler
Gauge
Standard values: Good
st
For 1 piston ring, 0.030.07mm
For 2nd piston ring, 0.040.06mm Feeler Gauge
Piston Ring
Limits:
For 1st piston ring, 0.1mm
For 2nd piston ring, 0.1mm
If the measurement exceeds the limit, replace the piston ring, and then remeasure the gap. Replace the
piston if the measurement is still out of the limit.
End Gap of Piston Ring
Ensure that the inner diameter of cylinder stays Piston

Fig.1.1.059
Pressed and Fixed
within the specified range. Feeler
Gauge
Piston
See "Cylindricality of Cylinder" Ring
Lubricate the piston and the piston ring with new

engine oil, then insert the piston ring till the piston
reaches the middle part of cylinder, measure end
gap of piston ring by the feeler gauge. Piston
Ring
Measured Point
Standard values:
For 1st piston ring, 0.20-0.35mm
For 2nd piston ring, 0.35-0.50mm
Limits:
For 1st piston ring, 0.8mm
For 2nd piston ring, 0.8mm
If the measurement exceeds the limit, replace the piston ring, and then measure again. Extend cylinder
bore through grinding and use the corresponding piston and piston ring if the measurement is still over
the limit.
Planeness of Cylinder Body
Remove any gasket material and eliminate the engine oil, sediment, carbon or other contaminants on
surface of cylinder body.
74
Mechanical Part of
Attention:
Be careful to prevent gasket materials from falling into the engine oil or coolant.
Ruler
Measure planeness of cylinder body in Fig.1.1.060
different directions at six positions using ruler
and feeler gauge.
Standard values: below 0.05mm
Limits: below 0.1mm

Feeler
If the limit is exceeded, replace cylinder body. Gauge
Cylindricality of Cylinder
Measure the cylinder degree at 6 different points per cylinder by using micrometer.
Standard values:
For cylinder bore: 75.0mm
For cylindricality: below 0.07mm
Diameter of Piston Skirt

Fig.1.1.061
Use outside micrometer to check whether the
piston skirt is distorted.
Standard values:74.973mm
Dial Indicator
Clearance between Piston and Cylinder Bore
Calculate per the actual measurement of piston skirt and cylinder bore.
(Gap) (inner diameter of cylinder) (diameter of piston skirt)
If the calculated value exceeds the limit, replace piston and piston ring assembly.
Boring Cylinder
a. The piston with extended size to be used should be determined in accordance with the cylinder
which has the highest bore.
Pistons of the following extended sizes, i.e. 0.25mm, 0.50mm, 0.75mm and 1.00mm, are applicable.
b. Measure the diameter of piston to be used.
After boring cylinder, clearance between piston and cylinder bore must be within standard range. The
75
Mechanical Part of
piston diameter should be measured at the position shown in Figure.
c. Calculate the boring size based on the piston diameter.
[Boring size] [outer diameter of piston] [clearance between piston and cylinder (0.02-0.04mm)]
[grinding margin (0.02mm)]
d. Boring each cylinder till it obtains the calculated boring size.
Attention:
To avoid the distortion due to heat during the boring course, bore the cylinders in following
sequence: Cylinder 2 Cylinder 4 Cylinder 1 Cylinder 3
e. Grind the cylinder till it meets the final processing size (outer diameter of piston clearance
between piston and cylinder)
Diameter of Main Crankshaft Journal

Measure the main crankshaft journal by the outside micrometer.
Standard value: 46.0mm
If it exceeds the standard, please follow the rules of selection to replace.
Diameter of Main Journal of Connecting Rod

Measure the diameter of main journal of
Fig.1.1.062 Dial Indicator
connecting rod by using outside micrometer.
Standard values:43.0mm
Replace the connecting rod bearing shell if
measurement exceeds standard value.
Gap of Connecting Rod Bearing Shell
Note: Use the plastic divider to perform the
measurement.
a. Clean any engine oil from the connecting rod
journal and connecting rod bearing shell.
b. Put the plastic divider on the connecting rod
Fig.1.1.063
journal, and asset it to a length equal to
bearing shell width. The plastic divider must
be placed at the center of connecting rod
journal and be parallel with the axial line of
connecting rod.
c. Lightly put the connecting rod cover to
specified place, and screw the bolt to specified
torque.
d. Dismount the bolt, then take off the connecting rod cover slowly.
e. Measure the pressed portion of plastic divider at the widest point by the scale which is printed on the
plastic divider bag.
76
Mechanical Part of
Standard value: 0.02 - 0.04mm + (0.01mm) expansion

Limit:0.1mm
Roundness and Cylindricality of Crankshaft
Measure sizes of each main crankshaft journal and
Fig.1.1.064
main connecting rod journal at four different
positions as shown in the figure.
The difference between X and Y of A and
B represents the roundness.
The difference between A and B of X and
Y represents the cylindricality.
Limits: For roundness: equal to or less than 0.05mm

For cylindricality: equal to or less than 0.05mm
Calibrate or replace the crankshaft if the measurements exceed the limits.
Clearance of Crankshaft
a. Wipe off oil from the crankshaft journal and the inner surface of bearing shell.
b. Mount the bearing shell.
c. Set the plastic divicer till its width equals to the width of bearing shell. Then put them on the journal
along the axial line of journal.
d. Lightly mount the crankshaft bearing shell cover, and screw the bolt till to specified torque.
e. Dismount the bolt and lightly take off the crankshaft bearing shell cover.
f. Measure the pressed portion of plastic divider Fig.1.1.065

Plastic Wire
at the widest point by the scale which is Gauge
printed on the plastic wire gauge bag.
Standard values: 0.02-0.04mm
Limit:0.1mm
Attention:
Fig.1.1.066 Round-angle Rolling Area
The connecting rod journal and main
journal of crankshaft should be rolled but
needn't to be machined to the reduced
size.
77
Mechanical Part of
Flywheel
Check whether the flywheel and the signal disk are distorted or cracked.
Attention:
Do not disassemble the flywheel.
Crankshaft signal wheel Fig.1.1.067
Check whether the crank signal wheel has

distortions, cracks and other anomalies.
Check whether the bolts are loose
3) Assembly
Blow away any oil and coolant from the cylinder body, the cylinder bore and the crankcase. Remove
any foreign bodies.
Attention:
Use goggles to protect your eyes.
Install the upper and lower main bearings shells.
Attention:
Select the bearing shells by using the identification marks of crankshaft (See the table
below). If the crankshaft can not be identified, measure the diameter of crankshaft, and then
select the corresponding bearing shell to match the crankshaft.
Crankshaft group marking
Main bearing 1 2 3 4 5
Hole group marking
0 (up / down) BlackBlack BlackYellow BlackRed BlackWhite BlackPurple
1 (up / down) YellowBlack YellowYellow YellowRed YellowWhite YellowPurple
2(up / down) RedBlack RedYellow RedRed RedWhite RedPurple
a. Remove any dust, dirt and oil from the matching surfaces of cylinder body and main bearing cap.
b. Install intermediate and upper bearing shells on the cylinder body
c. Be aware of direction of bearing shell during the installation.
Bearings shells with oil holes and slots should be installed at block side; other shells should be
installed at the main bearing cap side.
For installation of bearings, clean before installation. Please apply engine oil to the bearing surface.
Do not use oil on the back, but to thoroughly clean it.
During installation, align the extrusion on bearing shell with the cut of cylinder body and main
bearing cap.
78
Mechanical Part of
Add oil to bearing surface
Install crankshaft on cylinder block. When rotating the crankshaft by hand, check whether the rotation of
crankshaft is smooth.
Install main bearing cap. Arrow Points to Timing Bearing Cap

Fig.1.1.068
Belt Side No
The main bearing cap can be identified through

mark.
Install the main bearing cap starting from the

front of the engine according to the ordering
numbers.
Arrow must point to engine front.
Screw the bolts for main bearing cap in

numerical sequence shown in right figure.
a. Apply new engine oil onto the thread and fixing surface of bolts of main bearing cap.
b. Tighten bolts for main bearing cap in steps.
Tightening torque: 352Nm
c. Screw all bearing cap bolts by 60-64 clockwise.
After installation of bolts of main bearing cap, verify that the crankshaft can be rotated smoothly by
hand.
Check the axial clearance of crankshaft. See Axial clearance of Crankshaft.
Install piston onto the connecting rod with

following instructions. Fig.1.1.069
a. Measure the following lengths (See right Figure).
A Distance from piston flange to piston flange
Piston
outside Connecting
Rod
B Distance from piston flange to piston flange
Pin
Piston
inside
C Length of piston pin.
D Thickness of small end of connecting rod.
b. Introduce the measurements into following
formula:
L [(A-C)-(B-D)]2
c. Insert push rod (special tool) into the piston pin, and then install guide sleeve.
d. When mounting the piston and the connecting rod, keep the front marks at same side.
e. Apply the engine oil onto the outer circle of piston pin.
f. Starting from the guide sleeve, press the guide sleeve, piston pin and push rod into the piston front
mark side.
79
Mechanical Part of
g. Screw in the guide sleeves, clearance Fig.1.1.070

between the two sleeves should be 3mm plus
the calculated L in Step 2.
h. With the front mark facing downwards, install
piston and connecting rod on mounting base
of piston pin.
i. Install piston pin by the press.
Guide Guide
Sleeve B Sleeve A
Attention:
If the pressing load exceeds specified value, replace the piston pin and piston assembly
and/or the connecting rod.
Standard value: 10854Nm
Install piston pin.
Attention:
When mounting the piston ring, do not damage the piston.
Do not damage the piston ring due to the excessive expansion.
a. Install oil ring

a) Install oil ring lining ring into the piston ring groove. Then install the upper and lower blades.
Attention:
Lining ring and blade can be installed in two directions There is no difference between
upper and lower blades.
Lining ring and blade size coloring scheme.
Table of lining ring and blade size coloring scheme

Size Color
Standard Colorless
Extended by 0.50mm Blue
Extended by 1.00mm Yellow
b) To install the blade, install one end of blade into the groove (as shown in the diagram) before
pressing the other areas to place.
Attention: Fig.1.1.071
Do install blades by using piston ring
expander, otherwise, they may break.
c) After installation of the blades, check whether
they can move smoothly in both directions.
Piston Ring
Expander
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Mechanical Part of
b. Install first and second piston rings.

Install first and second piston rings with the identification marks facing upwards (on the piston top side)
by using expander.
Notes: Piston ring opening direction
Schematic Diagram for Piston Ring Location
Opening direction of first gas ring Opening direction of combined oil ring lower blade
Opening direction of lining

ring of combined oil ring
Opening direction of second gas ring

Opening direction of combined oil ring upper blade
Engine front-end
Install bearing shell onto the connecting rod and the connecting rod cover.
Apply engine oil onto bearing surface of shells before installation. Do not use engine oil on the back
but to thoroughly clean it.
Install piston and connecting rod assembly onto the crankshaft.
Place the crankshaft journal which is corresponding to the connecting rod to be mounted at the just
center of bottom.
Apply sufficient engine oil onto cylinder bore, piston and crankshaft journal.
Align air ring opening with oil ring opening. See Fig.1.1.097.
Schematic Diagram for Piston Ring Location
Opening direction of first gas ring Opening direction of combined oil ring lower blade
Opening direction of lining

ring of combined oil ring
Opening direction of second gas ring

Opening direction of combined oil ring upper blade
Engine front-end
Install piston rod assembly in corresponding cylinder according to marks on connecting rod.
Make sure that the front mark on piston top faces to timing belt, and then press the piston and
connecting rod assembly into the cylinder from the cylinder upside.
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Mechanical Part of
Make the piston ring with front mark facing the front Fig.1.1.072
end of engine by the piston ring compressor or other
suitable tool, then install piston ring onto piston
head.
Attention:
Do not damage cylinder wall or crankshaft
journal by the big end of connecting rod.
Do not to damage big bonnet and connecting
rod fitting surface
Install connecting rod cover.
During installation, first use high pressure gas for

blowing the expansion sections. Fig.1.1.073
When tightening connecting rod bolt, the order of

5Nm10Nm13Nm+45+45alternate methods
should be followed. After piston connecting rod
assembly is installed, verify that clearance for the
connecting rod big end is 0.10 - 0.30mm.
Attention:
Connecting rod bolts can only be used once..
Before installing nut, apply engine oil on its thread and seat.
Install rear oil seal housing of crankshaft with rear oil seal assemble to the cylinder block.
Installation of knock sensor, Hall sensors, oil pressure switch.
Attention:
Do not screw the nut when grasping the joint.
If the knock sensor is shocked, replace with a new one.
Note: Be sure that there is no foreign body at the matching surface of cylinder body or the back side of
knock sensor.
Be aware of following to install with steps contrary to dismantlement.
Flywheel
Alternately tighten bolts to specified torque.
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Mechanical Part of
XIV. Diagnosis of Common Troubles

Diagnosis List of Common Troubles
Trouble Possible Cause Resolution

The cylinder gasket is leaky. Replace cylinder gasket.
The piston ring is damaged or worn. Replace the piston ring.
Low cylinder pressure The cylinder or the piston is worn. Repair or replace the piston or the
cylinder body.
The valve seat is worn or damaged. Repair or replace the valve seat.
The volume of engine oil is insufficient. Check oil level.
The engine oil pressure sensor failed. Replace sensor.
The engine oil filter is blocked. Replace filter.
Oil pump rotor or cover damaged Replace.
Low oil pressure
The viscosity of engine oil is low. Check. Change oil as required.
The plunger of engine oil pressure switch is constantly Repair.
open.
The bearing gap is high. Replace.
High engine oil The plunger of engine oil pressure switch is constantly Repair.
pressure closed.
The engine supporting bolt loosened Tighten
The transmission mounting support loosened. Tighten
The engine support loosened Tighten
Engine quiver
The heat shield for engine is damaged. Replace.
The engine support heat shield is damaged. Replace.
The heat shield for transmission is damaged. Replace
The engine oil is thin (low oil pressure). Change oil.
Noise of valve
The valve or the valve guide is damaged or worn. Replace.
Noise from The oil is insufficient. Check the level of engine oil.
connecting rod
The engine oil is thin (the oil pressure is low). Change oil.
bearing shell and the
main bearing shell The bearing gap is wide. Check and then determine the cause.
The radiator or the radiating pipe is leaky. Repair or replace.
The water tank cover is not sealed. Tighten or replace the cover.
Poor cooling
The thermostat is leaky. Replace the thermostat pad.
performance
The radiator is leaky. Repair or replace.
The water pump is leaky. Replace.
Jam in radiator The coolant contains the impurities. Replace the coolant.
The water tank cover is not strictly sealed. Replace.
The cooling system is jammed. Rinse or replace.
High temperature of
The thermostat is at fault. Replace.
coolant
The belt skids. Adjust or replace.
The water pump is at fault. Replace.
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Mechanical Part of
Trouble Possible Cause Resolution

The sensor is at fault. Repair or replace.
The fan is at fault. Repair or replace.
The coolant is insufficient. Replenish
Low temperature of The thermostat is at fault. Replace.

coolant The sensor or the wire harness is at fault. Repair or replace.
The sensor or the starter is at fault. Repair or replace.
Ineffective fan
The fan relay or the wire harness is damaged. Repair or replace.
The joint loosened. Tighten it
Exhaust system leaks The exhaust pipe or the muffler is damaged. Repair or replace.
Exhaust pipe gasket damaged Replace.
The muffler loosened Tighten it
The rubber pad cut off Replace.
Abnormal noise
The exhaust pipe or muffler contacts vehicle body. Correct
The exhaust pipe or the muffler is damaged. Repair or replace.
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Mechanical Part of
XV. Parameters for Maintenance
1. List for Technical Parameters of Engine
Technical Parameters list of Engine
Item Standard Value Limits

Camshaft
Camshaft base circle diameter (mm) 36
Diameter of camshaft journal (mm) 32.033-32.082
Cylinder head and valve
Planeness of cylinder gasket surface (mm) 0.03 0.1
Total height of cylinder head (mm) 112.9-113.1
1.35 0.85 0.85
Thickness of valve edge (mm)
1.85 1.35 1.35
Diameter of valve stem (mm) 5
Clearance between valve stem and Intake valve 0.020-0.047 0.10
valve guide (mm) Exhaust valve 0.030-0.057 0.15
Conical angle of valve 45-45.5 -
Intake valve 53.21 53.71
Protrusion of valve stem (mm)
Exhaust valve 54.10 54.60
Intake valve 89.61 89.11
Total length of valve (mm)
Exhaust valve 90.94 90.44
Free height of valve spring (mm) 43.1 42.7
152/33.4 -
Load / mounting height of valve spring (N)/(mm)
310/25.2 -
Perpendicularity of valve spring 2 4
Contact width of valve seat (mm) 0.9-1.3 -
Inner diameter of valve guide (mm) 5 -
Protrusion of valve guide (mm) 23.0 -
Extended by
10.655-10.665 -
0.05mm
Diameter of size-extended valve guide on Extended by
10.855-10.865 -
cylinder head (mm) 0.25mm
Extended by
11.105-11.115 -
0.50mm
Extended by
31.925-31.945 -
0.3mm
Intake
Extended by
32.225-32.245 -
Diameter of size-extended valve seat 0.6mm
ring hole (mm) Extended by
28.425-28.445 -
0.3mm
Exhaust
Extended by
28.725-28.745 -
0.6mm
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Mechanical Part of
Item Standard Value Limits

Oil pump and oil pan
Addendum gap of oil pump 0.06-0.18
Side clearance of oil pump(mm) 0.04-0.11
Clearance of oil pump housing 0.10-0.18 0.35
Piston and connecting rod
Reference outer diameter of piston 75.0
(mm)
st
1 piston ring 0.03-0.07 0.1
Side clearance of piston ring mm)
2nd piston ring 0.02-0.06 0.1
st
1 piston ring 0.15-0.30 0.8
nd
Gap of piston ring opening (mm) 2 piston ring 0.30-0.50 0.8
Oil ring 0.20-0.50 1.0
Outer diameter of piston pin (mm) 18.0
Pressing load on piston pin (under room temperature) (N) 4900-14700
Oil gap of crankshaft pin (clearance of connecting rod journal) (mm) 0.014-0.059 0.1
Side clearance of big end of connecting rod (mm) 0.10-0.35 0.4
Crankshaft and cylinder body
Axial clearance of crankshaft (mm) 0.09-0.27 0.25
Diameter of main journal of crankshaft (mm) 46.0
Diameter of connecting rod journal (mm) 40.0
Clearance of main journal of crankshaft (mm) 0.014-0.034 0.1
Plainness of surface of cylinder body gasket (mm) 0.05 0.1
Total height of cylinder body (mm) 280
Cylindricality of cylinder body (mm) <0.007
Reference cylinder bore (mm) 75.0 -
Clearance between piston and cylinder (mm) 0.01-0.035
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Mechanical Part of
2. Tightening Torques
List of fastener tightening torque
Name Specification Qty. Tightening Torques (Nm)
High strength bolt
Main bearing cap bolt M91.2574.5 10 352Nm +60-64
(Synchronous fastening machine) 5Nm 13Nm
Connecting rod bolts tightening +90 - 94
M60.7533 8
torque (Manual) 5Nm 10Nm 13Nm +45 +45
alternate tightening
Camshaft bearing cap bolt M6135 16 111
Front camshaft bearing cap bolt M81.2530 3 201
Cylinder head bolt M91.25143.5 10 24.52Nm +180-184
Crankshaft pulley bolt M141.554 1 50Nm2Nm+602or165 Nm5 Nm
Flywheel bolt M111.2525 6 1005
Exhaust camshaft sprocket bolt M1230 1 8810
Valve timing adjuster bolt M1041 1 64.55.5
E-type bolt
Crankshaft rear oil seal bolt M610 E8 6 7.60.6
Rear lug blot M820 E10 2 18.41.4
Intake manifold bolt M840 E10 5 181.0
Oil pan bolt M612 E8 14 7.60.6
Sprocket cover bolt I M1090 E14 2 39.53.0
Sprocket cover bolt II M1050 E14 2 39.53.0
Sprocket cover bolt III M630 E10 2 8.40.6
Bolt M620 E10 M620 E10 2 8.40.6
Bolt M612 E10 M612 E10 3 8.40.6
Bolt M645 E10 M645 E10 2 8.40.6
Bolt M625 E10 M625 E10 7 8.40.6
Bolt M612 E8 M612 E8 1 8.40.6
Bolt M625 E10 M625 E10 2 8.40.6
Cylinder head cover bolt M627 E10 10 91.0
Oil filter bracket bolt M830 E12 3 201
Heater water returning pipe bolt M620 E8 2 7.60.6
Hydraulic oil rail bolt M835 E12 2 18.41.4
Plug
Main oil passage plug I Inner hex M20 2 605
Main oil passage plug II Inner hex M12 1 355
Water drainage plug Inner hex M12 1 255
Oil passage plug Inner hex M10 1 202
VVT oil passage plug M141.514 1 445
Oil drainage plug M141.514 1 395
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Mechanical Part of
Other bolts
Set track bolts M6112 2 102
Dynamic track bolts M81.2515 1 23.54.5
Starter bolt M855 2 243
Oil pressure switch R 1/8 1 102
Spark plug M14 4 344
Exhaust manifold stud M8112 6 222.5
Q1840830 (exhaust manifold M830 See "Standard parts and threaded connections not
2
bracket bolt) mentioned in table above"
Catalytic gas shroud nut M61 3 101
Q2580614 (crank signal wheel bolt) M6 3 12.52.5
Water temperature sensor 1 204
Hall sensor bolt Inner hex M6116 2 8.40.6
Knock sensor bolt Inner hex M81.2530 1 204
Exhaust manifold nut M8 5 352
Throttle self-tapping screw 4 60.5
Absolute pressure sensor 9.01
self-tapping screw
Square head bolt M101.2590 1 475
Idle wheel bolt M101.2538 1 499
Oxygen sensor 2 355
Oil filter After contact mounting surface, turn by 3 / 4 laps or
1
11 1Nm
Standard parts and threaded connections not mentioned in table above
M6 9-11
M8 20-25
M10 30-50
M12 60-80
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Mechanical Part of
Section II Engine Lubrication System

I. Precautions
Application Steps of Sealant:
1. Remove any old sealant on the seal gasket by using scraper.
Fig. 1.2.001
Scraper
Attention:
Thoroughly remove old sealant from grooves, fixed bolts and bolt holes on sealant
application surface.
2. Wipe sealant surface and matching surface clean with special cleaner, remove water drops, grease
and foreign substances.
3. Set the sealant with specified type completely on appointed position.
1) Install the matching parts in a certain period of time after sealant applied.
2) If there is any dirt on sealant, remove immediately.
3) Do not retighten the bolt and nut after installation.
4) Fill oil and coolant 30min after installation.
89
Mechanical Part of
II. Preparation
1. Repair Tools
List of repair tools
No. Tool Outline Drawing Explanation
1 Oil pressure gauge Measure oil pressure
Connect oil pressure

2 Hose gauge to cylinder
body
Oil pressure switch Dismount and mount

3
socket oil pressure switch
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Mechanical Part of
III. Lubrication system schematic diagram
Lubrication System Diagram of 1.3L Engine
Main oil gallery
Main oil gallery of

cylinder head
VVT screen
Bearing hole of first air intake
Filter Main bearing camshaft OCV (Oil control valve)
C3 oil gallery of air intake camshaft
Main shaft Timing chain lubrication nozzle C1 cylinder head C1 cylinder head
Pressure- gallery (left side) gallery (right side)
journal of
Automatic tensioner
limiting valve
crankshaft Air intake Oil gallery of first
Oil pump camshaft camshaft bearing cap C1 oil gallery of C2 oil gallery of
valve first camshaft first camshaft
bearing cap bearing cap
Connecting rod Exhaust camshaft
journal of C1 oil gallery of air C2 oil gallery of air
crankshaft intake camshaft intake camshaft
Air intake Exhaust
camshaft camshaft
bearing hole 2, bearing hole 2,
Connecting rod 3, 4, 5 3, 4, 5 VVT (valve timing adjuster)
Oil pickup
bearing
Air intake cam with Exhaust cam with Remarks:

mechanical tappet 1. Splashing means is used for lubrication of cam and
mechanical tappet tappet
2. Oil returning of VVT is achieved through OCV
internal valve plug.
3. Oil ports at front air intake camshaft are defined
respectively as C2, C1 and C3.
Oil pan
IV. Engine Oil
1. Check
1) Engine oil level
Note: Before starting the engine, park the vehicle steadily to check oil level. If engine has been started,
stop engine and check it after 10min.
Pull out the oil gauge and clean it .

Fig. 1.2.002
Insert the gauge; confirm that the oil level in
engine is between the two marks as shown.
Please adjust the oil level if it is out of range.
2) Appearance of engine oil
Check the engine oil for any white turbidity

and/or severe pollution.
If the oil is turbid or polluted, it may be caused by engine coolant. Please repair or replace the
damaged parts.
3) Leakage of engine oil
Check the following areas for oil leakage.
Oil pan
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Mechanical Part of
Oil drainage bolt on oil pan
Oil pressure switch
Oil filter
Matching surface of cylinder body and cylinder head
Front and rear oil seals of crankshaft
Matching surface of oil pump and cylinder body
4) Inspect oil pressure
Attention:
As the temperature of engine oil is high, please prevent yourself from being hurt.
Check oil pressure after vehicle parked.
Check oil level. Please refer to Engine oil Fig. 1.2.003

level.
Lift the vehicle, disconnect harness connector

at oil pressure switch and remove the oil
pressure switch.
Install oil pressure gauge and hose.

Fig. 1.2.004
Start engine and warm up to normal working temperature.
Inspect oil pressure when engine operates with no load.
Note: The engine pressure will increase when the temperature of engine oil is low.
If there is obvious difference, please inspect oil circuit and oil pump for leakage.
Install the pressure switch in accordance with the following steps after inspection:
a. Remove any used sealant attached on pressure switch and engine.
b. Apply sealant as specified and tighten the pressure switch.
Please use the specified sealant: LT5699 or equivalent.
92
Mechanical Part of
c. After the engine is warmed up, make sure there is no oil leakage during normal operation of engine.
2. Change Oil
Attention:
As the temperature of engine oil is high, please protect yourself from being hurt.
Avoid direct contact of your skin with waste oil for a long time. If contact has taken place,
wash thoroughly with soap or detergent as soon as possible.
Warmup the engine to check engine compartment for oil leakage. Please refer to Leakage of
engine oil.
Stop the engine and wait for 10min.
Loosen engine oil filler cap and remove the oil drain bolt.
Discharge the engine oil.
Install the oil drain bolt with new washer.
Attention:
Be sure to clean oil drain bolt and install with new gasket.
Tightening torque of oil drain bolt: 34-44Nm
Fill new oil.
Please refer to Maintenance for specification and viscosity of oil.
Oil volume: 4L
Attention:
Do not pull out oil gauge when filling oil.
The oil filling volume varies with oil temperature and oil drainage time, thus the above data
are only for reference.
Always use oil gauge to check oil filling volume.
Warm up engine and check the oil drain bolt and oil filter for oil leakage.
Stop engine and wait for 10min.
Check the oil level. Please refer to Engine Oil Level.
93
Mechanical Part of
V. Oil Filter
Fig. 1.2.005
1) Dismantlement
Dismount the oil filter with an oil filter spanner.
Attention:
Use original oil filter provided by JAC or equivalent.
As the temperatures of engine and engine oil are high, please proetct yourself from being
hurt.
During dismantlement, prepare a cleaning cloth to absorb leaked or splashed oil.
Do not make the engine oil stick on drive belt.
Thoroughly wipe and dry the engine oil splashed on the engine and vehicle.
2) Installation
Remove any foreign substances attached on

Fig. 1.2.006
mounting surface of oil filter.
Apply a film of engine oil on oil seal surface of

new oil filter.
Tighten the oil filter until the O-ring seating on

the installation surface; tighten the oil filter by
more 0.75 lap or get the tightening torque to
11 1N m.
Attention:
The oil filter must be tightened with filter spanner.
If the filter is tightened by hand, oil leakage may occur due to inadequate tightening torque.
1) Check oil level. Please refer to Engine Oil.
2) Start engine to check whether there is oil leakage.
3) Stop engine and wait for 10min.
4) Check oil level and fill as required. Please refer to Engine Oil.
94
Mechanical Part of
V. Oil Pan and Engine Oil Pump
1. Parts
12
13
6
14 10 8
7 2
5
11
15 4 3
Breakdown drawing of oil pan and oil pump
1 - oil filter bracket gasket 2 - oil filter bracket bolt 3 - oil filter 4 - oil pan bolt 5 oil pan assembly 6 - oil
pickup 7 - oil pickup bolt 8 - oil filter bracket 9 oil drainage bolt 10 oil drainage bolt washer 11 -
water pump seal 12 - oil pump assembly 13 - automatic tensioners observation manhole cover 14 -
crankshaft front oil seal 15 - Pump
2. Dismantlement
Caution:
Do not discharge engine oil when engine is hot so as to avoid being hurt.
1) Remove external mounted generator, power steering pump, cylinder head cover and other parts to
the oil pump assembly.
2) Discharge engine oil. Please refer to Change Engine oil.
95
Mechanical Part of
3) Dismount oil pan. Fig. 1.2.007

a. First, use loosening agent for sealants in order
to prevent oil pan sealing surface from
deformation.
b. Loosen the fixed bolts according to following

sequence: center-both sides.
Tightening torque:7.60.6 Nm
c. Knock the special tool into the space between Fig. 1.2.008
oil pan and cylinder body as shown in Fig.
1.2.008.
d. Slightly knock the side of special tool, in order

to make the tool move along the sealing
surface of oil pan/cylinder body, and then
dismount the oil pan.
Attention:
Do not damage the matching surface.
4) Dismount oil pump housing assembly.

Fig. 1.2.009
5) Dismount oil pickup.
Attention:
3. Check after Dismantlement
1) Oil pickup
Remove any attached foreign bodies of oil pickup.
2) Oil pump housing assembly
Check the oil hole of oil pump casing assembly for blockage, and clean it if necessary.
Check the oil pump casing assembly for crack or other damage. If there is any, please replace.
4. Installation
1) Install oil filter set.
96
Mechanical Part of
2) Install pump housing assembly.
3) Install external generator, power steering pump, cylinder head cover and other parts on the oil pump
assembly.
4) Install oil filter.
Clean the oil filter mounting surface on oil pump housing.
Apply some oil on O-ring of oil filter.
Tighten oil filter until the O-ring seating on the installation surface; re-tighten the oil filter by 0.75 lap
or get the tightening torque to 11 1N m.
Attention:
The oil filter must be tightened with filter spanner. If the filter is tightened by hand, oil
leakage may occur due to inadequate tightening torque.
5) Install oil pan.
Clean cylinder block and oil pan mating surface to ensure that there are no oil and other impurities.
Apply sealant as shown in diagram below.
Fig. 1.2.010 Oil pan
Apply sealant
as shown in
figure.
Specified sealant: LT5699 or equivalent.
97
Mechanical Part of
7) Install oil drainage bolt on oil pan

Fig. 1.2.011
The oil drainage bolt gasket for the oil pan is a
one-time product, new one should be used
after removal.
Install the oil drainage bolt washer of oil pan

shown in the figure.
Attention:
After the installation of oil pan, wait at least

30min before filling engine oil.
1) Check the oil level and fill as required. Please refer to Engine Oil.
2) Start engine and make sure there is no oil leakage.
3) Stop engine and wait for 10min.
4) Recheck the oil level. Please refer to Engine Oil.
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Mechanical Part of
Section III Cooling System of Engine

I. Cooling Circuit
1. Cooling Circuit Diagram
Heater water returning pipe bolts I

Fixing bolts of coolant pump pulley
Heater water returning pipe bolts II

Seal ring of water pump
Water pump assembly
Bolts for water pump
Coolant pump puller
Heater water returning pipe
Throttle pre-heating outlet hose
Throttle pre-heating outlet hose

Spacer of heater water returning pipe
Thermost subassembly
Water pump feeder
Water pump inlet bolt
Cooling circuit diagram

2. Principle Diagram of Cooling
Radiator
Expansion
tank
Thermostat
Thermostat
casing
Air throttle body
Warm air heat
exchanger
Water pump
Cylinder
Thermostat on body
Thermostat off
Cylinder
cover
Basic diagram of cooling
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Mechanical Part of
II. Engine Coolant
1. Check
1) Level check
After the engine cooled, check whether coolant level in reservoir is between MIN and Max marks.
Adjust level if necessary.

Fig. 1.3.005
2) Leakage check
Apply pressure to cooling system with leak

Fig. 1.3.006
detector of radiator cap to detect any leakage.
3) Test pressure
Caution:
Please do not dismount radiator cap when engine is very hot, otherwise the high-pressure
engine coolant overflowing from radiator will cause severe burns.
Attention:
Test pressure over specified value may cause radiator damaged.
When it is detected that the engine coolant is insufficient, fill engine coolant into radiator. If
any parts are damaged, please repair or replace.
2. Change Coolant
Caution:
To avoid being burned, please do not change coolant when engine is hot.
Wrap up the radiator cap with thick cloth, and turn to open it carefully. Release the pressure
in radiator first, and then fully remove cap.
100
Mechanical Part of
Be careful not to splash engine coolant onto the drive belt.
1) Discharge engine coolant
Dismount the deflector on right side of engine.
Open the water drain plug at the bottom of radiator, and then open the radiator cover.
If necessary, remove coolant reservoir to discharge coolant and clean the reservoir before
reinstallation.
Check the discharged engine coolant for rust or other impurities or discoloration.
If it is polluted, please wash the engine cooling system. Refer to Wash Cooling System.
2) Refill coolant
Install removed coolant reservoir and water drain plug of radiator.
Attention:
Be sure to clean the water drain plug and install with new O-ring.
Make sure all the hose clamps have been tightened firmly.
Dismount the air filter upper cover and air intake hose. Please refer to Air Filter Assembly.
Disconect the outlet pipe of warm water pipe. Please lift the hose as high as possible.
Fill coolant into radiator and reservior until specified level is achieved. The coolant should be filled
slowly allowing air in system can be bleed gradually.
Attention:
The original engine coolant provided by JAC must be used. Please refer to Recommended
Oil and Lubricant.
Disconnect when engine coolant overflows from warm water pipe, and then reconnect and
continue to fill engine coolant.
Install air filter upper cover and air intake hose. Please refer to Air Filter Assembly.
Install radiator cap.
Warm up engine until the thermostat is turned on.
Touch the lower water pipe of radiator to detect whether there is any warm water flows out, so as to
verify that the thermostat has been turned on.
Attention:
Check the engine water temperature indicator to avoid overheating of engine.
Stop engine to lower the engine temperature.
Cooling time can be reduced by using fan.
Fill coolant in radiator through the filler if necessary.
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Mechanical Part of
Fill engine coolant in reservoir to the MAX position.
Install the radiator cap and repeat steps - more than twice until the engine coolant level does
not lower any more.
Run the engine to check the cooling system for leakage.
3) Wash cooling system
Install the dismounted radiator water drainage plug and reservoir.
Attention:
Be sure to clean the water drainage plug and mount the new O-ring.
Dismount air filter upper cover and air intake hose. Please refer to Air Filter Assembly.
Remove outlet pipe of warm water pipe. Please lift the hose as high as possible.
Fill engine coolant into radiator and coolant reservoir, and install radiator cap.
Remove connection when engine coolant overflows from warm water pipe, and then reconnect and
continue to fill engine coolant.
Install the air filter upper cover and air intake hose. Please refer to Air Filter Assembly.
Run engine to warm it up to normal working temperature.
Increase engine speed for several times with no load applied to the engine.
Stop engine and wait for it to cool.
Discharge the water in system. Please refer to Discharge engine coolant.
Repeat steps - until the radiator begins to discharge the cleared water.
III. Radiator
Caution:
Please do not dismount radiator cover when engine is very hot, otherwise the high-pressure
engine coolant will cause severe burns. Wrap up the radiator cover with thick cloth and
slowly turn it to discharge the air pressure inside. Turn and open the radiator cover and take
it off carefully after the pressure is fully released.
1) Dismantlement
Dismount engine deflector. Please refer to Deflector.
Discharge engine coolant in radiator. Please refer to Replace Engine Coolant.
Attention:
Operate after engine is cooled.
Please do not make the engine coolant splash onto the drive belt.
Dismount air intake pipe and take it off.
Disconnect the harness connector of radiator fan motor and move it aside.
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Mechanical Part of
Dismount the inlet and outlet hoses of radiator and returning hose of coolant reservoir.
Dismount bracket of radiator and take off the radiator and fan subassembly.
Attention:
Please do not damage or scratch the radiator core during dismantlement.
Disassemble cooling fan sub-assembly from radiator.
2) Installation
Install in the reverse order with dismantlement.
3) Check after Installation
Check if there is any engine coolant leakage with leak detector for radiator cover. Please refer to
Leakage Check.
Start and warm up the engine. Visually inspect whether there is any coolant leakage.
2. Inspect Radiator Cap
1) Pull out the negative pressure valve and open it. Check if it can be fully closed after pressure
release.
Make sure there is no dirt on or damage to negative pressure valve seat of radiator cover.
Make sure the opening and closing operations

of negative pressure valve are normal. Fig. 1.3.007
2) Inspect relief pressure of radiator cap.
Standard value: 78-98KPa

Fig. 1.3.008
Limit: 59KPa
Connect the radiator cap to the leak detector for
radiator and apply engine coolant to sealing face of
the cover.
Replace radiator cap if operation of negative
pressure valve is abnormal or the relief pressure
decreases below limit.
3. Inspect Radiator
Check the radiator for slurry or blockage. If necessary, wash the radiator surface with following
methods.
Be careful not to bend or damage the radiating fin.
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Mechanical Part of
When washing the radiator without dismantling it, please dismount all accessories such as cooling
fan, wind collection cover and horn. Then wrap up the harness connectors with adhesive tape to
prevent water from flowing in.
1) Wash back of radiator core from top to bottom with the water hose pointing to the radiator vertically.
2) Wash each surface of radiator core every 1min.
3) If no dirt is washed off radiator, washing must be stopped.
4) Vertically blow the back radiator downwards with compressed air. Apply the compressed air with
pressure lower than 490KPa and keep the distance above 30cm.
5) Blow each surface of radiator core with compressed air every 1min until no water is blown out.
V. Radiator Cooling Fan
1) Dismantlement
Dismount the air intake pipe and take it off.
Disconnect the harness connector of radiator fan motor and move it aside.
Dismount the radiator cooling fan sub-assembly.
Attention:
Do not damage or scratch radiator core during dismantlement.
2) Installation
1) Disassembly
Dismount the cooling fan from fan motor.
Dismount the fan motor from wind collection cover.
2) Check after disassembly
Cooling fan
Check the cooling fan for cracks or abnormal bend. If any, replace the cooling fan.
Fan motor
Check the motor for sticking.
3) Assembly
Assemble in the reverse order with disassembly.
V. Water Pump
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Mechanical Part of
Attention:
Be careful not to splash the engine coolant onto the drive belt while dismantling the water
pump.
If the water pump can not be disassembled, it should be replaced as a whole.
After the installation of water pump, connect the hose, fix it with clamping band, and then
check if there is any leakage with leak detector for radiator cover.
1) Dismantlement
Fig. 1.3.009
Discharge the engine coolant in radiator.
Please refer to Replace Engine Coolant.
Loosen the fixed bolt for belt pulley of water

pump.
Dismount the drive belt. Please refer to Drive Fig. 1.3.010

Belt.
Dismount the fixed bolt for water pump.
Attention:
Check the water pump body assembly for severe corrosion, leakage of water-seal and erosion.
Check the water pump bearing for jamming or other damages. Replace the bearing if necessary.
3) Installation
Clean water pump installation seat.
Installation of pumps and replacement of the pump seals.
Attention:
Do not let the seal ring drop during installation.
Alternately and evenly tighten fixing bolts of water pump.
a. Install belt pulley of water pump.
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Mechanical Part of
b. Install drive belt and adjust it in accordance with specified tension. Please refer to Drive Belt.
c. Fill engine coolant. Please refer to Refill engine coolant.
Check if there is any coolant leakage with leak detector for radiator cap. Please refer to Leakage
Check.
Start and warm up the engine. Visually inspect if there is any engine coolant leakage.
VI. Thermostat Sub-assembly
1) Dismantlement
Discharge the engine coolant through water drain

Fig. 1.3.011
plug of radiator. Please refer to Replace Engine
Coolant.
Attention:
Operate after the engine has cooled.
Please do not splash the engine coolant onto

the drive belt.
Disassemble water inlet pipe and heater returning

Fig. 1.3.012
pipe of radiator at thermostat side.
Disconnect the harness connectors of coolant

temperature sensor and water temperature alarm
switch and fixed bolts for support racks of harness
connectors of front and rear oxygen sensors, and
then remove them.
Unscrew water pump inlet bolt, remove the

thermostat. Fig. 1.3.013
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Mechanical Part of
2) Check after Dismantlement Fig. 1.3.014
Thermostat
Inspect opening of thermostat valve at normal room

temperature.
Temperature of thermostat (ON): 82 (initially open)
95 (fully open)
Maximum lift of valve stem: 8mm
Please replace the thermostat when the measurement exceeds the specified range.
Water pump inlet and thermostat housing
Check them for cracks and other damages.
3) Installation
Be aware of following precautions to install with steps contrary to dismantlement.
Be careful not to splash engine coolant onto the engine and wipe and dry the engine coolant with
cleaning cloth.
Replace the thermostat seal ring.
Attention:
Do not apply engine oil or other oil substances to the seal ring.
Water pipes on thermostat housing must be installed solidly.
When mounting thermostat, its poppet valve

Fig. 1.3.015
must be set at the highest position.
Highest
If the water temperature alarm switch needs to

Fig. 1.3.016
be reused, apply specified sealant to its
thread.
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Mechanical Part of
If the engine coolant temperature sensor

Fig. 1.3.017
needs to be reused, apply specified sealant to
its thread.
Check for any coolant leakage with leak

detector of radiator cap. Please refer to
Leakage Check.
Start and warm up the engine. Visually inspect if there is any engine coolant leakage.
VII. Water Piping Sub-assembly
1. Dismantlement
Discharge the engine coolant through water drainage plug at the bottom of radiator. Please refer to
Replace Engine Coolant.
Attention:
Operate after the engine has cooled.
Dismount the air filter assembly. Please refer to Air Filter Assembly.
Dismount the upper and lower water hoses of radiator.
Dismount the warm water hose and minor cycle water piping.
Unscrew water inlet pipe bolt before disassembling the water inlet pipe from back of water pump.
Attention:
Please dismount the negative terminal of battery before dismantlement.
2. Installation
Be aware of following precautions and install with steps contrary to dismantlement.
1) Firmly insert each hose. Mount the clamp properly so that it will not clamp the raised position of
water piping.
2) Replace the steel water returning pipe gasket of heater.
Attention:
Do not apply engine oil or other oil substances to the seal ring.
Water pipes on thermostat housing must be installed solidly.
1) Check if there is any engine coolant leakage with leak detector for radiator cap. Please refer to
Leakage Check.
2) Start and warm up the engine. Visually inspect if there is any engine coolant.
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Mechanical Part of
VIII. Trouble Analysis
Table for Overheating Cause Analysis
Symptom Item should be inspected

Water pump Worn or loosening of drive
malfunction belt
Stuck of thermostat at
closed position
Blockage due to dust or
Improper heat radiation paper scraps
Radiator is damaged
Mechanical damage
Excessive foreign
The radiator cooling is
substances (corrosion,
blocked
pollutants, sand, etc.)
The cooling fan fails to
Failed Parts of Cooling System
work
The resistance for fan
Insufficient air flow rotation is too large Fan assembly
The fan blade is
damaged
Damaged wind collection

cover
Incorrect blend ratio of

coolant
Poor quality of engine
Viscous engine coolant
coolant
Loose clamp
Coolant hose
Broken hose
Water pump Improper sealing
Looseness
Poor sealing
Insufficient engine coolant Engine coolant leaks Broken radiator coolant
Radiator cap
reservoir
Broken radiator core
Breakage of stock solution
Coolant reservoir
tank
Excessively high engine
speed in the case of
The engine is no-load
Abnormal driving
overloaded
Long-term traveling
Trouble of Parts of Other Systems
Driving at ultra high-speed

Drive train failure
Wheel and tyre with

incorrect specifications

mounted
Braking drag
Incorrect ignition timing
The vent of bumper is

blocked
Cover mounted
The radiator grill is
Blockage of slurry or
Poor ventilation blocked
paper scraps
The radiator is blocked
The condenser is
Poor ventilation
blocked
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Mechanical Part of
IX. Parameters for Maintenance
Technical specification for cooling system
Temperature of thermostat opening 82 (Initially open) 95 (Fully open)

Maximum lift of thermostat valve stem >8mm
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Mechanical Part of
Section IV Fuel Supply System of Engine

I. General Precautions
Caution:
The following rules should be complied with during the replacement of parts of fuel pipeline.
Set the mark Attention: combustive in workshop.
Be sure to operate in the well-ventilated area, and prepare C02 fire extinguisher in the operation
workshop.
Do not smoke during the fuel system servicing. No fire in working area.
Hold the discharged fuel in the container and cover it. Put the container in safe area.
When disassembling the fuel pipe components, note the following:
Disconnect negative pole of battery.
Replace with new clips all the time.
Do not distort the fuel pipe during installation.
Please operate on level ground.
Connect the fuel pipe joint and make sure the joint has been fixed. Make sure the joint and resin
pipe dont contact any adjacent parts.
Do not excessively tighten the hose clips to prevent damage of hose.
Check each connection for fuel leakage according to following steps after installation of fuel pipe.
- Set the ignition switch at ON position to apply fuel pressure on fuel pipeline (do not start the
engine). Then check each connection for fuel leakage.
- Start the engine, increase its speed and check each connection for fuel leakage.
Only the original fuel filler cap provided by JAC can be used.
Please refer to Fuel Evaporative Emission System for maintenance of parts of the system.
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Mechanical Part of
II. Preparation
The special tools are listed in the table below:
List of Special Tools
S.N. Tool Outline Diagram No. Explanation
Fuel pressure Measure fuel

1 JACT1F018
gauge pressure
III. Fuel System
1. Check Fuel Pipe
Check the fuel pipeline, fuel filler cap and fuel tank for proper installation, leakage, crack, damage, loose
connection, worn and aging.
2. Inspect Fuel Pressure
Attention:
Always keep the joints of fuel hose sealed with O-ring.
Do not operate electrical system during inspection.
Prepare a container under the fuel pipe to be disconnect to avoid fuel splash.
1) Fully release fuel pressure. Please refer to Release Fuel Pressure.
2) Dismount the nut for fuel pressure inspection door on fuel injector guide rail.
3) Connect fuel pressure gauge.
4) Set ignition switch at ON position and check for fuel leakage.
5) Start engine and check if there is fuel leakage.
6) Obtain the reading shown in fuel pressure gauge.
Fuel pressure: 350KPa
Attention:
Do not check fuel pressure during system operation.
During the Inspection of fuel pressure, please always check the fuel piping for leakage.
7) If the check result is not good, turn to the next step.
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Mechanical Part of
8) Check for the following matters.
- Blockage of fuel hose and fuel pipe.
- Blockage of fuel filter.
- Fuel pump and its control circuit.
IV. Fuel Injector and Guide Rail
1. Dismantlement
Caution:
Do read the General Precautions before dealing with fuel system. Please refer to General
Precautions.
1) Disconnect the PCV hose joint at intake

Fig. 1.4.001
manifold side.
2) Disconnect the injector wiring harness

Fig. 1.4.002
connector
3) Disconnect the joint of fuel hose on fuel guide

Fig. 1.4.003
rail.
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Mechanical Part of
Attention:
Please prepare the container and cleaning cloth in advance as fuel leakage may take place.
Avoid the naked flame and spark.
Please keep any parts away from heat source. Special attention must be paid when welding
around them.
Do not expose the parts to the electrolyte of battery or other fluid.
Keep the connection clean and prevent damage and foreign substance, and properly cover
the connection with plastic bag or equivalent.
4) Dismount the fixing bolt for fuel guide rail.

Fig. 1.4.004
5) Take off the fuel guide rail with injector from intake manifold.
Attention:
Avoid interference with fuel injector during removal.
Absorb the fuel leaked from fuel pipe with cleaning cloth.
6) Dismount the fuel injector from fuel guide rail with following steps:
a. Pry and dismount the snap-in.
b. Straightly pull out the fuel injector from fuel pipe.
Attention:
Pay attention to the leakage of residual fuel in fuel pipe.
Do not damage the nozzle of fuel injector.
Do not make it fall off or knock it.
Do not disassemble it.
1) Fuel Injector
Check the upper and lower seal rings of fuel injector for crack, aging and breakage. If any, please
replace.
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Mechanical Part of
Check the injection hole of fuel injector for blockage. If any, please wash or replace by using special
instrument.
2) Fuel Guide Rail
Check the fuel inspection hole for damage and jamming. If any, please replace.
Check if there is residuum in guide rail. If any, please clean.
3. Installation
1) Be aware of following precautions when mounting new O-ring on fuel injector.
As the upper and lower O-rings are different, do not confound them.
Fuel pipe side: thick one
Nozzle side: thin one
Please mount the O-ring by your hands.
Lubricate the O-ring with petrol.
Do not wash O-ring with solvent.
Verify that there is no foreign substance on O-ring and its matching part.
Make sure the O-ring will not be scraped by tool or fingernail, and it is not distorted or stretched
during installation.
Insert new O-ring into fuel injector straightly. Fig. 1.4.005

Do not deflect or distort it.
2) Mount fuel injector on fuel pipe with

following steps.
: thick one
: thin one
a. Insert the snap into the fixing groove on

fuel injector. Insert the snap slice D into raised
position F of fuel injector.
Attention:
Replace with the new snap every time.
Make sure there is no interference between the snap and O-ring.
b. Insert fuel injector into fuel pipe where snap has been mounted.
Attention:
Make sure the direction of insertion aligns with the axis.
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Mechanical Part of
Insert the snap slice C into the raised position B of fuel pipe.
Make sure the flange A of fuel pipe is properly mounted in the fixing groove on snap flange.
c. Make sure the fuel injector will not move or fall off. Installation is completed.
3) Install fuel pipe guide rail and fuel injector assembly inside intake manifold.
Attention:
Be careful not to make fuel injector nozzle contact with other parts.
4) For the following steps, install with steps contrary to dismantlement.
Check for fuel leakage with following steps.
1) Set the ignition switch at ON position (when the engine stops), and then check the connection of
fuel pipe for leakage.
2) Start the engine, increase its speed and recheck the connection of fuel pipe for leakage.
V. Fuel Filter
1. Dismantlement
Caution:
Do read the General Precautions before dealing with fuel system. Please refer to General
Precautions.
Attention:
The fuel filter should be periodically replaced in accordance with the maintenance
instruction specified in Users Manual.
1) Open the fuel filler cap.

Fig. 1.4.006
2) Release the pressure in fuel tank.
3) Dismount the rear seat cushion. Please refer

to Rear Seat.
4) Dismount the service lid for fuel tank.
Directly prize it up with flat end screwdriver.
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Mechanical Part of
5) Disconnect the fuel pipe joint 1 (at fuel pump

Fig. 1.4.007
side), joint 2 (at fuel filter side) and grounding
end 3 of fuel filter.
Attention:
1
The fuel filter should be wrapped up with towel
or equivalent, so as to avoid injection of
residual fuel.
Disconnect joint with following methods:
Hold the side edge of joint and press the

Fig. 1.4.008
raised position of joint to pull out the fuel pipe.
3
If the joint attaches to the resin pipe, push and
pull the joint for several times until it moves,
and then pull out the joint.
Attention:
The joint can not be disconnected when 2

the raised position is fully pressed down.
Do not excessively distort the joint.
Do not disconnect the joint with any tool.
Prevent the resin pipe from being heated. Special attention must be paid when welding
around the resin pipe.
Prevent the resin pipe from contacting acidic fluid such as electrolyte of battery.
Do not bend or distort the resin pipe during installation and dismantlement.
To keep the connection clean and prevent from damage and foreign substance, please fully
cover them with plastic bag or equivalent.
6) Take off the fuel filter and fuel pipe.

Fig. 1.4.009
2. Installation
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Mechanical Part of
1) Fuel filter
Be aware of correct installation direction of

Fig. 1.4.010
fuel filter.
towards fuel inlet pipe side
2) Connector
Connect the connector of fuel supply hose according to following methods:
Check the connection for foreign substance or damage.
Make the connector align with the resin pipe and insert the connector straightly until click is heard.
Check whether the connector is connected properly with following methods after connection.
Visually inspect that 2 raised positions have been connected to the connectors.
Stretch the resin pipe and its connector hard

Fig. 1.4.011
to verify that they have been firmly connected.
Check whether there is fuel leakage with following steps.
1) Set ignition switch at ON position (when engine stopped), and then check the connection of fuel
pipe for leakage.
2) Start engine, increase its speed and recheck the connection of fuel pipe for leakage.
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Mechanical Part of
VI. Fuel Pump Assembly
Figure of fuel pump assembly
1. Dismantlement
Caution:
Do read the General Precautions before dealing with fuel system. See General
Precautions.
1) Check fuel level indicated on fuel meter. If the meter indicates full or to be full, discharge the fuel
from tank until the meter indicates that the fuel level is lower than position E.
Attention:
If fuel level exceeds mounting surface of fuel level sensor, the fuel may overflow during the
dismantlement of fuel level sensor.
2) Open the fuel filler cap.
3) Release the pressure in fuel tank.
4) Dismount the rear seat cushion. Please refer to

Fig. 1.4.012
Rear Seat.
5) Dismount the service lid for fuel tank.
Directly prize it up with flat end screwdriver.
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Mechanical Part of
6) Disconnect the harness connector of fuel

Fig. 1.4.013
pump and fuel pipe joint.
Fuel pipe joint of fuel pump
1
Harness connector of fuel harness 2
Disconnect the joint with following methods:
Hold the side edge of joint and press the raised position of joint to pull out the pipe.
If the joint sticks on the resin pipe, push and pull the joint for several times until it moves, and then
pull out the joint.
Attention:
The joint can not be disconnected until the raised position is fully pressed down. Do not
excessively distort the joint.
Do not disconnect the joint with any tool.
Prevent the resin pipe from being heated. Special attention must be paid when welding
around the resin pipe.
Prevent the resin pipe from contacting with acidic fluid such as electrolyte of battery.
Do not bend or distort the resin pipe during installation and dismantlement.
To keep the connection clean and prevent damage and foreign substance, please fully cover
them with plastic bag or equivalent.
7) Loose and take off the locknut with special tool. Fig. 1.4.014
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Mechanical Part of
8) Take off the Y-ring. Fig. 1.4.015
Attention:
Tilt the fuel pump when it is taken out, so

as to avoid broken of fuel level sensor.
To avoid residual fuel from being polluted,

wrap the Y-ring with cloth to pull it out
straightly.
9) Take off the fuel pump. Fig. 1.4.016
1) Fuel pump
Visual Inspection
Check for broken or fuel impurity. If any, please replace or wash it.
Inspect Fuel Pump Operation
Actuate the fuel pump with 12V regulated power supply directly and check if the operation is normal.
Attention:
Do not make the fuel pump operation for a long time, so as to avoid damage of pump
plunger.
2) Y-ring
Check it for material loss and broken.
3) Locknut
Check for deformation, crack, material loss, broken, and damage at mounting thread.
4) Fuel Level Sensor
Check the fuel float for interference and oxidation of its surface.
3. Installation
1) Fuel pump assembly
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Mechanical Part of
The Y-ring must fully fit with fuel tank during installation.
Tilt the fuel pump to facilitate its installation and pay attention to its direction.
There should be no turn-up on Y-ring during the installation.
Pre-tighten the locknut during its installation, and then tighten it horizontally.
2) Connector
Insert the connector of fuel supply hose with following methods:
Check the connection for any foreign substance and damage.
Make the connector align with the resin pipe and insert the connector straightly until click is heard.
Check whether the connector is properly connected with following methods after connected.
Visually check whether the 2 raised positions have been connected to the connectors.
Stretch the resin pipe and its connector hard and make sure they have been firmly connected.
Check for fuel leakage with following steps.
1) Set ignition switch at ON position (when engine stops), and then check the connection of fuel pipe
for leakage.
2) Start the engine, increase its speed and recheck the connection of fuel pipe for leakage.
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Mechanical Part of
VII. Fuel Tank Assembly
Breakdown diagram of fuel tank assembly

1-Filler cap 2-Filler tube 3-Fuel tank 4-Fastening band of fuel tank 5-Service lid 6-Locknut 7-Y-ring
8-Fuel pump 9-Fuel filter 10-Thermal baffle
1 Dismantlement
Caution:
Do read the General Precautions before dealing with fuel system. See General
Precautions.
Discharge fuel tank if necessary. Please refer to Fuel Pump.
Please operate on level ground.
Carry out the dismantlement steps 1-6 of fuel pump. Please refer to Fuel Pump.
Disconnect fuel supply hose and vent hose.
Disconnect EVAP hose.
Support the fuel tank with special jack.
Attention:
The fastening band of fuel tank should not be blocked in supporting position.
Dismount the clamping bands of filler tube and fuel tank, and then disconnect the filler tube and fuel
tank.
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Mechanical Part of
Dismount fastening band of fuel tank.

Fig. 1.4.017
Manually support the tank and carefully lower
the jack to dismount fuel tank.
Attention:
Make sure all connections have been

disconnected.
Make sure there is no interference with

vehicle.
2) Check after dismantlement
Fuel tank
Check for impurity of fuel. If any, clean it with hot water.
Capacity of fuel tank: 45L
EVAP hose and clips
Check the hose for blockage, corrugation, deformation and breakage.
Check the clips for damage or breakage.
Reinforced plate and its backing plate
Check the surface of reinforced plate for scratch and deformation.
Check the backing plate for crack, material loss, deformation and breakage.
3) Installation
Firmly hold fuel supply hose to insert it.
Do not set the hose clamp in expansion area of fuel pipe.
Please refer to Fuel Pipe Joint for precautions of fuel pipe joint connection.
Check for leakage with following steps.
Set ignition switch at ON position (when engine stops), and then check the connection of fuel
pipeline for leakage.
Start the engine, increase its speed and recheck the connection between piping and fuel pipe of fuel
system for leakage.
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Mechanical Part of
Section V Emission Control System of Engine

I. Fuel Evaporation Control System
1. Description
Intake manifold
Air cleaner
EVAP carbon canister

solenoid valve
Fuel evaporation
EVAP carbon Air
canister
Fuel tank
Schematic diagram of fuel evaporation system
The fuel evaporation system is used to reduce hydrocarbon compositions emitted into ambient air from
fuel system. Reduction of hydrocarbon is achieved by using active carbon in EVAP carbon canister.
When the engine is stopped or fuel is filled, the fuel evaporation from sealed fuel tank will be introduced
into EVAP carbon canister with active carbon and stored there. During operation of engine, the fuel
evaporation in EVAP carbon canister will be introduced into intake manifold through clean passage.
EVAP carbon canister is controlled by ECM. With engine running, evaporation flow controlled by EVAP
canister solenoid is adjusted with direct proportion of increased air flow. During deceleration and idling,
the evaporation passage may be cut off by EVAP carbon canister solenoid.
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Mechanical Part of
2. Diagram of Fuel Evaporative Emission Pipeline
1
6
Diagram of fuel evaporative emission pipeline
1-Carbon canister assembly 2-Fuel inlet hose of engine 3-Pipe connecting carbon canister with solenoid valve
4-Hose connecting carbon canister with solenoid valve 5-Fuel inlet pipe of engine 6-Fuel filter
Note:
Fig. 1.5.001
Do not use soap water or any other detergent
when installing vacuum pipe or cleaning pipeline.
3. Inspection of parts
1) EVAP carbon canister
Check EVAP carbon canister with following

methods:
a. Plug port 1, blow at port 3, make sure the air

flows out from port 2 freely.
b. Plug port 3, blow at port 1, make sure the air

flows out from port 2 freely.
Dismount the vacuum hose
Loose the clamps between carbon canister and fuel tank and carbon canister solenoid valve with
slip-joint pliers, pull out the vacuum hose.
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Mechanical Part of
Dismount the carbon canister
Lift the carbon canister and dismount it from the

Fig. 1.5.002
Left front frame
bracket on inner lining of left fender.
2) EVAP carbon canister solenoid valve
The air flow rate is controlled by the opening of evaporation by-pass passage in EVAP carbon canister
solenoid valve. The solenoid valve will repeat the operations of ON and OFF with signal from ECM to
actuate the variation of valve opening, so as to optimize engine control. The optimum value memorized
in ECM lies on the state of engine. When the engine operates, flow rate of fuel evaporation from EVAP
carbon canister is adjusted along with the variation of air flow.
Instruction of parts
Flow rate of fuel evaporation from EVAP carbon canister is controlled by duty cycle of ON/OFF of the
solenoid valve. The solenoid valve is actuated by ON/OFF duty cycle signal from ECM. The wider the
pulse width in ON condition is, the more fuel evaporation will flow through the valve.
Dismantlement
Fig. 1.5.003
a. Disconnect the vacuum hose of EVAP carbon
canister solenoid valve.
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Mechanical Part of
b. Disconnect the harness connector of EVAP

Fig. 1.5.004
carbon canister solenoid valve.
c. Take off EVAP carbon canister solenoid valve

Fig. 1.5.005
from the bracket.
3) Filler cap
Vacuum relief valve is mounted at the filler cap. When the pressure in fuel tank is high (more fuel
evaporation), the vacuum relief will be closed, so as to avoid emission of fuel evaporation to ambient air.
When the pressure in fuel tank is low (negative pressure), the vacuum relief valve will be opened, so as
to enable the outside air to get into fuel tank.
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Mechanical Part of
II. Forced Ventilating System of Crankcase
1. System Illustration
The forced ventilating system of crankcase is used to bring the cylinder blow-by gas in crankcase back
to intake manifold.
It is the forced ventilating valve (PCV) which brings the cylinder blow-by gas in crankcase back to intake
manifold. With throttle partially opening, the intake manifold sucks blow-by gas of crankcase through
PCV valve. In normal conditions, the ventilation volume of PCV valve is sufficient to suck all blow-by gas
of crankcase and a little air. The vent air is brought into crankshaft through air intake pipe. Ventilation
hose inhales fresh air from the rear end of the air filter to the crankcase to keep the crankcase pressure
at a certain range. When the air throttle is fully open, the vacuum degree is not sufficient to open PCV
valve and thus unable to suck blow-by gas of crankcase. The air flows through connecting hose in
reversed direction. In vehicles with severe blow-by gas, PCV valve can not meet the requirements
because part of air may get into the air intake pipe at any time during operation.
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Mechanical Part of
2. Inspection of Element
Check the PCV (forced ventilation of crankcase) valve as shown below:
1) Operation principle
Operation principle list of PAV valve
No vacuum High vacuum
Valve chamber cover side Valve chamber cover side

Operating state of engine Out of work Operating state of engine Idling or deceleration
PCV valve Out of work PCV valve Fully open
Variation of vacuum Limited Variation of vacuum Slight
Moderate No
Valve chamber cover side Valve chamber cover side

Improper acceleration and
Operating state of engine Normal operation Operating state of engine
high speed
PCV valve Normal operation PCV valve Retardant operation
Variation of vacuum Large Variation of vacuum Extremely large
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Mechanical Part of
2) Dismantlement and Installation
Dismantlement
a. Disconnect the PCV valve hose from cylinder

cover. Fig. 1.5.006
b. Remove the PCV valve from cylinder

Fig. 1.5.007
cover.
PCV valve: Hissing may be produced during

normal working of valve with air flows through. Fig. 1.5.008
When finger touches the valve at the entrance,
you can immediately feel a strong vacuum VVT valve
pressure.
Vent hose of PCV valve
a. Check the hose and joint for leakage.
b. Disconnect all hoses and clean with compressed air. If the blockage in hose can not be cleared,
replace.
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Maintenance Manual of Tojoy Sedan Electrical Part of Engine
Chapter 2 Electrical Part of Engine
Section 1 Ignition System

I. Ignition coil
1. Parts
Ignition coil
2. Dismantlement & Installation
1) Dismantlement
Attention:
Fig. 2.1.001
Be sure that the ignition switch is in the
OFF position.
Dismount the trimming cover of engine. Refer

to Intake Manifold section.
Disconnect the wiring harness connectors of

the ignition coil from high voltage ignition coil.
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Remove high-voltage ignition coil bolt to

Fig. 2.1.002
remove coil.
Dismount the spark plug with special socket.
Attention:
Please do not drop or shake it.
High-voltage ignition coil
Check the primary coil resistance between both terminals.
Primary coil resistance: 0.77-0.95
Check the secondary coil resistances at the high voltage ends between No.1 cylinder and No.4
cylinder, and that between No.2 cylinder and No.3 cylinder.
Secondary coil resistance: 7.75-10.23 K
Attention:
The ignition coil harness connector must be disconnected for secondary coil resistance
measurement.
Spark plug
Check the spark plug:
Check insulator of spark plug for damage and broken.
Check spark plug for carbon deposit. See the following table for causes of carbon deposit.
Causes of Carbon Deposit
Phenomenon Black charcoal Hard charcoal

Reason Impurity in the fuel or high fuel-air ratio. Impurities in the fuel; wrong ignition
timing, or untight spark plug.
Check spark plug electrodes for damage.
Inspect clearance of spark plug.

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Inspect clearance of spark plug by using feeler.
Standard value: 0.7-0.8 mm
If the clearance is beyond the standard value, replace.
Check sparking ability of spark plug.
a. Connect spark plug to high voltage circuit.
b. Keep the distance between edge of spark plug and the grounding metal at about 14 mm.
c. Start the engine for about 3s, check whether there are sparks produced between the edge of spark
plug and the grounding metal.
Attention:
During check, be careful not to get an electric shock.
If the clearance is less than 14 mm, the sparks may also be produced even though the high
voltage wire has trouble.
If there are no sparks, replace spark plug.
3) Installation

II. Diagnosis of Common Troubles
Diagnosis Common Troubles
Symptom Possible causes Solution

The engine cant or is Trouble of ignition coil or ignition switch Check or replace the ignition coil or the
difficult to start. ignition switch
Trouble of spark plug Check or replace spark plug
Disconnected high voltage wire Check the high voltage wire
Unstable idle speed Trouble of high voltage wire or spark Check the high voltage wire or check or
plug Replace spark plug
Trouble of ignition coil Check or replace the ignition coil
Engine surge or poor Trouble of high voltage wire. Check the high voltage wire
acceleration Trouble of spark plug Check or replace spark plug
Poor. fuel economy Trouble of spark plug Check or replace spark plug
III. Parameters for Maintenance

Maintenance Specification of Ignition System
High voltage Primary coil resistance 0.77-0.95

Ignition coil Secondary coil resistance 8.70.87 K
Spark plug Spark plug clearance 0.7-0.8mm
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Section 2 Starting and Charging System

I. Principle Diagram of Starting and Charging System
Central electric box

120 A fuse
30 A fuse link
battery
link
Ignition switch
Charging
alarm light
Combined
device
Anti-theft relay
Electric generator
ETACSlow level Rectifier

Magnetic
effective field
winding
Starter
Stator
winding
Solenoid
Electric switch
motor
One-way clutch
Principle Diagram of Starting and Charging System
II. Battery
1. How to use battery
Attention:
If the engine is necessary to be started with auxiliary battery and jumper wire, 12 V auxiliary
battery should be used.
When jumper wires are connected with battery, make sure that the jumper wires are clamped
to the terminals of battery and have good contact.
2. Methods to prevent excessive discharging of battery
The following precautions should be particularly emphasized to prevent excessive discharging of battery.
Always keep surface of battery (esp. the top) clean and dry.
The connecting part of the terminals should be clean and tightened.
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If the vehicle is not used for a long time, the cathode terminal of battery should be disconnected.
Check charging condition of battery.
3. Check
1) Visual inspect
Check terminals of battery for damage and electrolyte leakage. If any, replace.
2) Voltage inspection: Inspect batter for proper voltage. (The following parameters is for reference
only)
If U>13.2V, inspect the electrical system.
If 12.5V<U<12.9V, the system is normal.
If 11V<U<12.4V, inspect charging system.
If U<11V, the battery is damaged or the charging system has trouble. Please inspect charging
system and battery.
4. Dismantlement and installation
1) Dismantlement
The ignition switch should be turned to the Fig. 2.2.001

OFF position.
Disconnect the negative terminal.
Dismount the positive terminal of battery and

Fig. 2.2.002
the fixed bolts of battery pressure plate, and
then take off the pressure plate.
Take off the battery.
Take off the bracket of battery.
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Bracket of battery
Check for erosion. If there is, clean with warm clean water.
Battery harness
Check for erosion and damage. Replace if there is any.
3) Installation
Attention:
During connection, the anode terminal of battery should be connected first.
After installation, terminals may be smeared with mineral oil.
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III. Starting System
1. System Description
Closed solenoid switch of starter provides a closed circuit between battery and starter. The starter is
connected with engine body for grounding. After the power supply and grounding are provided, the
starter can turn the crankshaft, and thus engine is started.
Components of Starter
1-M port 2-S port 3-B port
1) Dismantlement Fig. 2.2.003

Disconnect the negative terminal of battery.
Note: Before disconnecting the cathode terminal of

battery, pull off the starter key first.
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Disconnect the harness connector of starter.

Fig. 2.2.004
Dismount the fixing bolts of starter, then take
off the starter.
2) Installation
Attention:
Be sure to tighten the nut of B port.
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3. Disassembly and Assemblage
1) Disassembly
Exploded View of Starter
1-Screw 2-Front support 3-Stop ring 4-Snap ring 5-Pinion 6-Gear ring 7-Solenoid switch 8-Plantery gear
9-Planetary gear 10-Ball 11-Gasket 12-Stator 13-Rotor 14-Electric brush retainer 15-Rear support
16-Fixing bolt
140
2) Check
Solenoid switch
Before check, disconnect negative terminal of battery.
Disconnect the M port of starter.
a. Test electrical connectivity between S port Connecting from

Fig. 2.2.005 the power
and switch body. supply
M
Replace solenoid switch if opened.
b. Test electrical connectivity between S port Connecting from

Fig. 2.2.006 the power supply
and M port.
M end
Replace solenoid switch if opened.
Pinion
a. Visual inspection of the meshing gear teeth
If the teeth are worn or damaged, replace meshing gear (check teeth of fly wheel in this step).
b. Check the teeth of pinion
If the teeth are worn or damaged, replace pinion (check teeth of rotor shaft gear in this step).
c. Check whether the pinion locks in one direction while turns smoothly in the other direction.
If it is able to lock or turnable in both directions, or if there is abnormal resistance, replace.
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Electric brush
Fig. 2.2.007
Check brush wearing with a caliper. if
excessive worn, replace.
Vernier caliper
Electric brush
Electric brush spring

Fig. 2.2.008
Depatch spring from the brush and use a
spring tension gauge to check tension
Electric brush
spring
Electric brush
Electric brush retainer

Fig. 2.2.009
a. Test insulation voltage between brush retainer
(positive) and bearings (negative) with an
ohmmeter. If broken, replace electric brush
retainer.
b. Check for electric brush smoothly moving.
If electric brush bracket is bent, replace. If the

sliding surface is dirty, clean.
Inspection of Stator
Fig. 2.2.010 Magnet
Check whether magnet is firmly fixed on the
stator; check for crack.
If the parts have any trouble, replace the

assembly.
Attention:
Please do not clamp the stator with a table

vice, nor hammer it.
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Inspection of Rotor Fig. 2.2.011

a. Check connectivity between adjacent fillets
with ohmmeter.
If open, replace.
b. Check conductivity between each copper

plate and shaft of commutator with ohmmeter.
If open, replace.
c. Check surface of commutator.

Fig. 2.2.012
If it is rough, use # 500 sandpaper to lightly
sand with method shown in figure.
Sand paper
d. Check diameter of commutator. Fig. 2.2.013

Check with a caliper; if it is less than the
specified value, replace.
Vernier
caliper
Commutator
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3) Assemblage
When assembling the starter, the bearing, the gear and the friction surface should be lubricated by
adding high temperature grease. And then conduct the following operations.
Gear clearance adjustment Fig. 2.2.014

Push the pinion out with the magnetic switch
energized, meanwhile check the clearance
between the pinion and the thrust piece with a
feeler.
Stop block
Gear clearance 0.5~1 mm
Pinion
If the clearance is out of range, adjust by using

Fig. 2.2.015
spacer.
Adjusting gasket
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4. Diagnosis flow chart of Common Troubles (if there is any abnormity found, disconnect negative pole
of battery at once.)
Inspection Flow Chart of Common Troubles of Starting System

Starter fails to stop. Replace the solenoid switch.
The engine fails to start.
Does engine run with Yes Yes

Does engine run normally?
revolving of crankshaft?
Inspect ignition/fuel system.
Yes
No
Inspect following items of
Abnormal
battery: 1. Charging condition
A Normal
2. Connection of terminal 3. Repair the starter.
Erosion of terminal.
Yes Yes
Does the gear shaft run? Check pinion clutch.
Does the starter run?
No No
Check the reduction gear, armature and the gear shaft.
Abnormal
Check the fuse and the fusible replace.
wire.
Normal
Inspect following items of
battery: 1. Charging condition Abnormal
2. Connection of terminal 3. 1. Charge battery.
Erosion of terminal. 2. Repair poor connection and A
eroded terminal of battery.
Normal
Abnormal
Inspect circuitry of starting
system. Repair.
Normal
Does magnet switch make No
Repair the starter.
noises during running?
Yes
Check the meshing condition
If wired as follows with no load, does
of pinion and gear ring. Yes
starter run? Replace solenoid switch.
Abnormal
1. Adjust the displacement of
pinion. 2. Inspect motion
mechanism of pinion. 3. Check
No
the gear ring. Repair the starter.
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IV. Charging System
The generator is used to provide DC voltage to vehicle electric system and keep charged condition of
battery. The voltage output is controlled by IC adjuster.
The B port supplies electricity to vehicle electric system and charging power supply to battery. The IC
adjuster checks the input voltage at port 4 (S port) and thereby controls output voltage.
After the powered and grounded, the charging alarm light will be lit. When generator provides sufficient
voltage, the grounding circuit will be opened, while the charging alarm light will be turned off. If the
charging alarm light is still on with engine running, it has troubles.
2. Charging alarm light
If the following situations presents with generator working, the warming function of IC adjuster will be
actuated, and the charging alarm light will be turned on.
No voltage is produced or the voltage is high.
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1) Dismantlement Fig. 2.2.016

Disconnect the negative pole of battery.
Disconnect harness connectors of generator.

Fig. 2.2.017
Loosen the adjusting supporting nut on generator. Then adjust tension with the tension adjusting
bolt.
Tightening torque: generator adjustment nut: 22.5 2.5 Nm
Generator supporting nut: 475 N.m
Fig. 2.2.018
Fig. 2.2.019
Dismount the belt of generator. Please refer to the Drive Belt section.
Take off the generator from the vehicle.
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2) Installation
Install with reversed order of dismantlement.
Before installing the generator, please inspect tension of generator belt. Please refer to the Drive
Belt.
Attention:
Tighten the nut of B port. Tightening torque: 10-12 Nm
Exploded View of Engine
1-Lock nut 2-Belt pulley 3-Spacer 4-Front end cover 5-Front bearing 6- Bearing cap 7-Bolt 8-rotor
9-Rear bearing 10-Stator 11- gasket 12- commutator 13-Electric brush retainer
14-Guide sleeve of slip ring 15-Rear cover
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1) Disassembly
Disassemble in the following order.
Belt pulley
Rear cover
Commutator assembly
Separate front and rear cover assembly.
Attention:
Be careful to avoid damage of stator assembly.
2) Check after disassembly
Inspect of rotor Fig. 2.2.020

a. Resistance test
Resistance: Approximately 2.0-2.5
If it is beyond the standard range, replace.
Slip ring
b. Insulator test
If electrically continued, replace.
c. Inspect wearing condition of slip ring.
If it is beyond the standard range, replace.
Carbon brush
a. Check carbon bush for smooth moving. The mark line of wearing limit of
Fig. 2.2.021 electric brush
If not, inspect carbon brush support and clean

as required.
b. Check wearing condition of carbon brush.
If Limit is exceeded, replace brush.

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Stator
a. Inspect continuity between terminals. Fig. 2.2.022 Lead
If not, replace.
b. Grounding test Lead

Fig. 2.2.023
If electrically continued, replace the stator.
Stator
core
3) Assembly
Rear bearing
Attention:
The rear bearing can not be reused after being taken off. Please with new one.
Lubrication of rear bearing out race is not permitted.
Installation of rear cover

Fig. 2.2.024
a. Mount the carbon brushes assembly, adjuster
assembly and stator.
b. Push the carbon brushes with fingers to install them on the stator.
Attention:
Be careful to avoid damage of slip ring surface.
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5. Trouble Diagnosis for Charging System
Be sure that the battery has been sufficiently charged before test of generator. A 30 V volt meter and a
proper test probe should be used in test. Inspection chart is helpful for inspection of generator.
Check the fusible wire before starting up.
Use a battery fully charged.
Inspection Flow Chart of Charging System
Disconnect the Conduct following

The ignition The alarm connector, and The alarm
check: 1. Bulb of
switch is on. light is off. ground the L-side light is off.
alarm light 2. Fuse of
harness. alarm light .
The alarm light is Perform following
on. inspection: 1. rotor 2.
The alarm light is Change
Slip ring of rotor 3.
on. damaged IC
Electric brush.
regulator.
Conduct the
The engine starts
The alarm light is following check: The engine The alarm light
with a rev of 1500
on. 1. Rotor runs at idle is off.
rpm.
2. Slip ring of speed.
rotor 3. Electric Normal.
brush
The alarm light is
The alarm light is Normal.
on.
off.
The engine rev is Change the

More than 16.0 V.
2500 rpm. damaged IC
Measure the regulator.
voltage of B port. Less than 13.0 V.
Change the
Conduct the following
damaged IC
check: 1. Rotor 2. Slip ring
regulator or
of rotor 3. Electric brush 4.
diode assembly.
Stator.
Alarm light: the charging alarm light in the combined instrument.

Attention:
If the charging system has trouble but the test results suggest normal, inspect connection of
B port (Inspect tightening torque and voltage drop).
Inspect conditions of rotor coil, rotor slip ring, electric brush and stator coil. Replace failure
parts as required.
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Electronic Control
Maintenance Manual of Tojoy Sedan System of Engine
Chapter III Electronic Control System of Engine

Section I Precautions
I. Precautions of Supplemental Restraint System (SRS)
Using the SRSs including airbag and pretensioner of safety belt together with the front seat safety belt
can contribute to reduction of the risk of injury and hazard severity of driver and front passenger in case
of crash. For information of proper maintenance of the system, please refer to Airbag part of this
manual.
Caution:
All maintenance operation should be carried out by JAC authorized franchised stores in
order to avoid increasing risk of personal injury and death due to the SRS system failure.
Improper maintenances, including incorrect dismantlement and installation of SRS system,

may cause wrong action of the system resulting in personal injury and death.
For dismantlement methods bell spring (hair spring) and airbag controller, please refer to the airbag
section.
Besides operations described in this manual, no electrically testing equipment should be used to
test any circuit of airbag system. The air bag circuit harness can be identified by the yellow or
orange harness or harness connectors.
II. General Precautions
1. Only digital electric meter should be used to inspect the electronic control system.
2. JAC genuine components should be used during maintenance, otherwise it is impossible to

guarantee the normal operation of system.
3. Only unleaded gasoline should be used for maintenance and operation.
4. Specified maintenance and diagnosis procedure should be followed to perform maintenance.
5. The disassembly and dismantlement for the system components are prohibited during
maintenance.
6. During maintenance process, the electronic elements (electronic control modules and sensors)
should be fetched and placed very carefully to avoid the falling down.
7. Keep strong awareness of environmental protection to effectively deal with waste of the
maintenance process.
III. Precautions in Maintenance
1. Temperature of electronic control module should never be higher than 80 during hot working
conditions simulation of trouble and other maintenance operations possibly resulting in the
temperature rising.
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Electronic Control
2. The electronic controlled injection system operates with high fuel pressure (approximately 350kPa).
Even with engine stopped, there is high pressure in fuel pipelines. Therefore, the fuel pipe should
not be dismantled casually during the course of maintenance. In case that it is necessary to repair
fuel system, pressure in fuel system should be released before dismantlement of fuel pipe.
3. The dismantlement of fuel pipe and the replacement of fuel filter should be carried out by the special
personnel in well-ventilated area.
4. Power supply of electric fuel pump should be turn off before pump is removed from fuel tank in order
to avoid sparks that may cause fire. The fuel injection pump should not be test with dry state or in
water, otherwise its service life may be shortened. In addition, the positive and negative poles of the
fuel injection pump must not be reversed.
5. During inspection of ignition system, the sparking should be detected only when it is necessary and
the time should be as short as possible. The air throttle must not be opened during inspection;
otherwise copious unburned full may flow into the exhaust pipe, accordingly leading to the damage
of three-way catalyst.
6. The manual adjustment is unnecessary because the idling regulation is completed solely by the
electronic controlled injection system. The throttle limiting screw of throttle body has been adjusted
by the manufacturer in factory; the initial position must not be changed by users arbitrarily.
7. Terminals of battery must not be reversed, otherwise electronic components may be damaged.
Negative grounding is used in this system.
8. Battery cable should not be disconnected with engine running. Before welding on vehicle, cable on
negative and positive poles of battery, and all electronic components should be removed.
9. Do not test input and output signal of components by puncturing the insulator of wire.
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Electronic Control
IV. Common tools for diagnose
Description of tool: diagnose tool of electronic controlled injection system
Function: reading/clearing DTC of electronic injection system, view data flow, test actions of parts, etc..
Fig. 3.1.001
Description of tool: ignition timing indicator
Function: inspect ignition timing
Fig. 3.1.002
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Electronic Control
Description of tool: digital universal meter
Function: measure characteristic parameters such as voltage, current and resistance of electronic
injection system
Fig. 3.1.003
Description of tool: vacuum gauge
Function: inspect air pressure of intake manifold
Fig. 3.1.004
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Electronic Control
Description of tool: cylinder pressure gauge
Function: inspect pressure in each cylinder
Fig. 3.1.005
Description of tool: fuel pressure gauge
Function: inspect pressure of fuel system, determine working states of fuel pump and fuel pressure
regulator.
Fig. 3.1.006
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Electronic Control
V Precautions for On-board diagnose (OBD) system of engine
The electronic control module (ECM) has an OBD system. The malfunction indicator lamp (MIL) of OBD
system will be lit to indicate the driver that there is malfunction caused by aging of the exhaust system.
Attentions:
Be sure to turn the ignition switch to OFF position and disconnect the cable of battery negative poles
before any repairing or inspection. The open circuit or short circuit of related switch, sensor and
solenoid valve may make the MIL lit.
After the operation, be sure to insert connectors and lock them firmly. Loose (unlocked) connectors
may result in the open circuit, accordingly making the MIL lit. (Make sure that there is no water,
grease and filth on the joint and port is not bent).
After the operation, be sure to route and fix the harness correctly. The interference between support
and harness etc. may result in short circuit, accordingly making the MIL lit.
After the operation, be sure to connect the rubber pipe properly. The failed connection of the rubber
pipe may cause lighting of MIL because of failure of the EVAP system and fuel injection system etc.
Be sure to clear any uneffective DTC from ECM before transferring vehicle to user (the repair is
done).
Be sure to use the 12V battery as the power supply.
Never disconnect cable of battery with engine running.
Be sure to turn ignition to OFF position and disconnect cable of battery before connecting or
disconnecting any ECM harness connectors. Otherwise the ECM may be damaged, because even
if the ignition is turned to OFF position, the ECM still has 12V voltage.
Turn the ignition switch to OFF position and disconnect the connecting wire cable of storage
batterybattery cathode before dismounting the any components.
Fig 3.1.007
Battery
Dont disassemble the ECM.

If one of the battery cable is disconnected, memory of ECM will return to the initial value. And the
ECM may start to control itself with initial value. When battery is disconnected, the engine will
operate a little differently, which doesnt mean any trouble. Dont replace any components because
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Electronic Control
of a little change.
When connecting the ECM harness connectors, push the deflector rod (1) downward mostly to lock
securely.
When Inserting the contact pin into the ECM

Fig 3.1.008
or pulling it out, be aware to avoid damaging Bent
contact pin port (bent or broken). When
connecting the contact pin, make sure that the
contact pin port of ECM is not bent or broken.
Connect the harness connectors of ECM

firmly. Poor connection may cause extremely Broken
high (fluctuation) voltage on the coil and
capacitor, accordingly resulting in damage of
IC.
The harness of the electronic control system of engine should be remained for a length of at least
10cm from the joint in order to avoid any trouble of the electronic control system of engine caused
by receiving the exterior noise signal and decreasing the operation of IC etc.
Keep the parts and harness of the electronic control system dry.
Inspect ECM with port and reference value to assure the normal function of ECM before replacing.
Even the very little leakage in the intake system may lead to the severe trouble.
Dont swing or vibrate the camshaft position sensor (phase) or the crankshaft position sensor
(position).
Perform DTC validation procedures or the whole function inspection after conduction of trouble
diagnosis. If repair is finished, DTC should not be seen in the validation procedures. Overall function
inspection should obtain a good result after repair completed.
When measuring the ECM with the circuit tester, never make two measuring devices contacted. If
the probes touch occasionally, the short circuit may be cause and the power transistor of ECM may
be damaged.
During measurement of input/output voltages, the grounding port must not be used. Otherwise the
transistor of ECM may be damaged. Ports other than the ECM may be used for gounding.
Fuel pump must not be used without fuel in pipes.
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Electronic Control
Tighten clamp of fuel hose to specified torque.

Fig 3.1.009
Dont step on accelerator pedal when starting
the vehicle.
Dont increase the speed of engine

immediately after starting the vehicle.
Dont speed up before shutting down the

engine.
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Electronic Control
Section II Structural Principle and Inspection of Engine Control System

I. System Description
Engine Control System Diagram
1-Carbon canister 2-Carbon canister solenoid valve 3-Electronic throttle body assembly 4-Intake air
temperature/pressure sensor 5-Injector 6-Camshaft position sensor 7-Ignition coil 8-Front oxygen
sensor 9- Three-way catalyst 10-Rear oxygen sensor 11-Coolant temperature sensor 12-Crankshaft
position sensor 13-Fuel filter 14-Electric fuel pump 15-Fuel tank 16- Diagnosis port 17-Engine control
module
Note: This diagram is the control diagram, if the sensor location doesnt match with
physical parts, actual conditions should prevail.
II. Multiple-point Fuel Injection System
Multiple-point fuel injection (MPI) system comprises of the sensor detecting engine operation and the
electronic control module (ECM).
The system is controlled based on signals from these sensors; actuators operate under control of the
ECM. ECM functions include fuel injection control, idle control and ignition timing control etc. and some
trouble diagnosis means for simplifying the troubleshooting in case of trouble.
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Electronic Control
2. Input/Output Signal
List of Input/Output Signal
Sensor Input Signal of ECM ECM Function Actuator
Engine speed
Hall sensor
Piston position
Absolute intake pressure sensor Intake quantity
Oxygen
Oxygen sensor concentration in
exhaust Control fuel injection
Fuel injector
and mixing
Throttle opening sensor Throttle opening
Knock sensor Knock of engine
Air conditioner
Air conditioner switch
pressure
Wheel speed sensor Vehicle speed
Coolant
Coolant temperature sensor
temperature
3. Starting Control
Special measures should be used to control the air flow, fuel injection and ignition timing during starting.
At the beginning of starting, air in the intake manifold is still and the internal pressure of the intake
manifold is ambient air pressure. Throttle closed and the electronic throttle is designated as a fixed
parameter depends on temperature. In similar process, a specific "injection timing" is designated as the
initial injection pulse. Fuel injection amount varies according to engine temperature in order to promote
fuel film formation on intake manifold and cylinder walls; thus, when the engine reaches a certain speed,
mixture should be thicker. Once the engine starts to run, the system immediately begin to reduce the
mixture concentration At end of starting cycle, the starting enrichment function will be completely
cancelled. In starting work conditions, spark advance are also adjusted and vary with the engine
temperatures, intake air temperatures and engine speeds.
4. Warming-up and Heating Control of Three-way Catalyst
With engine started at low ambient temperature, intake quantity of cylinder, fuel injection and electronic
ignition are all adjusted to compensate the higher requirement of the engine torque; this process
continues until the temperature is proper. During this stage of running, the most important factor is the
quick heating of the three-way catalyst, for fast transition to the three-way catalyst functioning can
markedly reduce the emission. Under this operation condition, the heating three-way catalyst may be
performed by postpone the ignition advance angle properly to take advantage of the exhaust gas.
5. Acceleration/Deceleration and Back-tow Fuel Cut Control
Part of the fuel injected to the intake manifold will not reach the cylinder in time to participate follow-up
combustion stroke. Instead, it forms a film on intake manifold wall. With increasing of load and injection
duration extension, fuel stored in the film will build up dramatically. When the throttle opening increases,
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part injected fuel will be absorbed by the film. Therefore, corresponding amount of fuel must be added
for compensation and to prevent the mixture from thinning during acceleration.
Once load factor is reduced, the additional fuel contained in the fuel film on intake manifold wall will be
re-released, and then it is necessary to reduce the injection duration accordingly during acceleration
course. Back-tow and towing operation condition refers to conditions that the power supplied by the
engine at the fly wheel is negative value. In this case, the engine friction and pumping gas loss can be
used to make vehicles slow down. In back-tow or towing operation condition, fuel injection is cut off in
order to reduce the fuel consumption and the emission, more importantly, the three-way catalyst can be
protected correspondingly. Once engine speed decreases to the specific fuel supply recovery speed
above idling, the fuel injection system will re-supply. In fact, ECM program has a rotation speed recovery
range which depends on the changes of such parameters as engine temperature, dynamic change of
engine speed, which can also prevent the engine speed from dropping to the specified minimum through
calculation. Once the fuel injection system re-supplies fuel, the supplemental fuel will be supplied by
using the initial injection pulse and the fuel film on the intake manifold wall will be formed. After
resumption of fuel injection, torque-based control system makes the increase of engine torque slow and
steady (smooth transition).
6. Idle Control
At idle speed, the engine does not provide torque to the fly wheel. To ensure the engine running stably at
the lowest possible idle speed, the closed-loop idle speed control system should keep the balance
between the generated torque and the "power consumption" of engine. The necessary power should be
generated with idling speed to meet the load requirements of all aspects, including those come from
internal friction from the engine crankshaft and valve mechanism, as well as the auxiliary components,
such as coolant pump. The system is based on the torque-based control strategy, which determines
required output torque of engine to maintain the required idle rotation speed under any operating
conditions with a closed-loop idle speed control strategy. The output torque increases with decreasing of
engine speed and decreases with rising of engine speed. The system request greater torque to
response to the new "disturbance factors", such as the switch of the air-conditioning compressor. With
low engine temperature, it is necessary to increase the torque to compensate the greater internal friction
loss and/or maintain higher idling speed. Sum of all these required output torque is delivered to the
torque coordinator to carry out the calculation to get the corresponding intake density, gas mixture
composition and ignition timing.
7. Closed-loop Control
Post treatment of three-way catalyst is an effective way to decrease the concentration of hazardous
substance in the exhaust gas. The three-way catalyst can decrease the HC, CO and NOX by 98% or
more and transform them into H2O, CO2 and N2. However this high efficiency can only be achieved in a
very narrow range near the excessive air factor of engine =1. The objective of the closed-loop control
is to ensure the gas mixture concentration at this range, thus, the closed-loop control system is used to
get this target. closed-loop control system functions only with oxygen sensor equipped. Oxygen sensor
can detect oxygen content of the exhaust gas at three-way catalyst side. Rarefied gas mixture (> 1)
produces a sensor voltage of about 100mV and the concentrated gas mixture ( <1) produces a sensor
voltage of about 900mV. In case of =1, the sensor voltage has a jump. closed-loop control responds to
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the input signal (>1= too thin mixture, <1= too thick mixture) to revise the control variable and produce
a correction factor as a multiplier to correct the fuel injection duration.
8. Evaporation Emission Control
Due to transfer of the external radiation heat and oil return heat, the fuel in tank is heated to form vapor.
According to limit of evaporative emission regulation, it is not permitted to exhaust the vapor containing
large quantity of HC composition directly into the atmosphere. The fuel vapor in the system is collected
with an active carbon canister through the conduit and flushed into the engine at appropriate time to
participate combustion. Flushing flow is controlled by the carbon canister control valve of ECM. The
control functions only when the closed-loop control system is running under the closed-loop condition.
9. Fuel Injection Control
The fuel injection timing and impulse width is controlled to provide the best mixing of air/fuel
corresponding to the ever-changing operation condition of engine. The fuel injector is installed at the
inlet of every cylinder. The fuel is drawn from tank by fuel pump and delivered to each fuel injector.
Normally, each cylinder has one fuel injection operation with two revolutions of crankshaft. Injection
sequence of cylinders is 1-3-4-2.
10. Ignition Timing Control
The primary current to the ignition coil is controlled by connecting and disconnecting the power transistor
of primary ignition circuit to regulate the ignition timing so that the best ignition timing can be provided
according to operating conditions of engine. Ignition timing is determined by the ECM according to the
engine speed, intake quantity, coolant temperature and atmospheric pressure.
11. Self-diagnosis Function
When abnormal situation is detected by the sensor or actuator related to the exhaust control, the alarm
lamp of engine (inspection lamp of engine) lights up to inform the driver. DTCs (diagnose trouble code)
corresponding of this abnormal situation will be set in these conditions. The RAM data inside the ECM
related to the sensor and actuator can be read with the diagnosis apparatus, and the actuator may be
driven forcibly in some cases.
12. Other Control Functions
1) Fuel Injection Pump
With relay connected, the fuel injection pump will be energized when the crankshaft starts to rotate or
with engine running.
2) Fan Relay Control
The speeds of the radiator fan and condenser fan is controlled with the engine coolant temperature,
vehicle speed and air conditioner switch signal (AC).
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III. On-board Diagnosis System
1. Description
On-board diagnosis system (hereinafter referred to as OBD system) is the diagnosis system integrated
in the engine control system to monitor the trouble components affecting the emission as well as the
main function state of the engine. It is capable of identifying, storing and showing the trouble information
through the self-diagnosis malfunction indicator lamp (MIL).
2. Trouble Information Record
Electronic control module constantly monitors the sensor, actuator, associated circuit, malfunction
indicator lamp (MIL) and battery voltage etc. as well as even the electronic control module itself, and
carries out the credibility detection for the output signal of sensor, the drive signal of actuator and the
internal signal (such as closed-loop control, coolant temperature, idling speed control and battery
voltage control etc.). Once a trouble is found in some link or a signal value is incredible, the electronic
control module immediately sets the trouble information record in RAM memory. Trouble information
record is stored in form of DTC and shown based on the order in which the troubles present.
The troubles can be divided into steady-state trouble" and "sporadic trouble" according to their
occurrence frequencies (for example, because of short term open circuit of harness or poor contact of
connector).
3. Malfunction Indicator Lamp (MIL) Instruction and Its Control Strategy
1) Malfunction indicator lamp (MIL): the indicator required by the regulation for the emission-related
components or system failure. Generally, MIL is an indicator lamp can display on the console with
shape in line with the requirements of regulation and standard.
2) MIL should be activated following the principles below:
In case of ignition switch in "ON" position (non-starting), MIL is continuously bright.
Within 3s after engine started, if there is no requirement in the trouble memory to light up the MIL,
MIL would extinguish.
When there is requirement to light up the MIL both in the trouble memory and the outside of the
ECM, MIL is lit.
When there is the requirement outside the ECM or in the trouble memory or due to the fire to blink
the MIL, MIL would blink with frequency of 1Hz.
4. Inspection steps
1) For the vehicles with OBD function, inspection should be carried out always with steps below:
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OBD Inspection Steps
1. Connect the diagnosis equipment to the

diagnosis connector to put through it.
2. Turn on ignition switch.
3. Read the trouble information (trouble code,

freeze frame): inquire in maintenance manual
to confirm the trouble component and type:
draw up maintenance solution with trouble
information and experiences.
4. Remove the trouble.
5. Clear memory: run the vehicle properly

following the corresponding trouble diagnosis
conditions: read trouble related information
and confirm the clearing of the trouble.
2) Connection of Diagnosis apparatus:
The K line protocol and ISO9141-2 standard diagnosis joint are adopted for the system as shown in the
figure.
Standard Diagnosis Connector
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This standard diagnosis joint is connected on the harness of engine steadily. The pins 4, 7 and 16 of the
standard diagnosis joint are used for engine electronic control system. The pin 4 of the standard
diagnosis joint is connected to the grounding wire: pin 7 is connected to the pin 57 of ECM, that is, the
K data line of the electronic control system of engine; pin 16 is connected to battery negative pole.
5. ECU control system common DTCs and Explanation
Modern engine management system divides the control system failures into the faults related to
emission control components and the failures not related to emission control components. Failures
related to the emission control are often indicated with malfunction indicating light (MIL) while those have
nothing to do with the emission control are usually indicated with the SVS indicator.
Activation rule of MIL of emission control related components failures:
Category A: As long as failures occur, system will light up the MIL light and record the DTC
Category B: In 2 continuous emission monitoring processes, failures occur in each process and then
system will light up the MIL light and record the DTC
Category E: In 3 continuous emission monitoring processes, failures occur in each process and then the
system will light up the MIL light and record the DTC
Precautions: An emission monitoring process is one work cycle in which all the OBD functional
tests can be completed. For OBD, National III emissions testing program can be used as
reference.
Fault indicator SVS not related to the emission control components activation rules:
Category C: When fault occurs, DTC is set and SVS lights up, but the MIL is not lit up
Category Z: The fault diagnosis system does not make any diagnosis for category Z failures
MT60 ECU common DTCs

DTC Explanation Information Default type
P0011 Slow response of VCP intake phase response B
P0012 Large error of VCP intake camshaft phase A
P0016 VCP intake cam tooth learning deviation out of range
P0026 Clogged hydraulic control valve of VCP intake
P0068 ETC air flow control failure
P0106 Rationality diagnosis of intake pressure / throttle position
P0107 Low voltage or open circuit of Intake pressure sensor circuit
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P0108 High voltage of intake pressure sensor circuit
P0112 Low voltage of intake air temperature sensor circuit
P0113 High voltage or open circuit of intake air temperature sensor circuit
P0117 Low voltage of coolant temperature sensor circuit
P0118 High voltage or open circuit coolant temperature sensor circuit
P0122 Low voltage of ETC throttle position sensor # 1 circuit
P0123 High voltage or open circuit of ETC throttle position sensor #1 circuit
P0131 Short circuit to low voltage of front oxygen sensor E
P0132 Short circuit to high voltage of front oxygen sensor E
P0133 Slow response of front oxygen sensor E
P0134 Open circuit of front oxygen sensor A
P0135 Failure of front oxygen sensor heating A
P0137 Rear oxygen sensor short circuit to the low voltage E
P0138 Rear oxygen sensor short circuit to high voltage E
P0140 Open circuit of rear oxygen sensor open circuit E
P0141 Overheating of rear oxygen sensor overheating A
P0171 Fuel system, thin E
P0172 Fuel system, thick E
P0222 Low voltage of ETC throttle position sensor # 2 circuit E
P0223 High voltage or open of ETC throttle position sensor 2 # circuit E
P0230 Oil pump relay failure C
P0261 1 # nozzle line low voltage A
P0262 1 # nozzle line high voltage A
P0267 3# nozzle line low voltage A
P0300 Misfire of one or more cylinders B
P0324 Knock control system failure C
P0325 Knock sensor failure E
P0336 Interference of crankshaft position sensor circuit signal C
P0337 Crankshaft position sensor circuit no signal
P0340 VCP intake camshaft position sensor state diagnosis A
P0341 VCP intake target wheel diagnose failure A
P0341 Camshaft position sensor rationality fault E
P0342 Camshaft position sensor no signal A
P0351 # 1 ignition coil failure A
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P0420 Deterioration diagnosis of catalytic converter A
P0458 Short circuit of canister solenoid valve to the low-voltage E
P0459 Short circuit of canister solenoid valve to high voltage E
P0480 Low-speed fan failure A
P0481 High-speed fan failure C
P0502 Speed sensor no signal C
P0504 Brake switch related faults E
P0506 Low idling speed E
P0507 High idling speed E
P0537 Low voltage of AC front evaporator temperature sensor circuit C
P0538 High voltage or open circuit of AC front evaporator temperature sensor circuit C
P0551 Power steering signal failure C
P0562 System voltage low C
P0563 System voltage high C
P0571 Brake indicator switch failure E
P0601 ROM checksum failure A
P0602 ECM programming error A
P0604 Main CPU RAM failure A
P0606 ECM processor failure A
P0641 ETC reference voltage A# amplitude fault A
P0646 AC clutch relay short circuit to low voltage C
P0647 AC clutch relay short circuit to high voltage C
P0650 Malfunction indicator light failure C
P0651 ETC reference voltage B # amplitude fault A
P0685 Main relay fault A
P0700 Transmission control system malfunction light request C
P0863 CAN communication malfunction of control system A
P1167 Front oxygen too thick fuel cutoff deceleration E
P1171 Front oxygen too thin at power deliveration E
P1336 58-teeth gear error, not learning A
P1396 Wheel speed sensor signal variation C
P1397 Wheel speed sensor no signal C
P1516 ETC steady throttle control fault A
P1690 Anti-theft alarm signal failure C
P2101 ETC throttle control fault A
P2104 Engine forced idle mode A
P2105 Engine forced shutdown mode A
P2106 Restriction mode of engine performance A
P2110 Engine Power Management mode A
P2119 ETC throttle back failure C
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P2122 Low voltage or open of electronic accelerator pedal position sensor 1 # circuit A
P2123 High voltage of electronic accelerator pedal position sensor 1 # circuit A
P2127 Low voltage or open of electronic accelerator pedal position sensor #2 circuit A
P2128 High voltage of electronic accelerator pedal position sensor #2 circuit A
P2135 ETC throttle position sensor 1 #, 2 #-related failures A
P2138 Electronic accelerator pedal position sensor 1 #, 2 #-related failures A
P2610 LPC failure C
P2610 LPC reset fault C
P161B Torque control rationality failure A
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IV. Engine Trouble Diagnosis

1. Trouble diagnosis general for engine control system
In case of failure with Engine Electronic control system components (such as sensor, ECM, injector), fuel
may be cut off or insufficient fuel will be supplied resulting in following conditions:
a. Starting hardship or failure of engine
b. Unstable idle
c. Poor drivability
If any of these situations occurs, first of all, carry out the regular inspection including the basic inspection
of engine (ignition system trouble and correct adjustment of engine etc.). Then inspect the
sub-assemblies of the electronic control system with trouble diagnose apparatus.
Attention:
Before dismantling or installing any component, read the DTC at first and then disconnect
battery negative poles.
Before disconnecting battery cables, firstly turn off the ignition switch. If battery cable is
disconnected with engine rungin or ignition at ON position, ECM may be damaged.
The harness between the ECM and sensor should be shielded by the grounding wire
connected to the vehicle body in order to prevent the interference from the ignition system
and radio. If fails, the harness should be replaced.
When checking the charging state of engine, dont disconnect the negative pole of battery to
prevent damage of ECM.
When using the outside charger to charge the battery, it is necessary to disconnect battery
cable to prevent damage of ECM.
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2. Trouble Diagnosis Flow Chart
The check starts
1. Acquire the symptom information

Ask the user for more information associated with symptom
1. Check the DTC

Check DTC and print DTC and freeze frame User described the
User described the
data, inspect related maintenance record symptom and
symptom and the
apparatus did not
apparatus displays DTC
User did not show DTC
describe the
2. Recognize the symptom symptom, but 4. Recognize the symptom
Attempt to diagnose the apparatus Attempt to diagnose the symptom
symptom described by the user. displays the described by the user.
DTC.
5. Implement the confirmation steps of DTC. 6. Implement the basic check.
Do not use the trouble diagnosis apparatus Inspect with trouble

diagnosis apparatus
Within the scope
of technical 7. Run the trouble diagnosis &
9. Use the trouble parameters
check mode
symptom table to check
troubled system Beyond the scope of
the technical
No troubled parameters
component found
8. Check the troubled
10. Check the troubled component through the component
diagnosis steps
Troubled component
found
Abnormal (DTC detected)
11. Repair or replace the troubled components
12. Final check Abnormal (symptom

Confirm no symptom found still exists)
Implement the DTC confirmation steps again,
and be sure to repaire the trouble properly.
Normal
The check ends
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3. Trouble Symptom Check Table
List of Trouble Symptom Inspection
Symptoms Check Order No.

Unable to communicate with Unable to communicate with all the systems 1
diagnosis apparatus Unable to communicate with ECM only 2
Engine alarm lamp failed to light up immediately after the
Engine alarm lamp and 3
ignition switch is turned to ON.
corresponding components
Engine alarm lamp keeps bright 4
No initial ignition (unable to start) 5
There is initial ignition but it burns incompletely (unable to
Start 6
start)
Too long starting duration (unable to start normally) 7
Unstable idle (fluctuant idle speed and hunting) 8
Idle Stability (abnormal idle speed) High idle speed (abnormal idle speed) 9
Low idle speed (abnormal idle speed) 10
The engine stops at the idle when it is cold. (stop with
11
deceleration)
The engine stops at the idle when it is hot. (stop with
Idle Stability (engine stops) 12
deceleration)
The engine stops at the start. (stop with acceleration) 13
The engine stops with deceleration 14
Vehicle surge, drop or instability of vehicle speed 15
Shock or vibration during acceleration 16
Shock or vibration during deceleration 17
Driving
Poor acceleration 18
Surge 19
Knock 20
Fail to stop engine 21
High concentration of CO and HC at the idle operation 22
Low voltage of alternator 23
Abnormal idling speed when starting the air conditioner 24
Abnormal operation of fan 25
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4. Symptom List
Symptom List
Items Symptoms
Starter drags the engine, but there is no combustion in cylinder and the engine
Failure of starting
does not start.
Start Extinguishment after
There is combustion in cylinder, but the engine extinguishes immediately.
combustion
Hard to start Engine starts after the crankshaft rotates a while.
Engine does not maintain a constant speed and the speed changes within range
Hunting
of idle speed.
Usually, it can be determined with the swing of tachometer pointer and the
Fluctuation of idle
Stability vibration transferred to the steering wheel, selector rod and body etc.
of idle Incorrect idle Engine is running idly at the incorrect rotation speed.
speed Extinguishment of engine When releasing the accelerator pedal, no matter whether the vehicle is moving,
(with deceleration) the engine stops.
Extinguishment of engine
When the accelerator pedal is depressed or being depressed, the engine stops.
(with acceleration)
The phenomenon of vehicle surge refers to that the vehicle speed (rotation
Vehicle surge, drop of speed of engine) responds slow when there is a need to accelerate and depress
speed down the accelerator pedal at the current vehicle speed or the temporary decline
of vehicle speed (rotation speed of engine) during acceleration.
Poor acceleration refers to that the vehicle is unable to acquire acceleration with
Poor acceleration the opening of air throttle even with stable acceleration; or refers to the disability
Driving to reach the maximum vehicle speed.
When firstly depressing down the accelerator pedal to speed up, engine speed
Instability
increases slowly.
Shock There is huge shock or vibration of engine with accelerating or decelerating.
Surge There is repeatedly forward surge when traveling with constant or variable speed.
There is a strong voice like the hammer against the cylinder wall during the driving
Knock
which is harmful to driving.
Parking Keep running(fail to stop)
5. General Trouble Inspection
Engine trouble inspection should begin with the basic system. In case of starting failure, unstable idle or
insufficient fuel supply, begin the following basic systems:
a. power supply: battery, fusible link and fuse wire
b. Grounding
c. Fuel supply: fuel pipe, fuel filter, fuel pump
d. Ignition system: spark plug, high tension line, ignition coil.
e. Emission control system: Leakage of vacuum system.
f. Others: ignition timing and idle.

The trouble of electronic control system of engine is generally caused by poor contact of the harness
connector. All the harness connectors should be checked to verify whether they are connected correctly.
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6. Inspection of Idling Speed
1) Conditions
Attention:
Check the regular items including spark plug, fuel injector and compression pressure of the
cylinder at beginning of inspection.
The engine coolant temperature is 80-95.
Lamps, electronic fan and all the accessories are turned off.
Shiftlever is at neutral position.
The steering wheel is at center (equipped with power steering system).
2) Connect the diagnosis apparatus.
3) Start engine and run it at the lowest idle speed.
4) Run engine for over 5s with speed of 2000-3000 rpm and then make the engine operate for 2min at
the idle speed.
5) Read idling speed (75050r/min).
7. Fuel Pressure Test
Attention:
Before disconnecting the fuel pipeline, it is necessary to release the fuel pressure inside the
fuel pipeline to eliminate the danger.
The O-ring should always be used to keep the seal of the connecting joint of fuel hose.
Dont operate the electrical system during inspection.
Note: Prepare a container under fuel pipe to avoid the fuel spillage when pipes disconnected.
1) Dismount the nut at fuel pressure inspection port on the guide rail of fuel injector.
2) Connect fuel pressure gauge.
3) With ignition switch at ON position, check for fuel leakage.
4) With engine running with idling speed, check for the fuel leakage.
5) Take down reading of fuel pressure gauge.
Fuel pressure: 350KPa
Attention:
Dont check fuel pressure with system operating.
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During inspection of fuel pressure, always to make sure whether there is fuel leakage in fuel
pipeline.
7) If the measured fuel pressure is more than the standard value, analyze the possible reasons
referring the following table and repair as required.
Fuel System Trouble Diagnosis Table 1
Phenomenon Possible Cause Troubleshooting

Blockage of fuel filter Replace the fuel filter
Too low fuel pressure Damaged fuel pump or poor sealing of fuel pressure
Replace fuel pump
regulator resulting in fuel leakage at returning side
Cementation of fuel pressure Replace fuel pump
Too high fuel pressure Repair or replace fuel
Blockage or bend of fuel return pipe
pipe
8) Turn off engine and check the changes of fuel pressure gauge reading for 5min. If the reading drops,
observe the reduction rate. Referring to following table to analyze and eliminate the trouble.
Fuel System Trouble Diagnosis Table 2
Phenomenon Possible Cause Troubleshooting

Fuel pressure drops slowly after engine
Leakage of fuel injector Replace injector
stopped
Fuel pressure drops completely after
Trouble of fuel pump Replace pump
engine stopped.
9) Reduce the pressure in fuel pipeline.
10) Disconnect the fuel pressure gauge and install the inspection port nut.
11) Check for fuel leakage with following steps.
Turn the ignition switch to the "ON" position (with engine stopped), and then check for leakage at the
joint of the fuel pipeline.
Start the engine and increase speed, inspect whether there is leakage at joint of fuel system.
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Section III Structural Principle and Inspection of Engine Electronic Components

I. Intake Manifold Absolute Pressure (MAP) Sensor
1. Description
1) MT60 EFI system uses speed density air metering method to detect the amount of air entering the
engine, thus control the fuel injection pulse width, realized precisely control of engine power output.
Sensors include the absolute pressure sensor and intake air temperature sensor. In addition, the
system can use air pressure cylinder judgment technology; with which an air pressure sensor is
installed near the cylinder 1 intake manifold; when the air valve opens in an instant, there will be an
instantaneous voltage drop about 1kPa on sensor. Which can be detected by ECU. When ECU
receives this signal, the compression TDC signal will be defined through processing with software
analysis.
2) Intake absolute pressure sensor (MAP) is a pressure sensitive variable resistor. Diaphragm inside of
sensor is connected with a magnet core placed through the coil. When intake pipe pressure
changes, the diaphragm will drive the core to movement and thus change output voltage of
sensor .With sensor output voltage, ECU can determine engine intake volume, with which and
reference to other signals, injection volume control is achieved. .MAP sensor is also used to
measure atmospheric pressure during starting; under certain conditions, it allows the ECM to be
adjusted automatically at different altitudes. ECM provides 5V voltage to MAP sensor and receives
voltage signal by the signal line. The sensor is grounded with a wire from its variable resistor. MAP
sensor input signal affects ECM fuel output and ignition timing control.
3) Intake temperature sensor element is a thermistor with negative temperature coefficient (NTC). Its
resistance increases with the intake air temperature decreases. Engine ECU detects intake air
temperature changes via a contrast circuit.
2. Installation Position
Fig. 3.3.001
Installed at rear of the electronic throttle.
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3. Circuit Diagram
Pin 13: 5V voltage signal
Pin 11: Manifold pressure sensor signal
Pin 14: Power ground
Pin 07: Intake air temperature sensor signal
Operating voltage: 5 0.1V
Fig. 3.3.002
Intake air temperature/

pressure sensor
4. Diagnosis
Sensor short circuit (to ground, to power supply);
Sensor circuit open;
Sensor detects the intake pressure exceeds the upper limit;
Sensor detects the Intake pressure exceeds the lower limit;
5. Trouble Solution
Mainly check the 4 connections of the sensor and connection with ECU for short circuit, open circuit;
Check sensor detection holes for blockage.
Whether a short circuit, open circuit, grounding problem exists in sensor wiring harness
Whether sensor is highly impacted resulting in sensor failure.
Operating pressure range: 12.5kPa - 115kPa
Operating temperature range: -40 - 125
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1) Dismantlement
Disconnect the wire harness connectors of intake

manifold pressure & temperature sensors. Fig. 3.3.002
Attention:
Make sure that the ignition switch is at Off

position.
Disassemble the fixing screws of the intake

pressure/temperature sensor with crosshead
Fig. 3.3.003
screw driver, remove the sensor.
2) Installation
Apply a small amount of engine oil on seal ring of sensor in order to facilitate the installation.
Make sure that adhesive of sensor and intake manifold is well, tighten the self-tapping screw
Verify reliable installation of wire harness connector.
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II. Coolant Temperature (ECT) Sensor
1. Instruction of Parts
Coolant temperature sensor is used to detect coolant temperature of engine and sent signal to ECM,
whereby used to control ignition timing and fuel injection pulse width during starting, idling and normal
driving, meanwhile provides signal for meters to indicates coolant temperature. A thermistor with
negative temperature coefficient (NTC) is used. Resistance of thermistor decreases with increasing of
temperature. ECM determines coolant with voltage output of sensor and provides optimal air/fuel mixing
to engine base on this voltage signal.
2. Installation Position of Element
See figure right for installation positions. Fig. 3.3.004
3. Wiring Diagram
Remarks: This model is equipped with a three-wire water temperature sensor, saving costs and ensuring
the unity of the system.
Pin 12: 5V Grounding
Pin 39: Cooling water temperature signal output
B port: To coolant temperature meter
Water temperature
sensor
To coolant temperature meter
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4. Diagnosis
Water temperature signal higher than the limit;
Water temperature signal lower than the limit;
Water temperature sensor short circuit, open circuit.
Room temperature resistance data: 2.5 5%k k
Characteristic parameters (standard)
5. Trouble Solution
Mainly check connections of the three wires on sensor with ECU, instrument for short circuit, open
circuit.
Short circuit, open circuit, grounding problems between sensor harness.
Grounding: poor grounding easily lead to excessively high engine water temperature indication;
Operating voltage: 5V;
Operating temperature range: -40 - 135
1) Dismantlement
Discharge coolant from radiator. Please refer to Fig. 3.3.005

"Change Engine Coolant".
Disconnect the wire harness connector of the

engine coolant temperature sensor.
Dismantle the engine coolant temperature sensor.
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2) Installation
Be aware of following precaution to install with steps contrary to dismantlement.
Apply surface sealant on threaded part of sensor and tighten with specified torque. Tightening
torque :16-24N. M
Verify reliable installation of wire harness connector.
With engine idlingvisually inspect coolant leakage.
III. Electronic throttle
Electronically controlled throttle valve assembly is the main component of intake control and
management in modern engine management system. It directly controls the engine air intake volume,
and thus controls speed and power output.
On electronically controlled throttle valve, the mechanical control mechanism throttle body control has
been instead by driving motor, drive gear mechanism, necessary mechanical transmission components
and more powerful and reliable special throttle position sensor.
Fig. 3.3.006
Installed in intake manifold.
3. Wiring diagram of throttle position sensor

Pin 65: output signal of throttle position sensor 1
Pin 21: 5V reference power supply
Pin 66: output signal of throttle position sensor 2
Pin 19: 5V ground
Pin 24: Controlled power
Pin 49: Throttle motor, high level
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G6 electronic
controlled throttle
valve body
4. Diagnosis
Throttle valve driving motor failure:
9 Drive motor assembly open circuit;
9 Drive motor assembly coil short circuit;
9 Drive motor assembly circuit burn out;
9 Drive motor assembly circuit excessively worn or damaged.
Throttle valve body unload failure:
9 Throttle valve gear excessively worn and damaged;
9 Throttle valve gear bearing clogged or damaged;
9 Throttle position sensor connection is poor; signal output is instability;
9 Valve blocked by impurities or sludge; clean regularly.
5. Solutions
Mainly inspect sensor and ECU wiring harness for short circuit, open circuit, grounding problems;
Detect jumping between sensor signal circuit and grounding with an universal meter during opening
and closing of throttle;
Operating temperature: -40 - 125 ;
Responding time: 100ms (fully open to fully closed), 150ms (fully closed to fully open)
Measurement range of throttle position sensor:
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Idling condition
Fully open condition

Idling condition
Fully open condition
6. Dismantlement and installation of throttle

position sensor Fig. 3.3.07
1) Dismantlement
Disconnect the wire harness connector of air

throttle position sensor.
Note: Be sure that the ignition switch is at the Off

position.
Dismantle the air throttle body assembly.
Fig. 3.3.08
Unscrew electronic throttle position sensor

screws, remove the sensor.
Fig. 3.3.09
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2) Installation
Be aware of following to install with steps contrary to dismantlement.
Verify that the of the wire harness connector is inserted securely.
Tighten self-tapping screw.
IV. Hall sensor
1. Component Description
Camshaft position sensor, crankshaft position sensors are Hall sensors and work together with the
signal wheel of camshaft and crankshaft which correspond to specific positions of engine. ECU
determines engine working conditions with digital voltage signals of the sensor to implements one
by one control.
Performance:
Operating temperature: -40150
System input voltage: 5.0V (powered by controller)
Working gap: 0.5-1.5 mm
2. Installation position
Close to the camshaft, crankshaft respectively.
Fig. 3.3.010 Fig. 3.3.011
3. Wiring Diagram
Pin 18: 5V reference voltage
Pin 30: signal of crankshaft position sensor
Pin 19: 5V grounding
Pin 46: 5V reference voltage
Pin 05: signal camshaft position sensor
Pin 45: 5V grounding

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4. Diagnosis
ECU real-time monitoring of the sensor and circuit
Sensor open circuit;
Internal short-circuit of sensor;
Hall element of sensor grounded;
Hall element of sensor short to reference voltage signal circuit.
5. Trouble Solution
Check sensor circuit for normal function and incorrect connection of grounding
Connect the sensor and wiring harness connector with a T connector to inspect power, grounding,
and signal circuit for normal working.
6. Removal and installation
1Removal
Disconnect the crankshaft position sensor, camshaft position sensor wiring harness connectors.
Fig. 3.3.012 Fig. 3.3.013
Unscrew fixing bolts, remove the sensor.
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Fig. 3.3.014 Fig. 3.3.015
2 Installation
Be aware of following precaution to install with steps contrarily.
Be aware of installation gap.
Standard: 0.5 - 1.5mm
Tightening torque: 7.8 - 9 N m
IV. Oxygen sensor
1. Component Description
Oxygen sensor is used to provide information for judging whether the oxygen in air inhaled to the fuel in
engine cylinder is excessive or not after combustion. ECU uses this quantitative information for defined
cycle control of the fuel cycle so that the three major toxic components can be mostly converted and
purified in the three-way catalytic converter.
The sensing component is a kind of porous ceramic tube; the wall is surrounded by the engine exhaust
while the inside is put through to the atmosphere. The oxygen sensor, based on concentration difference
inside and outside, calculates indirectly the fuel injection pulse width to be transmitted to ECU for
controlling of fuel injection. Simultaneously, it detects rear oxygen sensor output data and compares with
front sensors data within the ECU to monitor the working conditions of the three-way catalyst converter.
Oxygen sensor operating voltage fluctuates between 0.1-0.9V; in 10 seconds it may change for 5-8
times; if it is lower, indicates that the sensor is aged and need to be replaced. The sensor can not be
repaired.
Fig. 3.3.016
Front (upstream) oxygen sensor is installed on the
exhaust manifold before the three-way catalyst
converter and the rear (downstream) oxygen sensor is
installed behind the three-way catalytic converter.
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3. Wiring diagram
Pin 40: Oxygen sensor A signal, high level
Pin 42: Oxygen sensor A signal, low level
Pin 88: Sensor heating cable control
D: To main relay power
Pin 10: Oxygen sensor B signal high level
Pin 20: Oxygen sensor B signal, low level
Pin 90: Sensor heating control
D: To main relay power
Heated oxygen sensor (front)
Heated oxygen sensor (rear)
4. Diagnosis
ECU detects the oxygen sensor circuit and ECU internal power amplifier circuit and testing circuit. If one
of the following conditions occurs, the oxygen sensor fault indicator will be set:
Battery voltage not reliable
Intake manifold absolute pressure signal not reliable
Engine coolant temperature signal not reliable
Injector drive-level fault
Oxygen sensor fault indication is set, with the fuel cycle quantitative control cut off; use the basic fuel
injection time stored in the ECU for the quantitative fuel control.
5. Diagnosis
Mainly check sensor wiring connection for short circuit, open circuit;
Sensor damages are generally caused by lead or phosphorus poisoning; so pay attention to the fuel
quality; meanwhile, excessive fuel consumption may also lead to sensor failure;
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Changes of the oxygen sensors should be not less than a certain times in certain period of time.
1) Dismantlement
Disconnect oxygen sensor harness connector.

Fig. 3.3.017
Remove oxygen sensor with special remover.

Fig. 3.3.018
Attention:
Plug mounting hole of the oxygen sensor with hairless cotton yarn to keep the debris or oil &
water away from the exhaust manifold.
Visually inspect appearance of oxygen sensor.
Reddish brown: lead poisoning
Off-white: normal
Black: carbon deposition
2) Installation
Be aware of routing of oxygen sensor wire harness.
After replacement of oxygen sensor, oxygen sensor should be coated with a layer of anti-rust oil to
prevent rust which impede removal.
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VII. Fuel Injector (INJ)
Fuel coming from the fuel pump is stored and distributed via the fuel rail components and provides the
fuel system with a more stable pressure environment in which the fuel supply pressure and quantity of
each cylinder will be balanced while the engine is running smoothly. Injector injects fuel as per the signal
from the ECM signal and defines fuel injection volume depending on opening time of injector solenoid
valve.
Fig. 3.3.019
It is installed on the fuel guide rail.
3. Wiring Diagram
Fuel Injector
4. Inspection
Attention:
Please clean the fuel injector and analyze with special cleaning and analysis instrument for
fuel inject at certain interval..
1) Check the resistance.
Note: check with wire harness connector disconnected.
Standard resistance: 11.4-12.6
2) Inspect operating time of the fuel injector with trouble diagnosis apparatus.
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Standard operation time: 2.0-3.0ms at the idle speed and more during the acceleration.
3) Check the operating sound of fuel injector.
Note: Use a stethoscope to check the click sound of the fuel injector at the idling speed or use
the fingers to check the vibration situation of fuel injector.
If vibration can not be felt, check the wire harness connector, fuel injector or the control signal of fuel
injector by ECM.
Please refer to Fuel System.
VII. Knock sensor
1. Description
Knock sensor is installed in the cylinder block side usually between the 2, 3-cylinder, it is helpful for
engine knock balance; the ECU uses the knock sensor output vibration frequency signal to judge
whether there is knock with ECU internal filtering. When the knock signal is detected, ECU will gradually
reduce it until the knock disappeared; and then gradually restore to the knock threshold; the cycle is
done repeatedly.
Fig. 3.3.020
Installed aside of cylinder.
3. Inspection
1) Wiring diagram
Pin 71: Knock sensor signal, low
Pin 72: Knock sensor signal, high
Knock sensor
Twisted pair (9 pitches/feet)
2) Check the resistance.
Resistance: greater than 1M

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4. Diagnosis:
ECU monitors the knock sensor, power amplifier circuit and testing circuit. If one of the following
circumstances is detected, knock sensor fault indication will be set:
Knock sensor failure;
Knock control data processing circuit fault;
Cylinder judging signal not reliable;
Sensor circuit failure.
After knock sensor fault flagging out the failure position, knock set control loop is Disconnect and the
advance angle of ignition stored in the ECU will be fixed to a safe angle by the software program. When
the error frequency drops below the set value, the fault indication will reset.

Fig. 3.3.021
1 Removal
Disconnect knock sensor harness connector.
Unscrew knock sensor locking nut, remove

the knock sensor. Fig. 3.3.022
Attention:
Do not drop or damage the sensor.
2) Installation
Install with reversed steps of disassembly.
Tightening torque: 16 - 24N m
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VIII. Air-conditioning switch and relay
1. Description
When air conditioner is turned on, the air conditioning switch will send the battery voltage signal to the
ECM. After air conditioner turned-on signal input, ECM drives electronic throttle to increase idling speed
of engine, and correct ignition advance angle. At the same time, ECM controls air conditioning relay to
make the compressor magnetic clutch working.
2. Inspection
With engine idling, use fault diagnostic apparatus to check air-conditioning switch for normal working.
Air conditioning switch Checklist
Items Air conditioning switch Normal direction

Off Off
Air conditioning switch
On On
Off Off (compressor clutch does not work)
Air compressor
On On (compressor clutch works)
IX. Continuously variable cam phase regulator and control valve
1. Description
Continuously variable cam phase regulator is used to change timing of admission gear. It controls the air
distribution phase through the continuous adjustment of the camshaft and crankshaft phase relationship.
VVT voltage control valve is a four-way pulse controlled solenoid valve which can move in double way; it
is used to control oil flow with axial movement of plunger. Engine ECU regulates the oil flow to rotor
blade sides with duty cycle signal regulated by pulse width. And based on this, the timing and phase of
camshaft relative to the crankshaft are controlled.
Target wheel
Control valve
Fig. 3.3.023 Fig. 3.3.024

Camshaft
position
sensor In figure:
Oil passage
Electrical
Phaser signal
Hydraulic
circuit
Crankshaft position
sensor Oil pump
The system's main functions:
Improve air intake efficiency;
In partial load, improve dilution control for better fuel economy;
Instead of the exhaust gas recirculation (EGR) system to reduce equivalent NOx emissions while
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potentially reducing HC emissions and thermal radiation;
WIth default variable cam phase system, it is helpful for cold starting performance and reducing HC
emissions.
Fig. 3.3.025 Fig. 3.3.026
3. Wiring diagram
Pin 99: variable valve timing control signal
A: Relay control
Air intake VVT valve
4. Diagnosis
One of the most complex areas of cam phase regulating control system is the diagnostic system. For the
cam sensor, target wheel and oil control valve, it must have the components level diagnostic features
and constantly determine cam signal integrity to ensure proper cam phase measurement. The oil control
valve drive signals should also be checked as fuel nozzle and ignition coil driver. For oil control valve and
phaser, there is often more responsible diagnosis. ECU checks the phaser and the oil control valve
regulator circuit to detect whether there are any of the following cases:
Intake VCP phase response slow;
Large error of air intake VCP camshaft phase;
Intake VCP cam tooth learning bias out of range;
Intake VCP hydraulic control valve blocked;
5. Trouble Solution
Check sensor signal for short circuit, open circuit;
Check wiring harness channeling;
Check sensor for short circuit with power line;
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Check VCP and oil control valve for blockage and normal ventilation;
Check working conditions of VCP as follows:
Item Value
Input voltage 11.5-18.0VDC; nominal 13.5 1.0VDC
*Average operating current at position * 1.0 amps
Maximum current 100% duty cycle, at -40 C, 15.5V, 2.5 amps
Ambient temperature -40 to 150C
Chamber temperature -40 to 150C
Temperature of solenoid valve -10 to 150C
Check working conditions of the oil control valve as follows:
Type Oil control solenoid valve
Coil impedance Nominal: 7.0 @20 C

5.6@-30 C
10.6 @150 C
Coil inductance 18mH@1KHz
Minimum current required for full stroke of 1.07 amps
plunger valve
Voltage input (through the coil) Nominal: 13 0.5 V
Minimum: 11.0 V
Max: 18.0 V (CARB required)
Starting response with normal voltage input <50 ms in the T coil <65 C
Close response <50 ms in the T coil <65 C
See the "timing sprocket system"
X. Canister solenoid valve
1. Description
Control air intake from the canister to the general intake piping. The adsorption amount of canister has
certain limits, if evaporation of gasoline attached to the canister is not consumed, it may emit into
ambient air resulting in pollution and increased insecurity.
Internal of canister valve is a solenoid valve structure and its opening is controlled with the digital pulse
square wave sent from the ECU. According to different engine operating conditions, canister solenoid
valve opening is also different; at big loading of the engine and idle time, canister solenoid valve is not
working in order to ensure the engine's output power.
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Fig. 3.3.027
3. Wiring diagram
A: Main relay output end
Pin 95: Canister solenoid valve control signal
Canister solenoid valve
4. Diagnosis
Short circuit of sensor with ground
Short circuit of sensor with power line
Open circuit of sensor
5. Trouble Solution
Check sensor signal for short circuit, open circuit;
Check wiring harness for channeling;
Check sensor circuit for short circuit with power line;
Check canister magnet valve for blockage and normal ventilation;
Operating Temperature: -40 - 120 ;
Coil resistance: 19 - 22;
Working voltage: 8 - 16V;
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Fig. 3.3.028
1 Removal
Disconnect hose at canister solenoid valve

side.
Disconnect the canister solenoid valve wiring

Fig. 3.3.029
harness connector.
Remove canister solenoid valve from the

Fig. 3.3.030
bracket.
2 Installation
Be aware of following precautions to install with steps contrary to removal.
When installing, air flow direction must meet requirement, meanwhile checking the canister solenoid
valve for wearing and cracks.
During the disassembly process, avoid water, oil and other liquid entering into the valve.
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XI. Ignition coil

Fig. 3.3.031
1. Description
Ignition coil converts the low voltage of the primary

winding into the high voltage of secondary winding
and discharged at spark plug to ignite the fuel air
mixture in cylinder.
MT60 uses separate ignition technology. Based on the principle that using electromagnetic coil mutual
inductance to produce high-energy, the primary coil powering time, power off time are controlled; by
using high voltage generated in the secondary coil, spark plug gap is broken, producing a strong spark tp
ignite the mixture. As in the engine exhaust stroke, air ionization is great while the resistance is very low,
only low-voltage will be able to break the spark plug gap. So the system uses a grouping ignition
technology which will not waste energy, achieving significant cost saving.
Ignition coil operating voltage range: 6 - 16V
Secondary ignition coil resistance: 8.7 0.87 K
Primary charge time: 2.15ms
Minimum ignition duration: 1.0ms
Minimum ignition energy: 35mJ.
Fig. 3.3.032
Installed at top of the cylinder head cover.
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3. Wiring diagram
Duel-core
screener
Duel-core
screener
4. Diagnosis
ECU does not function to diagnose ignition coil failures. Therefore, if there is any failure of ignition coil,
no DTC is set. Only by checking the ignition coil resistance can the proper working of the ignition coil be
determined; under normal circumstances, the ignition coil heats up more during working, but overheated
temperature of the ignition coil causes increaseing in ignition coil resistance, resulting in instability of
engine work, automatic flameout and other failures. But the ECU can detect the control cable of the
ignition coil. When failure of an ignition coil is detected, injector of corresponding cylinder will be turned
off.
Control cable short circuit with ground;
Control cable short circuit with power line;
Control circuit open.
5. Diagnosis
Internal short circuit, open circuit of coil;
Coil leakage, cracks in the housing;
Aging coil leading to energy shortage in ignition.
For removal and installation, please see "Ignition System."
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XII. Electric Fuel Pump
1. Description
It is used to deliver the fuel to the main fuel supply pipe from the fuel tank at a certain fuel pressure and
flow, and maintain the stable fuel pressure (through the fuel pressure regulator).
It is installed inside the fuel tank
3. Wiring diagram
Pins description: the electric fuel pump has two pins, and the fuel pump casings next to the two pins are
marked with "+" and "-" signs, which represent respectively the connections to the positive (fuel pump
relay) and ground.
Fuel pump relay
Fuel pump
4. Inspection
1) Check internal resistance of fuel pump.
Internal resistance should not be zero or infinity.
2) Check the fuel pressure
Refer to Fuel System.
Refer to Fuel Pump Assembly.
Attention:
In order to prevent accidental damage of fuel pump, please do not run the fuel pump without
fuel.
In case that the fuel pump need to be replaced, please pay attention to the cleaning of fuel
tank and pipeline and replacement of fuel filter.
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XIII. Electronic Control Module (ECM) of Engine
1. System description
Delphi MT60 engine control system takes the MT60 Engine Control Module (ECU) as the core of the
system and it is characterized by computerized closed-loop control, sequential multi-point fuel injection,
direct ignition without distributor block and catalytic converter post treatment.
MT60 Engine Control Module (ECU) is a kind of ECU Delphi EFI developed exclusively for China market.
The engine control module uses the latest electronic hardware technology with higher cost/performance
ratio; the hardware uses 16-bit microprocessor with adequate memory, has high-strength computing
speed and flexible definition of input and output ports; the software is the second generation software of
control programmed with Delphi Modular C Language, meeting all current technical specifications in
Euro IV engines and OBD emission regulations.
1 Functions
Vehicle main power relay control
Speed-density airflow
Closed-loop controlled multi-point sequential fuel injection (package MAP CID cylinder pressure
judgment)
Closed-loop controlled multi-point sequential fuel injection
Oil supply in different ways including oil returning, without returning, semi-free oil return, etc.
Fuel pump controlled
Direct ignition without distributor; ECU built-in ignition module for 4-cylinder sequential ignition
Electronic throttle controls air flow volume, with rapid and accurate response; ECU is used to
achieve torque control and improved reliability
VVT-i (electronically controlled variable intake cam phase adjustment device) controls the engine's
intake volume, with improved torque and power
Knock control
Canister solenoid valve control
Air conditioning, cooling radiator fan control
Mileage memory
Over-voltage protection
Electronic anti-theft device
CAN-BUS communication interface for communication with automatic transmission control module
and ABS system
Open, modular C Language programming, etc.
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2 ECM pin definitions:
ECM pin definition list
Pin Function Pin Function

1 Ignition coil C drive (4 cylinder) 51 Radiator fan 2 (high speed)
2 Ignition Coil B drive (3 cylinder) 52 Radiator fan 1 (low speed)
3 Ignition Coil D drive (2 cylinder) 53 Brake switch input (active LOW)
4 Power grounding 54 CAN high (for diagnostic)
5 Camshaft position sensor 1 55 CAN low (for diagnostic)
6 Standby terminal 56 Brake indicator switch signal input (active HIGH)
7 Intake air temperature sensor 57 KW2000 communication cable

8 Standby terminal 58 Wheel speed signal input
9 Standby terminal 59 Standby terminal
10 Oxygen Sensor B 60 Air conditioning request signal (active HIGH)
11 Intake manifold pressure sensor 61 Power steering pressure switch (active LOW)
12 5V ground 62 Standby terminal
13 5V reference voltage # 1 63 Electrical load (active HIGH)
14 5V ground 64 Air conditioning pressure switch
15 5V ground 65 Throttle position sensor # 1
16 5V reference voltage # 1 66 Throttle position sensor # 2
17 Battery power + 67 5V ground
18 5V reference voltage # 1 68 Speed sensor
19 5V ground 69 5V ground
21 5V reference voltage # 2 71 Knock sensor low
22 Standby terminal 72 Knock sensor high
23 Standby terminal 73 Standby terminal
24 Throttle motor low 74 Chassis ground
25 Controlled power 75 Chassis ground
26 Ignition coil A drive (1 cylinder) 76 Standby terminal
27 Power source 77 Air conditioning clutch relay
28 Power source 78 2-cylinder injector
29 Power source 79 3-cylinder injector
30 58X position sensor 80 1-cylinder injector
31 58X signal low (only for VR sensor) 81 4-cylinder injector

32 Pedal position sensor # 1 82 Vehicle maintenance tip light
34 Pedal position sensor # 2 84 Standby terminal
Air-conditioning front evaporator temperature
35 85 Standby terminal
sensor
36 Standby terminal 86 Fuel pump relay (high drive)
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Pin Function Pin Function

37 Oil level sensor 87 Standby terminal
38 Oil temperature sensor 88 Oxygen sensor A heating control
39 Coolant temperature sensor 89 Standby terminal
40 Oxygen sensor A 90 Oxygen sensor B heating control
41 Electrical load (active LOW) 91 Standby terminal
42 5V ground 92 (Emission) MIL
43 5V reference voltage # 2 93 Standby terminal
44 5V ground 94 Main relay control
45 5V ground 95 Canister cleaning solenoid valve
46 5V reference voltage # 2 96 Fuel pump relay (low drive)
47 IGN signal (ignition IGN location) 97 Speed signal output
Ancillary electrical power signal (ignition lock
48 98 Standby terminal
ACC position)
49 Throttle motor high 99 Variable valve timing control 1 (intake)
50 Controlled power 100 Standby terminal
* Specific pin number is subject to harness schematic diagram (standby terminal defined as empty pin).
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3) Electrical Principle Diagram
Injector
Canister solenoid valve
Heated oxygen sensor (front)

Air intake VVT valve
Pen ignition coil

Heated oxygen sensor (rear)
Duel-core
shielded cable
Intake air temperature/
pressure sensor
Water temperature sensor
To coolant temperature meter Duel-core

shielded cable
Oil temperature sensor

(only applied as required)
Speed sensor
Knock sensor
Twisted pair (9 pitches/feet)

G6 electronic controlled
throttle body Speedometer
Fuel meter
Tachometer
Water temperature sensor Coolant temperature meter
Fault indicator
Maintenance
light
Accelerator pedal
sensor 1
Accelerator pedal
sensor 2
Brake switch
Brake indicator
Temperature control High/low voltage

AC switch switch for evaporator switch
Fuel pump relay
Fuel pump
Mid-voltage
switch
Battery
AC relay
AC clutch
Load of blower
Load of headlight
Radiator fan relay
Ignition switch Radiator fan
Condensator fan 2#
Condensator fan 1#
Condensator fan
Main
relay
Battery
Grounding with vehicle body close to ECN
Single point help on engine
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Electronic Control
Fig. 3.3.033
Installation position is shown in the figure right.
5. Inspection
1) Read the engine trouble record with the data wire K.
2) Check whether the connecting wire of ECM for normal conditions and put the focus on the ECM
power supply and grounding line.
3) Check for normal conditions of external sensor and reliability of output signal normal connection of
its circuit.
4) Check whether the actuator is normal and whether its line is intact.
5) Finally, replace the ECM to carry out the test.
1) Dismantlement
Turn the ignition switch to OFF position to dismantle the negative terminal of battery.
Dismantle the lower part of the console referring to console.
Disconnect the wire harness connector of ECM port. Refer to Precautions.
Unscrew fixing bolts of ECM to remove the ECM.
2) Installation
For precautions about the installation, please refer to Precautions.
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Section IV Trouble Diagnosis Procedures for Engine Control System

I. Diagnosis with DTC
1. Instruction
1) The following Repair can be carried out only after the current stable trouble has been identified,
otherwise the diagnosis will be wrong.
2) The "multi-meter" hereinafter refers to the digital multi-meter and it is not permitted to use the analog
multi-meter to check the electric control system circuits.
3) When carrying out the Repair for the vehicle with the anti-theft system, if the requirement of
replacing the ECM is included in the "Next Steps" column, it is necessary to program the ECM after
replacement.
4) If the DTC points to low voltage of a specific circuit, it indicates that the circuit is likely to have short
circuit with ground or open circuit; if the DTC points to high voltage of a specific circuit, it indicates
that the circuit is likely to have short circuit with power circuit; if the DTC points to a circuit trouble, it
indicates that the circuit is likely to have broken circuit or a variety of line troubles.
2. Diagnosis Help
1) If the DTC can not be erased, it means the trouble is stable; in case of the sporadic trouble, it is
necessary to check whether the connector of wire harness is loosened.
2) The check has been accomplished with steps above and nothing unusual has been found.
3) Effects of the maintenance of vehicle, cylinder pressure and mechanical ignition timing etc. on the
system should not be neglected during the inspection and repairing.
4) Replace the ECM to carry out the test.
If the DTC can be cleared at this time, it means the trouble site is at ECM; if the DTC still can not be
erased at this point, then remount the original ECM and repeat the procedures again to carry out the
Repair.
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3. DTC Diagnosis
ECM pins referred to below should be subject to the actual wire harness diagrams.
DTC P0011 Intake VCP phase response too slow

Set emergency control scheme: Fault indicator lights up until the fault disappears
Normal measurement
Terminals: MT60 VCP control
signals
Variable timing control signals: 99 B 0-1000mV
Main relay: \ A 12V
Reference
Judging conditions Possible causes of the malfunction troubleshooting
programs
1. Connector not in place 1. Reconnect
2. Variable timing control signal circuit open 2. Repair harness
Engine running 3. Variable timing control signal circuit grounded 3. Repair harness
fault duration > 2 seconds 4. Main relay circuit fault 4. Repair harness
5. Sensor damaged 5. Change sensor
6. Timing control signal input of ECM failure 6. Change ECM
DTC P0026 Intake VCP hydraulic control valve blocked

Fault indicator lights up until the fault disappears
Set emergency control scheme:
Close intake VCP hydraulic control valve
Normal measurement
Terminals: MT60 VCP control
signals
Main relay: \ A 12V
Variable timing control signals: 99 B 0-12V square wave
Judging conditions Possible causes of the malfunction Reference troubleshooting programs
1. Hydraulic control valve drive circuit short with
1. Repair harness
system power supply positive side
Duration > 2 seconds 2. Replace control valve
2. Hydraulic control valve damaged
3. Change ECM
3. ECM failure
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DTC P0107 Low voltage or open circuit of intake pressure sensor circuit
Engine stopped: 100kPa
Engine idling:32kPa
Engine running: manifold pressure changes with the throttle opening
Pressure Normal measurement
Terminals: MT60
sensor signals
5V reference voltage:
13 5V
Manifold pressure signal: 11 0.5-4.5V
Sensor signal/grounding: 14 0V
Reference troubleshooting
Judging conditions Possible causes of the malfunction
programs
1. Connector not in place
2. Harness pressure signal line open 1. Reconnect
Engine running 3. Harness pressure signal line to ground short 2. Repair harness
No TPS failure circuit
3. Repair harness
MAP14.017 kPa 4. 5V reference voltage circuit open
4. Repair harness
RPM1050 rpm 5. Sensor signal ground circuit open
5. Repair harness
6. Harness 5V reference voltage and reference
TPS18.75 % 6. Repair harness
ground reversed (This failure may cause sensor
Fault duration> 2.5 seconds damaged) 7. Change sensor
7. Sensor damaged 8. Change ECM
8. ECM MAP signal input fault
DTC P0108 Intake pressure sensor circuit high voltage

Engine stopped: 100kPa
Set emergency control scheme: Engine idling:32kPa
Engine running: manifold pressure changes with the throttle opening
variations
Pressure Normal measurement
Terminals: MT60
sensor signals
5V reference voltage: 13 5V
Manifold pressure signal: 11 0.5-4.5V
Engine running 1. Constraint pressure signal circuit
No TPS failure shorted with 5V reference voltage or 1.Repair harness
MAP98.117kPa positive power supply 2.Change sensor
TPS19.141% 2. Sensor damaged 3.Change ECM
Fault duration> 2.5 seconds 3. ECM pressure signal input fault
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DTC P0112 Intake air temperature sensor circuit low voltage

Set emergency control scheme: Intake temperature is equal to the coolant temperature, but not more than
44.25 degrees
Temperature Normal measurement
Terminals: MT60
sensor signals
Intake air temperature signal: 07 0.5-4.5V
1. Reconnect
2. Temperature signal circuit open
Engine operating time> 120 2. Repair harness
3. Sensor signal grounding open
seconds 3. Repair harness
4. Temperature signal circuit to positive power
MAT> -38.25 degrees 4. Repair harness
supply short circuit
Fault duration> 2.5 seconds 5. Change sensor
5. Sensor damaged
6. Change ECM
6. ECM signal input failure
DTC P0113 Intake air temperature sensor circuit high voltage

Set emergency control scheme: Intake temperature is equal to the coolant temperature, but not more than
44.25 degrees
Intake air
Normal measurement
Terminals: MT60 temperature
signals
sensor
Intake air temperature signal: 07 0.5-4.5V
Engine operating time60

1. Temperature signal to ground short circuit 1. Repair harness
seconds
MAT148.5 degrees
3. ECM signal input failure 3. Change ECM
Fault duration2 seconds
DTC P0117 Coolant temperature sensor circuit low voltage

Set emergency control scheme: Starts with the intake air temperature, increasing to 79.5 degrees with time
before fixing it
Normal measurement
Terminals: MT60 Coolant temperature sensor
signals
Coolant temperature signal: 39 A 0.5-4.5V
Sensor signal/grounding: 12 C 0V
1. Reconnect
2. Temperature signal circuit open
Engine operating time10 2. Repair harness
3. Sensor signal grounding open
seconds 3. Repair harness
4. Temperature signal to positive power supply
CTS-38.25 degrees 4. Repair harness
short circuit
Fault duration2 seconds 5. Change sensor
5. Sensor damaged
6. Change ECM
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DTC P0118 Coolant temperature sensor circuit high voltage or open

Set emergency control scheme: Starts with the intake air temperature, increasing to 79.5 degrees with time
before fixing it
Normal measurement
Terminals: MT60 Coolant temperature sensor
signals
Coolant temperature signal: 39 A 0.5-4.5V
Sensor signal/grounding: 12 C 0V
Engine operating time2s 1. Temperature signal circuited with ground short

1. Repair harness
circuit
CTS135 degrees 2. Change sensor
2. Sensor damaged
Fault duration2 seconds 3. Change ECM
DTC P0122 ETC throttle position sensor # 1 circuit low voltage

With idling, set the throttle position sensor opening 0%; at other rotating
Set emergency control scheme: speed, the throttle position sensor opening changes with the rotating speed
Automatic zero calibration function of throttle position sensor suspended
Cleaning function suspended for the time being
Normal measurement
Terminals: MT60 Throttle position sensor
signals
5V reference voltage: 21 A 5V
Throttle position 1 signal: 65 D 0.5-4.5V
Sensor signal/grounding: 19 F 0V
Engine running, but the 1. Sensor signal line to positive power supply or
1. Repair harness
speed <3000rpm no MAP reference voltage circuit short circuit
failure, and MAP <70kpa 2. Change sensor
2. Sensor damaged
DTC P0123 ETC throttle position sensor #1 circuit high voltage or open
At idling, set the throttle position sensor opening 0%; at other rotating speed,
Set emergency control scheme: the throttle position sensor opening changes with the rotating speed
Normal measurement
signals
Throttle position 1 signal: 65 D 0.5-4.5V
2. Sensor signal circuit open 2. Repair harness
Fault duration2 seconds 3. Sensor signal line to ground short circuit 3. Repair harness
209
Electronic Control
DTC P0131 Front oxygen sensor short circuit to low voltage

Fault indicator lights up until the fault disappears and closes off ignition switch
System closed loop delayed
Heated Normal measurement
Terminals: MT60
oxygen sensor signals
System main power supply: \ D 12V
Heated drive: 88 C 0V
Oxygen sensor and high signal: 40 B 0-1000mV fluctuation
Oxygen sensor and low signal: 42 A 0V
1. Heating drive circuit to positive power supply
1. Repair harness
short circuit
Duration1 seconds 2. Change sensor
2. Sensor damaged
3. Change ECM
3. ECM signal output interface failure
DTC P0132 Front oxygen sensor open short to high voltage

Terminals: MT60
2. Harness Heating drive circuit open 2. Repair harness
No main relay fault
3. Harness Heating drive to ground short circuit 3. Repair harness
Duration> 1 sec
5. ECM signal output interface failure 5. Change ECM
DTC P0133 Front oxygen sensor response too slow

Terminals: MT60
No main relay fault
3. Harness Heating drive short with ground 3. Repair harness
Duration> 1 sec
210
Electronic Control
DTC P0137 Rear oxygen sensor short circuit to the low voltage
Terminals: MT60
1. Heating drive circuit short with positive power
1. Repair harness
supply
Duration1 seconds 2. Change sensor
2. Sensor damaged
3. Change ECM
DTC P0138 Front oxygen sensor short circuit to high voltage

Terminals: MT60
No main relay fault
3. Harness Heating drive grounded 3. Repair harness
Duration> 1 sec
DTC P0222 ETC throttle position sensor # 2 circuit low voltage

Normal measurement
signals
Throttle position 2 signal: 66 E 0.5-4.5V
Engine running, but the 1. Sensor signal line to positive power supply or
1. Repair harness
speed <3000rpm no MAP reference voltage circuit short
failure, and MAP <70kpa 2. Change sensor
2. Sensor damaged
211
Electronic Control
DTC P0223 ETC throttle position sensor # 2 circuit high voltage or open circuit
Normal measurement
signals
Throttle position 2 signal: 66 E 0.5-4.5V
Fault duration2 seconds 3. Sensor signal line grounded 3. Repair harness
DTC P0230 Fuel pump relay failure

None
Normal measurement
Terminals: MT60 Fuel pump relay
signals
See Electrical System
System main power supply \ Description 12V
Sensor signal/grounding: 96 0V (work), 12V (stop)
Description
2. Connection to system main power supply circuit 1. Reconnect
open 2. Repair harness
3. Relay drive circuit to negative system power 3. Repair harness
Duration1.5625 seconds supply terminal circuit short 4. Repair harness
4. Relay drive circuit open 5. Replace relay
5. Relay damaged 6. Change ECM
DTC P0325 Knock sensor failure

Fault indicator lights up until closing off ignition switch
Adopts safety spark advance angle table data
Normal measurement
Terminals: MT60 Knock sensor
signals
Knock signal high: 72 0-1V
Knock signal low: 71 0V
2. Knock signal circuit open 2. Repair harness
Engine running2000rpm
3. Sensor signal circuit short 3. Repair harness
MAP>50kPa
4. Knock signal circuit to other circuits short 4. Repair harness
Duration5 seconds
212
Electronic Control
DTC P0336 Crankshaft position sensor circuit signal interference

None
Normal measurement
Terminals: MT60 Crankshaft position sensor
signals
> 400mV sine wave
Sensor signal: 30 2 (with sensor B)
> 400mV sine wave
Voltage signal: 18 3
(with sensor A)
System grounding: 19 1 0V
Engine running
5 consecutive cycles and 1. Poor signal line shielding 1. Use shielded cable
the number of teeth fed into 2. 58x gear ring has metal impurities 2. Clean 58x gear ring
the ECM is not equal to 58
DTC P0337 Crankshaft position sensor circuit no signal

Set emergency control scheme: None
Engine can not start
Normal measurement
Terminals: MT60 Crankshaft position sensor
signals
> 400mV sine wave
Sensor signal: 30 2 (with sensor B)
> 400mV sine wave
Voltage signal: 18 3
(with sensor A)
System grounding: 19 1 0V
Start engine
No engine speed signal
2. Signal high and low reversed 2. Repair harness
MAP decreases .9509 kPa 3. Signal circuit open 3. Repair harness
0.8VSystem voltage drops 4. Signal lines to other circuit short 4. Repair harness
0.8V
6. ECM signal input interface failure 6. Change ECM
Duration2 seconds
DTC P0341 Camshaft position sensor rationality fault

Injection sequence having 50% dislocation for 360 degrees
Camshaft position Normal measurement
Terminals: MT60
sensor 1 signals
5V reference voltage: 46 3 5V
Camshaft signal: 05 2 0-5V square wave
Sensor signal/grounding: 45 1 0V
2. Reference voltage circuit open 2. Repair harness
3. Signal grounding circuit open 3. Repair harness
Engine running
4. Camshaft signal circuit open 4. Repair harness
6 ECM interface failure 6. Change ECM
213
Electronic Control
DTC P0342 Camshaft position sensor no signal

Injection sequence having 50% dislocation for 360 degrees
Normal measurement
Terminals: MT60 Camshaft position sensor
signals
Camshaft signal: 05 2 0-5V square wave
2. Reference voltage circuit open 2. Repair harness
3. Sensor grounding circuit open 3. Repair harness
Engine running
4. Sensor signal grounding circuit open 4. Repair harness
6. ECM interface failure 6. Change ECM
DTC P0351 # 1 ignition coil failure

Set emergency control scheme: 1-cylinder fuel injection stops
Target idle speed increased to 1200rpm
Normal measurement
Terminals: MT60 Ignition coil
signals
System main power supply: \ 12V
0-12V approximate
1-cylinder drive: 26 square wave signal
induced peak> 300V
1. 1-cylinder drive circuit short with the positive
1. Repair harness
power line
Duration of 1.25 seconds 2.Ignition coil damaged
2. Ignition coil damaged
3. Change ECM
3. ECM failure

Normal measurement
Terminals: M60
Ignition coil signals
0-12V approximate
induced peak> 300V
1. Repair harness
power line
Duration of 1.25 seconds 2. Replace ignition coil
3. Change ECM
3. ECM failure
214
Electronic Control

Normal measurement
signals
0-12V approximate
induced peak> 300V
1. -Cylinder drive circuit short with the positive
1. Repair harness
power line
3. Change ECM
3. ECM failure

Normal measurement
signals
0-12V approximate
induced peak> 300V
1. Repair harness
power line
3. Change ECM
3. ECM failure
DTC P0458 Canister magnet valve to the low-voltage short circuit

Close off canister magnet valve
Normal measurement
Terminals: MT60 Canister magnet valve
signals
System main power supply: \ A 12V
Magnet valve drive: 99 B 0-12V square wave
Judging conditions Possible causes of the malfunction programs
1. Magnet valve drive circuit short with system positive
1. Repair harness
power line
Duration>2 seconds 2. Replace solenoid valve
2. Solenoid valve damaged
3. Change ECM
3. ECM failure
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Electronic Control
DTC P0459 Canister solenoid valve short with high voltage circuit
Close off canister magnet valve
Normal measurement
Terminals: MT60 Canister magnet valve
signals
System main power supply: \ A 12V
Magnet valve drive: 99 B 0-12V square wave
1. Reconnect
2. Magnet valve drive circuit short with system
2. Repair harness
negative power line
3. Repair harness
Duration>5 seconds 3. Magnet valve drive circuit open
4. Repair harness
4. Connection with system main power open
5. Replace magnet valve
5. Magnet valve damaged
6. Change ECM
6. ECM failure
DTC P0480 Low-speed fan failure

None
Fan not working (open), water temperature rises to 98 degrees, high speed
fan turned on, fan always working(to ground short circuit)
Terminals: MT60 Low-speed fan relay Normal measurement signals
Vehicle OEM to provide
Battery: \
instructions 12V
Relay drive: 51 0V (work), 12V (stop)
instructions
1. Reconnect
2. Relay drive circuit short with system negative
2. Repair harness
power line
3. Repair harness
Duration>3 seconds 3. Relay drive circuit open
4. Repair harness
4. Connection with battery circuit open
5. Replace relay
5. Relay damaged
6. Change ECM
6. ECM failure
DTC P0481 High-speed fan failure

None
Fan not working (open), water temperature rises to 98 degrees, high speed
fan turned on, fan always working(to ground short circuit)
Normal measurement
Terminals: MT60 Low-speed fan relay
signals
Battery: \
instructions 12V
Relay drive: 52 0V (work), 12V (stop)
instructions
2. Relay drive circuit short with system negative 2. Repair harness
power line 3. Repair harness
Duration>3 seconds
3. Relay drive circuit open 4. Repair harness
4. Battery cable opened 5. Replace relay
5. Relay damaged 6. Change ECM
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Electronic Control
6. ECM failure
DTC P0502 Speed sensor no signal

Driving restrictions may be taken
Normal measurement
Terminals: MT60 Speed sensor
signals
Sensor signal/grounding: 68 / 0-12V square wave
Engine running 1. Reconnect
2. Transmission to the instrument signal
Speed <2kph MAP<25.82Kpa 2. Replace flexible shaft or signal line
circuit open
1200 rpm<Engine RPM<5000 3. Repair harness
3. Instrument to ECM wiring open
rpm 4. Replace speed sensor
4. Speed sensor damaged
Throttle closed 5. Repair or replace instrument
5. Instrument failure
Duration>5 seconds 6. Change ECM
6. ECM failure
DTC P0562 System voltage low

System fuel injection stopped
Normal measurement
Terminals: MT60 Ignition switch
signals
Ignition switch 17 12V
Description
Connect ignition switch
1. Generator regulator damaged 1. Replace damaged voltage regulator
System voltage7.6V
2. Wrong use of a low voltage battery 2. Use the correct battery
Duration>5 seconds
DTC P0563 System voltage high

System fuel injection stopped
Normal measurement
Terminals: MT60 Ignition switch
signals
Ignition switch 17 12V
Description
Connect ignition switch 1. Generator regulator damaged 1. Replace damaged voltage regulator
System voltage <17.2V
Duration>5 seconds 2.Wrong use of a high voltage battery 2. Use the correct battery
217
Electronic Control
DTC P0571 Brake light switch failure

Does not light up (open)
Always on (to ground short circuit)
Normal measurement
Terminals: MT60 System failure indicator
signals
Ignition switch: \ 12V
Description
LED drive: 56 OFF=12V, ON=0V
Description
1. Failure bulb not properly installed. 1. Reinstall light bulb

2. Connection to ignition switch broken. 2. Repair harness
Duration>2 seconds
3. Drive circuit lines short with negative power line 3. Repair harness
4. Fault bulb damage 4.Replace bulb
DTC P0601 ROM verification failure

Normal measurement
Terminals: MT60 ECM
signals
ECM: See Electrical System Description \

Fault exists ECM failure Change ECM
DTC P0646 Air conditioning clutch to low voltage short circuit

Disconnect the clutch relay circuit
Normal measurement
Terminals: MT60
signals
Air conditioning clutch signal: 77 0-12V square wave
1. Clutch drive circuit short with system positive
1. Repair harness
power line
Duration >2 seconds 2. Replace of air conditioning clutch
2. Air conditioning clutch damaged
3. Change ECM
3. ECM failure
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Electronic Control
DTC P0647 Air conditioning clutch short with high voltage circuit
Disconnect the clutch relay circuit
Normal measurement
Terminals: MT60
signals
Air conditioning clutch signal: 77 0-12V square wave
2. Clutch driving circuit short with system negative 2. Repair harness
power line
Duration>5 seconds 3. Clutch drive circuit open 3. Repair harness
4. Connection with system main power open 4. Repair harness
5. Air conditioning clutch damaged 5. Replace of air conditioning clutch
6. ECM failure 6. Change ECM
DTC P0650 Fault indicator malfunction

Does not light (open)
Always on (to ground short circuit)
Normal measurement
Terminals: MT60 System failure indicator
signals
Ignition switch: \ 12V
Description
LED drive: 92 =12V=0V
Description
1.Failure bulb not properly installed 1. Reinstall light bulb
2. Connection to ignition switch circuit failure 2. Repair harness
Duration>2 seconds
3. Drive circuit lines short with negative power line 3. Repair harness
4. Fault bulb damage 4. Replace bulb
DTC P1397 Wheel speed sensor no signal

Driving restrictions may be taken
Normal measurement
Terminals: MT60 Speed sensor
signals
Sensor signal/grounding: 97 / 0-12V square wave
Engine running 1. Connector not in place

1. Reconnect
Speed<2kph 2. Transmission to the instrument signal circuit
2. Replace flexible shaft or signal line
MAP<25.82Kpa 1200 open
3. Repair harness
rpm<Engine RPM<5000 3. Instrument to ECM wiring open
rpm 4. Replace speed sensor
4. Speed Sensor damaged
Throttle closed 5. Repair or replace instrument
5. Instrument failure
Duration>5 seconds 6. Change ECM
6. ECM failure
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Electronic Control
Electronic accelerator pedal position sensor 1 # line low voltage or open

DTC P2122 circuit
Electronic
accelerator Normal measurement
Terminals: MT60
pedal position signals
sensor 1
Accelerator pedal signal 1 32 4 0.5-4.5V
1. Accelerator pedal position sensor
signal short with the 5V reference 1.Repair harness
Engine running voltage or positive power line 2.Change sensor
Fault duration> 2.5 seconds
2. Sensor damaged 3.Change ECM
3. ECM pressure signal input fault
DTC P2123 Electronic accelerator pedal position sensor 1 # high voltage

Electronic
Terminals: MT60
sensor 1
Accelerator pedal signal 1: 32 4 0.5-4.5V
programs
Engine running
3. Sensor signal line grounded 3. Repair harness
Electronic accelerator pedal position sensor #2 circuit low voltage or open

DTC P2127 circuit
Electronic
Terminals: MT60
sensor 2
1. Accelerator pedal position sensor
signal short with the 5V reference 1.Repair harness
Engine running
voltage or positive power line 2.Change sensor
Fault duration2.5 seconds 2. Sensor damaged 3.Change ECM
3. ECM pressure signal input fault
220
Electronic Control
DTC P2128 Electronic accelerator pedal position sensor #2 circuit high voltage
Electronic
Terminals: MT60
sensor 2
programs
Engine running
3. Sensor signal line grounded 3. Repair harness
221
Electronic Control
II. Diagnosis by Trouble Phenomena

1. Instruction
Before carrying out the trouble diagnosis steps with the engine trouble phenomenon, it is necessary to
firstly conduct the preliminary check:
1) Confirm that the malfunction indicator lamp of engine operates normally.
2) Check with trouble diagnoses apparatus to confirm that there is no trouble information record.
3) Confirm existence of the trouble complain from owner and the conditions about the occurrence of
the trouble.
And then check the appearance:
1) Check fuel pipes for leakage.
2) Check vacuum pipes for breakage or kink and proper connection.
3) Check intake pipes for blockage, leakage, flatness or damage.
4) Check high-voltage wire of ignition system for broken, aging, verify correct ignition sequence.
5) Check grounding position of wire harness for clean and firm.

6) Check the connector of each sensor and actuator for the looseness or poor contact.
Attention: If any of above-mentioned phenomena exists, firstly conduct maintenance operation

against it; otherwise the following trouble diagnosis and maintenance will be affected.
2. Diagnosis Help
1) Confirm that there is no trouble record related to engine.
2) Confirm the existence of the trouble complained by the owner.
3) The check has been done with steps above, and there is nothing unusual found.
4) It is not permitted to neglect the effects of the maintenance of vehicle, cylinder pressure, mechanical
ignition timing and fuel etc. on the system during the Repair process.
5) Replace the ECM to test.
If the trouble phenomenon can be cleared at this time, it means the trouble site is at ECM; if the trouble
phenomenon still exists at this point, reinstall the original ECM and repeat the procedures again to carry
out the Repair.
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Electronic Control
Trouble phenomenon 1: during the start-up, the engine does not run or runs slowly
General trouble position:
1. Battery; 2. Starter; 3.Wire harness or ignition switch; 4.Mechanical part of engine
General diagnosis procedure:
No. Operating Steps Detection Results Subsequent Steps
Check the voltage between the two terminals of battery with Yes Next step
1 multi-meter to see whether it is about 8-12V during starting of
engine. No Replace battery
Yes Next step

With ignition switch at the starting position, check voltage of
2 Repair or replace
starter negative terminal to verify that it is above 8V. No
wire harness
Repair or replace the

Dismantle the starter to check its operating state. Mainly Yes
3 starter
check for sticking due to open circuit or poor lubrication.
No Next step
Change with
If the trouble only present in winter, then check whether too Yes lubricating oil of
4 large resistance of starter is caused by improper selection of proper grade
the lubricating oil for engine or the gearbox oil.
No Next step
Remove large
Check engine for too large internal mechanical resistance; if it Yes internal resistance of
5 is a case, the failure of rotation or the slow rotation of starter engine
may occur.
No Repeat above steps
223
Electronic Control
Trouble phenomenon 2: Engine start to run but can not be started successfully during the
start-up
1. No fuel in the fuel tank; 2. Fuel injection pump; 3.Crankshaft position sensor; 4.Ignition coil;
5.Mechanical part of engine
Detection
No. Operating Steps Subsequent Steps
Results
Connect the fuel pressure gauge (the access point is at the front Yes Next step
end of the induction manifold of the fuel distribution pipe
assembly) to the engine, and start the engine to determine
1 Repair the fuel supply
whether the readings of fuel pressure gauge when idling is at No
about 260kPa; disconnect vacuum hose of pressure regulator system
and observe whether fuel pressure is about 300kPa.
Connect the electric control system diagnosis apparatus to the Yes Next step
2 engine to observe the data of "rotating speed of engine" and start Repair crankshaft
the engine to observe whether there is speed signal output. No
position sensor circuit
Pull out the high-voltage wire of one of the cylinders and connect Yes Next step
the spark plug to make the spark plug electrodes around 5mm
3
away from the engine body, and start the engine to check No Repaire ignition system
whether there is blue and white high-voltage spark.
Eliminate mechanical
Check the pressure of all the cylinders and observe whether the Yes
4 trouble of engine
pressure of engine cylinders is insufficient.
No Next step
Connect the adapter of electric control system and turn on the Yes Diagnosis help
5 ignition switch to check power supplies of pins #16, #17, #8 and
#51; check groundings of pins #5, #43 and #48. No Repair related circuit
224
Electronic Control
Trouble phenomenon 3: Difficulty in warm start

1. Poor quality of fuel; 2.Fuel injection pump; 3.Coolant temperature sensor; 4.Ignition coil
Detection
Results
Connect the fuel pressure gauge (the access point is at the front end Yes Next step
of the induction manifold of the fuel distribution pipe assembly) to the
engine and start the engine to check whether the reading of fuel
1 Repair fuel supply
pressure gauge at idle condition is at about 260kPa. Disconnect No
vacuum hose on pressure regulator and observe whether fuel system
pressure is about 300kPa.
Pull out the high-voltage wire of one of the cylinders and connect the Yes Next step
spark plug to make the spark plug electrodes about 5mm away from
2
the engine body, and start the engine to check whether there is the No Repair ignition system
blue and white high-voltage spark.
Pull out connector of coolant temperature sensor and start the Repair circuit or
Yes
engine to observe whether the engine is successfully started at this replace the sensor
3 time. (Alternatively, connect a 300 ohm resistance in series at the
connector of coolant temperature sensor to observe whether the No Next step
engine is successfully started at this time.)
Check the vacuum pipe of fuel pressure regulator for the shedding or Yes Repair or replace
4
air leakage. No Next step
Check fuel conditions and observe whether the trouble phenomenon Yes Change fuel
5
occurs just after adding fuel. No Next step
6 ignition switch to check power circuits of the pins #16, #17, #8 and
225
Electronic Control
Trouble phenomenon 4: Difficulty in cold start

1. Poor quality of fuel; 2. Fuel injection pump; 3.Coolant temperature sensor; 4.Fuel injector; 5.Ignition
coil; 6.Air throttle body and idle bypass air passage; 7.Mechanical part of engine

Connect the fuel pressure gauge (the access point is at the Yes Next step
front end of the induction manifold of the fuel distribution pipe
assembly) to the engine and start the engine to check
whether the reading of fuel pressure gauge at idle condition is No
at about 260kPa. Disconnect vacuum hose on pressure system
regulator and observe whether fuel pressure is about 300kPa.
Pull out the high-voltage wire of one of the cylinders and Yes Next step
connect the spark plug to make the spark plug electrodes
2 about 5mm away from the engine body, and start the engine Repair the ignition
to check whether there is the blue and white high-voltage No
system
spark.
Pull out the connector of coolant temperature sensor and start Repair circuit or
Yes
the engine to observe whether the engine is successfully replace the sensor
started at this time. (Alternatively, connect a 2500 ohm
3
resistance in series at the connector of coolant temperature
sensor to observe whether the engine is successfully started No Next step
at this time.)
Wash the air throttle
Gently step down the accelerator pedal to observe whether it Yes
4 and idle air passage
is easy to start.
No Next step
Dismantle the fuel injector and check whether there is Failure of

Yes
5 leakage or blockage in the fuel injector with the cleaning Replacement
analyzer special for fuel injector. No Next step
Check the fuel conditions and observe whether the trouble Yes Change fuel
6
phenomenon occurs just after adding the fuel. No Next step
Eliminate the
Check the pressure states of all the cylinders of engine and Yes mechanical trouble of
7 observe whether the pressure of engine cylinder is engine
insufficient.
No Next step
8 ignition switch to check power line of pins #16, #17, #8 and
226
Electronic Control
Trouble phenomenon 5: Engine speed is normal, but it is difficult to start all the time
1. Poor quality of fuel; 2. Fuel injection pump; 3.Coolant temperature sensor; 4.Fuel injector; 5.Ignition
coil; 6.Throttle body and idle bypass air passage; 7.Intake passage; 8.Ignition timing; 9.Spark plug;
10.Mechanical part of engine
Repair air intake

Yes
1 Check air filter for blockage and intake passage for leakage. system
No Next step
Connect the fuel pressure gauge (the access point is at the front Yes Next step
end of the induction manifold of the fuel distribution pipe assembly)
to the engine and start the engine to check whether the reading of
fuel pressure gauge at idle condition is at about 260kPa. No
Disconnect vacuum hose on pressure regulator and observe system
whether fuel pressure is about 300kPa.
Pull out the high-voltage wire of one of the cylinders and connect Yes Next step
the spark plug to keep the spark plug electrodes about 5mm away
3 Repair the ignition
from the engine body, then start the engine to check whether there No
is the blue and white high-voltage spark. system
Check the spark plug of each cylinder to observe whether model Yes Next step
4
and gap are in compliance with the specification. No Adjust or replace
Pull out the connector of coolant temperature sensor and start the Repair the lien or
Yes
5 engine to observe whether the engine is successfully started at this replace the sensor
time. No Next step
Wash throttle and

Yes
6 Gently step down the throttle to observe whether it is easy to start. idling air passage
No Next step
Dismantle the fuel injector and check whether there is leakage or Failure of
Yes
7 blockage in the fuel injector with cleaning analyzer special for fuel Replacement
injector. No Next step
Check fuel condition and observe whether the trouble phenomenon Yes Change fuel
8
occurs just after adding the fuel. No Next step
Eliminate the
Check pressure of all the cylinders and observe whether the Yes mechanical trouble of
9 engine
pressure of engine cylinder is insufficient.
No Next step
Yes Next step

Check whether the ignition sequence of engine and ignition timing
10 Repair the ignition
is in line with the specification. No
timing
11 ignition switch to check power lines of pins #16, #17, #8 and #51;
check groundings of pins #5, #43 and #48. No Repair related circuit
227
Electronic Control
Trouble phenomenon 6: Normal start-up but unstable idling at any time

1. Poor quality of fuel; 2.Fuel injector ; 3.Spark plug; 4.Throttle body and idle bypass air passage;
5.Intake passage; 6.Idle adjustor (step motor ); 7.Ignition timing; 8.Spark plug; 9.Mechanical part of
engine.
Detection
Results
Repair the intake

Yes
1 Check air filter for blockage and intake passage for leakage. system
No Next step
Yes Wash or replace

2 Check idle adjustor for sticking.
No Next step
Check the spark plug of each cylinder to observe whether its model Yes Next step
3
Check air throttle body and idle bypass air passage for carbon Yes Wash
4
deposit. No Next step
Dismantle the fuel injector and use the cleaning analyzer special for Failure of
Yes
5 fuel injector to check whether there is leakage, blockage or too poor Replacement
flow in the fuel injector. No Next step
6
Eliminate the
7 engine
pressure difference of each engine cylinders is large.
No Next step
Check whether the ignition sequence of engine and ignition timing is Yes Next step
8
in compliance with specification. No Repair ignition timing
9 ignition switch to check power lines of the pins #16, #17, #8 and #51;
228
Electronic Control
Trouble phenomenon 7: Normal start-up but unstable idling during the warming-up
1. Poor quality of fuel; 2. Coolant temperature sensor; 3.Spark plug; 4.Throttle body and idle bypass
air passage; 5.Intake passage; 6.Idle adjustor; 7.Mechanical part of engine.
Detection
Results
Repair air intake

Yes
1 Check air filter for blockage and air intake passage for leakage. system
No Next step
Check the spark plug of each cylinder to observe whether its model Yes Next step
2
Wash related
Dismantle the idle adjustor to check whether there is carbon deposit Yes
3 components
in the air throttle body, idle adjustor or idle bypass air passage.
No Next step
Pull out the connector of coolant temperature sensor and start the Repair circuit or
Yes
4 engine to observe whether the idle speed of engine is unstable replace sensor
during warming-up. No Next step
Dismantle the fuel injector and check whether there is leakage, Failure of
Yes
5 blockage or too poor flow in the fuel injector with cleaning analyzer Replacement
special for fuel injector. No Next step
6
Eliminate the
7 pressure difference of each engine cylinders is large. engine
No Next step
8 ignition switch to check power lines of pins #16, #17, #8 and #51;
229
Electronic Control
Trouble phenomenon 8: Normal start-up but unstable idle speed after warmed-up
1. Poor quality of fuel; 2. Coolant temperature sensor; 3.Spark plug; 4.Air throttle body and idle bypass
air passage; 5.Intake passage; 6.Idle adjustor; 7.Mechanical part of engine.
Detection
Results
Check air filter for blockage and air intake passage for Yes Repair the intake system
1
leakage. No Next step
Check spark plug of each cylinder to observe whether its Yes Next step
2
model and gap are in compliance with the specification. No Adjust or replace
Dismantle the idle adjustor to check whether there is Yes Wash related components
3 carbon deposit in the air throttle body, idle adjustor and
idle bypass air passage. No Next step
Pull out the connector of coolant temperature sensor and Repair circuit or replace
Yes
4 start the engine to observe whether the idle speed of sensor(s)
engine is unstable during warm-up process. No Next step
Dismantle the fuel injector and check whether there is Yes Failure of replacement
5 leakage, blockage or too poor flow in the fuel injector
with cleaning analyzer special for fuel injector. No Next step
Check fuel condition and observe whether the trouble Yes Change fuel
6
Eliminate mechanical trouble

Check pressure of all the cylinders and observe whether Yes
7 of engine
the pressure difference of each engine cylinders is large.
No Next step
Connect the adapter of electric control system and turn Yes Diagnosis help
on the ignition switch to check power lines of the pins
8
#16, #17, #8 and #51; check groundings of pins #5, #43 No Repair related circuit
and #48.
230
Electronic Control
Trouble phenomenon 9: Normal start-up but unstable idling speed or flameout with partially load
(for example, when the air conditioner is on)
1. Air conditioning system; 2. Idle adjustor; 3.Fuel injector
Detection
Results
Wash related
Yes
Dismantle the idle adjustor to check whether there is carbon deposit components
1
in the air throttle body, idle adjustor and idle bypass air passage.
No Next step
Observe whether power output of engine is increased air conditioner Yes To step 4
operation, namely, use the electric control system diagnosis
2
apparatus to observe the changes of ignition advance angle, fuel
No Next step
injector pulse width and intake volume.
Connect the adapter of electric control system and disconnect the Yes Next step
connecting wire of the pin #75 of electronic control module to check
3
whether there is high level signal at the wire harness end with AC Repair air conditioning
No
turned on. system
Yes Next step

Inspect pressure of air conditioning system, electromagnetic clutch of
4
compressor and the compressor pump of air conditioner.
No Repair AC system
Dismantle the fuel injector and check whether there is leakage, Yes Failure of replacement
5 blockage or too poor flow in the fuel injector with cleaning analyzer
special for fuel injector. No Next step
231
Electronic Control
Trouble phenomenon 10: Normal start-up but too high idling speed
1. Throttle body and idle bypass air passage; 2.Vacuum pipe; 3.Idle adjustor; 4.Coolant temperature
sensor; 5.Ignition timing
Detection
Results
Yes Adjust
1 Check throttle cable for catching or overtension..
No Next step
Yes Repair intake system
2 Check air intake system and vacuum pipeline or leakage.
No Next step
Wash related
Yes
Dismantle the idle adjustor to check whether there is carbon deposit components
3
in the air throttle body, idle adjustor and idle bypass air passage.
No Next step
Repair circuit or
Pull out the connector of coolant temperature sensor and start the Yes
replace sensor
4 engine to observe whether the idle speed of engine is too high at this
time. No Next step
Yes Next step

Check whether the ignition timing of engine is in compliance with the
5
specification.
No Repair ignition timing
232
Electronic Control
Trouble phenomenon 11: Engine speed fails to increase or flameout occurs during acceleration
1. Poor quality of fuel; 2. Intake pressure sensor and air throttle position sensor; 3.Spark plug; 4.
Throttle body and idle bypass air passage; 5.Intake passage; 6.Idle adjustor; 7.Fuel injector;
8.Ignition timing; 9.Exhaust pipe.

Yes Repair intake system
1 Check air filter for blockage.
No Next step
assembly) to the engine and start the engine to check whether
the reading of fuel pressure gauge when idling is at about No
260kPa; disconnect vacuum hose from pressure regulator to system
see whether fuel pressure is about 200kPa.
Check spark plug of each cylinder to observe whether its Yes Next step
3
Dismantle the idle adjustor to check whether there is carbon Wash related
Yes
4 deposit in the air throttle body, idle adjustor and idle bypass components
air passage. No Next step
Yes Next step
Check whether the intake pressure sensor, air throttle position
5 Repair circuit or
sensor and their circuits are normal. No
replace sensor(s)
Dismantle the fuel injector and check whether there is leakage Yes Failure of replacement
6 or blockage in the fuel injector with cleaning analyzer special
for fuel injector. No Next step
7
Check whether the ignition sequence of engine and ignition Yes Next step
8
timing is in compliance with specification. No Repair ignition timing
Yes Next step
9 Check whether the operation of the exhaust pipe is smooth. Repair or replace the
No
exhaust pipe
10 ignition switch to check power lines of the pins #16, #17, #8
and #51; check groundings of pins #5, #43 and #48. No Repair related circuit
233
Electronic Control
Trouble phenomenon 12: Slow response of acceleration
1. Poor quality of fuel; 2. Intake pressure sensor and air throttle position sensor; 3.Spark plug;
4 .Throttle body and idle bypass air passage; 5.Intake passage; 6.Idle adjustor; 7.Fuel injector;
8.Ignition timing; 9. Exhaust pipe
Repair air intake

Yes
1 Check air filter for blockage. system
No Next step
the reading of fuel pressure gauge when idling is at about No
260kPa. disconnect vacuum hose from pressure regulator to system
Check the spark plug of each cylinder to observe whether its Yes Next step
3
Dismantle the idle adjustor to check whether there is carbon Wash related
Yes
4 deposit in the air throttle body, idle adjustor and idle bypass air components
passage. No Next step
Yes Next step

5 Repair circuit or
sensor and its circuit are normal. No
replace sensor
7
8
timing is in line with the specification. No Repair ignition timing
Repair or replace the

9 Check whether the operation of the exhaust pipe is smooth. No
exhaust pipe
234
Electronic Control
Trouble phenomenon 13: Powerlessness and poor performance during acceleration

1. Poor quality of fuel; 2.Intake pressure sensor and air throttle position sensor; 3.Spark plug;
4.Ignition coil; 5. Throttle body and idle bypass air passage; 6.Intake passage; 7.Idle adjustor;
8.Fuel injector; 9.Ignition timing ; 10.Exhaust pipe.
Check whether there are such troubles as the clutch slipping, Yes Repair
1 low tire pressure, braking drag, wrong size of tire and incorrect
alignment of four wheels etc. No Next step
Yes Repair air intake system

2 Check air filter for blockage.
No Next step
3
the reading of fuel pressure gauge when idling is at about No Repair fuel supply system
260kPa. Disconnect vacuum hose from pressure regulator to
Pull out the high-voltage wire of one of the cylinders and Yes Next step
connect the spark plug to keep the spark plug electrodes about
4 No Repair ignition system
5mm away from the engine body, and start the engine to check
whether the strength of high-voltage spark.
Check the spark plug of each cylinder to observe whether its Yes Next step
5
model and gap is in compliance with the specification. No Adjust or replace
Dismantle the idle adjustor to check whether there is carbon Wash the related
Yes
6 deposit in the air throttle body, idle adjustor and idle bypass air components
passage. No Next step
Yes Next step
7 Repair circuit or replace
sensor and its line are normal. No
sensor
9
10
timing is in line with the specification. No Repair ignition timing
Repair or replace exhaust
11 Check whether the operation of the exhaust pipe is smooth. No
pipe
235

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Maintenance Manual of Tojoy Sedan Contents

Chapter 1 Mechanical Part of Engine ..................................................... 33

I. General Precautions ..................................................................................................33

Section II Engine Lubrication System ....................................................................... 89

Section III Cooling System of Engine ........................................................................ 99

I. Cooling Circuit ...........................................................................................................99

Section IV Fuel Supply System of Engine ............................................................... 111

I. General Precautions ................................................................................................111

III. Fuel System .............................................................................................................112

Section V Emission Control System of Engine........................................................ 125

I. Fuel Evaporation Control System ............................................................................125

Chapter 2 Electrical Part of Engine....................................................... 132

I. Ignition coil ...............................................................................................................132

Section 2 Starting and Charging System ................................................................ 135

I. Principle Diagram of Starting and Charging System ................................................135

Chapter III Electronic Control System of Engine................................. 152

I. Precautions of Supplemental Restraint System (SRS) ............................................152

I. System Description ..................................................................................................160

I. Intake Manifold Absolute Pressure (MAP) Sensor ...................................................176

III. Electronic throttle .....................................................................................................181

I. Diagnosis with DTC .................................................................................................205

Chapter 1 Mechanical Part of Engine

6. Parts Needed to Be Tightened with Specified Angle

1) Use the angle spanner to finally screw up following engine parts:

- Cylinder head bolt

- Bolt of main bearing cap

- Connecting rod bolt

2) Please follow the specified tightening methods.

II. Precautions on Sealant

Do not damage the matching faces.

Insert the scraper, and then knock its side

For the positions where it is difficult to use

such as a screwdriver, be careful not to

2. Application Steps of Sealant

1) Remove the attached old sealant from the

Thoroughly remove the old sealant from

3) Position sealant with the specified size.

Put the sealant into the groove for it (if any).

Eliminate any dirt from the sealant.

1. Tools for Maintenance

List of Special Tools

Installer for rear Used to install

2. List of Auxiliary Materials for Assembling Engine

List of Auxiliary Materials for Assembling Engine

No. Name Application Specification and Grade

3. List of Auxiliary Materials for Assembling Cylinder head

List of Auxiliary Materials for Assembling Cylinder head

No. Name Present Material and Model Assembly Position

IV. Engine Assembly

Air duct and air filter assembly. See Air Duct.

Battery, battery base and base support. See Battery.

Radiator assembly and radiator fan. See Radiator.

3. Dismantlement of Related Elements in Engine Compartment

Disconnect the following pipelines and put them aside.

Use plugs to prevent leakage when disconnecting the pipelines.

Inlet pipe of fuel injector. See Fuel Injector.

PVC hose. See Fuel Evaporation Control System.

Oil inlet pipe joint of clutch. See Hydraulic Pipeline of Clutch.

Low and high-pressure pipes of air compressor. See Air Compressor.

Dismount the steering fluid reservoir.

Dismantling of shifting cable.

Engine coolant temperature sensor

Crankshaft position sensor