Académique Documents
Professionnel Documents
Culture Documents
Chapter I Overview..........................................................................................................1
Section I General Instructions ...................................................................................................... 1
I. Summary .............................................................................................................................. 1
II. Operations ............................................................................................................................ 1
Section II Vehicle Information ..................................................................................................... 2
I. Identification Information Position ........................................................................................ 2
II. Nameplate ............................................................................................................................ 2
III. Vehicle Identification Number (VIN) ..................................................................................... 3
IV. Engine Number..................................................................................................................... 4
Section III Lifting, Protection and Towing of Vehicle.................................................................. 6
I. Lifting of Vehicle ................................................................................................................... 6
II. Protection of Vehicle............................................................................................................. 6
III. Towing of Vehicle ................................................................................................................. 7
Chapter II Service............................................................................................................8
Section I Service............................................................................................................................... 8
I. Prepara tools ........................................................................................................................ 8
II. General Service.................................................................................................................... 8
III. Regular Service .................................................................................................................... 9
IV. Recommended Oil and Lubricant....................................................................................... 10
V. Service of Engine ............................................................................................................... 11
VI. Service of Chassis and Body ............................................................................................. 19
VII. Maintenance Data .............................................................................................................. 27
Maintenance Manual for J2 Sedan Overview
Chapter I Overview
Section I General Instructio
ons
I. Summary
This Manual provides the procedures required by service operations, including:
1. Structure and composition
2. Principles
3. Dismantlement and installation steps
4. Inspection methods
5. Adjustment & commissioning methods
6. Common trouble diagnosis procedures
7. Technical parameters
The simple operations that can be conducted through the observation of vehicle are left out in this
Manual. No description is given for the necessary basic skills of maintenance technicians in this Manual.
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Maintenance Manual for J2 Sedan Overview
1
2
Position of vehicle ID
II. Nameplate
1. Position of nameplate: at the firewall of engine compartment.
2. Instructions of nameplate
Brand: Jianghuai
Example of Nameplate
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Maintenance Manual for J2 Sedan Overview
Digitals
Part 1: Word Manufacturer Identification (WMI), consists of 3 numbers according to GB16737, which
should be applied, approved and filed. WMI for JAC is LJ1, which applicable for freight truck, incomplete
vehicle, bus, passenger car, tractor and special vehicle of JAC. Word Manufacturer Identification (WMI)
is shown in table below.
Part 2: vehicle description Code (VDS), as specified in GB 16737, this part should be made up with 6
digitals to presents basic features of vehicle model.
VDS making-up:
Digitals
Inspection digit
Body type
Vehicle type
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Maintenance Manual for J2 Sedan Overview
② Body type
④ Truck wheelbase / passenger cars, buses and chassis length: R> 2390 - 2600
1: gasoline ≤70Kw
⑤ Code of engine type and rated power 2: gasoline >70-90Kw
3: gasoline >90-110Kw
Digitals
Production SN
Factory assembled
Year
IV Engine Number
1. Position of engine number
Engine number is stamped on the exhaust side of cylinder block (See figure below).
Fig. 2.1.001
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Maintenance Manual for J2 Sedan Overview
Fig. 2.1.002
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Maintenance Manual for J2 Sedan Overview
Supporting point
2. Operation of Lifter
The lifter should be operated strictly in accordance with the specifications of manufacturer.
Caution:
The operation against the specifications may cause damage of vehicle or personnel injury or
even death.
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Maintenance Manual for J2 Sedan Overview
④ Check the towing rope by pulling it to make sure both ends are fixed firmly on the towing hole.
2) Rear towing hook: It can used to tow another vehicle only under emergency (when a vehicle is
trapped in a ditch, heavy snow or mud pit). When using the rear towing hook, always keep the rope
or chain perpendicular to hook. Don’t apply force to the towing hook from any ohter directions. Don’t
start towing sharply otherwise damage may be caused.
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Maintenance Manual for J2 Sedan Service
Chapter II Service
Section I Service
I. Preparation
1. Maintenance Tools
1. Exterior of Vehicle
Item Inspection
Tyre Use an air gauge to inspect the pressure of tyres (including spare tyre) in the service
station regularly; adjust pressure in accordance with technical data if necessary. Check
whether there’s any damage, crack or excessive worn tear carefully.
Windshield Clean the windshield regularly. Check whether there’s any crack or other damage of the
windshield every six months or more frequently. Repair as required.
Windshield
If the wiper doesn’t work efficiently, check for worn or torn.
wiper blade
Door and Check whether all of the doors, engine hood, boot cover and tail door can be normally
engine hood opened and closed normally, whether all the door locks are locked closely. Lubricate as
required. Moreover, If the vehicle often travels on the salt-spread roads or in the areas
with corrosive substances, always inspect lubricating conditions.
Tyre exchange The tyre exchange should be conducted after each 8000 km traveling.
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Maintenance Manual for J2 Sedan Service
Vehicle lamps Verify that headlamps, brake indicators, tail lamps, turning signal indicator and other
lighting units work normally and have been stably fixed. Meanwhile, inspect focusing
function of headlamp.
2. Interior of Vehicle
The following inspection and maintenance items should be performed regularly.
List of Items to be Regularly Inspected for Interior of Vehicle
Item Inspection
Alarm light and Make sure all the alarm lights and buzzers are working normally.
buzzer
Windshield wiper Check whether the wiper and cleaner are working normally; check whether there
and washer is any crack in the wiper.
Check whether the air can be correctly bled from the air outlet of defroster,
Windshield defroster whether the heater or air conditioner can breathe enough air during operation of
heater or air conditioner.
Check whether the free travel of steering wheel is in the standard range. Inspect
Steering wheel changes of steering performance, such as the free travel beyond range, hard
steering and abnormal noise etc.
Check whether all the components of seat belt system are flexible and working
Seat Belt normally and fixed firmly and stably. Check seat belt for cracking, worn out or
other damage.
Check whether the pedal can be operated smoothly, make sure that the pedal
Throttle pedal
would not be seized or loaded unevenly. Keep floor pad away from the pedal.
Check if the pedal can be operated smoothly; make sure the pedal still keeps an
Brake pedal and appropriate distance from the bottom plate when it is completely pressed down.
booster Inspect the function of brake vacuum booster. Make sure that the bottom plate
pad is away from the pedal.
Parking brake Check travel of handle.
3. Engine and Vehicle Chassis
The following inspection and maintenance items should be regularly performed.
List of Items to be Regularly Inspected for the Engine and Vehicle Chassis
Item Inspection
Cleaning liquid for windshield Check whether there is adequate cleaning liquid in reservior.
Level of engine coolant Check the coolant level when the engine is cold.
Engine oil level Stop the vehicle on a level ground and turn off engine; check oil
level.
Levels of brake fluid and clutch fluid Make sure that the levels of brake fluid and clutch fluid are
between the “MAX” line and “MIN” marks on reservoir.
Battery Inspect conditions of voltage and battery poles.
Liquid leakage After the vehicle has been stopped for a while, check for any
leakage of fuel, engine oil, coolant or other liquid under the
vehicle. Water drop from the air conditioner which has just
been used is normal. In case of obvious leakage or petrol fume,
find out the causes and repair immediately.
Each item is expressed in travel distance and time (months), whichever comes first (distance or time)
should be used as the basis for inspection.
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Maintenance Manual for J2 Sedan Service
Service cycle (odometer readings and the number of months, whichever comes first)
Item 1000km 1 10 20 30 40 50 60 70 80 90 100
Month — 6 12 18 24 30 36 42 48 54 60
I: every 10,000 km or 6 months
1 Driving belt
R: every 60,000 km or two years
Check oil and gas control systems of
2 I I
crankcase for normal working
3 Spark plug I I R I I R I I R I
4 Change coolant R R R R R
Notes:
C *---For cleaning operation of fuel injector, it is recommended that dedicated fuel injector cleaning
analyzer is used; Check every 3 months or 5000km; if there are nozzle clogging or blockage failures and
they are non-product quality problems, they should be maintained at users’ expenses.
"Harsh conditions of use" specifications are only used in severe conditions of use of vehicles. Harsh
conditions of use include the following:
① Driving in dusty areas or the vehicle is regularly exposed to salty air or sea water.
④ In the cold season, the engine idles a long time or used frequently in short-distance traveling.
⑥ As tractor
⑦ As taxi or leasing
⑧ At temperatures above 32 ℃, driving in urban heavy traffic for more than 50% of the total travel
time.
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Maintenance Manual for J2 Sedan Service
⑨ At a temperature below 30 ℃, driving at 120km/h or higher speed limits for more than 50% of the
total travel time.
⑩ Overloaded traveling.
Which listed below are the types of oil and lubricant recommended by JAC:
V. Service of Engine
Warnings
1) Check for belt aging, crack, wear and oil stain. Replace as required.
■ Inspection should be conducted in the engine cold state or when it has been stopped after 30min.
■ Range of tension force – Alternator belt: 500±50N Please be noted that the experience equation for
tensioning force of reused belt is as below: Tensioning force for new belt * 1.2/1.5
Attention:
:
■ For checking belt tension installation, firstly adjust to the specified value, then turn the crank
for more than two laps to re-adjust to the specified value in order to avoid tension between
pulleys changing.
2. Adjustment of Tension
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Maintenance Manual for J2 Sedan Service
■ After replaced with new belt, adjust the belt tension so as to meet requirements.
■ During installation of belt, make sure that the belt is in correct engagement with the pulley
groove.
■ Do not over wind or bend belt; for used belt, be aware of mounting direction.
Caution:
■ Wrap the radiator cap with thick cloth and unscrew it carefully. Release the pressure inside
the radiator at first, and then completely unscrew it to open the radiator.
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Maintenance Manual for J2 Sedan Service
■ If coolant overflows from the heater outlet pipe, disconnect pipe and reconnect and then
continue the filling of coolant.
⑥ Install air filter upper cover and intake hose. Please refer to “Air Filter Assembly”.
⑦ Install radiator cap.
⑧ Warm up the engine until the thermostat is switched on.
■ Examine if there’s warm water flowing out by touching the lower hose of radiator, such as to check
whether the thermostat has been switched on.
Attention:
■ Watch on engine temperature meter, such as to avoid overheating of engine.
⑨ Stop the engine, allow engine temperature drops.
■ The cooling time can be reduced by using fan.
⑩ Fill engine coolant in coolant until the MAX level reached.
⑪ Install radiator cap, and repeat steps ③-⑨ for more than two times until the level of engine coolant
doesn’t go down any more.
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Maintenance Manual for J2 Sedan Service
Attention:
■ For installation of radiator cap, please wipe the radiator filler carefully to clear away any
paraffin residue or foreign substance.
3) Inspection of radiator
Check for any mud or clogging situation in radiator. If any, clean with following method.
■ Be aware not to twist or damage the radiation fins.
■ In case of cleaning without dismounting the radiator, all accessories such as cooling fan, wind
collection hood and horn should be dismounted. Wrap connectors of wire harness with adhesive
tape for water proofing.
① Wash back of radiator fins from the top to the bottom with water spraying normal to radiator.
② Wash each surface of the radiator every other minute.
③ In case no dirt is washed away from the radiator, the washing work should be stopped.
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Maintenance Manual for J2 Sedan Service
④ Blow the back of radiation core with compressed air vertically from top to bottom. The pressure of
compressed air should be less than 490 KPa, and a distance of more than 30 cm should be kept.
⑤ Blow radiator core surface with compressed air every other minute until no water can be blown
away.
4) Check for leakage of cooling system
① Check for leakage through applying pressure to the cooling system with a leakage detector of
radiator cap.
■ Test pressure: 157 KPa
Fig. 2.2.003
Caution:
■ Never remove the radiator cap with engine hot;
otherwise the high temperature and high
pressure liquid overflowing from the radiator
may cause severe scald.
Attention:
■ A pressure exceeds the specified test
pressure may cause damage to the radiator.
■ In case the engine coolant is found decreased, please refill engine coolant into the radiator.
Check the fuel pipeline, fuel filler cap and fuel tank for
Fig. 2.2.004
incorrect installation, leakage, crack, damage, loose
connection, worn or aged.
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Maintenance Manual for J2 Sedan Service
■ Blow back of air filter element with compressed air until nothing can be blown away.
3) Installation
Attention:
■ Long-time direct contact between skin and the used oil should be avoided. In case contacted,
wash with soap or detergent thoroughly as soon as possible.
1) Warm up the engine, and check for any oil leakage in the engine compartment. Refer to “Leakage of
engine oil”.
3) Loosen engine oil filler cap, and then remove the oil drain screw plug.
Attention:
■ Any dirt such as iron debris on oil drain screw plug must be cleaned, and new gaskets
should be installed.
For specification and viscosity of engine oil, please refer to “Recommended Oil and Lubricant”.
Attention:
■ During the filling of engine oil, please do not remove oil gage.
■ The filling amount of engine oil may vary according to oil temperature and oil drain time.
Quantity above is for reference only.
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Maintenance Manual for J2 Sedan Service
■ Oil rule should be used all the way to check whether the filling amount of engine oil is
proper.
7) Warm up the engine, check areas around the oil drain screw plug and oil filter for leakage.
1) Dismantlement
Attention:
Attention:
■ Manual tightening may cause oil leakage due to the inadequate tightening torque.
3) Post-installation inspection
① Inspect oil level, and fill engine oil when it is inadequate. See also “Engine Oil”.
④ Inspect oil level, and fill engine oil. See also “Engine Oil”.
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Maintenance Manual for J2 Sedan Service
1) Dismantlement
Attention:
In the following conditions, if carbon deposition frequently occurs with standard ignition plug, the hot
ignition plug should be used:
In the following conditions, in case ignition knock frequently occurs with standard ignition plug, the cold
ignition plug should be used:
Attention:
■ If there’s carbon deposition on ignition plug end, remove with ignition plug cleaner.
■ During the replacement interval, the ignition plug gap should be checked when it is
necessary.
3) Installation
Install with steps contrary to dismantlement. Tightening torque of ignition plug: 25-30 N·m.
1) Dismantlement
Caution:
■ Be sure to read the “General Precautions” before any handling of fuel system. See “General
Precautions”.
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Maintenance Manual for J2 Sedan Service
2) Installation
3) Post-installation inspection
① Turn ignition switch to “ON” (with engine stopped), and then check for leakage at the joints of fuel
pipeline.
② Start engine and run with increased speed, check again for fuel leakage at the joints of fuel pipeline.
11. Inspect the Evaporator passage of Fuel Evaporative Emission System (EVAP)
1) Visually check whether the installation position of EVAP evaporator pipeline is correct, and if it is
free from leakage, crack, damage, loose connection, scratching or ageing etc.
2) Check vacuum release valve of fuel tank cap for blockage or sticking etc. See “Fuel Evaporative
Emission System”.
Check for proper positions of exhaust pipe, muffler and fixed support, and anyleakage, crack, damage,
loose connection, worn or ageing.
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Maintenance Manual for J2 Sedan Service
If the fluid level is low, check clutch system for any leakage.
Check for correct installation positions of liquid pipelines and operation cylinders, and any crack,
damage, loose connection, worn or ageing.
Inspect oil level and whether there is any leakage. For detailed information, refer to “Inspection of
Manual Transmission Oil”.
1) Thoroughly drain oil from drain plug, and then refill with new gear oil. For detailed information, refer
to “Change Manual Transmission Oil”.
2) Inspect oil level. For detailed information, refer to “Inspection of Manual Transmission Oil Level”.
6. Wheel Balance
1) Dismantlement
② Dismount the old balance blocks from both sides of the wheel, clear any foreign matters from treads
of tyre.
Note: for new tyre(s), the tape on the tyre should be removed.
Attention:
① Take the center hole as guide to install the wheel on balancer. Start the balancer.
② When unbalance values of both inner side and outer side of tyre have been indicated on the display
of wheel balancer, multiply the unbalance value of outer side with 5/3, so as to define the weight of
balance blocks which will be actually applied. Then, select the outer side balance block of which
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Maintenance Manual for J2 Sedan Service
weight is nearest to the calculated value, and install it to the specified outer side position, or at the
specified angle relative to wheel.
Attention:
■ The balance block of outer side should be installed before inner side.
■ Prior to the installation of balance block, fitting surface on wheel must be thoroughly
cleaned.
Attention:
■ The balance block should not be reused; it should be replaced every time.
Attention:
■ At most two balance blocks are allowed to be installed.
⑤ Start the balancer. Make sure the residual unbalance value of both inner side and outer side is only
5 g or less.
■ In case the residual unbalance value of either side is more than 5 g, please repeat the installation
steps for balance block.
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Maintenance Manual for J2 Sedan Service
Attention:
■ In order to keep the paintwork free from damage, be sure not to splash brake fluid onto the
paintwork. If the fluid is splashed onto the paintwork, please clean with water immediately.
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Maintenance Manual for J2 Sedan Service
3) Wash the inner side of fluid reservoir and refill with new brake fluid.
1) Brake disc
2) Brake drum
Check whether the inner diameter and circular runout of brake drum are in the scope of standard values.
If not, corresponding processing or replacement should be performed.
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Maintenance Manual for J2 Sedan Service
■ Standard thickness: 9 mm
■ Limit thickness: 2 mm
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Maintenance Manual for J2 Sedan Service
1) Steering gear
2) Steering pull-rod
Check ball joint, dust boot and other components for loosening, worn, damage and grease leakage.
Check for proper clearance between front/rear axles and suspension components and any crack,
damage, worn or other damages.
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Maintenance Manual for J2 Sedan Service
Fig. 2.2.024
Check dust boot and drive shaft for any crack, worn,
damage or grease leakage.
16. Lubricating Door Lock, Hinge and Engine Hood Lock Pin
Lubricating Points of Door Lock, Hinge and Engine Hood Lock Pin
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Maintenance Manual for J2 Sedan Service
Attention:
■ The seat belt assembly including retractor and other accessories (such as fixing bolt, guide
rail device) should be inspected every time after collision.
We suggest that you should replace seat belt assembly after collision, unless it is free of any damage
after slight impact.
And the seat belt assembly which is not used during the accident should also be checked, please
replace any damaged seat belt assembly.
In case a front collision which activates both driver and passenger’s airbags happens, the seat belt
pre-tensioner should be replaced, even though the seat belt is not used at all.
■ If any component of seat belt assembly has problems, please do not repair it, but replace the seat
belt assembly.
■ In case the seat belt is broken, worn or damaged, don’t repair but replace the seat belt assembly.
■ While the snap ring open, check whether the snap ring and lock tongue function normally.
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Maintenance Manual for J2 Sedan Service
Attention:
■ Tightening torques listed above are the standard values which are applicable for following
conditions:
■ The torques listed above are not applicable for following conditions:
b. If bolt surface is coated with oil, the torque should be reduced to 85%.
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Maintenance Manual for J2 Sedan Contents
Engine Volume
I. Precautions................................................................................................................ 92
II. Preparation ................................................................................................................ 93
III. Engine Oil................................................................................................................... 94
IV. Oil Filter ...................................................................................................................... 96
V. Oil Pan and Engine Oil Pump .................................................................................. 98
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.
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
3) Make sure that the surfaces of threads and pedestal are clean and coated with engine oil.
2) Wipe sealant surface and matching surface clean with a special cleaner, remove water drops, grease
and foreign substances.
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
■ 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.
■ 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.
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
III. Preparation
Fix camshaft
1 End forked clamp timing
sprocket
JAC-T1D001
Used together
2 Pin with the end
forked clamp
Used to
Locating tool for install and
3
piston pin dismantle 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
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
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
9 JAC-T3F001 the valve oil
valve oil seal
seal
Functioning as
Guide for front a guide during
11 oil seal of JAC-T3F003 the installation
crankshaft of front oil seal
of crankshaft
Used to install
Installer for front
the front oil
12 oil seal of JAC-T3F004
seal of engine
crankshaft
crankshaft
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
Fig.1.1.004 Fig.1.1.005
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
■ 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, and clutch fluid Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust — Leakage —
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
V. Drive Belt
Warnings:
■ Be sure to operate only when engine stopped.
1) Check belt for aging, crack, wear and oil stain. Replace as required.
■ Inspection should be conducted with cold state of engine or when it has been stopped for at least
30min.
■ Tension range - Generator belt: 500±50N. Please be noted that the experience equation for
tensioning force of reused belt is as below: Tensioning force for 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
Part Method
Generator belt Screw adjusting bolt of generator
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.
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
3. Generator Belt
1) Loosen the generator adjusting nuts and supporting nuts. Then adjust the tension by using the
adjusting bolt.
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
1. Parts
Diagram of Positions
② Loosen the lock clips from the air cleaner Fig. 1.1.009
upper cover.
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
③ Disconnect the locking clamp of intake hose, and then take off upper cover and intake hose.
Check whether there is any crack or wearing on the air duct assembly. If any, replace.
3) Installation
Attention:
1) Dismantlement
Fig. 1.1.013
① Loosen the lock clips of air cleaner upper
cover and lift the upper cover.
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
■ 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
1. Intake Manifold
1) Dismantlement
Caution:
■ Do not discharge the engine coolant when the engine is hot, otherwise you would be scalded.
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
■ Fuel injector
■ Accelerator cable
■ Water hose joint (insert a plug to prevent the engine coolant leakage)
■ PCV hose
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
⑨ Dismount the fixing bolt and nut of intake manifold. Fig. 1.1.018
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.
— 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
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
Caution:
■ Perform this operation after the exhaust system has completely cooled down.
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.
Fig. 1.1.022
⑤ Unscrew fixing bolt to remove the exhaust manifold.
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
3) Installation
Attention:
1. Parts
5
1
3 6
1- Rear muffler; 2- Lug; 3- Front muffler; 4- Front exhaust pipe; 5-Three-element Catalytic Converter;
6- Bellow; 7-Rear oxygen sensor
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.
Attention:
■ 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
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
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.
■ 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.
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
Balance
shaft gear
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
h) Check timing
Timing mark
for camshaft
chain wheel
Timing mark of
secondary chain
Timing mark of
primary chain
Timing mark for balance
shaft chain wheel
Timing mark of
secondary chain
Timing mark for crankshaft
chain wheel
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
2) Installation
Reverse the above steps for installation. Be aware of timing and tightening torque during installation.
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
1. Parts
1 – Intake camshaft subassembly 2 – Intake camshaft chain wheel 3 – Chain wheel bolts
4 – Exhaust camshaft chain wheel 5 – Exhaust camshaft subassembly 6 – Mechanical tappet
7 – Balance shaft retaining bolt 8 – Balance shaft gear 9 – Balance shaft
10 – Balance shaft rear end cap gasket 11 – Balance shaft rear end cap
12 – Balance shaft rear end cap bolts
1) Disassembly of camshaft
⑥ Remove camshaft position sensor from rear end of the cylinder head.
Tightening torque: 9 - 11 N • m
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
Attention:
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
① Camshaft
4) Installation
Assembly of camshaft machenism: All parts camshaft assembly should be assembled according to
grouped drawings.
① 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)
2.91<L1≤2.93 2.70 270 0.19-0.25
2.93<L1≤2.95 2.72 272 0.19-0.25
2.95<L1≤2.97 2.74 274 0.19-0.25
2.97<L1≤2.99 2.76 276 0.19-0.25
2.99<L1≤3.01 2.78 278 0.19-0.25
3.01<L1≤3.03 2.80 280 0.19-0.25
3.03<L1≤3.05 2.82 282 0.19-0.25
3.05<L1≤3.07 2.84 284 0.19-0.25
3.07<L1≤3.09 2.86 286 0.19-0.25
3.09<L1≤3.11 2.88 288 0.19-0.25
3.11<L1≤3.13 2.90 290 0.19-0.25
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Distance between intake camshaft base circle Top end thickness of Mechanical tappet Valve clearance
and valve tappet L1 mechanical tappet label (mm)
3.13<L1≤3.15 2.92 292 0.19-0.25
3.15<L1≤3.17 2.94 294 0.19-0.25
3.17<L1≤3.19 2.96 296 0.19-0.25
3.19<L1≤3.21 2.98 298 0.19-0.25
3.21<L1≤3.23 3.00 300 0.19-0.25
3.23<L1≤3.25 3.02 302 0.19-0.25
3.25<L1≤3.27 3.04 304 0.19-0.25
3.27<L1≤3.29 3.06 306 0.19-0.25
3.29<L1≤3.31 3.08 308 0.19-0.25
3.31<L1≤3.33 3.10 310 0.19-0.25
3.33<L1≤3.35 3.12 312 0.19-0.25
3.35<L1≤3.37 3.14 314 0.19-0.25
3.37<L1≤3.39 3.16 316 0.19-0.25
3.39<L1≤3.41 3.18 318 0.19-0.25
3.41<L1≤3.43 3.20 320 0.19-0.25
3.43<L1≤3.45 3.22 322 0.19-0.25
3.45<L1≤3.47 3.24 324 0.19-0.25
3.47<L1≤3.49 3.26 326 0.19-0.25
3.49<L1≤3.51 3.28 328 0.19-0.25
3.51<L1≤3.53 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
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
② 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
and valve tappet L2 mechanical tappet tappet label (mm)
2.99<L2≤3.01 2.70 270 0.27-0.33
3.01<L2≤3.03 2.72 272 0.27-0.33
3.03<L2≤3.05 2.74 274 0.27-0.33
3.05<L2≤3.07 2.76 276 0.27-0.33
3.07<L2≤3.09 2.78 278 0.27-0.33
3.09<L2≤3.11 2.80 280 0.27-0.33
3.11<L2≤3.13 2.82 282 0.27-0.33
3.13<L2≤3.15 2.84 284 0.27-0.33
3.15<L2≤3.17 2.86 286 0.27-0.33
3.17<L2≤3.19 2.88 288 0.27-0.33
3.19<L2≤3.21 2.90 290 0.27-0.33
3.21<L2≤3.23 2.92 292 0.27-0.33
3.23<L2≤3.25 2.94 294 0.27-0.33
3.25<L2≤3.27 2.96 296 0.27-0.33
3.27<L2≤3.29 2.98 298 0.27-0.33
3.29<L2≤3.31 3.00 300 0.27-0.33
3.31<L2≤3.33 3.02 302 0.27-0.33
3.33<L2≤3.35 3.04 304 0.27-0.33
3.35<L2≤3.37 3.06 306 0.27-0.33
3.37<L2≤3.39 3.08 308 0.27-0.33
3.39<L2≤3.41 3.10 310 0.27-0.33
3.41<L2≤3.43 3.12 312 0.27-0.33
3.43<L2≤3.45 3.14 314 0.27-0.33
3.45<L2≤3.47 3.16 316 0.27-0.33
3.47<L2≤3.49 3.18 318 0.27-0.33
3.49<L2≤3.51 3.20 320 0.27-0.33
3.51<L2≤3.53 3.22 322 0.27-0.33
3.53<L2≤3.55 3.24 324 0.27-0.33
3.55<L2≤3.57 3.26 326 0.27-0.33
3.57<L2≤3.59 3.28 328 0.27-0.33
3.59<L2≤3.61 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
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
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)
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
③ Disconnect the fuse of fuel pump, otherwise the fuel may be sprayed out during measurement.
④ Use special ignition coil and spark plug removal tool. See "Ignition Coil" and the "Spark Plug."
⑥ Install a cylinder pressure gauge (with joint) on the spark plug hole.
⑦ 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.
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.
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
2. Parts
1) Dismantlement
① Discharge engine coolant and oil. See “Change Engine Coolant” and “Change Engine Oil”.
Attention:
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
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.
Attention:
■ The total grindable margin of matching surface between cylinder head and cylinder body
should not be greater than 0.2mm.
3) Installation
Fig.1.1.042
① Install new cylinder gasket.
② 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.
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
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.1.1.043
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.
■ 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”.
③ Then, perform the installation steps which are just contrary to dismantlement.
4) Check after 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.
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
XII. Valves
1. 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
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
compressor.
Attention:
2) Assembly
b. Install the new valve oil seal with the special Fig1.1.047
tool shown in Fig.1.1.044 JAC-T3F001
Attention:
④ Install valve.
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
■ After installation, lightly knock the edge of valve stem with a rubber hammer to check the
mounting condition.
Bad Bad
■ 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°
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3. Valve guide
Fig.1.1.050
■ 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
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End Face of
Standard values: 图 1.1.052 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
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)
1. Parts
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
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
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
⑩ Dismount bearing shell from the connecting rod and the connecting rod cover.
Attention:
■ Identify their mounting positions, and properly place them to avoid confusion.
⑪ Dismount ring from the piston.
Check the side clearance of piston ring before dismounting. See “Check after Disassembly” below.
Attention:
Fig.1.1.055
■ Use the piston ring expander.
Piston Ring
⑫ 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
Fig.1.1.056 Push Rod
the mounting base of piston pin (special tool).
c. Push out the piston ring by the press.
Front
d. Detach the connecting rod from piston. Mark
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Fig.1.1.059
2) Check after Disassembly
If measurement is not within the standard range, replace the thrust washer and repeat measurement. If it
is still over limit, replace the crankshaft.
② Big End Clearance of Connecting Rod
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st
For 1 piston ring, 0.03~0.07mm
For 2nd piston ring, 0.04~0.06mm 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.
④ End Gap of Piston Ring
Standard values:
Limits:
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.
Remove any gasket material and eliminate the engine oil, sediment, carbon or other contaminants on
surface of cylinder body.
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
Attention:
■ Be careful to prevent gasket materials from falling into the engine oil or coolant.
⑥ Cylindricality of Cylinder
Measure the cylinder degree at 6 different points per cylinder by using micrometer.
Standard values:
Standard values:74.973mm
Dial Indicator
Calculate per the actual measurement of piston skirt and cylinder bore.
If the calculated value exceeds the limit, replace piston and piston ring assembly.
⑨ 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.
After boring cylinder, clearance between piston and cylinder bore must be within standard range. The
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
[Boring size] = [outer diameter of piston] + [clearance between piston and cylinder (0.02-0.04mm)]
- [grinding margin (0.02mm)]
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)
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
Attention:
Fig.1.1.069 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.
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
⑮ Flywheel
Check whether the flywheel and the signal disk are distorted or cracked.
Attention:
■ Do not disassemble the flywheel.
○
16 Crankshaft signal wheel Fig.1.1.070
3) Assembly
① 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.
② 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) Black/Black Black/Yellow Black/Red Black/White Black/Purple
1 (up / down) Yellow/Black Yellow/ Yellow/Red Yellow/
Yellow/Purple
Yellow White
2(up / down) Red/Black Red/Yellow Red/Red Red/White Red/Purple
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.
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
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: 35±2N·m
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”.
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
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
mark side.
g. Screw in the guide sleeves, clearance between Fig.1.1.073
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: 108±54N·m
⑦ 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.1.1.074
■ 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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Maintenance Manual for J2 Sedan Mechanical Part of Engine
Opening direction of first gas ring Opening direction of combined oil ring lower blade
⑧ 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.
⑨ 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
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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Maintenance Manual for J2 Sedan Mechanical Part of Engine
Attention:
■ Before installing nut, apply engine oil on its thread and seat.
⑪ Install rear oil seal housing of crankshaft with rear oil seal assemble to the cylinder block.
⑫ Installation of knock sensor, Hall sensors, oil pressure switch.
Attention:
■ Do not screw the nut when grasping the joint.
Note: Be sure that there is no foreign body at the matching surface of cylinder body or the back side of
knock sensor.
⑬ Be aware of following to install with steps contrary to dismantlement.
■ Flywheel
Alternately tighten bolts to specified torque.
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2. Tightening Torques
List of fastener tightening torque
Name Specification Qty. Tightening Torques (Nm)
High strength bolt
Main bearing cap bolt M9×1.25×74.5 8 35±2Nm +60°-64°
(Synchronous fastening machine) 5Nm → 13Nm
Connecting rod bolts tightening +90 ° - 94 °
M6×0.75×33 6
torque (Manual) 5Nm → 10Nm → 13Nm +45 ° +45 °
alternate tightening
Camshaft bearing cap bolt M6×1×35 12 11±1
Front camshaft bearing cap bolt M8×1.25×30 3 20±1
Cylinder head bolt M9×1.25×143.5 8 24.5±2Nm +180°-184°
Crankshaft pulley bolt M14×1.5×54 1 50Nm±2Nm+60°±2° or 165 Nm±5 Nm
Flywheel bolt M11×1.25×25 6 100±5
Exhaust camshaft sprocket bolt M12×30 1 88±10
E-type bolt
Crankshaft rear oil seal bolt M6×10 E8 6 7.6±0.6
Rear lug blot M8×20 E10 2 18.4±1.4
Intake manifold bolt M8×40 E10 4 18±1.0
Oil pan bolt M6×12 E8 14 7.6±0.6
Sprocket cover bolt I M10×90 E14 2 39.5±3.0
Sprocket cover bolt II M10×50 E14 2 39.5±3.0
Sprocket cover bolt III M6×30 E10 2 8.4±0.6
Bolt M6×20 E10 M6×20 E10 8 8.4±0.6
Bolt M6×12 E10 M6×12 E10 11 8.4±0.6
Bolt M6×45 E10 M6×45 E10 6 8.4±0.6
Bolt M6×25 E10 M6×25 E10 11 8.4±0.6
Bolt M6×12 E8 M6×12 E8 22 8.4±0.6
Cylinder head cover bolt M6×27 E10 10 9±1.0
Oil filter bracket bolt M8×30 E12 3 20±1
Heater water returning pipe bolt M6×20 E8 2 7.6±0.6
Hydraulic oil rail bolt M8×35 E12 2 18.4±1.4
Bolts of exhaust manifold bracket M8×20 E12 2 20±1
Plug
Main oil passage plug I Inner hex M20 2 60±5
Main oil passage plug II Inner hex M12 1 35±5
Water drainage plug Inner hex M12 1 25±5
Oil passage plug Inner hex M10 1 20±2
Oil drainage plug M14×1.5×14 1 39±5
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
Other bolts
Bolts of balance shaft gear M8×15×1.25 1 23.5±4.5
Bolts of balance shaft chain wheel M8×18×1.25 1 45±5
Set track bolts M6×1×12 2 10±2
Dynamic track bolts M8×1.25×15 1 23.5±4.5
Starter bolt M8×55 2 24±3
Oil pressure switch R 1/8 1 10±2
Spark plug M14 3 27.5±2.5
Exhaust manifold stud M8×1×12 6 12±2
Catalytic gas shroud nut M6×1 3 10±1
Q2580614 (crank signal wheel M6 12.5±2.5
3
bolt)
Water temperature sensor 1 20±4
Hall sensor bolt Inner hex M6×1×16 2 8.4±0.6
Knock sensor bolt Inner hex M8×1.25×30 1 20±4
Exhaust manifold nut M8 5 35±2
Throttle bolts 4 6±0.5
Absolute pressure sensor 6±0.5
self-tapping screw
Square head bolt M10×1.25×90 1 47±5
Idle wheel bolt M10×1.25×38 1 49±9
Oxygen sensor 2 35±5
Oil filter After contact mounting surface, turn by 3 / 4 laps
1
or 11 ± 1Nm
Bolts of heat shield 1 10±1
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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Maintenance Manual for J2 Sedan Mechanical Part of Engine
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.
1) Install the matching parts in a certain period of time after sealant applied.
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II. Preparation
1. Repair Tools
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
1. Check
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.
② If the oil is turbid or polluted, it may be caused by engine coolant. Please repair or replace the
damaged parts.
■ Oil pan
■ Oil filter
Attention:
■ As the temperature of engine oil is high, please prevent yourself from being hurt.
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
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.
⑥ Install the pressure switch in accordance with the following steps after inspection:
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.
① Warmup the engine to check engine compartment for oil leakage. Please refer to “Leakage of
engine oil”.
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
③ Loosen engine oil filler cap and remove the oil drain bolt.
Attention:
■ Be sure to clean oil drain bolt and install with new gasket.
Attention:
■ The oil filling volume varies with oil temperature and oil drainage time, thus the above data
are only for reference.
⑦ Warm up engine and check the oil drain bolt and oil filter for oil leakage.
1) Dismantlement
Attention:
■ As the temperatures of engine and engine oil are high, please proetct yourself from being hurt.
■ Thoroughly wipe and dry the engine oil splashed on the engine and vehicle.
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2) Installation
Attention:
■ If the filter is tightened by hand, oil leakage may occur due to inadequate tightening torque.
4) Check oil level and fill as required. Please refer to “Engine Oil”.
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1. Parts
1 – Engine oil pump assembly 2 – Automatic tensioner sight hole cover 3 – Front crankshaft oil seal
4 – O-ring 5 – Engine oil collector filter gasket 6 – Engine oil collector filter 7. Oil drainage bolt
washer 8. Oil drainage bolt 9 – Engine oil filter 10 – Oil sump assembly
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.
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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.
Attention:
Attention:
1) Oil pickup
■ 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.
3. Installation
3) Install external generator, power steering pump, cylinder head cover and other parts on the oil pump
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assembly.
■ 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.
■ Clean cylinder block and oil pan mating surface to ensure that there are no oil and other impurities.
Apply sealant
as shown in
figure.
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
Attention:
1) Check the oil level and fill as required. Please refer to “Engine Oil”.
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Thermost subassembly
Radiator
Expansion
tank
Thermostat
Thermostat
casing
Air throttle body
Warm air heat
exchanger
Water pump
Cylinder
Thermostat on body
Thermostat off
Cylinder
cover
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1. Check
1) Level check
After the engine cooled, check whether coolant level in reservoir is between MIN and Max marks.
2) Leakage check
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:
■ 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.
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② Open the water drain plug at the bottom of radiator, and then open the radiator cover.
③ If necessary, remove coolant reservoir to discharge coolant and clean the reservoir before
reinstallation.
④ 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
Attention:
■ Be sure to clean the water drain plug and install with new O-ring.
② Make sure all the hose clamps have been tightened firmly.
③ Dismount the air filter upper cover and air intake hose. Please refer to “Air Filter Assembly”.
④ Disconect the outlet pipe of warm water pipe. Please lift the hose as high as possible.
⑤ 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.
⑥ Install air filter upper cover and air intake hose. Please refer to “Air Filter Assembly”.
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:
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⑪ Install the radiator cap and repeat steps ③-⑨ more than twice until the engine coolant level does
not lower any more.
Attention:
■ Be sure to clean the water drainage plug and mount the new O-ring.
② Dismount air filter upper cover and air intake hose. Please refer to “Air Filter Assembly”.
③ Remove outlet pipe of warm water pipe. Please lift the hose as high as possible.
④ 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.
⑤ Install the air filter upper cover and air intake hose. Please refer to “Air Filter Assembly”.
⑦ Increase engine speed for several times with no load applied to the engine.
⑩ Repeat steps ①-⑨ until the radiator begins to discharge the cleared water.
III. Radiator
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⑤ Dismount the inlet and outlet hoses of radiator and returning hose of coolant reservoir.
⑥ Dismount bracket of radiator and take off the radiator and fan subassembly.
Attention:
■ Please do not damage or scratch the radiator core during dismantlement.
⑦ 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.
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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■ 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.
1) Dismantlement
② Disconnect the harness connector of radiator fan motor and move it aside.
Attention:
2) Installation
1) Disassembly
① Cooling fan
Check the cooling fan for cracks or abnormal bend. If any, replace the cooling fan.
② Fan motor
3) Assembly
V. Water Pump
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Attention:
■ Be careful not to splash the engine coolant onto the drive belt while dismantling the water pump.
■ 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. 1.3.005
① Discharge the engine coolant in radiator.
Please refer to “Replace Engine Coolant”.
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
Attention:
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b). Install drive belt and adjust it in accordance with specified tension. Please refer to “Drive Belt”.
■ 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.
1) Dismantlement
Attention:
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
① Thermostat
■ Inspect opening of thermostat valve at normal
room temperature.
Temperature of thermostat (ON): 82℃ (initially open)
95℃ (fully open)
Please replace the thermostat when the measurement exceeds the specified range.
3) Installation
① Be careful not to splash engine coolant onto the engine and wipe and dry the engine coolant with
cleaning cloth.
Attention:
■ Do not apply engine oil or other oil substances to the seal ring.
Highest
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■ Start and warm up the engine. Visually inspect if there is any engine coolant leakage.
2) Start and warm up the engine. Visually inspect if there is any engine coolant.
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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
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Caution:
The following rules should be complied with during the replacement of parts of fuel pipeline.
■ 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.
■ Connect the fuel pipe joint and make sure the joint has been fixed. Make sure the joint and resin
pipe don’t contact any adjacent parts.
■ 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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II. Preparation
Fuel pressure
1 JAC-T1F018 Measure fuel pressure
gauge
Check the fuel pipeline, fuel filler cap and fuel tank for proper installation, leakage, crack, damage,
loose connection, worn and aging.
Attention:
■ Prepare a container under the fuel pipe to be disconnect to avoid fuel splash.
2) Dismount the nut for fuel pressure inspection door on fuel injector guide rail.
4) Set ignition switch at “ON” position and check for fuel leakage.
Attention:
■ During the Inspection of fuel pressure, please always check the fuel piping for leakage.
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
1. Dismantlement
Caution:
■ Do read the “General Precautions” before dealing with fuel system. Please refer to “General
Precautions”.
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
Attention:
■ Please prepare the container and cleaning cloth in advance as fuel leakage may take place.
■ Please keep any parts away from heat source. Special attention must be paid when welding
around them.
■ Keep the connection clean and prevent damage and foreign substance, and properly cover the
connection with plastic bag or equivalent.
5) Take off the fuel guide rail with injector from intake manifold.
Attention:
■ Absorb the fuel leaked from fuel pipe with cleaning cloth.
6) Dismount the fuel injector from fuel guide rail with following steps:
Attention:
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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Maintenance Manual for J2 Sedan Mechanical Part of Engine
■ Check the injection hole of fuel injector for blockage. If any, please wash or replace by using
special instrument.
■ Check the fuel inspection hole for damage and jamming. If any, please replace.
3. Installation
■ As the upper and lower O-rings are different, do not confound them.
■ 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.
③ : thick one
⑤ : thin one
Attention:
b. Insert fuel injector into fuel pipe where snap has been mounted.
Attention:
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
■ 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.
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 “User’s Manual”.
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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.
Attention:
2
■ The joint can not be disconnected when the
raised position is fully pressed down. Do not
excessively distort the joint.
■ 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.
2. Installation
Be aware of following precautions to install with steps contrary to dismantlement.
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1) Fuel filter
2) Connector
② Make the connector align with the resin pipe and insert the connector straightly until “click” is
heard.
③ 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.
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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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.
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■ 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.
■ 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 Fig. 1.4.014
tool.
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Attention:
1) Fuel pump
① Visual Inspection
■ Check for broken or fuel impurity. If any, please replace or wash it.
■ 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
3) Locknut
■ Check for deformation, crack, material loss, broken, and damage at mounting thread.
■ Check the fuel float for interference and oxidation of its surface.
3. Installation
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■ 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.
■ Pre-tighten the locknut during its installation, and then tighten it horizontally.
2) Connector
② Make the connector align with the resin pipe and insert the connector straightly until “click” is
heard.
③ 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.
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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1) Dismantlement
Caution:
■ Do read the “General Precautions” before dealing with fuel system. See “General Precautions”.
① Carry out the dismantlement steps 1-6 of fuel pump. Please refer to “Fuel Pump”.
Attention:
■ The fastening band of fuel tank should not be blocked in supporting position.
⑤ Dismount the clamping bands of filler tube and fuel tank, and then disconnect the filler tube and
fuel tank.
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Attention:
① Fuel tank
■ Check the backing plate for crack, material loss, deformation and breakage.
3) Installation
■ Please refer to “Fuel Pipe Joint” for precautions of fuel pipe joint connection.
① Set ignition switch at “ON” position (when engine stops), and then check the connection of fuel
pipeline for leakage.
② Start the engine, increase its speed and recheck the connection between piping and fuel pipe of fuel
system for leakage.
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1. Description
Intake manifold
Air cleaner
Fuel evaporation
EVAP carbon Air
canister
Fuel tank
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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1
6
Note:
Fig. 1.5.001
Do not use soap water or any other detergent when
2
installing vacuum pipe or cleaning pipeline. 1 3
3. Inspection of parts
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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Lift the carbon canister and dismount it from the Fig. 1.5.002 左前车架
Left front frame
bracket on inner lining of left fender.
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.
① 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.
② Dismantlement
Fig. 1.5.003
a. Disconnect the vacuum hose of EVAP carbon
canister solenoid valve.
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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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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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Maintenance Manual for J2 Sedan Mechanical Part of Engine
2. Inspection of Element
1) Operation principle
Moderate No
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Maintenance Manual for J2 Sedan Mechanical Part of Engine
① Dismantlement
vacuum pressure.
b. Disconnect all hoses and clean with compressed air. If the blockage in hose can not be cleared,
replace.
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1. Parts
Ignition coil
1) Dismantlement
Attention:
Fig. 3.1.001
■ Be sure that the ignition switch is in the
“OFF” position.
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Maintenance Manual for J2 Sedan Electrical Part of Engine
Attention:
Attention:
■ The ignition coil harness connector must be disconnected for secondary coil resistance
measurement.
② Spark plug
■ Check spark plug for carbon deposit. See the following table for causes of carbon deposit.
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Maintenance Manual for J2 Sedan Electrical Part of Engine
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:
■ If the clearance is less than 14 mm, the sparks may also be produced even though the high
voltage wire has trouble.
3) Installation
Install with steps contrary to dismantlement.
II. Diagnosis of Common Troubles
Diagnosis Common Troubles
Symptom Possible causes Solution
The engine can’t or is Trouble of ignition coil or ignition Check or replace the ignition coil or the
difficult to start. switch 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 0.77-0.95Ω
Ignition coil Secondary coil resistance 8.7±0.87 KΩ
Spark plug Spark plug clearance 0.7-0.8mm
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Maintenance Manual for J2 Sedan Electrical Part of Engine
120 A 中央电器盒
Central electric
熔断片
30 A fuse link 熔断片
fuse
box 熔断片
20 A fuse link
30A 120A
link 20A
Battery
蓄电池
START 点火开关
Ignition switch
LOCK
ACC ON O/S
Combined
组合仪表
充电指示灯
Charging
alarm light
device
- +
B S L
Electric
发电机
generator
R2
整流器
Rectifier Magnetic
ETACS-low level effective field磁场绕组 Df
R1
ETACS-低电平有效 winding R3
接地
Grounding
起动机 ZD
Starter
定子绕组
Stator winding R4
Tr1
ENG Tr2
电动机
Electric 电磁开关
Solenoid
switch
motor
单向离合器
One-way clutch
II. 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.
■ Always keep surface of battery (esp. the top) clean and dry.
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Maintenance Manual for J2 Sedan Electrical Part of Engine
■ If the vehicle is not used for a long time, the cathode terminal of battery should be disconnected.
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)
④ If U<11V, the battery is damaged or the charging system has trouble. Please inspect charging
system and battery.
1) Dismantlement
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Maintenance Manual for J2 Sedan Electrical Part of Engine
① Bracket of battery
■ Check for erosion. If there is, clean with warm clean water.
② Battery harness
3) Installation
Attention:
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Maintenance Manual for J2 Sedan Electrical Part of Engine
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.
Fig. 3.2.003
Components of Starter
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Maintenance Manual for J2 Sedan Electrical Part of Engine
2) Installation
Attention:
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Maintenance Manual for J2 Sedan Electrical Part of Engine
1) Disassembly
4
1
11
10
8 9
16
3
2
15
14
13
12
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
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2) Check
① Solenoid switch
“M”
■ Replace solenoid switch if opened.
② Pinion
■ If the teeth are worn or damaged, replace meshing gear (check teeth of fly wheel in this step).
■ 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.
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③ Electric brush
Fig. 3.2.008
■ Check brush wearing with a caliper. if
excessive worn, replace.
Vernier caliper
Electric brush
Electric brush
spring
Electric brush
⑥ Inspection of Stator
■ Check whether magnet is firmly fixed on the Fig. 3.2.011 Magnet
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■ If open, replace.
■ If open, replace.
Sand paper
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.
Pinion
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4. Diagnosis flow chart of Common Troubles (if there is any abnormity found, disconnect negative
pole of battery at once.)
Yes Yes
Does engine run with Does engine run normally?
revolving of crankshaft?
Inspect ignition/fuel system.
No
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
No
Does magnet switch make
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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1. System Description
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.
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.
③ Loosen the adjusting supporting nut on generator. Then adjust tension with the tension adjusting
bolt.
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Fig. 3.2.019
Fig. 3.2.020
④ Dismount the belt of generator. Please refer to the “Drive Belt” section.
⑤ Take off the generator from the vehicle.
2) Installation
■ Before installing the generator, please inspect tension of generator belt. Please refer to the “Drive
Belt”.
Attention:
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1) Disassembly
① Belt pulley
② Rear cover
③ Commutator assembly
Attention:
a. Resistance test
Slip ring
b. Insulator test
② Carbon brush
a. Check carbon bush for smooth moving. The mark line of wearing limit of
Fig. 3.2.022 electric brush
③ Stator
■ If not, replace.
Stator
core
3) Assembly
① Rear bearing
Attention:
■ The rear bearing can not be reused after being taken off. Please with new one.
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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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.
Change the
Conduct the following
damaged IC
check: 1. Rotor 2. Slip ring
Alarm light: the “charging” alarm light in the regulator or
of rotor 3. Electric brush 4.
combined instrument. diode assembly.
Stator.
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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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.
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.
1. Only digital electric meter should be used to inspect the electronic control system.
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.
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.
2. The electronic controlled injection system operates with high fuel pressure (approximately 350kPa).
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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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Function: reading/clearing DTC of electronic injection system, view data flow, test actions of parts, etc..
Fig. 4.1.001
Fig. 4.1.002
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Function: measure characteristic parameters such as voltage, current and resistance of electronic
injection system
Fig. 4.1.003
Fig. 4.1.004
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Fig. 4.1.005
Function: inspect pressure of fuel system, determine working states of fuel pump and fuel pressure
regulator.
Fig. 4.1.006
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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.
■ 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 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
battery cathode before dismounting the any components.
Fig 4.1.007
Battery
■ 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 4.1.008
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. Broken
■ Connect the harness connectors of ECM
firmly. Poor connection may cause extremely
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.
■ Don’t 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.
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Diagnosis Diagnosis
Sensors Actuators
Engine
control valve
Fuel
Carbon canister Intake
pressure Phase Ignition
pressure/ sensor
temperature regulator coil
sensor
Throttle body assembly Oxygen sensor
Three-way
catalytic
Fuel injector converter
Throttle position Knock
Water temperatrue
sensor
sensor sensor
Stepping
motor
Fuel
filter
Speed
sensor
Diagnosis Product
interface Fuel tank manufactured by
UAES
Electric fuel pump ansd
brakckt assembly
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Engine speed
Hall sensor
Piston position
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
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cancelled. In starting work conditions, spark advance are also adjusted and vary with the engine
temperatures, intake air temperatures and engine speeds.
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.
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, 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
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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. λClosed-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 λ=1. The objective of the λ 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. λ 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 (λ> 1)
produces a sensor voltage of about 100mV and the concentrated gas mixture (λ <1) produces a sensor
voltage of about 900mV. In case of λ=1, the sensor voltage has a jump. λ closed-loop control responds
to the input signal (λ>1= too thin mixture, λ<1= too thick mixture) to revise the control variable and
produce a correction factor as a multiplier to correct the fuel injection duration.
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 λ closed-loop control system is running under the closed-loop
condition.
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.
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.
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
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related to the sensor and actuator can be read with the diagnosis apparatus, and the actuator may be
driven forcibly in some cases.
With relay connected, the fuel injection pump will be energized when the crankshaft starts to rotate or
with engine running.
The speeds of the radiator fan and condenser fan is controlled with the engine coolant temperature,
vehicle speed and air conditioner switch signal (AC).
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).
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 λ 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).
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Function
Function diagnosis
Electronic
diagnosis control unit
Data
collection Control command
Sensors
Actuators
Engine
★ The malfunction indicator lamp lights up after the ignition switch is turned on (ON) and then goes
out after 4s.
★ If the engine is started within 4s, the malfunction indicator lamp goes out upon detection of speed
signal.
★ After the K-line is grounded for more than 2.5s, the malfunction indicator lamp will flash at a
frequency of 2Hz.
★ The malfunction indicator lamp will be always on after the ignition switch is turned on (ON).
★ After the engine is started, the malfunction indicator lamp will go out upon detection of speed
signal. If the malfunction indicator lamp in question is defined as ON mode in the malfunction
category, the malfunction indicator lamp will be always on after the corresponding conditions are
met.
4. Inspection steps
1) For the vehicles with OBD function, inspection should be carried out always with steps below:
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The “K” line protocol and ISO9141-2 standard diagnosis joint are adopted for the system as shown in
the figure.
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 15 of ECM, that is, the
“K” data line of the electronic control system of engine; pin 16 is connected to battery negative pole.
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found
Normal
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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 to reach the maximum vehicle speed.
Driving
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.
There is repeatedly forward surge when traveling with constant or variable
Surge
speed.
There is a strong voice like the hammer against the cylinder wall during the
Knock
driving which is harmful to driving.
Keep running(fail to
Parking
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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1) Conditions
Attention:
■ Check the regular items including spark plug, fuel injector and compression pressure of the
cylinder at beginning of inspection.
② Lamps, electronic fan and all the accessories are turned off.
4) Run engine for over 5s with speed of 2000-3000 rpm and then make the engine operate for 2min at
the idle speed.
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.
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:
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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.
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.
10) Disconnect the fuel pressure gauge and install the inspection port nut.
① Turn the ignition switch to the "ON" position (with engine stopped), and then check for leakage at
the joint of the fuel pipeline.
② Start the engine and increase speed, inspect whether there is leakage at joint of fuel system.
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1. Description
1) 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.
2) 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. 4.3.001
Installed on the back of throttle
3. Circuit Diagram
Pin 19: 5V voltage signal
Pin 59: Manifold pressure sensor signal
Pin 40: Power ground
Pin 25: Intake air temperature sensor signal
Operating voltage: 5 ± 0.1V
5V power supply 1
Intake pressure/
temperature
Sensor grounding
sensor
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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 ℃
6. Dismantlement and Installation
1) Dismantlement
Attention:
2) Installation
Be aware of following precautions and install with steps contrary to dismantlement.
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■ 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.
1. Instruction of Parts
The engine coolant temperature sensor measures the engine coolant temperature and sends the signal to
the ECM for control of ignition timing and fuel injection pulse width during start, idling, and normal
running. It adopts one negative temperature coefficient thermistor, of which the resistance reduces
following the increasing of the temperature. Depending on the voltage output of the sensor, the ECM
judges the temperature of coolant and sends gas mixture with best air-fuel ratio to the engine.
3. Wiring Diagram
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Coolant temperature
sensor
4. Diagnosis
5. Trouble Solution
It mainly checks the connections between wires of sensor and ECU and between wires of sensor
and instruments for presence of short-circuit and open-circuit.
Grounding: poor grounding easily lead to excessively high engine water temperature indication;
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1) Dismantlement
2) Installation
■ Apply surface sealant on threaded part of sensor and tighten with specified torque. Tightening
torque :16-24N. M
1. Instruction of Parts
This sensor is one angle sensor with linear output characteristic and is composed of two arc sliding
contact resistors and two sliding contact arms. The hinges of the sliding contact arms are coaxial with
the throttle shaft. A 5V supply voltage US is applied onto two sides of the sliding resistors. At the
rotation of the throttle, the sliding contact arms rotate as well to move on the sliding contact resistors
and output the potential UP of the contact as voltage output. Therefore, it’s actually a rotation angle
potentiometer that outputs a voltage signal in proportional to the throttle position.
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2. Installation Position
Fig. 4.3.006
It’s installed on throttle body.
Pin39: 5V grounding
Throttle Position
Sensor
4. Diagnosis
5. Solutions
Mainly inspect sensor and ECU wiring harness for short circuit, open circuit, grounding problems;
Shift the multimeter to Ohm measurement scale and connect two probes of the multimeter to 1# and
2# pines of the sensor respectively to measure the resistance. The measurement at ambient
temperature shall be 2kΩ±20%. Connect two probes to the 1# and 3# pins respectively and rotate
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the throttle. The resistance measurement shall vary linearly following the opening of the throttle.
The measurement on 2# and 3# pins shall be on the contrary.
Note: While observing the variation of resistance, pay attention to observe for presence of high
resistance leap.
1) Dismantlement
2) Installation
1. Component Description
The crankshaft position sensor is used to provide the engine speed information and crankshaft top
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dead center information in the ignition system. It’s composed of a permanent magnet and a coil
enwinding the magnet. The crankshaft signal wheel is one toothed disc, which originally has 60
teeth, but with two missing teeth. The signal wheel is installed on the crankshaft and rotates along
with the crankshaft. When the tip of tooth passes through the tip of crankshaft position sensor, the
signal wheel made of ferromagnetic material cuts the magnetic force line of permanent magnet in
the speed sensor to generate induced voltage within the coil as the speed signal output.
Performance:
2. Installation position
Fig. 4.3.009
Crankshaft Position
Sensor
3. Wiring Diagram
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Speed sensor
4. Diagnosis
5. Trouble Solution
Check sensor circuit for normal function and incorrect connection of grounding
Connect the sensor and harness to check whether the connections of power supply, grounding wire,
and signal wire are normal.
1)Removal
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Fig. 4.3.010
Fig. 4.3.011
2) Installation
1. Component Description
This sensor provides crankshaft phase information to the ECU, namely differentiating the
compression top dead center and the exhaust top dead center of the crankshaft.
This sensor is manufactured by means of the Hall theory in which the Hall voltage is subject to the
varying magnetic field induction strength.
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B
Theory of Hall sensor: When a current IS flows
through a semi-conductor chip, one Hall voltage is
generated in the right-hand direction of the
current, of which the voltage UH is in proportion
to the magnetic field induction B (perpendicular to
the current IS) and the current IS. The Hall voltage
is subject to the varying magnetic field induction
I strength B.
UH
Performance:
2. Installation position
Fig. 4.3.012
Camshaft position
sensor
3. Wiring Diagram
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Phase sensor
4. Diagnosis
5. Trouble Solution
Check sensor circuit for normal function and incorrect connection of grounding
Connect the sensor and harness to check whether the connections of power supply, grounding wire,
and signal wire are normal.
1)Removal
Fig. 4.3.013
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Fig. 4.3.014
2) Installation
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.
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2. Installation position
Fig.4.3.015
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.
3. Wiring diagram
Downstream
oxygen
sensor Main
relay
Upstream
oxygen
sensor
Main
relay
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:
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;
Changes of the oxygen sensors should be not less than a certain times in certain period of time.
1) Dismantlement
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.
Off-white: normal
2) Installation
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■ After replacement of oxygen sensor, oxygen sensor should be coated with a layer of anti-rust oil to
prevent rust which impede removal.
1. Instruction of Parts
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.
2. Installation Position
Fig. 4.3.018
It is installed on the fuel guide rail.
3. Wiring Diagram
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To main relay
4. Inspection
Attention:
■ Please clean the fuel injector and analyze with special cleaning and analysis instrument for fuel
inject at certain interval..
2) Inspect operating time of the fuel injector with trouble diagnosis apparatus.
■ Standard operation time: 2.0-3.0ms at the idle speed and more during the acceleration.
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.
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.
3. Inspection
1) Wiring diagram
Knock sensor
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:
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.
Attention:
2) Installation
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
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With engine idling, use fault diagnostic apparatus to check air-conditioning switch for normal working.
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.
3. Wiring diagram
4. Diagnosis
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5. Trouble Solution
2) Installation
■ 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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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.
This engine adopts independent ignition technology and utilizes the theory of high energy utilization by
the mutual inductance of electromagnetic coil to control the energization time and power-off moment of
the secondary coil and utilize the high voltage generated in the secondary stage of the coil to puncture
the gap of spark plug, generate strong spark, and ignite the gas mixture. Due to high air ionization
degree and low resistance during engine exhaust stroke, it only needs a low voltage to puncture the gap
of spark plug. Therefore, this system adopts grouped ignition technology, which will not waste any
energy and will save a great amount of cost.
Fig. 4.3.024
2. Installation position
Fig. 4.3.025
Installed at top of the cylinder head cover.
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3. 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.
4. Diagnosis
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).
2. Installation Position
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.
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4. Inspection
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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1. System description
The greatest characteristic in the electronic control system of the M7 engine is the adoption of
torque-based control strategy. The torque-based control strategy is mainly intended to link a great
amount of different control objectives. This is the sole method to integrate flexibly all kinds of functions
into different variants of ECU depending on the engine and vehicle models.
In the engine electronic control system, the sensors are functioned as input parts to measure all kinds of
physical signals (temperature, pressure, etc.) and convert to corresponding electric signals, the ECU is
functioned to receive the input signals from sensors, calculate and process as per preset programs,
generate corresponding control signals, and output to power drive circuits, and the power drive circuits
execute different actions by driving corresponding actuators and control the engine to run as per preset
control strategy. At the same time, the malfunction diagnosis system of ECU monitors various
components and control functions in the system. Once a malfunction is detected and confirmed, the
system will save the malfunction code and activate the “Limp home” function. Upon the detection that
the malfunction is resolved, the system will resume to normal values.
1) Functions
Improve control function of gas mixture under static and dynamic conditions
λ closed-loop control
Idling control
Limp home
etc.
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* Specific pin number is subject to harness schematic diagram (standby terminal defined as empty pin).
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3. Installation Position
Fig. 4.3.026
Installation position is shown in the figure right.
4. Inspection
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.
1) Dismantlement
① Turn the ignition switch to “OFF” position to dismantle the negative terminal of battery.
2) Installation
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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.
■ 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.
Fault code: P0107 “the intake pressure sensor is short to ground”
Check if the intake pressure in the data flow is about 101kpa Yes To Step 5
2
(depending on the air pressure then).。 No Next step
Unplug the connector of intake pressure sensor on the harness, and Yes To Step 5
3 measure if the voltage between Pins 3# and 1# of this connector is
about 5V by the multimeter. No Next step
Check if the circuits connecting Pins 40#, 19# and 59# of ECU Repair or replace
Yes
4 respectively to Pins 1#, 3# and 4# of sensor connector are short to the harness
ground. No Next step
Start the engine and run the engine idly. Slowly depress the
accelerator pedal and almost open the throttle completely; observe the Yes Diagnosis help
change of the “Intake pressure” value on the diagnosis meter, and at
5 this moment, the displayed value shall not change significantly; fast
depress the accelerator pedal and almost open the throttle completely, Replace the
and at this moment, the displayed value can reach above 90kpa No
sensor
instantly.
Fault code: P0108 “the intake pressure sensor is short to power source”
Check if the intake pressure in the data flow is about 101kpa Yes To Step 5
2
(depending on the air pressure then). No Next step
Unplug the connector of intake pressure sensor on the harness, and Yes To Step 5
3 measure if the voltage between Pins 3# and 1# of this connector is
about 5V by the multimeter. No Next step
Check if the circuits connecting Pins 40#, 19# and 59# of ECU Repair or replace
Yes
4 respectively to Pins 1#, 3# and 4# of sensor connector are open or the harness
short to power source. No Next step
Start the engine and run the engine idly. Slowly depress the
accelerator pedal and almost open the throttle completely; observe the Yes Diagnosis help
change of the “Intake pressure” value on the diagnosis meter, and at
5 this moment, the displayed value shall not change significantly; fast
depress the accelerator pedal and almost open the throttle completely, Replace the
and at this moment, the displayed value can reach above 90kpa No
sensor
instantly.
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Fault code: P0112 “the signal voltage of intake temperature sensor is too low”
Unplug the connector of intake temperature sensor on the harness, Yes Next step
and check if the resistance between Pins 1# and 2# of sensor
3
corresponds to its temperature by the multimeter (refer to the relevant Replace the
section in this repair manual for the details). No
sensor
Unplug the connector of intake temperature sensor on the harness, Yes To Step 5
4 and check if the voltage between Pins 1# and 2# of this connector is
about 5v by the multimeter. No Next step
Check if the circuits connecting Pins 40# and 25# of ECU Repair or replace
Yes
5 respectively to Pins 1# and 2# of sensor connector are open or short the harness
to power source. No Next step
Start the engine and run the engine idly. Observe the change of the Yes Diagnosis help
“Intake temperature” value on the diagnosis meter, and at this
6
moment, the displayed value increases along with the rising of engine Replace the
intake temperature. No
sensor
Fault code: P0113 “the signal voltage of intake temperature sensor is high”
Observe if the “Intake temperature” in the data flow is equivalent to Yes To Step 5
the temperature inside the intake pipe (depending on the engine
2
temperature then). Notice: if the displayed value is always -40℃, the
circuit may be open. No Next step
Unplug the connector of intake temperature sensor on the harness, Yes Next step
and check if the resistance between Pins 1# and 2# of sensor
3
corresponds to its temperature by the multimeter (refer to the relevant Replace the
section in this repair manual for the details). No
sensor
Unplug the connector of intake temperature sensor on the harness, Yes To Step 5
4 and check if the voltage between Pins 1# and 2# of this connector is
about 5v by the multimeter. No Next step
Check if the circuits connecting Pins 40# and 25# of ECU Repair or replace
Yes
5 respectively to Pins 1# and 2# of sensor connector are short to the harness
ground. No Next step
Start the engine and run the engine idly. Observe the change of the Yes Diagnosis help
“Intake temperature” value on the diagnosis meter, and at this
6
moment, the displayed value increases along with the rising of engine Replace the
intake temperature. No
sensor
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Fault code: P0117 “the circuit voltage of engine coolant temperature sensor is too low”
Unplug the connector of coolant temperature sensor on the harness, Yes Next step
and check if the resistance between Pins 1# and 2# of sensor
3
corresponds to its temperature by the multimeter (refer to the relevant Replace the
section in this repair manual for the details). No
sensor
Unplug the connector of coolant temperature sensor on the harness, Yes To Step 6
4 and check if the voltage between Pins 1# and 2# of this connector is
about 5v by the multimeter. No Next step
Check if the circuits connecting Pins 40# and 41# of ECU Repair or replace
Yes
5 respectively to Pins 1# and 2# of sensor connector are open or short the harness
to power source. No Next step
Start the engine and run the engine idly. Observe the change of the Yes Diagnosis help
“Coolant temperature” value on the diagnosis meter, and at this
6
moment the displayed value shall increase with the rising of engine Replace the
coolant. No
sensor
Fault code: P0118 “the circuit voltage of engine coolant temperature sensor is too high”
Unplug the connector of coolant temperature sensor on the harness, Yes Next step
and check if the resistance between Pins 1# and 2# of sensor
3
corresponds to its temperature by the multimeter (refer to the relevant Replace the
section in this repair manual for the details). No
sensor
Unplug the connector of coolant temperature sensor on the harness, Yes To Step 6
4 and check if the voltage between Pins 1# and 2# of this connector is
about 5v by the multimeter. No Next step
Check if the circuits connecting Pins 40# and 41# of ECU Repair or replace
Yes
5 respectively to Pins 1# and 2# of sensor connector are short to the harness
ground. No Next step
Start the engine and run the engine idly. Observe the change of the Yes Diagnosis help
“Coolant temperature” value on the diagnosis meter, and at this
6
moment the displayed value shall increase with the rising of engine Replace the
coolant. No
sensor
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Fault code: P0122 “the circuit voltage of throttle position sensor is at the extremely low limit”
Observe if the value of “Throttle opening” is between 4% and 10% Yes Next step
2
(depending on the bus model). No To Step 5
Slowly depress the accelerator pedal to fully open the throttle, and Yes Next step
observe if the value of “Throttle opening” in the data flow increases
3
to 85-95% along with the increase of throttle opening (depending on
the bus model). No To Step 5
Replace the
Repeat Step 3 and observe if the value of “Throttle opening” in the Yes
4 sensor
data flow springs during change.
No Next step
Unplug the connector of throttle position sensor on the harness, and Repair or replace
Yes
check if the circuits connecting Pins 39#, 18# and 26# of ECU the harness
5
respectively to Pins 1#, 2# and 3# of sensor connector are short to
ground. No Next step
Replace the
Check if the voltage between Pins 1# and 2# of this connector is Yes
6 sensor
about 5V by the multimeter.
No Diagnosis help
Fault code: P0123 “the circuit voltage of throttle position sensor is at the extremely high limit”
Observe if the value of “Throttle opening” is between 4% and 10% Yes Next step
2
(depending on the bus model). No To Step 5
Slowly depress the accelerator pedal to fully open the throttle, and Yes Next step
observe if the value of “Throttle opening” in the data flow increases
3
to 85-95% along with the increase of throttle opening (depending on
the bus model). No To Step 5
Replace the
Repeat Step 3 and observe if the value of “Throttle opening” in the Yes
4 sensor
data flow springs during change.
No Next step
Unplug the connector of throttle position sensor on the harness, and Repair or replace
Yes
check if the circuits connecting Pins 39#, 18# and 26# of ECU the harness
5
respectively to Pins 1#, 2# and 3# of sensor connector are open or
short to power source. No Next step
Replace the
Check if the voltage between Pins 1# and 2# of this connector is Yes
6 sensor
about 5V by the multimeter.
No Diagnosis help
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Start the engine and run the engine idly till the coolant temperature Yes Diagnosis help
reaches to the normal value. Observe the change of the value of
2
“Oxygen sensor voltage” on the diagnosis meter, and at this moment,
the displayed value shall change fast between 100mV and 900mV. No Next step
Check if the circuits connecting Pins 39# and 45# of ECU Repair or replace
Yes
respectively to Pin 3# (relative to gray connecting wire of oxygen the harness
3
sensor) and Pin 4# (relative to black connecting wire of oxygen
sensor) of sensor connector are short to ground. No Next step
A. Check if the intake system has serious leakage. Make check and
B. Check if the fuel injector is blocked. repair according
Yes
to diagnosis
C. Check if the spark plug clearance is too big.
4 results.
D. Check if the resistance of live wire branch is too high.
E. Check if the intake valve guide is worn. No Diagnosis help
Etc.
Fault code: P0131 “the circuit voltage of upstream oxygen sensor signal is too low”
Start the engine and run the engine idly till the coolant temperature Yes Diagnosis help
reaches to the normal value. Observe the change of the value of
2
“Oxygen sensor voltage” on the diagnosis meter, and at this moment,
the displayed value shall change fast between 100mV and 900mV. No Next step
Check if the circuits connecting Pins 39# and 45# of ECU Repair or replace
Yes
respectively to Pin 3# (relative to gray connecting wire of oxygen the harness
3
sensor) and Pin 4# (relative to black connecting wire of oxygen
sensor) of sensor connector are short to power source. No Diagnosis help
Fault code: P0132 “the circuit voltage of upstream oxygen sensor signal is too high”
Start the engine and run the engine idly till the coolant temperature Yes Diagnosis help
reaches to the normal value. Observe the change of the value of
2
“Oxygen sensor voltage” on the diagnosis meter, and at this moment,
the displayed value shall change fast between 100mV and 900mV. No Next step
Check if the circuits connecting Pins 39# and 45# of ECU Repair or replace
Yes
respectively to Pin 3# (relative to gray connecting wire of oxygen the harness
3
sensor) and Pin 4# (relative to black connecting wire of oxygen
sensor) of sensor connector are short to power source. No Diagnosis help
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Start the engine and run the engine idly till the coolant temperature Yes Diagnosis help
reaches to the normal value. Observe the change of the value of
2
“Oxygen sensor voltage” on the diagnosis meter, and at this moment,
the displayed value shall change fast between 100mV and 900mV. No Next step
Check if the circuits connecting Pins 39# and 45# of ECU Repair or replace
Yes
respectively to Pin 3# (relative to gray connecting wire of oxygen the harness
3
sensor) and Pin 4# (relative to black connecting wire of oxygen
sensor) of sensor connector are open. No Diagnosis help
Fault code: P0171 “the closed loop control self leaning of off-line air/fuel ratio test is too infrequent”
(Note: the following diagnosis procedures are applicable to the case that the fault codes of intake
pressure sensor, canister control valve, oxygen sensor and so on do not occur together; if the relevant
fault codes exist at the same moment, please firstly solve other faults and then make check and repair
according to the following procedure.)
Connect the fuel pressure meter to the fuel system inlet pipe, and Yes Next step
3 observe if the fuel pressure remains at 350kPa or so under all the Check and repair
work conditions. No
the fuel system
Check if the circuits connecting Pins 39# and 45# of ECU Repair or replace
Yes
respectively to Pin 3# (relative to gray connecting wire of oxygen the harness
4
sensor) and Pin 4# (relative to black connecting wire of oxygen
sensor) of sensor connector are short to ground. No Next step
A. Check if the intake system has serious leakage; Make check and
B. Check if the fuel injector is blocked. repair according
Yes
to diagnosis
C. Check if the spark plug clearance is too big.
5 results.
D. Check if the resistance of live wire branch is too high.
E. Check if the intake valve guide is worn. No Diagnosis help
Etc.
Fault code: P0172 “the closed loop control self leaning of off-line air/fuel ratio test is too frequent”
(Note: the following diagnosis procedures are applicable to the case that the fault codes of intake
pressure sensor, canister control valve, oxygen sensor and so on do not occur together; if the relevant
fault codes exist at the same moment, please firstly solve other faults and then make check and repair
according to the following procedure.)
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Connect the fuel pressure meter to the fuel system inlet pipe, and Yes Next step
3 observe if the fuel pressure remains at 350kPa or so under all the Check and repair
work conditions. No
the fuel system
Check if the circuits connecting Pins 39# and 45# of ECU Repair or replace
Yes
respectively to Pin 3# (relative to gray connecting wire of oxygen the harness
4
sensor) and Pin 4# (relative to black connecting wire of oxygen
sensor) of sensor connector are short to power source. No Next step
Fault code: P0201 “the control circuit of fuel injector of Cylinder 1# is open”
Check if the circuit between Pin 2# of the fuel injector connector of Repair or replace
Yes
6 Cylinder 1# and Pin 50 of ECU is open or short to power source or the harness
ground. No Diagnosis help
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Fault code: P0202 “the control circuit of fuel injector of Cylinder 2# is open”
Check if the circuit between Pin 2# of the fuel injector connector of Repair or replace
Yes
6 Cylinder 2# and Pin 63 of ECU is open or short to power source or the harness
ground. No Diagnosis help
Fault code: P0203 “the control circuit of fuel injector of Cylinder 3# is open”
Check if the circuit between Pin 2# of the fuel injector connector of Repair or replace
Yes
6 Cylinder 3# and Pin 49 of ECU is open or short to power source or the harness
ground. No Diagnosis help
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Fault code: P0327 “the circuit voltage of knocking sensor signal is too low”
Unplug the knocking sensor connector on the harness, and check if Yes Next step
2 the resistance between Pins 1# and 2# of knocking sensor is higher Replace the
than 1MΩ by the multimeter. No
sensor
Check if the circuits connecting to Pins 1# and 2# of knocking sensor Repair or replace
Yes
3 connector to Pins 30# and 31# of ECU are open or short to power the harness
source or ground. No Next step
According to the specifications, replace the knocking sensor, test the Yes Diagnosis help
4 car and make engine rotation speed higher than 2200rpm. Check if
the fault code P0327 appears again. Check if it is a
No
sporadic fault
Fault code: P0328 “the circuit voltage of knocking sensor signal is too high”
Unplug the knocking sensor connector on the harness, and check if Yes Next step
2 the resistance between Pins 1# and 2# of knocking sensor is higher Replace the
than 1MΩ by the multimeter. No
sensor
Check if the circuits connecting to Pins 1# and 2# of knocking sensor Repair or replace
Yes
3 connector to Pins 30# and 31# of ECU are open or short to power the harness
source or ground. No Next step
According to the specifications, replace the knocking sensor, test the Yes Diagnosis help
4 car and make engine rotation speed higher than 2200rpm. Check if
the fault code P0328 appears again. Check if it is a
No
sporadic fault
Unplug the phase sensor connector on the harness, and check if the Yes To Step 4
2 voltage between Pins 3# and 1# of this connector is about 12V by the
multimeter. No Next step
Repair or replace
Check if the circuit connecting Pin 3# of phase sensor to Pin 87# of Yes
the harness
3 main relay is open or short to ground.
Check if Pin 1# of phase sensor is grounded improperly. No Next step
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Check if the voltage between Pin 2# of phase sensor and the negative Yes To Step 6
4
pole of power source is about 9.9V. No Next step
Repair or replace
Check if the circuit connecting to Pin 2# of phase sensor connector to Yes
5 the harness
Pin 42# of ECU is open or short to power source or ground.
No Next step
Yes Diagnosis help
6 Check if the signal panel of camshaft is good. Replace the
No
signal panel
Unplug the phase sensor connector on the harness, and check if the Yes To Step 4
2 voltage between Pins 3# and 1# of this connector is about 12V by the
multimeter. No Next step
Repair or replace
Check if the circuit connecting Pin 3# of phase sensor to Pin 87# of Yes
the harness
3 main relay is open or short to ground.
Check if Pin 1# of phase sensor is grounded improperly. No Next step
Check if the voltage between Pin 2# of phase sensor and the negative Yes To Step 6
4
pole of power source is about 9.9V. No Next step
Repair or replace
Check if the circuit connecting to Pin 2# of phase sensor connector to Yes
5 the harness
Pin 42# of ECU is open or short to power source or ground.
No Next step
Yes Diagnosis help
6 Check if the signal panel of camshaft is good. Replace the
No
signal panel
Unplug the phase sensor connector on the harness, and check if the Yes To Step 4
2 voltage between Pins 3# and 1# of this connector is about 12V by the
multimeter. No Next step
Repair or replace
Check if the circuit connecting Pin 3# of phase sensor to Pin 87# of Yes
the harness
3 main relay is open or short to ground.
Check if Pin 1# of phase sensor is grounded improperly. No Next step
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Check if the voltage between Pin 2# of phase sensor and the negative Yes To Step 6
4
pole of power source is about 9.9V. No Next step
Repair or replace
Check if the circuit connecting to Pin 2# of phase sensor connector to Yes
5 the harness
Pin 42# of ECU is open or short to power source or ground.
No Next step
Yes Diagnosis help
6 Check if the signal panel of camshaft is good. Replace the
No
signal panel
Unplug the phase sensor connector on the harness, and check if the Yes To Step 4
2 voltage between Pins 3# and 1# of this connector is about 12V by the
multimeter. No Next step
Repair or replace
Check if the circuit connecting Pin 3# of phase sensor to Pin 87# of Yes
the harness
3 main relay is open or short to ground.
Check if Pin 1# of phase sensor is grounded improperly. No Next step
Check if the voltage between Pin 2# of phase sensor and the negative Yes To Step 6
4
pole of power source is about 9.9V. No Next step
Repair or replace
Check if the circuit connecting to Pin 2# of phase sensor connector to Yes
5 the harness
Pin 42# of ECU is open or short to power source or ground.
No Next step
Yes Diagnosis help
6 Check if the signal panel of camshaft is good. Replace the
No
signal panel
Fault code: P0444 “the control circuit of canister control valve is open”
Repair or replace
Check if the circuit of power supply side of canister control valve is Yes
3 the harness
open or short to ground.
No To Step 2
4 Check if the resistance between Pins 1# and 2# of the canister control Yes Next step
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Repair or replace
Check if the circuit connecting Pin 2# of canister control valve Yes
6 the harness
connector to Pin 37# of ECU is open.
No Diagnosis help
Fault code: P0458 “the voltage of control circuit of canister control valve is too low”
Repair or replace
Check if the circuit of power supply side of canister control valve is Yes
3 the harness
open or short to ground.
No To Step 2
Yes Next step
Check if the resistance between Pins 1# and 2# of the canister control
4 Replace the
valve at 20℃ is between 22Ω and 30Ω by the multimeter. No
control valve
Check if the voltage between Pin 1# of the canister control valve Yes Diagnosis help
5 connector and the negative pole of power source is about 3.7V by the
multimeter. No Next step
Repair or replace
Check if the circuit connecting Pin 2# of canister control valve Yes
6 the harness
connector to Pin 37# of ECU is short to ground.
No Diagnosis help
Fault code: P0459 “the voltage of control circuit of canister control valve is too high”
Repair or replace
Check if the circuit of power supply side of canister control valve is Yes
3 the harness
open or short to ground.
No To Step 2
Yes Next step
Check if the resistance between Pins 1# and 2# of the canister control
4 Replace the
valve at 20℃ is between 22Ω and 30Ω by the multimeter. No
control valve
Check if the voltage between Pin 1# of the canister control valve Yes Diagnosis help
5 connector and the negative pole of power source is about 3.7V by the
multimeter. No Next step
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Fault code: P0480 “the control circuit of cooling fan relay is open (low speed)”
Unplug the A/C condenser cooling fan relay, turn the ignition key to Yes To Step 4
“ON” position, and check if the voltage between the relay power
2
supply side (namely Pins 30# and 87# of relay) and the negative pole
of power source is about 12V. No Next step
Repair or replace
Check if the circuit of power supply side of A/C condenser cooling Yes
3 the harness
fan relay is open or short to ground.
No To Step 2
Check if the voltage between the control side of A/C condenser Yes Replace the relay
4 cooling fan relay (namely Pin 86# of relay) and the negative pole of
power source is about 3.7V by the multimeter. No Next step
Repair or replace
Check if the circuit connecting to Pin 86# of relay control side to Pin Yes
5 the harness
62# of ECU is open or short to power source or ground.
No Diagnosis help
Fault code: P0481 “the control circuit of cooling fan relay is open (high speed)”
Unplug the A/C condenser cooling fan relay, turn the ignition key to Yes To Step 4
“ON” position, and check if the voltage between the relay power
2
supply side (namely Pins 30# and 87# of relay) and the negative pole
of power source is about 12V. No Next step
Repair or replace
Check if the circuit of power supply side of A/C condenser cooling Yes
3 the harness
fan relay is open or short to ground.
No To Step 2
Check if the voltage between the control side of A/C condenser Yes Replace the relay
4 cooling fan relay (namely Pin 86# of relay) and the negative pole of
power source is about 3.7V. No Next step
Repair or replace
Check if the circuit connecting to Pin 86# of relay control side to Pin Yes
5 the harness
52# of ECU is open or short to power source or ground.
No Diagnosis help
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Fault code: P0506 “the idle speed is the lower than the target idle speed”
2 Check if the adjusting screw, cable and condition of throttle are good. Do the necessary
No repair and
maintenance
Yes Next step
Fault code: P0507 “the idle speed is the higher than the target idle speed”
2 Check if the adjusting screw, cable and condition of throttle are good. Do the necessary
No repair and
maintenance
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Fault code: P0508 “the drive pin of stepping motor is short to ground”
Unplug the idle regulator connector, and check if the resistances Yes Next step
2 between Pins A and D and Pins B and C of stepping motor at 20℃
are 53±5.3Ω. Replace the
No
stepping motor
Check if the circuits connecting Pins A, B, C and D of stepping motor Repair or replace
Yes
3 connector respectively to Pins 22#, 21#, 35# and 36# of ECU are the harness
short to ground. No Diagnosis help
Fault code: P0509 “the drive pin of stepping motor is short to power source”
Unplug the idle regulator connector, and check if the resistances Yes Next step
2 between Pins A and D and Pins B and C of stepping motor at 20℃
are 53±5.3Ω by the multimeter. Replace the
No
stepping motor
Check if the circuits connecting Pins A, B, C and D of stepping motor Repair or replace
Yes
3 connector respectively to Pins 22#, 21#, 35# and 36# of ECU are the harness
short to power source. No Diagnosis help
Fault code: P0511 “the drive pin of stepping motor is in open circuit”
Unplug the stepping motor connector, and check if the resistances Yes Next step
2 between Pins A and D and Pins B and C of idle regulator at 20℃ are
53±5.3Ω by the multimeter. Replace the
No
stepping motor
Check if the circuits connecting Pins A, B, C and D of stepping motor Repair or replace
Yes
3 connector respectively to Pins 22#, 21#, 35# and 36# of ECU are the harness
open. No Diagnosis help
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Fault code: P0645 “the control circuit of A/C compressor relay is open”
Unplug the A/C compressor relay, turn the ignition key to “ON” Yes To Step 4
position, and check if the voltage between the relay power supply
2
side (namely Pins 87# and 85# of relay) and the negative pole of
power source is about 12V. No Next step
Repair or replace
Check if the circuit of relay power supply side is open or short to Yes
3 the harness
ground.
No To Step 2
Check if the voltage between the control side of A/C compressor Yes Replace the relay
4 relay (namely Pin 86# of relay) and the negative pole of power source
is about 3.7V. No Next step
Repair or replace
Check if the circuit connecting control side of A/C compressor relay Yes
5 the harness
(namely Pin 86# of relay) to Pin 61# of ECU is open.
No Diagnosis help
Fault code: P0646 “the control circuit of A/C compressor relay is short to ground”
Unplug the A/C compressor relay, turn the ignition key to “ON” Yes To Step 4
position, and check if the voltage between the relay power supply
2
side (namely Pins 87# and 85# of relay) and the negative pole of
power source is about 12V. No Next step
Check if the circuit of relay power supply side is open or short to Repair or replace
3 Yes
ground. the harness
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Repair or replace
Check if the circuit connecting control side of A/C compressor relay Yes
5 the harness
(namely Pin 86# of relay) to Pin 61# of ECU is short to ground.
No Next step
Yes Diagnosis help
Fault code: P0647 “the control circuit of A/C compressor relay is short to power source”
Unplug the A/C compressor relay, turn the ignition key to “ON” Yes To Step 4
position, and check if the voltage between the relay power supply
2
side (namely Pins 87# and 85# of relay) and the negative pole of
power source is about 12V. No Next step
Repair or replace
Check if the circuit of relay power supply side is open or short to Yes
3 the harness
ground.
No To Step 2
Check if the voltage between the control side of A/C compressor Yes Replace the relay
4 relay (namely Pin 86# of relay) and the negative pole of power source
is about 3.7V by multimeter. No Next step
Repair or replace
Check if the circuit connecting control side of A/C compressor relay Yes
5 the harness
(namely Pin 86# of relay) to Pin 61# of ECU is short to power source.
No Next step
Yes Diagnosis help
Fault code: P1651 “the control circuit of engine malfunction lamp (SVS) is in trouble”
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Check if the circuit connecting pin of engine malfunction lamp Repair or replace
Yes
4 control side to Pin 23# of ECU is open or short to power source or the harness
ground. No Next step
Yes Diagnosis help
5 Check if the bulb of engine malfunction lamp operates normally.
No Replace the bulb
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.
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.
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.
If the trouble phenomenon can be cleared at this time, it means the trouble site is at ECM; if the trouble
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phenomenon still exists at this point, reinstall the original ECM and repeat the procedures again to carry
out the Repair.
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:
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
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
Yes internal resistance of
5 it is a case, the failure of rotation or the slow rotation of
engine
starter may occur.
No Repeat above steps
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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
whether the readings of fuel pressure gauge when idling is at Repair the fuel supply
No
about 260kPa; disconnect vacuum hose of pressure regulator system
Connect the electric control system diagnosis apparatus to the Yes Next step
2 engine to observe the data of "rotating speed of engine" and
Repair crankshaft
start 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 Yes Next step
connect the spark plug to make the spark plug electrodes
3
around 5mm away from the engine body, and start the engine to No Repaire ignition system
check 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
Turn on the ignition switch and check whether the power Yes Diagnosis help
5
supply and earthing are normal.
No Repair related circuit
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Detection
No. Operating Steps Subsequent Steps
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
pressure gauge at idle condition is at about 260kPa. Disconnect Repair fuel supply
No
vacuum hose on pressure regulator and observe whether fuel system
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 about 5mm away
2
from the engine body, and start the engine to check whether there is No Repair ignition system
the 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 Yes Repair or replace
4
or 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
Turn on the ignition switch and check whether the power supply Yes Diagnosis help
6
and earthing are normal.
No Repair related circuit
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Trouble phenomenon 5: Engine speed is normal, but it is difficult to start all the time
General trouble position:
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
General diagnosis procedure:
No. Operating Steps Detection Results Subsequent Steps
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
2 assembly) to the engine and start the engine to check whether the
reading of fuel pressure gauge at idle condition is at about Repair fuel supply
No
260kPa. Disconnect vacuum hose on pressure regulator and system
observe whether fuel pressure is about 300kPa.
Pull out the high-voltage wire of one of the cylinders and connect Yes Next step
3 the spark plug to keep the spark plug electrodes about 5mm away
from the engine body, then start the engine to check whether there Repair the ignition
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 Replacement
fuel injector.
No Next step
Check fuel condition and observe whether the trouble Yes Change fuel
8
phenomenon 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
10
timing is in line with the specification. Repair the ignition
No
timing
Turn on the ignition switch and check whether the power supply Yes Diagnosis help
11
and earthing are normal.
No Repair related circuit
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Detection
No. Operating Steps Subsequent Steps
Results
No Next step
Check the spark plug of each cylinder to observe whether its model Yes Next step
3
and gap are in compliance with the specification.
No Adjust or replace
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
Check fuel condition and observe whether the trouble phenomenon Yes Change fuel
6
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
7
pressure difference of each engine cylinders is large. engine
No Next step
Check whether the ignition sequence of engine and ignition timing Yes Next step
8
is in compliance with specification.
No Repair ignition timing
Turn on the ignition switch and check whether the power supply Yes Diagnosis help
9
and earthing are normal.
No Repair related circuit
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Trouble phenomenon 7: Normal start-up but unstable idling during the warming-up
General trouble position:
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.
General diagnosis procedure:
Detection
No. Operating Steps Subsequent Steps
Results
No Next step
Check the spark plug of each cylinder to observe whether its model Yes Next step
2
and gap are in compliance with the specification.
No Adjust or replace
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
Check fuel condition and observe whether the trouble phenomenon Yes Change fuel
6
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
7
pressure difference of each engine cylinders is large. engine
No Next step
Turn on the ignition switch and check whether the power supply Yes Diagnosis help
8
and earthing are normal.
No Repair related circuit
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Trouble phenomenon 8: Normal start-up but unstable idle speed after warmed-up
General trouble position:
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.
General diagnosis procedure:
Detection
No. Operating Steps Subsequent Steps
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 Yes Next step
2 its 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 Repair circuit or replace
Yes
4 and 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
phenomenon occurs just after adding the fuel.
No Next step
Turn on the ignition switch and check whether the Yes Diagnosis help
8
power supply and earthing are normal.
No Repair related circuit
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Trouble phenomenon 9: Normal start-up but unstable idling speed or flameout with partially load
(for example, when the air conditioner is on)
Detection
No. Operating Steps Subsequent Steps
Results
Wash related
Dismantle the idle adjustor to check whether there is carbon deposit Yes
1 components
in the air throttle body, idle adjustor and idle bypass air passage.
No Next step
Connect the adapter of electric control system and disconnect the Yes Next step
connecting wire of the pin #75 of electronic control module to
3
check whether there is high level signal at the wire harness end with Repair air
No
AC turned on. conditioning system
Inspect pressure of air conditioning system, electromagnetic clutch Yes Next step
4
of 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
Turn on the ignition switch and check whether the power supply Yes Diagnosis help
6
and earthing are normal.
No Repair related circuit
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Trouble phenomenon 10: Normal start-up but too high idling speed
General trouble position:
1. Throttle body and idle bypass air passage; 2.Vacuum pipe; 3.Idle adjustor; 4.Coolant temperature
sensor; 5.Ignition timing
General diagnosis procedure:
Detection
No. Operating Steps Subsequent Steps
Results
Yes Adjust
1 Check throttle cable for catching or overtension..
No Next step
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
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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.
Check fuel condition and observe whether the trouble Yes Change fuel
7
phenomenon occurs just after adding the fuel.
No Next step
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
Turn on the ignition switch and check whether the power Yes Diagnosis help
10
supply and earthing are normal.
No Repair related circuit
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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
No Next step
Connect the fuel pressure gauge (the access point is at the Yes Next step
front end of the induction manifold of the fuel distribution
2 pipe assembly) to the engine and start the engine to check
whether the reading of fuel pressure gauge when idling is at Repair fuel supply
No
about 260kPa. disconnect vacuum hose from pressure system
regulator to see whether fuel pressure is about 300kPa.
Check the spark plug of each cylinder to observe whether its Yes Next step
3
model and gap are in compliance with the specification.
No Adjust or replace
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
Dismantle the fuel injector and check whether there is Yes Failure of replacement
6 leakage or blockage 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
7
phenomenon occurs just after adding the fuel.
No Next step
Check whether the ignition sequence of engine and ignition Yes Next step
8
timing is in line with the specification.
No Repair ignition timing
Turn on the ignition switch and check whether the power Yes Diagnosis help
10
supply and earthing are normal.
No Repair related circuit
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Electronic Control System
Maintenance Manual for J2 Sedan of Engine
Check fuel condition and observe whether the trouble Yes Change fuel
9
phenomenon occurs just after adding the fuel.
No Next step
Check whether the ignition sequence of engine and ignition Yes Next step
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
Turn on the ignition switch and check whether the power Yes Diagnosis help
12
supply and earthing are normal.
No Repair related circuit
239
1.0 Table of Common Malfunction Codes for UAES Control
System of 3-Cylinder Engine
DTC Information Introduction of Malfunction Codes (UAES)
P0030 Open-circuit of upstream oxygen sensor heating control circuit
P0031 Short-circuit of upstream oxygen sensor heating control circuit to ground
P0032 Short-circuit of upstream oxygen sensor heating control circuit to power supply
P0036 Open-circuit of downstream oxygen sensor heating control circuit
P0037 Short-circuit of downstream oxygen sensor heating control circuit to ground
P0038 Short-circuit of downstream oxygen sensor heating control circuit to power supply
P0053 Inappropriate heating internal resistance of upstream oxygen sensor
P0054 Inappropriate heating internal resistance of downstream oxygen sensor
P0105 No signal variation of air intake pressure sensor (Frozen)
P0106 Inappropriate air intake pressure sensor
P0107 Short-circuit of air intake pressure sensor to ground
P0108 Short-circuit of air intake pressure sensor to power supply
P0112 Low signal voltage of air intake pressure sensor
P0113 High signal voltage of air intake pressure sensor
P0117 Low voltage of engine coolant temperature sensor circuit
P0118 High voltage of engine coolant temperature sensor circuit
P0122 Out-of-lower-limit of throttle position sensor circuit voltage
P0123 Out-of-upper-limit of throttle position sensor circuit voltage
P0130 Inappropriate upstream oxygen sensor signal
P0131 Low upstream oxygen sensor signal circuit voltage
P0132 High upstream oxygen sensor signal circuit voltage
P0133 Aged upstream oxygen sensor
P0134 Malfunction of upstream oxygen sensor circuit signal
P0136 Inappropriate downstream oxygen sensor signal
P0137 Low downstream oxygen sensor signal circuit voltage
P0138 High downstream oxygen sensor signal circuit voltage
P0140 Malfunction of downstream oxygen sensor circuit signal
P0170 Inappropriate closed-loop control self-learning of off-line testing air-fuel ratio
P0171 Thin closed-loop control self-learning of off-line testing air-fuel ratio
P0172 Thick closed-loop control self-learning of off-line testing air-fuel ratio
P0201 Open-circuit of 1# fuel injector control circuit
P0202 Open-circuit of 2# fuel injector control circuit
P0203 Open-circuit of 3# fuel injector control circuit
P0261 Short-circuit of 1# cylinder fuel injector control circuit to ground
P0262 Short-circuit of 1# cylinder fuel injector control circuit to power supply
P0264 Short-circuit of 2# cylinder fuel injector control circuit to ground
P0265 Short-circuit of 2# cylinder fuel injector control circuit to power supply
P0267 Short-circuit of 3# cylinder fuel injector control circuit to ground
P0268 Short-circuit of 3# cylinder fuel injector control circuit to power supply
DTC Information Introduction of Malfunction Codes (UAES)
P0300 Detection of misfire in various cylinders
P0301 Detection of misfire in 1# cylinder
P0302 Detection of misfire in 2# cylinder
P0303 Detection of misfire in 3# cylinder
P0321 No detection of missing tooth BM signal after certain angle rotation of crankshaft
P0322 No pulse signal of speed sensor (open-circuit or short-circuit)
P0327 Low voltage of knock sensor signal circuit
P0328 High voltage of knock sensor signal circuit
P0340 Inappropriate installation location of phase sensor
P0341 Poor contact of phase sensor
P0342 Short-circuit of phase sensor to ground
P0343 Short-circuit of phase sensor to power supply
P0420 Aged oxygen storage capacity of three-way catalytic converter (out-of-limit of emission)
P0444 Open-circuit of carbon canister control valve control circuit
P0458 Low voltage of carbon canister control valve control circuit
P0459 High voltage of carbon canister control valve control circuit
P0480 Open-circuit of cooling fan relay control circuit (low speed)
P0481 Open-circuit of cooling fan relay control circuit (high speed)
P0501 Inappropriate vehicle speed sensor signal
P0506 Lower idling control speed against target speed
P0507 Higher idling control speed against target speed
P0508 Short-circuit of stepping motor drive pin to ground
P0509 Short-circuit of stepping motor drive pin to power supply
P0511 Open-circuit of stepping motor drive pins
P0560 Inappropriate system battery voltage signal
P0562 Low system battery voltage
P0563 High system battery voltage
P0602 Programming error of electronic control unit
P0627 Open-circuit of fuel pump relay control circuit
P0628 Short-circuit of fuel pump relay control circuit to ground
P0629 Short-circuit of fuel pump relay control circuit to power supply
P0645 Open-circuit of A/C compressor relay control circuit
P0646 Short-circuit of A/C compressor relay control circuit to ground
P0647 Short-circuit of A/C compressor relay control circuit to power supply
P0650 Malfunction of malfunction indicator lamp circuit
P0691 Short-circuit of cooling fan relay control circuit to ground (low speed)
P0692 Short-circuit of cooling fan relay control circuit to power supply (low speed)
P0693 Short-circuit of cooling fan relay control circuit to ground (high speed)
P0694 Short-circuit of cooling fan relay control circuit to power supply (high speed)
P1651 Malfunction of SVS lamp drive circuit
P2177 Out-of-upper-limit of air-fuel ratio closed-loop control self-learning (Medium load zone)
DTC Information Introduction of Malfunction Codes (UAES)
P2178 Out-of-lower-limit of air-fuel ratio closed-loop control self-learning (Medium load zone)
P2195 Aged upstream oxygen sensor
P2196 Aged upstream oxygen sensor
P2270 Aged downstream oxygen sensor
P2271 Aged downstream oxygen sensor