4-2.0L Gasoline Engine

Refine MPVWorkshop Manual 2.
0 Engine Volume
Table of Contents
Table of Contents
Chapter 1 General Description of Engine

General...........................................................................................................................GI-2
Specifications and parameters....................................................................................GI-5
Tightening torque ........................................................................................................GI-9
Fault diagnosis.................................................................................................................GI-11
Special tools ...................................................................................................................GI-12
Chapter 2 Engine Electrical System

General
Specifications and parameters...........................................................................................................EE-2
Trouble shooting ................................................................................................................................EE-3
Ignition system（DOHC）
General ...............................................................................................................................................EE-5
Ignition coil.........................................................................................................................................EE-6
Disassembling and assembling .........................................................................................................EE-6
Test of spark plugs..............................................................................................................................EE-8
Charging system
General ...............................................................................................................................................EE-9
Inspection ...........................................................................................................................................EE-9
Disassembling and assembling ........................................................................................................EE-15
Visual inspection of battery ............................................................................................................EE-20
Starting system
General .............................................................................................................................................EE-23
Inspection .........................................................................................................................................EE-24
Components ......................................................................................................................................EE-25
Disassembling and assembling .......................................................................................................EE-26
Chapter 3 Engine Control System

Delphi Control System
System functions................................................................................................................................EC-3
ECM control structure ....................................................................................................................EC-4
System functions...........................................................................................................................EC-5
Crankshaft position sensor...............................................................................................................EC-5
Table of Contents
Speed density type air flow meter....................................................................................................EC-5

Cylinder-judgment sequential control............................................................................................EC-5
Closed-loop control..........................................................................................................................EC-5
Grouped control ..............................................................................................................................EC-5
Fuel injection function ....................................................................................................................EC-5
Fuel pump control ........................................................................................................................EC-5
Idle speed control function .............................................................................................................EC-5
Correction of engine mixture .........................................................................................................EC-5
Self-diagnosis of faults … ................................................................................................................EC-6
Protection function of 3-way catalytic reactor overheat system… … … … … … … … … … … … ..EC-6
Air conditioning compressor control..............................................................................................EC-6
Radiating fan control ......................................................................................................................EC-6
Mileage counter................................................................................................................................EC-7
System development – complete vehicle emission calibration … … … … ....................................EC-7
Working principle of electrojet control and executive module
Pressure and intake temperature sensor (TEM P)......................................................................EC-7
Throttle position sensor (TPS).......................................................................................................EC-9
Coolant temperature sensor (THW, CTS)....................................................................................EC-10
Knock sensor (KS.KNK)...............................................................................................................EC-12
Oxygen sensor（HO2S）...............................................................................................................EC-14
Electronic control unit ECU..........................................................................................................EC-18
Electric fuel pump (PUMP)...........................................................................................................EC-20
Electromagnetic injector (INJ)......................................................................................................EC-22
Idle actuator stepping motor (IDLE)............................................................................................EC-25
Ignition coil (C0IL).........................................................................................................................EC-27
Steel fuel distribution pipe assembly … … … … … … … … … … … … … … … … … … … … … … … EC-28
Crankshaft position sensor (speed sensor CKPS) ........… … … … … … … … … … … … … … … … EC-29
Canister solenoid valve (EVAP)....................... … … … … … … … … … … … … … … … … … … … ..EC-31
Air conditioning control system (A／C)........... … … … … … … … … … … … … … … … … … … … EC-32
Fan control (FAN) ........................… … … … … … … … … … … … … … … … … … … … … … … … ..EC-34
Basic principle of fault diagnosis of electrojet system
Fault information record...............................................................................................................EC-35
Fault status.....................................................................................................................................EC-35
Fault type.......................................................................................................................................EC-35
Four types of faults........................................................................................................................EC-35
Table of Contents
Limp home.....................................................................................................................................EC-35
Fault alarm....................................................................................................................................EC-35
Fault read out................................................................................................................................EC-35
Clearing of fault information record..........................................................................................EC-37
Fault locating................................................................................................................................EC-37
List of engine fault code ........................................................................................................EC-38
Fault locating method
Element fault................................................................................................................................EC-39
When starting, the engine not running or running slowly ......................................................EC-65
When starting, engine can run by trailing, but cannot start successfully...............................EC-66
Difficult startup of hot vehicle.....................................................................................................EC-68
Speed is normal, but always difficult to start… … … … … … … … … … … … … … … .................EC-69
Difficult startup of cold vehicle...................................................................................................EC-70
Idle unstable at any time… … … … … … … … … … … … … … … … … … … … … … .....................EC-72
Idle unstable during warming up...............................................................................................EC-73
Idle unstable at the end of warming up.....................................................................................EC-74
Idle unstable or fire cut-off when using load (air conditioning).............................................EC-75
Periodically unstable (Self-learning must be carried out after ECU power off) … … … … ..EC-76
Too high idle speed (Self-learning must be carried out after ECU power off) … … … … ......EC-77
Speed cannot be increased or fire is cut-off when accelerating… … … … … … … … ...............EC-78
Reacting slowly when accelerating.............................................................................................EC-79
Performance is poor, asthenic when accelerating… … … … … … … … … … … … ........................EC-80
Air conditioning system fault … … … … … … … … … … … … … … … … … … … … … … … … … … EC-81
Fault diagnosis of electrojet system
Causes of engine electrojet system fault........................................................................................EC-81
Chapter 4 Engine Mechanical System

Timing system
Components......................................................................................................................................EM-3
Disassembling...................................................................................................................................EM-4
Inspection.........................................................................................................................................EM-6
Assembling........................................................................................................................................EM-7
Oil sump and filter
Disassembling.................................................................................................................................EM-10
Assembling......................................................................................................................................EM-11
Oil pump and balance shaft
Table of Contents
Components....................................................................................................................................EM-11
Inspection........................................................................................................................................EM-13
Assembling......................................................................................................................................EM-16
Cylinder head assembly
Components....................................................................................................................................EM-18
Inspection........................................................................................................................................EM-19
Assembling......................................................................................................................................EM-20
Valve mechanism
Inspection........................................................................................................................................EM-22
Assembling......................................................................................................................................EM-24
Crankshaft connecting rod mechanism and cylinder block
Components....................................................................................................................................EM-26
Inspection........................................................................................................................................EM-27
Assembling......................................................................................................................................EM-30
Piston connecting rod
Components....................................................................................................................................EM-31
Inspection........................................................................................................................................EM-32
Assembling......................................................................................................................................EM-33
Cooling system
Components....................................................................................................................................EM-35
Inspection .......................................................................................................................................EM-36
Assembling......................................................................................................................................EM-36
Radiator and thermostat

Components....................................................................................................................................EM-37
Inspection........................................................................................................................................EM-38
Assembling......................................................................................................................................EM-38
Radiator cover
Components....................................................................................................................................EM-39
Table of Contents
Inspection........................................................................................................................................EM-40
Radiator fan motor assembly

Components....................................................................................................................................EM-40
Inspection........................................................................................................................................EM-41
Assembling......................................................................................................................................EM-42
Thermostat
Components ...................................................................................................................................EM-43
Inspection........................................................................................................................................EM-44
Assembling......................................................................................................................................EM-44
Intake system
Components....................................................................................................................................EM-45
Inspection.......................................................................................................................................EM-47
Assembling.....................................................................................................................................EM-47
Exhaust system
Components...................................................................................................................................EM-48
Disassembling................................................................................................................................EM-48
Assembling.....................................................................................................................................EM-48
Engine and gearbox assembly

Assembling......................................................................................................................................EM-49
General Description of Engine GI-1
Chapter 1 General Description of Engine
General...........................................................................................................................GI-2
Specifications and parameters....................................................................................GI-5
Tightening torque ........................................................................................................GI-9
Fault diagnosis.................................................................................................................GI-11
Special tools ...................................................................................................................GI-12

Gasoline engine (2.0 L4)

General
Series HFC4GA3 gasoline engine is a multipoint

electric injection gasoline engine with displacement
volume of 2.0L developed independently by Anhui
Jianghuai Automobile Co., Ltd. on the basis of
digesting the multipoint electric injection gasoline
engine of the similar type in China and abroad; it is at
internationally advanced level. It can be used as the
power for off-road vehicle, and car of intermediate
and top grade, and can also be used as the renewal
power of the imported vehicle of the similar type.
This engine is compact in construction, strong in
power, and quite high in performance-price ratio.
Engine identification number
The engine identification number is stamped on the

right front side of the cylinder upper part.
Explanation of the engine identification number

Model
Middle
Position Head
Product serial number
Number of Displacement
Items Enterprise code Type code Technical platform
cylinders volume
Digits 1 2 3 4 5
Engine model composition is as follows:
HFC 4 G A 3
1 2 3 4 5
1. Enterprise code
HFC—Jianghuai Automobile Co., Ltd.
2. Number of cylinders
4— 4 cylinders
3. Engine fuel type code

G— Gasoline engine
4. Technical platform
A— Type A technical platform
B— Type B technical platform
C— Type C technical platform
D— Type D technical platform
5. Engine displacement volume

1—Gasoline engine 2.4L
3—Gasoline engine 2.0L
Engine ex-works number
The engine ex-works number is composed of 8 digits.

For example: ☆ 5 3 0 0 0 3 6 9 ☆
Year Engine Ex-works number
Year
Year Code Year Code Year Code Year Code
2001 1 2009 9 2017 H 2025 S

2002 2 2010 A 2018 J 2026 T
2003 3 2011 B 2019 K 2027 V
2004 4 2012 C 2020 L 2028 W
2005 5 2013 D 2021 M 2029 X
2006 6 2014 E 2022 N 2030 Y
2007 7 2015 F 2023 P 2031 1
2008 8 2016 G 2024 R 2032 2
Engine
Engine type Code
Gasoline CKD 1
engine Chain made parts 3
5
Ex-works number
The ex-works number is composed of 6 digits.
Model HFC4GA3
Type In line, double overhead camshaft, 16 valves
Number of cylinders 4
Cylinder diameter×stroke（mm） 85×88
Displacement volume（L） 2.0
Compression ratio 10:1
Type of cylinder sleeve None
Rated speed （r/min） 6000
Power （KW） 95
Maximum torque（N.m） 172
Maximum torque speed （r/min） 3000
Idle speed （r/min） 750±30
Fully complying with minimum specific fuel consumption 270－280
(g/KW.h)
Ratio of oil to fuel ≤0.15％
Crankshaft rotation direction (facing to power output Anticlockwise
terminal)
Ignition sequence 1－3－4－2
Starting method Electrical starting
Lubrication method Pressure and splash lubrication combined
Cooling method Water cooling
Overall dimension （L×W×H）mm 644.5×689×736.8
Net mass （Kg） 165
Specifications and parameters
Description Specifications and parameters Limit value

General
Type Transverse, double overhead camshaft
Number of cylinders 4
Cylinder diameter 85 mm
Stroke 88 mm
Displacement volume 2.0L
Compression ratio 10:1
Ignition sequence 1-3-4-2
Valve timing
Intake valve
Open （BTDC） 18º
Close （ABDC） 54º
Exhaust valve
Open （BBDC） 56º
Close （ATDC） 8º
Cylinder head
Manifold mounting surface 0.15 mm 0.3 mm
planeness
Oversized dimension of valve-seat bore repair Intake
0.3 mm O.S. 35.3-35.325 mm
0.6 mm O.S. 35.6-35.625 mm
Exhaust
0.3 mm O.S. 33.3-33.326 mm
0.6 mm O.S. 33.6-33.625 mm
Oversized dimension of valve guide bore repair (intake and exhaust)
0.05 mm O.S. 12.05-12.068 mm
0.05 mm O.S. 12.25-12.268 mm
0.05 mm O.S. 12.50-12.518 mm
Camshaft
Cam height 35.493 mm 34.993mm
Intake 35.317 mm 34.704mm
Exhaust 35.039 mm 34.704mm
Journal outer diameter 26mm
Bearing clearance 0.040-0.076 mm
End play 0.1-0.2 mm

Valve
Valve length
Intake 109.5 mm
Exhaust 109.7 mm
Valve stem outer diameter
Intake 6.565-6.580 mm
Exhaust 6.530-6.550 mm
Cone angle 45º-45º5’
Valve head thickness (edge)

Intake 1.0mm 0.7 mm
Exhaust 1.5mm 1.0 mm
Valve stem and valve guide clearance

Intake 0.020-0.047 mm 0.1mm
Exhaust 0.050-0.085 mm 0.15mm
Valve guide
Length
Intake 45.5 mm
Exhaust 50.5 mm
Maintenance dimension 0.05,0.25,0.50 mm
Valve seat
Seat contact width 0.9-1.3 mm
Cone angle of the seat 44º-44º5’
Maintenance dimension 0.1mm
0.6mm out of tolerance
Valve spring
Free length 45.82 mm 44.82
Bearing capacity 25.3kg/40mm
Deflection Less than 1.5ºat assembling height 4º
Cylinder body
Cylinder diameter 85＋0.03 mm
Out of roundness and taper of Less than 0.01 mm
cylinder diameter
Planeness of engine top Less than 0.05 mm 0.1 mm
Piston
Outer diameter 84.97-85 mm
Piston and cylinder clearance 0.02-0.04 mm
Ring groove width
No.1 1.22-1.24 mm
No.2 1.51-1.53 mm
Oil ring 2.81-2.83 mm
Maintenance dimension 0.5 mm out of tolerance
Piston ring
Side play
No.1 0.03-0.07 mm
No.2 0.02-0.06 mm 0.1 mm
Oil ring 0.06-0.15 mm
End play
No.1 0.25-0.35 mm 0.8 mm
No.2 0.40-0.55 mm 0.8 mm
Oil ring side doctor-bar 0.10-0.40 mm 1.0 mm
Connecting rod
Bending 0.05 mm
Skewness 0.1 mm
Side play of connecting rod big 0.10-0.25 mm 0.1 mm
end and crankshaft
Piston pin open tension 1250±500 kg
Rod journal outer diameter
Connecting rod bearing free play 48-48.015 mm
Crankshaft main bearing free play 0.015-0.048 mm 0.1 mm
No.1, 2, 4, 5 journal 0.018-0.036 mm
No.3 journal 0.024-0.042 mm 0.1 mm
Crankshaft
Journal outer diameter 56.982-57.000mm
Out of roundness of journal Less than 0.015 mm
Taper of journal Less than 0.005 mm
Axial clearance 0.05-0.25 mm 0.25mm
Flywheel
Running out 0.13 mm
Oil pressure at idle 80 kPa
[Oil temperature is 75-90℃] (11.6 psi)
Oil pump
Top clearance
Driving gear 0.16-0.21 mm 0.25 mm
Driven gear 0.18-0.21 mm 0.25 mm
Side clearance
Driving gear 0.08-0.14 mm 0.25 mm
Driven gear 0.06-0.12 mm 0.25 mm
Safety spring
Free length 46.6 mm
When loading [61N] 40.1 mm
Right balance shaft
Front journal diameter 18.467-18.480mm
Rear journal diameter 40.951-40.967mm
Clearance
Front 0.020-0.061 mm
Rear 0.050-0.091 mm
Left balance shaft
Front journal diameter 18.467-18.480mm
Rear journal diameter 40.951-40.967mm
Clearance
Front 0.020-0.054 mm
Rear 0.042-0.083 mm
Cooling method Forced circulation with fan
Cooling system capacity 7.0L
Thermostat
Type Wax-type thermostat
Normal open temperature 82℃
Open temperature range 80℃-84℃
Complete open temperature 95℃
Radiation temperature
Main valve open pressure 107.9±14.7 kPa
Main valve close pressure 83.4 kPa
Vacuum valve open pressure -8.86kPa
Air filter
Type Dry
Filter element Paper filter element
Exhaust pipe
Muffler Dissipative muffler
Suspension system Rubber suspension device
Coolant temperature sensor
Type Thermistor type
Resistance
20℃ 2.45±0.14 KΏ
80℃ 0.3222KΏ
Tightening torque
Description Nm
Engine bracket spacer bolt 90-110
Engine bracket nut 60-80
Engine bracket bolt 60-80
Engine bracket to cross-member bolt and nut 55-65
Front stop bracket to cross-member bolt 40-55
Front stop spacer bolt and nut 50-65
Rear stop bracket to cross-member bolt 50-65
Rear stop spacer bolt and nut 50-65
Drive shaft bracket bolt 60-80
Drive shaft mounting spacer bolt 90-110
Air conditioner compressor and support 23-27
Power steering gear oil pump and support 35-45
Front exhaust pipe and exhaust manifold 30-40
Rocker arm cover bolt 8-10
Center cover bolt 4-5
Camshaft crankshaft bolt 80-100
Camshaft bearing cover bolt 19-21
Crankshaft position sensor 10-13
Throttle valve seat 15-22
Air filter mounting bolt 8-10
Crankshaft sprocket wheel bolt 110-130
Shock absorber belt pulley and crankshaft sprocket wheel 20-30
Use new parts 63+ loosening +20±2+90º+90º
Not use new parts
Intake manifold support 18-25
Tension pulley support bolt 23-27
Automatic tensioner bolt 20-27
Tensioner belt pulley bolt 43-55
Idler pulley bolt 30-42
Front exhaust pipe clamping bolt 20-30
Oil sump (top and bottom) 10-12
Crankcase drain plug 35-45
Oil strainer 15-22
Oil pump sprocket wheel nut 50-60
Oil pressure switch 8-12
Oil filter support bolt 20-27
Oil pump bolt 15-18
Oil seal cover bolt 10-12
Description Nm
Plug cover 20-27
Front cover bolt 20-27
Driven gear bolt 34-40
Engine cooling pump belt pulley bolt 8-10
Timing belt upper cover 8-10
Timing belt lower cover 8-10
Safety plug 40-50
Flywheel 130-140
Capstan 130-140
Timing belt rear right cover 10-12
Timing belt rear left cover (upper) 10-12
Connecting rod cover bolt 20+90º
Crankshaft bearing cover bolt 25+90º
Generator suspension device
M18 25-30
M10 35-55
Generator bracket bolt 20-25
Generator connecting bolt
M9×90 8-12
M8×40 20-25
Engine cooling pump to cylinder bolt 20-27
Engine coolant temperature sensor 20-40
Engine coolant inlet sealing member bolt 10-15
Air filter mounting bolt 8-10
Resonator mounting bolt (nut) 8-10
Throttle valve body to intake manifold 15-22
Intake manifold mounting bolt (M8) 15-20
Intake manifold mounting nut 30-42
Tension bar bracket to tension bar bolt 35-55
Ignition coil bolt 8-12
Power transistor bolt 10-12
Front exhaust manifold to cylinder bolt 20-30
Central exhaust pipe to catalytic converter nut 30-40
Central exhaust pipe to main muffler bolt 30-40
Central exhaust pipe to support bolt 10-15
Suspension device to engine bolt 10-15
Suspension device to main muffler bolt 10-15
Exhaust manifold nut（8） 25-30
Exhaust manifold nut (10) 35-55
Oxygen sensor 40-50
Description Nm
Air filter support bolt 10-13
Exhaust manifold cover and exhaust connection bolt 12-15
Oxygen sensor to exhaust manifold 40-50
Front exhaust pipe support bolt 20-30
Main muffler lug support bolt 10-20
Oil height gauge 12-15
Stud bolt 30-40
Tensioner arm assembly 17-26
Balance shaft bolt 34-40
Startup motor to cylinder connection bolt 27-35
Radiator-fan motor bolt 8-10
Oil delivery pipe to cylinder body 10-13
Fault diagnosis
Phenomena Possible causes Repair
Cylinder head gasket damaged Replace the piston

Piston ring worn out or damaged Replace the piston ring
Compression pressure
Piston or cylinder worn out Repair or replace the piston ring or
low
cylinder body
Valve seat worn out or damaged Repair or replace the valve and seat ring
Oil height not sufficient Check the oil
Oil pressure switch fault Replace the oil pressure switch
Oil filter blocked Replace the filter
Oil pressure dropped Oil pump gear or cover worn out Replace the oil pump gear or cover
Oil become thin Replace the oil and locate the cause
Oil safety valve failed (opened) Repair
Bearing clearance too big Replace the bearing
Oil pressure high Oil safety valve failed (closed) Repair
Engine stop baffle loosened (front, rear) Re-fasten
Driving shaft mounting support loosened Re-fasten
Engine mounting bracket loosened Re-fasten
Engine over-vibration Central member loosened Re-fasten
Driving shaft mounting space damaged Replace
Engine installation guard plate damaged Replace
Engine stop baffle damaged Replace
Oil thin (oil pressure low) Adjust
Valve noise Valve stem or valve guide worn out or Replace
damaged
Oil supply insufficient Check the oil height
Connecting rod and
Thin or thinned oil Adjust and locate the causes
main bearing noise
Bearing clearance too big Replace
Phenomena Possible causes Repair

Belt tension incorrect (generator tensioner, Adjust the belt tension
Timing belt noise timing belt)
Coolant leaking Fill to specified level

Coolant level low Radiator core connector damaged Replace
Hose eroded or cracked Replace
Radiator cover valve or spring fault Replace
Thermostat fault Replace
Engine water pump fault Replace
Radiator blocked Foreign matters in coolant Replace
Connector loosened Re-tighten
Exhaust pipe leaking
Pipeline or muffler damaged Repair or replace
Partition in muffler separated Replace
Rubber suspension device damaged Replace
Abnormal noise
Pipeline or muffler contacting body Correct it
Pipeline or muffler damaged Repair or replace
Special tools
Tool Picture Purpose
To disassemble balance shaft front

Balance shaft bearing puller
bearing
To disassemble balance shaft rear

Balance shaft bearing puller
bearing
To erect balance shaft front/rear

Balance shaft bearing erector
bearing
Guide plate To disassemble and erect balance

shaft rear bearing
To disassemble and erect front nut

Cock spanner
cap stopper
Camshaft front oil seal

To erect camshaft front oil seal
erector
Front shaft front oil seal To erect crankshaft front oil seal
guide
To erect camshaft oil seal

Camshaft oil seal erector
Used as guide when pressing in

Camshaft oil seal guide rod camshaft oil seal
To disassemble and install cylinder

Cylinder head bolt sleeve
head bolt
To disassemble and erect front nut

Valve guide erector
cap stopper
Valve spring compressor

To disassemble and erect
Valve spring compressor intake/exhaust valve
seat
Valve stem oil seal erector To erect valve stem oil seal
Valve guide mounting

To erect valve guide
accessory
Crankshaft rear oil seal 1. To erect engine rear oil seal

erector 2. To erect crankshaft rear oil seal
Piston pin
assembling/disassembling
piston pin
kit

Plugging blade piston pin
Cross-member stud bolt To disassemble and erect

sleeve cross-member stud bolt
Engine Electrical System EE-1
Chapter 2 Engine Electrical System
General
Specifications and parameters...........................................................................................................EE-2
Trouble shooting ................................................................................................................................EE-3
Ignition system（DOHC）
General ...............................................................................................................................................EE-5
Ignition coil.........................................................................................................................................EE-6
Disassembling and assembling .........................................................................................................EE-6
Test of spark plugs..............................................................................................................................EE-8
Charging system
General ...............................................................................................................................................EE-9
Inspection ...........................................................................................................................................EE-9
Disassembling and assembling ........................................................................................................EE-15
Visual inspection of battery ............................................................................................................EE-20
Starting system
General .............................................................................................................................................EE-23
Inspection .........................................................................................................................................EE-24
Components ......................................................................................................................................EE-25
Disassembling and assembling .......................................................................................................EE-26
General
Specifications and parameters
Ignition
2.0 L4
Model
Primary coil resistance 0.5±0.05Ω
Secondary coil resistance 5200±400Ω
Spark plugs
2.0 L4
Spark plug clearance 0.9-1.1 mm
Starter motor
2.0 L4
Model Deceleration drive
Voltage 12V
Power 1.2kw
No-load characteristic
Terminal voltage 11V
Current intensity 90A or below
Speed 2.800rpm
Number of teeth of gear ８
Gear clearance 0.5-2.0mm
Generator
2.0 L4
Model Battery voltage induction
Rated power 13.5V/95A
Voltage regulator model Built-in electronic type
Regulator setting voltage 14.4±0.3V
Temperature compensation -10±3Mv/℃
Batteries
All engines
Model MF 68 AH,MF 90 AH
Ampere hour
5HR 55AH or more
Cold startup ［-17.8℃］ 540AH or more
Reverse capability 122min
Specific gravity［25℃］ 1.280±0.01
Note:
Cold start current intensity is the current that the battery can supply for 30s and maintain 7.2 or higher
terminal voltage under specified temperature. Reverse capability rated value is the time quantum that
battery supplies 25A and maintain minimum terminal voltage of 10.5 at 26.7℃.
Tightening torque
Description Ｎ·m
Generator terminal (B+) 5-7
Starter motor terminal (B+) 10-12
Battery terminal 4-6
Spark plug 20-30
Trouble shooting
Ignition system
Phenomena Causes Repair
Ignition locking switch fault Replace the ignition locking switch
Ignition coil fault Check the ignition coil
Engine fails to start or is Power transistor fault Check the power transistor
difficult to start (start Ignition spark plug fault Replace the spark plug
crankshaft normal) Ignition high tension wire broken or Check the high tension wire
damaged
Spark plug fault Replace the spark plug
Spark plug fault Check the spark plug
Rough idle or stopping High tension wire fault Check the high tension wire
Ignition coil fault Check the ignition coil
Engine slow acceleration Spark plug fault Replace the spark plug
or unable to accelerate High tension wire fault Check the high tension wire
Less running mileage Spark plug fault Replace the spark plug
Charging system
When the ignition switch is Fuse blown out Charge or replace the fuse
“On”, engine not running, Light burnt out Replace the light
charging alarm indicator High tension wire connector loosened Tighten the loosened connector
light not lit Electronic voltage regulator fault Replace the voltage regulator
When engine is running, the Belt is loosened or worn Adjust the tension or replace the
battery requires frequently driving belt
re-charging, the charging Battery wire loosened, eroded or Repair or replace the wire
alarm display light not go damaged
out. Fuse blown out Replace the fuse
Fuse blown out Replace the fuse
Electronic voltage regulator or Detect the generator
generator fault
Line fault Check the line
Engine slow Driving belt loosened or worn Adjust the tension or replace the
acceleration/unable to driving belt
accelerate Line connector loosened or circuit Tighten the loosened connector or
Overcharging opened repair the line
Poor grounding Repair
Electronic voltage regulator or Check the generator, repair or replace
generator fault it if it is fault
Battery is old Replace the battery
Electronic voltage regulator fault Replace the electronic voltage
regulator
Voltage induction line fault Repair the line
Starting system
Engine is unable to run Battery voltage low Charge or replace the battery
Battery wire loosened, eroded or worn Repair, replace the wire
Starter motor fault Repair the starter motor
Ignition switch fault Replace the ignition switch
Ignition locking switch fault Replace the ignition locking switch
Engine running slowly Battery voltage low Replace the ignition locking switch
Battery wire loosened, eroded or worn Repair or replace the wire
Starter motor fault Repair the starter motor
Starter running continuously Starter motor fault Repair the starter motor
Replace the ignition switch Ignition switch fault
Starter is running, but the Driving gear broken, or the starter Repair the starter motor
engine not running motor damaged
Gear ring teeth broken Replace the flywheel ring gear or
torque converter
Ignition system (DOHC)
General
Ignition timing is controlled by engine control module
(ECM); the ignition timing data of the engine running
condition is stored in ECM by programmer. The
engine running conditions (speed, load, warming
status, etc.) are detected by various kinds of sensors.
Based on these induction signals and the data stored
in ECM, the signal to cut off primary current is sent to
power transistor. The ignition coil is activated, and
timing is controlled at the best point.
Crankshaft position sensor
Camshaft position sensor

Ignition coil
1. Measuring of primary coil resistance
The resistance value of the two pins shown is 0.5±0.05Ω.
2. Measuring of secondary coil resistance

To measure the resistance between the ignition coil HV terminals
The standard value is: 5200±400Ω
Disassembling and assembling

1. Disconnect the battery negative terminal.
2. Remove the air bag module.
Note:
SRS is so designed that it still can supply sufficient power to eject
the air bag within about 30s even if the battery is disconnected,
therefore, if maintenance is carried out on SRS system soon after
the battery wire is disconnected, severe human injury would
happen due to sudden ejection of the air bag.
3. Loosen the taper screw and lift upward the horn pad and remove it.
4. Unscrew the locking nut and gasket.
5. Pull out the shock absorber, lift upward and remove it.
6. Use special tool to remove the steering wheel.
Note:
Do not use hammer to strike when disassembling the steering wheel.
7. Remove the upper/lower sleeve of the steering column.
8. Remove the lower cover.
9. Disconnect the connector and remove the multi-function switch.
10. Remove the mounting bolts, and separate the ignition switch from the steering column.
Inspection:
1. Separate the connectors under the steering column.
2. Check the conduction between the switch terminals.
3. If the conduction not complying with the stipulation, replace the switch.
Terminal Door alarm switch

Ignition switch Lock
and key lighting
Position Key 1 2 3 4 5 6 1 2 3 4 RO RE
Pull out ○ ○ L L
Lock
L F
Accessory ○ ○ F F
Insert in
Open ○ ○ ○ ○ F F
Start ○ ○ ○ F F
Note:
○—○ indicating conduction between terminals
RO: turn the locking bar
RE: return the locking bar Ignition switch
L: locked
F: free
Note: Door alarm switch
If the engine cannot run, make sure whether the
drive axle range switch is at “parking” or
“neutral” position. If “cannot run” phenomenon
only happens on a certain shifting lever position, Ignition switch Door alarm switch
not on the other shifting positions, the most of the
reason is the problem of the driving axle range
switch.
Test of spark plugs
1. Remove the spark plug and the wire connecting the
spark plugs.
2. Start the engine with the spark plug outer electrode
grounded.
3. Check and make confirmation there is discharge
phenomenon between the electrodes at this time.
Note:
incorrect insulation incorrect insulation
When replacing spark plug, use resistance linear
positive component.
correct
incorrect insulation
Test of spark plug wire
With engine at idle speed, check whether there is any

change in engine running performance when
disconnecting one spark plug wire each time.
Note:
Wear rubber gloves when operating.
1. If there is no change in engine performance, check

spark plug resistance and check spark plug itself.
2. Check whether there is any cracking on the cover

and casing.
3. Measure the resistance.

Charging system
General
The charging system includes battery, generator with

built-in regulator, charging indicator light and line. stator
There are 6 built-in diodes (3 positive, 3 negative), rotor
each diode rectifies AC into DC. Therefore, the front
generator’
s “B”terminal is AC power. In addition, the bearing
rear
charging voltage of this generator is regulated by the
bearing
battery voltage detection system. The generator is
regulated by the battery voltage detection system. The
main parts of the generator include: rotor, stator,
rectifier, brush, bearing and V-belt pulley. The brush
holder includes one built-in type electronic voltage
regulator.
Inspection
Voltage drop measurement of generator output

line
This test is to determine whether the line between the

generator “B”terminal and the battery (+) terminal is
normal by using voltage drop method.
generator
Preparations
1. Turn the ignition switch to “Off”.
Note:
To locate the abnormality of the connector, do not ammeter

use the method to check the two terminals and one
connector at the same time during the test.
2. Connect digital ammeter in between the generator

voltmeter battery
“B” and battery(+) pole. Connect the (+) wire of
voltmeter to “B” terminal, (-) wire to battery (-)
terminal.
Test conditions
1. Start the engine.
2. Turn On the headlight, fan, motor, etc., the voltmeter reading under this condition.
Results
1. The voltmeter can display standard value.
The standard value: maximum 0.2V
2. If the voltmeter value is greater than the predicted value (maximum above 0.2V), the line may have problem.
Under this condition, check the line connecting from the generator “B”terminal to the battery (+) pole for
whether the connection is loosened, whether the wiring harness color is changed due to heat, etc. Before
testing, resume them.
3. After the test is completed, set the engine to idle speed, turn off the headlight, fan, motor and ignition
switch.
Test of output current
This test is to determine whether the output current of the generator is normal.
Preparations
1. Prior to the test, check the following items, and correct them if necessary.
(1) Check whether the operation of battery installed on the vehicle is normal or not. The battery used to test the
output current must be discharged partially. If fully charged battery is used, correct result cannot be obtained
due to insufficient load.
(2) Check the tension of the engine driving belt.
2. Turn off the ignition switch.
3. Disconnect the battery grounding line.
4. Disconnect the generator output lead wire from the generator “B”terminal.
5. Connect DC ammeter (0 ~ 100A) in between the “B”terminal and the disconnected output lead wire, and
make sure the negative pole (-) wire of the ammeter is connected to the disconnected output lead wire.
Note:
Tighten each connector, because there is heavy current passing through, never rely on clamp.
6. Connect voltmeter (0 ~ 20V) in between the “B”
voltmeter ammeter
terminal and the grounding wire. Connect the positive
pole (+) wire with the generator “B” terminal, and check
generator
earth the negative pole (-) wire.
7. Connect the engine tachometer, and connect the
battery grounding wire.
8. Open the engine head.
Test
1. Check whether the voltmeter reading is the same as the battery voltage. If the voltmeter reading is 0V, the
reason may be the line between the generator “B”terminal and the battery (-) pole is opened, fuse burnt out or
poor grounding
2. Start the engine and turn on the headlight.
3. Set the headlight to high beam, set the heater, fan switch to high, increase rapidly the engine speed to
2500rpm, maximum current output value through ammeter.
Note:
After startup of the engine, the charging current drops rapidly. Therefore, the above-mentioned
operation must be carried out rapidly so as to read out the correct maximum current value.
Results:
1.The ammeter reading must be higher than the limit value. If it is lower than the limit value but the engine
output lead wire is normal, remove the generator from the vehicle and test it.
Limit (95A engine): 63A
Note:
The rated output current is indicated in the nameplate of the generator body.
The output current changes as the electrical load and the generator temperature change. As a result, the
rated output current may not be obtained. Under such condition, keep the headlight On to let the
battery discharge, or add other vehicles’lights to increase electrical load. If the temperature of the
generator itself or the atmospheric temperature is too high, the rated output current may not be
obtained. Under this condition, lower the temperature before being tested again.
2. After the output current test is completed, decrease the engine speed to idle speed and turn off the ignition
switch.
3. Disconnect the battery grounding wire.
4. Remove the ammeter, voltmeter and engine tachomerer.
5. Connect the generator output lead wire to the generator “B”terminal.
6. Connect the battery grounding wire.
Test of voltage regulation
The purpose of this test is to check whether the electronic voltage regulator can regulate voltage correctly.
Preparations
1. Before the test, check the following items, and correct them if necessary.
☆Check whether the battery installed on the vehicle has been completely charged.
☆Check the generator driving belt tension.
2. Set the ignition switch to “OFF”.
4. Connect a digital voltmeter in between the generator “S (L)”terminal and the grounding wire. Connect the
voltmeter (+) lead to the generator “S (L)”terminal. Connect (-) lead to the grounding wire or the battery (-)
pole.
5. Disconnect the generator output line from generator “B”terminal.
6. Connect in series a DC ammeter (0 ~ 100A) in

between the “B”terminal and the disconnected output ammeter
line. Connect the ammeter (-) lead to the disconnected
output line.
7. Install the engine tachomerer and connect the
battery grounding wire.
voltmeter
Test
1.Turn on the ignition switch, and check whether the voltmeter displays the following value.
Voltage: battery voltage
If the reading is 0V, the reason may be the line between the generator “S (L)”terminal and the battery (+) pole
is opened or the fuse burnt out.
2. Start the engine, and turn off all the lights and accessories.
3. Run the engine at the speed of approx. 2500rpm, when the generator output current is dropped to 10A or
lower, read the voltage reading.
Results:
1. If the voltage readings are the same as the value in the voltage regulation Table listed below, the voltage
regulator function is normal. If the readings are not within the standard value, the voltage regulator or the
generator is fault.
Voltage regulation table
Voltage regulator ambient temperature ℃ Regulation voltage (V)
-20 14.2-15.4
20 13.9-14.9
60 13.4-14.6
80 13.1-14.5
2. After the test is completed, decrease the engine speed to idle speed, turn off the ignition switch.
4. Remove the voltmeter, ammeter and generator tachomerer.
5. Connect generator output lead wire to generator “B”terminal.
6. Connect the battery grounding wire.
Test of generator output line voltage drop
This test is to determine whether the line between the generator “B” terminal and the battery (+) pole
(including fuse) is normal.
1. Check the following items before the test.
☆ Installation and line connector of the generator
☆ Generator driving belt tension
☆ Fuse
☆ Whether the generator has abnormal noise when it is running
2. Set the ignition switch to position OFF.
3. Disconnect the battery negative lead.
4. Disconnect the generator output line from the generator “B”terminal. Connect in series a DC ammeter with
measurement range of 0 ~ 100A in between the “B”terminal and the disconnected output line. (Connect the
ammeter (+) lead to “B”terminal, connect the ammeter (-) lead to the disconnected output line).
Note:
It is suggested to use inductive ammeter, which can make measurement without disconnecting the
generator output line. Use this ammeter can reduce the voltage drop produced due to loosening of the
“B”terminal connector.
5. Connect a digital voltmeter in between the generator “B”terminal and the battery (+) pole. (Connect the
voltmeter (+) lead to “B”terminal, connect the voltmeter (-) lead to the battery (+) pole).
6. Re-connect the battery (-) lead.
7. Connect a tachomerer or speed measurement tool.
8. Start the engine.
9. Turn On and Off the headlight and other lights to adjust the generator load and let the ammeter a bit higher
than 30A, with the engine running at approx. 2500rpm.
Limit value: maximum 0.3V

ammeter
Note:
When the generator output current is high, and

the value displayed in the ammeter cannot be
dropped to 30A, set the value to 40A. Read out the voltmeter voltmeter (digital type)
value in the voltmeter. Under this condition, the
limit value becomes maximum 0.4V.
battery
10. If the voltmeter reading is still higher than the limit value, the generator output lead wire might be fault.
Check the line between the generator “B”terminal and the battery (+) pole (including fuse). If the terminal
connection is not tightened securely or the wiring harness color changed due to heat, repair or re-test.
11. After the test, make the engine run at idle speed.
12. Turn Off all the lights and set the ignition switch to position OFF.
13. Disconnect the tachomerer or the test tool.
14. Disconnect the battery (-) lead.
15. Disconnect the ammeter and the voltmeter.
16. Connect the generator output line to the generator “B”terminal.
17. Connect the battery (-) lead.
adjusting bolt
engine
support bolt
Torque
Disassembling and re-assembling
front hood rotor rear bearing

holder assembly
Screw(4EA)
belt pulley front bearing
hexagon nut
rectifier cover –B terminal
spacing ring Screw(4EA)
flange
cover
regulator
rear hood assembly
stator assembly
Disassembling:
1. Remove the 4 through bolts.
2. Insert a flat screwdriver in between the front

support and the stator core, and pry downward.
Note:
a. Do not insert the screwdriver too deep, so as to

avoid damage of the stator core.
b. As there is a locking ring on the race of rear

bearing, the rear cover might be very difficult to
remove. For convenient removing of the rear
cover, use a 200W electric iron to heat the bearing
cover face; do not use gun, as it may damage the
diode assembly.
3. Make the belt pulley edge upward and use soft vice
to fix the rotor.
Note:
Never let the vice damage the rotor.
4. Remove the belt pulley nut, spring washer, belt

pulley and the spacing ring.
5. Remove the front support and the 2 sealing

members.
6. Remove the stator assembly from the vice jaw.
7. Remove the brush holder screw, rectifier screw and

nut from the “B”terminal.
8. Remove the stator assembly from the rear support.
9. Remove the oil deflector from the brush holder.
10. If the stator has been removed, unsolder the 3

stator lead wires from the main diode on the rectifier.
Note:
a. When soldering or unsoldering, make sure heat

on the electric iron will not be transferred to the
diode for a long time.
b. Do not exercise too much force on the diode lead

wire.
11. When separate the rectifier from the brush holder,

unsolder the two plates soldered on the rectifier.
Inspection
Rotor
1. Check whether the rotor has connectivity, and

make sure it is conducted in between the slip ring. If
the resistance is too small, there must be short-circuit.
If not conducted, turn it off, and replace the rotor
assembly.
Resistance value: approx. 3.1Ω
2. Check the grounding condition of the rotor coil,

check whether the slip ring has been conducted with
the rotor core. If it is conducted, replace the rotor
assembly.
Stator
1. Make conduction test for the stator coil, check

whether it is conducted in between the coil leads, if
not conducted, replace the stator assembly.
2. Check the grounding condition of the coil, and

check whether the coil has been conducted with the
stator core. If it is conducted, replace the stator
assembly.
Rectifier
Test of positive pole rectifier
Check the conduction in between the positive pole

rectifier and stator coil lead connection terminal by
using an ohmmeter, the ohmmeter must be conducted
only on one direction, if it is conducted on two
directions, the diode has been broken down. Replace
the rectifier assembly.
Test of negative pole rectifier
Check the conduction in between the negative pole

rectifier and stator coil lead connection terminal, the
ohmmeter must be conducted only on one direction, if
it is conducted on two directions, the diode has been
broken down. Replace the rectifier assembly
Test of three groups of diodes
Check the conduction of the 3 diodes by connecting

the ohm wire to the two pins of each diode, each
diode must be conducted only on one direction. If it is
conducted on two directions, the diode has defect, the
heat sink assembly must be replaced.
Replacing of brush
1. Measure, as shown in the figure, the extended

length of the brush if the measured value is below the
following limit valve, replace the brush.
Limit value: 2mm or less
2. The brush can be taken off if the brush lead has

been unsoldered.
3. When installing a new brush, insert the new brush

into the brush holder, and then solder the lead.
Re-assembling
The re-assembling procedure is opposite to the

disassembling procedure. Pay attention to the
following when re-assembling:
Before installing the rotor to the rear support, insert a

piece of steel wire through a small hole on the rear
support to support the brush. When the rotor has been
installed, take out the steel wire.
Visual inspection of battery
Check the lid or cover for any obvious indication

to cause electrolyte damage, e.g. cracking,
breaking. Determine the cause of damage and Replace the
repair according to the situation. Use soda water battery
solvent to clean the corrosion.
Check electrolyte height Replace the

battery
Replace the
battery
Test the battery Replace the

battery
Replace the
battery
Test the load, (using battery test instrument) Replace the

battery
Battery is normal
1. Check the current
2. Check list
Responsibility
Description Troubles Causes Repair
User Manufacturer
* Battery terminal damaged * Careless ○
* Battery wire tightened to Replace
tight
Visual
Lid cracked * Careless Replace ○
inspection
* Electrolyte leaking
lid cracked * Careless Replace ○ ○
Lid leaking * Poor lid sealing Replace
* Electrolyte height in * Single cell short-circuited Replace ○ ○
between single cell poles * Temperature too high, Replace ○
Electrolyte
greater than 10mm causing evaporation
height
* Electrolyte insufficient * Excessive waste of the Replace
inspection
electricity, resulting in
electrolyte loss
1. Battery voltage >13.2V 1. Excessive charging Replace ○
2. 12.5V< battery voltage 2. Normal Check the electrical
<12.9V system
3. 12.0V< battery voltage 1. Insufficient charging Test the battery load ○
<12.4V(Pure discharge) (refer to the load
Voltage
4. 11.0V< battery voltage 2. Internal fault test below) ○
inspection
<12.0V(Excessive discharge)
5. Battery voltage: 11.0V or 1. Charging condition fault Replace ○

lower 2. Battery discharging for a ○
long time ○
3. Internal circuit opened
3. Load test
a. The battery voltage must be as shown in the Table below under the condition of half current of the cold
startup power and battery discharged for 15s.
Regulation voltage table
Ambient temperature Regulation voltage

Above 20℃ 9.6V
～18℃ 9.5V
～10℃ 9.4V
～4℃ 9.3V
～-1℃ 9.1V
～-7℃ 8.9V
～-12℃ 8.7V
b. When the voltage is not within the specified value,
carry out the load test again and charge.
c. If the battery’
s output exceeds 12.5V after it is
charged and kept still for 2h, and the voltage exceeds
the standard value after the load test, the battery can
be used.
Visual inspection of battery
1. Make sure the ignition switch and all the

accessories are at position OFF.
2. Disconnect the battery wire (disconnect the

negative wire first).
3. Remove the battery from the vehicle.
Note:
When the battery lid is cracked or leaking, never

let the electrolyte damage your skin. When
disassemble the battery, wear thick rubber gloves.
1. Check whether the battery stand is damaged due to

electrolyte leaking, if acid corrosion exists, its
surrounding has to be cleaned with clean hot water
and soda water. Use wire brush to clean and wipe
clean with wet side dipped with soda water.
2. Use the solvent same as that in step (4) to clean the
battery top.
3. Check whether the battery lid and box has
cracking. If there is any cracking, replace the battery.
4. Clean the battery post with suitable tool.
5. Use suitable battery cleaning tool to clean the inner
surface of the terminal clamp. Replace the damaged
or worn wire and damaged terminal clamp.
6. Install the battery onto the vehicle.
7. Connect the wire terminal to the battery post, and
make sure the terminal head is aligned with the post
top.
8. Tighten the terminal nut.
9. Apply mineral oil to all the connectors after
tightening.
Note:
When battery is under charging, flammable gas

would be generated under the lid of each cell, no
open flame is allowed around the battery. Never
smoke when the battery is charging or the battery
just be charged. Never break the circuit of the
battery post under charging, because when the
circuit is disconnected, spark would occur.
Starting system
General
The starting system includes battery, starter motor,

electromagnetic switch, ignition switch, connection
line and battery wire. When the ignition key is turned
to start position, current passes through and excites
the electromagnetic coil of the starter. The
electromagnetic piston and clutch shifting lever is
driven (activated), the clutch pinion engages with the
annular ring and starts the motor.
To prevent the damage due to over rotating of motor

pivot when starting the engine, the clutch pinion
moves at overspeed.
Inspection
Check starter motor relay
Remove the starter motor relay, and check the

conduction between the terminals. If the conduction is
not within the specified range, replace the relay.
Terminal No.
85 86 87 30
Condition
Before excited ○ ○
Being excited ○ ○ ○ ○
Relay
Check ignition lock switch
Remove the ignition lock switch and check the

conduction between the terminals. If the conduction is
not within the specified range, replace the switch.
Terminal No.
1 2
Condition
Pushed up ○ ○
Released
Components
electromagnetic coil
split ring
screw
sun gear gasket A

ball
planet gear
planet gear seat screw
ring gear
overrunning clutch
stop ring
front support
rear support
brush holder
armature
centering bracket
assembly
2. Remove the speedometer and shaft wire.
3. Disconnect the starter motor connection and terminal.
4. Remove the starter motor assembly.
5. The assembling procedure is opposite to the disassembling procedure.

starter motor
Torque
Operation inspection: switch
Pinion clearance adjusting procedure when repair
1. Disconnect the excitation coil lead from the M

terminal of the excitation coil.
starter excitation coil lead
2. Connect a 12V battery between S terminal and M
motor
terminal.
3. Move out the pinion.
Note:
To prevent overheat of the coil, this test must be

completed quickly (within 10min).
4. Use feeler gauge to check the stopper clearance

of the pinion (pinion clearance).
Pinion clearance: 0.5-2.0mm
stopper
pinion clearance
pinion
5. If the pinion clearance exceeds the specified value,

adjust the clearance by adding or reducing shims
between the electromagnetic coil and the front
support.
Test of electromagnetic switch suction
1. Disconnect the excitation coil lead from M terminal

of the electromagnetic switch.
2. Connect a 12V battery in between M terminal and

S terminal.
Note: 12V battery

starter
To prevent coil from overheating, this test must be motor
completed quickly (within 10s).
3. If the pinion is moved out, the suction coil is good,

if unable to move out, replace the electromagnetic
switch.
Test of electromagnetic switch retentivity:
1. Disconnect the excitation coil lead from M terminal starter excitation coil lead
motor
2. Connect a 12V battery in between S terminal and

the switch body.
Note: To prevent coil from overheating, this test
must be completed quickly (within 10s).
3. If the pinion is moved out, every thing is normal, if
the pinion moves forward and backward repeatedly,
the retaining circuit is broken, if the circuit is broken,
replace the electromagnetic switch.
Test of no-load running
Place the starter motor into a vice with soft clamp,
and connect a fully charged 12V battery to the starter
motor as follows:
laminated carbon plate rheostat
1. Connect the test ammeter (scale of 100A) and the
laminated carbon plate rheostat, as shown in the ammeter
figure.
starter
motor voltmeter battery
12V
2. Start the motor and connect in parallel a voltmeter
(scale of 12V).
3. Turn the carbon plate to position OFF.
4. Connect the battery wire from the battery (-) wire
post to the starter motor body.
5. Adjust the carbon plate until the battery voltage
reading is 11V.
6. Confirm the maximum current is within the
specified range, and the starter motor running is
balance and free.
Current: maximum 90 amps
Speed: minimum 3000rpm
Test of electromagnetic switch return
1. Disconnect the excitation coil lead from M terminal
2. Connect a 12V battery in between the M terminal
and the motor body.
Note: To prevent coil from overheating, this test
must be completed quickly (within 10s).
3. Pull the pinion out and release, if the pinion starter
motor excitation coil lead
returns back quickly to its original position, every
thing is normal. If unable to return, replace the
electromagnetic switch.
Inspection
Check the steering gear
1. Place the armature onto a V-pad, check the radial

runout by dial gauge.
Armature radial runout
Standard value: 0.05 mm
Limit value: 0.1 mm
2. Check the steering gear outer diameter.
Standard value: 29.4mm
Limit value: 28.4mm
3. Check the undercut depth between the sector gear.
Standard value: 0.5mm sector undercut

gear
Limit value: 0.2mm
mica
Brush holder
Check the conduction between the brush holder plate

and the brush holder, it must not be conducted in
normal case.
Overrunning clutch
1. With the clutch hood supported, rotate the pinion,

the driving pinion must rotate smoothly on one
direction, but must not rotate in reverse direction.
If the clutch function is abnormal, replace the

releasing
overrunning clutch assembly.
locking
2. Check whether the pinion is worn or curled. If

yes, replace the overrunning clutch assembly. If the
pinion is damaged, also check whether the ring gear
has been worn or curled.
Front/rear support bush
Check whether the bush has been worn or curled. If

yes, replace the front support assembly or the rear
support assembly.
Re-assembling of stop ring and split ring
Use suitable tool to pull out the overrunning clutch

stop ring and split ring.
Clean starter motor parts
1. Do not immerse the parts in the cleaning agent.

If so, the centering bracket and excitation coil
assembly or a armature would damage the insulation.
These parts can be cleaned only by cloth.
2. Do not immerse the drive parts into cleaning agent, limit line
the overrunning clutch has been pre-lubricated in
factory, the agent would clean away the lubricant.
3. The drive parts can be cleaned by brush dipped

with cleaning agent, then dry it with cloth.
Replacing of carbon brush and spring
1. If the carbon brush is worn or immersed in oil,

replace it.
2. When replacing the excitation coil carbon brush,

nip to break the worn carbon brush with pliers, but
not damage the carbon brush lead wire.
3. Polish the carbon brush lead wire with sand paper

so as to ensure its good solderability.
4. Insert the lead wire into the hole on the new carbon
brush and solder it. Make sure the carbon brush
surface is not polluted by the remaining soldering tin
of the lead wire new carbon
carbon brush
5. When replacing the grounding carbon brush, slip brush
lead wire welding
out the carbon brush from the carbon brush bed by point(make
sure there is
prying up the position spring.
no remaining
soldering tin
on the carbon
brush surface)
Disassembling
Disassembling of split ring and stop ring
1. Use box wrench to press the stop ring to the split

ring side.
2. After taking off the split ring (using split ring

pliers), take off the stop ring and the overrunning
clutch.
Engine Control System EC-1
Chapter 3 Engine Control System

System functions................................................................................................................................EC-3
ECM control structure ....................................................................................................................EC-4
System functions...........................................................................................................................EC-5
Crankshaft position sensor...............................................................................................................EC-5
Speed density type air flow meter....................................................................................................EC-5
Cylinder-judgment sequential control............................................................................................EC-5
Closed-loop control..........................................................................................................................EC-5
Grouped control ..............................................................................................................................EC-5
Fuel injection function ....................................................................................................................EC-5
Fuel pump control ........................................................................................................................EC-5
Idle speed control function .............................................................................................................EC-5
Correction of engine mixture .........................................................................................................EC-5
Self-diagnosis of faults … ................................................................................................................EC-6
Protection function of 3-way catalytic reactor overheat system… … … … … … … … … … … … ..EC-6
Air conditioning compressor control..............................................................................................EC-6
Radiating fan control ......................................................................................................................EC-6
Mileage counter................................................................................................................................EC-7
System development –complete vehicle emission calibration … … … … ....................................EC-7
Working principle of electrojet control and executive module
Pressure and intake temperature sensor (TEM P)......................................................................EC-7
Throttle position sensor (TPS).......................................................................................................EC-9
Coolant temperature sensor (THW, CTS)....................................................................................EC-10
Knock sensor (KS.KNK)...............................................................................................................EC-12
Oxygen sensor（HO2S）...............................................................................................................EC-14
Electronic control unit ECU..........................................................................................................EC-18
Electric fuel pump (PUMP)...........................................................................................................EC-20
Electromagnetic injector (INJ)......................................................................................................EC-22
Idle actuator stepping motor (IDLE)............................................................................................EC-25
Ignition coil (COIL).........................................................................................................................EC-27
Steel fuel distribution pipe assembly … … … … … … … … … … … … … … … … … … … … … … … EC-28
Crankshaft position sensor (speed sensor CKPS) ........… … … … … … … … … … … … … … … … EC-29
Canister solenoid valve (EVAP)....................... … … … … … … … … … … … … … … … … … … … ..EC-31
Air conditioning control system (A／C)........... … … … … … … … … … … … … … … … … … … … EC-32
Fan control (FAN) ........................… … … … … … … … … … … … … … … … … … … … … … … … ..EC-34
Fault information record...............................................................................................................EC-35
Fault status.....................................................................................................................................EC-35
Fault type.......................................................................................................................................EC-35
Four types of faults........................................................................................................................EC-35
Limp home.....................................................................................................................................EC-35
Fault alarm....................................................................................................................................EC-35
Fault read out................................................................................................................................EC-35
Clearing of fault information record..........................................................................................EC-37
Fault locating................................................................................................................................EC-37
List of engine fault code ........................................................................................................EC-38
Element fault................................................................................................................................EC-39
When starting, the engine not running or running slowly ......................................................EC-65
When starting, engine can run by trailing, but cannot start successfully...............................EC-66
Difficult startup of hot vehicle.....................................................................................................EC-68
Speed is normal, but always difficult to start… … … … … … … … … … … … … … … .................EC-69
Difficult startup of cold vehicle...................................................................................................EC-70
Idle unstable at any time… … … … … … … … … … … … … … … … … … … … … … .....................EC-72
Idle unstable during warming up...............................................................................................EC-73
Idle unstable at the end of warming up.....................................................................................EC-74
Idle unstable or fire cut-off when using load (air conditioning).............................................EC-75
Periodically unstable (Self-learning must be carried out after ECU power off) … … … … ..EC-76
Too high idle speed (Self-learning must be carried out after ECU power off) … … … … ......EC-77
Speed cannot be increased or fire is cut-off when accelerating… … … … … … … … ...............EC-78
Reacting slowly when accelerating.............................................................................................EC-79
Performance is poor, asthenic when accelerating… … … … … … … … … … … … ........................EC-80
Air conditioning system fault … … … … … … … … … … … … … … … … … … … … … … … … … … EC-81
Fault diagnosis of electrojet system
Causes of engine electrojet system fault........................................................................................EC-81
Engine Control System

SRV gasoline engine adopts Delphi control system.

Delphi MT20 engine management system is a system with MT20 and MT20U engine control module (ECM)
as the core, having the characteristics of computer closed-loop control, multipoint fuel sequential injection,
distributor-free grouped direct ignition and 3-way catalytic reactor after treatment.
MT20U engine control module (ECM) is an ECM specially developed by Delphi for the Chinese electrojet
market. The engine module has adopted the latest electronic hardware technology, which has a high
performance-price ratio; the hardware adopts 16-digit microprocessor, which has sufficient memory and high
operational speed, with freely defined I/O ports; the software adopts the second generation control software
written in Delphi modular C language. The ECM has met all the technical specifications required by present
European Code III.
The system functions include:
1. Complete vehicle main power supply relay control
2. Speed density air measuring method
3. Closed-loop control multipoint sequential fuel injection (including MAP CI pressure cylinder-judgment)
4. Oil supply method without return oil
5. Fuel pump operation control
6. Distributor-free direct ignition, ECM built-in ignition module drives grouped ignition (also supports
4-cylinder sequential ignition)
7. Linear EGR control
8. Stepping motor idle control
9. Knock control
10. Air conditioning, cooling water tank fan control
11. Overvoltage protection
12. Electronic anti-theft
13. System self-diagnostic function
14. Open-type, modular C language programming

ECM control structure
12V power
12V battery
12V switch power

12V ignition Ignition coil A A Ignition system
System power grounding wire Ignition coil B B control

System power
management
Ignition and injection grounding
Fuel pump relay
5V voltage
5V reference Injector A A
Fuel supply
5V voltage feedback
5V reference Injector B B
system control
Injector C C
Speed and crankshaft position sensor
Delphi Injector D D
MT20
Engine cylinder sequence judgment
Intake manifold absolute pressure sensor A/Hi A/Hi

Idle speed control valve
Throttle position sensor A/Lo A/Lo

Idle speed control valve Idle speed
System signal Coolant temperature sensor B/Hi B/Hi
Idle speed control valve control system
Engine control module (ECM)
input
Intake temperature sensor B/Lo B/Lo
Idle speed control valve
Oxygen sensor Evaporation

Canister cleaning solenoid valve
exhaust system
Speed sensor
( )
Electrical cooling (high speed) fan relay Cooling system
Power steering signal
control
( )
Electrical cooling (low speed) fan relay
Air conditioning request signal

Air conditioning clutch relay Air conditioning
Air Air conditioning load signal
conditioning Air conditioning fan relay system control
system signal First evaporator temperature signal
Second evaporator temperature signal (ECM) Engine speed signal
Engine fault indicating-lamp Communication

Diagnosis request signal
Diagnosis and and anti-theft
anti-theft signal (KW2000)
Serial communication （KW2000） control
Thief-proofer control signal
Thief-proofer control
EGR signal
EGR feedback
Spare Europe - Second oxygen sensor signal EGR control

Liner EGR valve Spare Europe -
-3 -3
3 signal 3 control
Fuel level sensor signal
System functions
1. Crankshaft position sensor 8. Idle speed control function
The system judges the crankshaft position and The idle speed control function refers to the control of
measures the engine speed according to 58X gear the engine speed by the system when the air throttle
signal so as to control accurately the engine ignition valve is in closed state. The system makes the actual
and fuel injection timing. speed comply with the target idle speed by adjusting
2. Speed density type air flow meter the following parameters:
ECM calculates the air capacity entering the cylinder - Idle air quantity control
through intake temperature and intake manifold - Fuel injection quantity control
pressure sensor so as to determine the air capacity - Ignition timing control
entering the cylinder, and make air-fuel ratio meet the
requirement of various operation conditions by Idle design control time
controlling the oil supply capacity. - Idle stability calibration
3. Cylinder-judgment sequential control - Acceleration operation condition calibration
To realize sequential control of the engine, the system - Deceleration operation condition calibration
adopts the traditional camshaft cylinder-judgment
technique. - Deceleration fuel cut-off
4. Closed-loop control - Engine transient operation condition fuel supply
calibration
The system adopts closed-loop control for fuel supply
and idle speed of the engine; the advantages of the - Constant running speed calibration
closed-loop control are that the system is able to - Mechanical and electrical load loading/unloading
eliminate the differences of the system and the related calibration
parts and components caused by manufacture and
Target idle speed is determined according to
operation wearing, improve the comprehensive
multiple input signals
consistency of the complete vehicle and reduce its
emission. - When the engine water temperature is quite low, the
system gives out quite high target idle speed to speed
5. Grouped control
up warming up; while for the engine using
The system divides the engine cylinders into two mechanical fan, when the engine coolant temperature
groups of 1 – 4, 2 – 3 to control the ignition is too high, the system will also applies quite high idle
separately; the grouped control makes the system speed for the purpose of increasing the air intake
structure optimized and simplified, thus, the cost of quantity of the cooling water tank.
the parts and components and their manufacture and
- When the external loads (e.g. air conditioning,
fabrication reduced.
power steering and various electrical loads) change,
6. Fuel injection function the system will increase its idle speed, so as to
The system adopts speed density method, and compensate the increased loads and keep the idle
multipoint sequential injection; each engine cycle is speed stable.。
supplied with fuel accurately through main pulse 9. Correction of engine mixture
width and corrected pulse width, and has the function
When the engine is at normal operation temperature,
of closed-loop control and self-learning function; the
part of its load control is closed-loop fuel control. At
hardware adopts Delphi’ s third generation injector,
this time, the system makes real-time correction of the
the latest type oil pressure regulator.
fuel injection quantity through the engine electronic
7. Fuel pump control control module according to the voltage signal fed
After the ignition switch is switched on, the fuel back by the oxygen sensor, so as to adjust the mixture
pump will run for 1.5s; if effective 58x signal concentration to near the theoretical air-fuel ratio, and
(crankshaft signal) not detected, the fuel pump stops ensure the conversion rate of the harmful gases in the
running; the engine starts running, after 2 effective exhaust gas converted by 3-way catalytic reactor to
58X signals have been detected by ECM, the fuel reach the best condition, and can keep better fuel
pump starts running. economical efficiency.
The pump stops after speed signal disappeared for
0.8s.
When the engine is within its normal operation 10. Self-diagnosis of faults
temperature and is running at full load, it is at
open-loop fuel control. At this time, to ensure the best Self-diagnosis of the system faults is an absolutely
power output of the engine, the system will control necessary function of the engine management system;
the oil injection quantity with relatively highly when operation of one or several parts in the system
concentrated air-fuel ratio, and increase properly the are abnormal, the system will prompt timely by fault
ignition advance angle with the pre-condition of no indicator light the vehicle user to make necessary
knock produced in the engine, the system will also inspection and maintenance.
use the exhaust temperature mathematical model set When the above-mentioned fault occurs, the system is
when calibrating to control the exhaust temperature so also able to adopt temporary emergency scheme to
as to protect the engine itself and the 3-way catalytic control the engine operation so as to guarantee the
reactor. user to drive the vehicle to the maintenance station for
The system judges the engine’ s full load condition is maintenance without anchoring on the roadside.
based on the signal provided by the throttle valve 11. Protection function of 3-way catalytic reactor
position sensor, normally, when the throttle opening overheat system
reaches above 80% ~ 90%, the system holds the
engine is at full load condition. The system adopts at right time the method to control
the air-fuel ratio to decrease the engine combustion
When the driver steps on the accelerator pedal to temperature according to the actual operation
accelerate the vehicle, the system will increase condition of the engine and the predicted rising
properly the fuel injection, so as to ensure the power tendency of the engine’ s exhaust temperature, and
required during engine acceleration is in proportion protect the 3-way catalytic reactor.
with the change rate of the jet valve opening.
3-way catalytic reactor rapid ageing technique
When accelerating, the system will first postpone
properly the ignition advance angle, then resume When the air conditioning switch is switched on, the
gradually; the purpose of doing so is to avoid the system will receive a signal called air conditioning
impact on the transmission system by too fast request signal, and will make preparations before
increased torque produced by brisk engine loading the air conditioning according to the engine’ s
acceleration. operation condition at that time, then switch on the air
conditioning compressor; the system will control On
When the acceleration condition is close to engine or Off of the air conditioning according to the needs
full load, the system will disconnect temporarily the of the air conditioning protection of itself;
vehicle air conditioning system so as to ensure the
engine’ s power output during acceleration. 12. Air conditioning compressor control
In any cases, whenever the engine speed exceeds the To ensure power output and protect the engine, the
highest speed set in the system, the system will cut off system would cut off the air conditioning operation
fuel supply to suppress the uncontrolled acceleration, under certain special operation conditions.
and protect the engine, prevent “galloping”; the Air conditioning operation conditions:
system resumes fuel supply as soon as the speed
becomes lower than the highest speed specified by the Coolant temperature Air conditioning state
system. 108℃ Air conditioning stops
During normal running of the engine, when the driver operation
releases the accelerator pedal, the vehicle enters 105℃ Air conditioning
coasting and trails the engine, at this time, the vehicle resumes operation
does not need the engine to supply power; but as the
air intake is in very small quantity after the throttle - Air conditioning can be started only after the engine
valve is completely closed, hazardous gas emission starts for 5s.
would be increased due to poor combustion of the
engine, therefore, the system will cut off the fuel - Air conditioning can be started only when the engine
supply at this time, thus, not only the generation of speed is higher than 600rpm and lower than 6200rpm.
hazardous emissions by the engine is reduced greatly, - After the air conditioning and the evaporator are
but also the fuel economic efficiency improved as started, the engine target idle increases by 150rpm.
well.
13. Radiating fan control
The engine, after several unsuccessful starts, will
have unburnt gasoline accumulated in the cylinder, it Electrical fan control function: the system can control
is commonly called “flooded cylinder”, at this time, two-speed cooling fan, and start different fan
the driver may step on the accelerator pedal to the end according to the water temperature, so as to reduce
to start the engine, the system will use automatically the engine’ s internal power consumption.
the very thin air-fuel ratio to discharge the surplus
gasoline in the cylinder during engine running.
14. Mileage counter Pressure diaphragm inside the intake pressure sensor
MT20’ s mileage accumulation function is provided is connected with a magnet core placed in the coil,
specially for mileage statistics as after-sale quality when the intake pressure in the intake pipe changes,
assurance, which should not replace the existing the diaphragm drives the magnet core to move, at this
speed and mileage meter. time, the output voltage of the sensor changes, and
ECU is able to convert the engine’ s intake quantity
The system makes mileage accumulation according to according to the output voltage of the sensor, and the
the vehicle speed signal obtained from the vehicle
engine fuel injection is controlled based on this signal
speed sensor. If the vehicle speed sensor signal is not
and by referring to other signals.
available, the system will be unable to accumulate the
service mileage of the engine. The intake temperature sensing module is a resistor of
15. System development – complete vehicle negative temperature coefficient (NTC), as the intake
emission calibration temperature rises, the resistance value drops, the
engine ECU monitors the change of intake
The complete vehicle emission calibration can be temperature through an internal comparison circuit.
carried out simply after the preliminary engine bed
calibration and the vehicle’
s drivability calibration is Fault diagnosis:
completed. Sensor line is short-circuited (short-circuited to
Calibration of the complete vehicle emission control ground, short-circuited to power supply).
is just to adjust accurately the open-loop fuel
Sensor line is open circuited.
calibration data set preliminarily within the vehicle
running range specified by the emission code test, so Sensor detected intake pressure exceeds upper limit.
as to optimize the vehicle’s emission performance.
Sensor detected intake pressure exceeds lower limit.
The following items are to be especially calibrated:
- Throttle control when vehicle starting Assembling:
- Effect of the engine idle air control system on the To be assembled on the intake manifold of the first
vehicle comprehensive emission performance cylinder, judge the cylinder according to the pressure
drop produced at the moment when the intake valve is
- Control of air-fuel ratio when vehicle accelerating opened.
and power raising
Trouble shooting:
- Adjustment of engine ignition timing
Check mainly whether there is short-circuit,
- Closed-loop control
open-circuit at the connection between the four wires
on the sensor and the ECU.
Working principle of electrojet
Whether the sensor detection hole is blocked.
control and executive module Whether there is short-circuit, open-circuit, grounding

phenomenon between the sensor wiring harness.
l. Pressure and intake temperature sensor (TEMP) Whether the sensor is out of use as a result of being
MT20 electrojet system adopts speed density air impacted
measuring method to detect air quantity entering the
Detection pressure range: 10 kPa 一 110 kPa
engine, thus, controlling the fuel injection pulse
width, and consequently, control accurately the Operation temperature range: -40～125℃
engine power output. In addition, this system has
adopted intake pressure cylinder-judgment technique,
with the intake pressure sensor installed nearby the
cylinder 1 intake manifold inlet, there will be a
transient pressure drop when the intake valve is
opened, which is about 1kPa, ECU detects this
transient pressure drop, and after ECU receives this
signal, it determines the compression top dead center
signal after software analysis and processing.
Intake temperature sensor
Circuit diagram of intake temperature sensor
Intake temperature sensor
intake
pressure/temperature
sensor
Circuit diagram of intake temperature sensor

Pins: Warning:
#1(A) intake pressure sensor signal (connecting to The throttle position sensor is strictly forbidden to
ECU #42) disassemble in normal case. This sensor has been
adjusted to the best position when ex-works.
#2 (B) standard 5V power (connecting to ECU #4)
Assembling:
#3 (C) intake temperature sensor signal (connecting to
ECU #27) The permitted tightening torque of fastening screw is
1.5Nm-2.5Nm.
#4 (D) sensor grounding wire (connecting to ECU
#21) Trouble shooting:
Operation voltage: 5.0V+／-0.1 V Check mainly whether there is short-circuit,

open-circuit on the connection between the three
2. Throttle position sensor (TPS)
wires of the sensor and ECU.
Purpose:
Whether there is short-circuit, open-circuit, grounding
MT20U TPS (throttle position sensor) is used to phenomenon between the sensor wiring harness.
provide ECU the throttle angle, angle rate and engine
Use universal meter to check whether bounce exists
idle position information. According to this
between the sensor signal terminal and the grounding
information, ECU can obtain the engine load
wire when open/close the throttle.
information, operation condition information (e.g.
startup, idle, reverse trailing, partial load, full load) Check whether the sensor resistance value exceeds
and acceleration and deceleration information. This much higher than the standard value; it may be caused
sensor is a three-wire type; ECU detects the valve by dirt inside the sensor.
opening by monitoring voltage change.
Operation voltage: 5+0.1V
Composition and principle:
Opening range: 7％～93％
The structure of this sensor is of sliding resistance
Sensor resistance value: 3k～12kΩ
strain gauge type (i.e. linearly variable resistance
type). ECU obtains the opening signal of the throttle Output signal when throttle is closed: 0.612～0.588V
by monitoring the voltage at the signal output Output signal when throttle is fully opened: 4.15～
terminal and by the comparison circuit in the 4.65V
computer. ECU interior does not receive voltage
signal directly, in this way, signal fluctuation problem
caused by voltage fluctuation can be prevented.
Fault diagnosis:
Throttle position sensor signal is higher than the

measurement range.
Throttle position sensor signal is lower than the

measurement range.
Throttle position sensor signal line short-circuited.
Throttle position sensor signal line is open-circuited.

EC-10
Throttle position sensor
Circuit diagram of throttle position sensor Throttle position sensor
Pins: Circuit diagram of throttle position sensor
1# (A) standard 5V power (connecting to ECU 20#)
2# (B) sensor grounding wire (connecting to ECU 5#)
3# (C) sensor signal (connecting to ECU 24#)
3. Coolant temperature sensor (THW, CTS)
Purpose:
This sensor is used to provide coolant temperature

information, to provide water temperature signal for the
engine ECU for control of ignition timing and for
injection pulse width at starting, idling and normal
operation; in addition, it also provides the water
temperature signal to the instrument for water
temperature display. Water temperature signal is the
most important signal for engine cold startup, because
the injection quantity during the cold startup is
determined by the signal provided by the water
EC-11
temperature sensor.
EC-12
This sensor is a thermistor of negative temperature
coefficient (NTC), its resistance value reduces as the
coolant temperature rises, the resistance value increases
as the coolant temperature drops, but not in linear
relationship. ECU monitors the water temperature
change through the internal comparison circuit in
accordance with the signal sent out by the sensor.
Fault diagnosis:
Water temperature signal is higher than the limit value.
Water temperature signal is lower than the limit value.
Water temperature sensor line is short-circuited,
open-circuited.
Normal temperature resistance value data: 2.5±5％KΩ
Assembling prompt: the maximum tightening torque is
20Nm.
Note:
This vehicle is assembled with three-wire type water
temperature sensor. The advantages of such sensor
are: cost saved and consistency of the system
maintained. The three wires of the sensor are
respectively:
5V standard power
Sensor signal wire (to ECU)
Sensor signal wire (to instrument)
Trouble shooting:
Check mainly whether there is short-circuit, open-circuit
on the connection between the three wires of the sensor
and ECU.
Whether there occurs short-circuit, open-circuit,
grounding phenomenon between the sensor wiring
harness.
Line earth and poor earth are liable to cause too high
temperature indication of the engine water temperature
gauge.
Operation voltage: 5V DC
Operation temperature range: -40— 135℃
Picture of coolant temperature sensor
Coolant temperature sensor

Circuit diagram of coolant temperature sensor
EC-13
To instrument
Pins:
This sensor has totally three pins, which are
interchangeable.
1# (A) sensor grounding wire (connecting to ECU 5#)
2# (B) water temperature sensor signal (connecting to
ECU 43#)
3# (C) to instrument water temperature gauge
Circuit diagram of coolant temperature sensor
Characteristic parameters (standard value):
Computer Instrument
Standard
Temperature Standard Temperature
resistance
℃ resistance Ω ℃
(dynamic) Ω
-20 28.502±1143 80 100-120
0 9399±301 90 41-46
20 3511±92 110 24-26
40 1465±34 120 20.5-23.5
60 6709±147
80 333.0±6.75
100 178±41
128 81.65±2.27
140 60.32±1.73
4. Knock sensor (KS, KNK)

Purpose:
This sensor is used to provide engine knock information
to ECU to make knock control.
Knock sensor is a kind of vibration acceleration sensor,
installed on the engine cylinder block, normally installed
in between cylinder 2 and 3, favorable for engine knock
balance. ECU uses the vibration frequency signal sent
out by the knock sensor, through ECU internal filtration,
to judge whether knock occurs on the engine; when
knock signal is detected, ECU will be reduced gradually
until no knock occurs, then is resumed gradually to the
edge of knock; it is repeated in this way.
EC-14
Fault diagnosis:
ECU monitors the knock sensor, power amplifier circuit

and detection circuit. Once one of the following cases is
found, the fault sign position of the knock sensor is set:
Knock sensor fault
Knock control data processing circuit fault
Cylinder-judgment signal not believable
Sensor line fault
After the knock sensor fault sign position is set, the

knock closed-loop control is off; and fix the ignition
advance angle stored in ECU at a safe angle through
software program. When the error frequency is
decreased to lower than the set value, the fault sign
position is reset.
Note for assembling:
Tightening torque: 20+5Nm
Trouble shooting:
Check mainly whether short-circuit and open-circuit

occur on the connection between the two wires of the
sensor and the pins in correspondence with ECU.
The sensor assembling torque, whether gasket is needed

during assembling.
Whether press fit between the sensor and the cylinder

block is not so good, or any foreign matters exist in
between the sensor and the cylinder block.
Operation temperature range: －40～150℃
Resistance value: ＞1MΩ
Knock sensor with cable
Knock sensor with cable

EC-15
Circuit diagram of knock sensor
Pins:
1(A) knock sensor signal 1(ECU 5#) knock sensor

Circuit diagram of knock sensor
2(B) knock sensor signal 2 (ECU 69#)
5. Oxygen sensor (HO2S)
Front oxygen sensor (FO2S)
Purpose:
This sensor is used to provide the information about

whether there is excessive oxygen after the fuel injected
to the cylinder is fully fired in the sucked air. ECU can
make closed-loop control of fixed fuel quantity by using
this information, so that the three main hazardous
compositions (HC, CO and NOx) in the engine exhaust
can be converted and purified to maximum extent in the
three-effect catalytic converter.
The sensing component of the oxygen sensor is a kind of

ceramic tube with small opening, the tube external is
surrounded by the engine exhaust, and the internal is
connected to atmosphere. The sensor calculates
indirectly the fuel injection pulse width according to the
internal and external oxygen concentration difference
and sends it to ECU, and the ECU controls again the
injection. Besides, the rear oxygen sensor output data are
detected and comparison is made between the data of the
EC-16
front and rear sensor within ECU so as to monitor
whether the operation of 3-way catalytic reactor is good.
The operation voltage of the sensor is fluctuated between

0.1 ~ 0.9V, it must change for 5 ~ 8 times within 10s; if
it is lower than this value, it indicates the sensor is aged,
and must be replaced. This sensor is impossible to repair.
Fault diagnosis:
ECU detects the oxygen sensor, line, ECU internal

power amplifier and detection circuit. Once one of the
following cases is found, the oxygen fault sign position
is set:
Battery voltage not believable
Intake manifold absolute pressure signal not believable
Engine coolant temperature signal not believable
Injector drive stage fault
After the oxygen sensor fault sign position is set,

closed-loop control of fixed fuel quantity is off, and the
basic injection time stored in ECU for fuel metering is
adopted.
Assembling:
Tightening torque of the oxygen sensor is 50~ 60Nm.

After the oxygen sensor is replaced, apply a layer of
rustproof oil to the oxygen sensor for easy removal.
Trouble shooting:
Check mainly whether the connections of the wires of

the sensor are secure, whether there are such phenomena
as short-circuit and open-circuit.
Damage of sensor is normally caused by lead, phosphor

poisoning, therefore, attention must be paid to the fuel
quality; besides, over-consumption of engine oil would
also be liable to cause sensor failure.
The number of changes of the oxygen sensor must not be

less than certain numbers within certain time.
Oxygen sensor
EC-17
Oxygen sensor
Circuit diagram of front oxygen sensor
Main relay
oxygen sensor
Circuit diagram of front oxygen sensor
Oxygen sensors all have cables. Another end of the cable

is electrical connector, wrapped with asbestos fireproof
covering.
All the connectors have four pins:
1# (A) oxygen sensor signal low level (connecting to

ECU 6#)
2# (B) oxygen sensor signal high level (connecting to

ECU 62#)
3# (C) connecting to main relay power supply
4# (D) sensor heating line control (connecting to ECU

61#)
Rear oxygen sensor (RO2S)
There is no big difference in structure and detection

between the front oxygen sensor and the rear oxygen
sensor; however, the purpose to provide the front oxygen
sensor and rear oxygen sensor for the vehicle differs
greatly.
Purpose:
EC-18
The purpose of the front oxygen sensor is to detect the
oxygen content in the exhaust so as to judge whether
over-injection is made.
The sensor converts the oxygen content in the exhaust

after combustion to electrical signals and sends them to
ECU, then ECU controls the fuel injection pulse width,
adjust air-fuel ratio according to these signals, so as to
control indirectly the engine tail gas emission.
The purpose of rear oxygen sensor is to detect the

oxygen content in the exhaust after 3-way catalytic
reactor; the sensor converts this signal to electrical signal
and sends it to ECU, and then ECU judges whether the
operation of 3-way catalytic reactor is good by
comparing the signals of the front oxygen sensor and the
rear oxygen sensor.
Fault diagnosis, trouble shooting, and signal detection,

etc. are the same as that of front oxygen sensor.
Internal structure of the sensor
Internal structure of oxygen

sensor
Circuit diagram of rear oxygen sensor
Main relay
EC-19
Circuit diagram of rear oxygen sensor

1# (A) oxygen sensor signal low level (connecting to
ECU 6#)
2# (B) oxygen sensor signal high level (connecting to
ECU 38#)
3# (C) connecting to main relay power supply
4# (D) sensor heating line control (connecting to ECU
64#)
6. Electronic control unit ECU
Purpose:
ECU is a control center of electronic-controlled engine,
consisting of only sensor signal input interface and
actuator driving circuit with microprocessor as the core.
It receives and processes the engine status signals
inputted by each sensor and sends out control signal to
the actuator to make the engine operate as per the preset
program and operate under the best condition, ensuring
excellence of dynamics, fuel economy and emission.
Normal operation voltage: 9-16V
Over voltage protection: +24V／-12V<60s
Composition:
Screened casing and printed circuit board, many
electronic control units are integrated on the printed
circuit board, used for control of electrojet system.
Assembling:
Fix it below the water guide of front windscreen together
with body computer (ECU) through a support; pay
attention to waterproof.
Operation temperature: -40— 105℃
Picture of ECU
Function:
Multipoint sequential fuel injection system Picture of ECU
Grouped ignition system
EC-20
Idle speed control
Automatic knock closed-loop control
Power for sensor: 5V/l00mA
λclosed-loop control, with selfadaptation.
Double oxygen sensor
Emission canister control
Air conditioning ECU control
Engine fault-indicating lamp
Output of engine speed signal
Fault self-diagnosis, having flashing code function
Receiving engine load signal
Trouble shooting:
The failure rate of ECU is very low, therefore, it is not

recommended to solve any problem simply by replacing
ECU, but check first the peripheral lines and sensor
components for any fault, when the peripheral
components are confirmed normal, then replace the
ECU.
Definition of ECU pins:

Pin Connection point Type Pin Connection point Type
1 Ignition switch control live wire Input 2 Unused
(power)
3 Speed signal sensor Input 4 5V standard power supply Output
5 5V standard power grounding wire Ground 6 Front oxygen sensor signal (low Input
level)
7 Unused 8 Unused
9 Unused 10 Unused
11 Diagnosis communication Output 12 Speed sensor signal (high level) Input
13 Unused 14 Unused
15 Unused 16 Unused
17 Battery power (+12V) Input 18 Battery power (+12V) Input
19 Unused 20 5V standard power supply Output
21 5V standard power grounding wire Ground 22 Unused
23 Unused 24 Throttle position sensor Input
EC-21
25 Unused 26 Air conditioner evaporator Input
temperature sensor
27 Intake manifold temperature sensor Input 28 Speed sensor signal (low level) Input
29 Unused 30 Diagnosis request Input
31 Engine fault indicator light Input 32 Ignition coil (1.4) Input
Pin Connection point Type Pin Connection point Type

33 Idle stepping motor drive coil B Output 34 Idle stepping motor drive coil A Output
35 Unused 36 Unused
37 Unused 38 Rear oxygen sensor signal (low Input

level)
39 Air conditioning request signal Input 40 Unused
41 Unused 42 Intake pressure sensor signal Input
43 Coolant temperature sensor signal Input 44 Unused
45 Engine speed signal Output 46 Air conditioning relay control Output
47 Fuel pump relay control Output 48 Unused
49 Unused 50 High speed fan control Input
51 Unused 52 Ignition coil Input
53 Idle stepping motor drive coil C Output 54 Idle stepping motor drive coil D Output
55 Injector 1# Input 56 Injector 2# Input
57 Unused 58 Unused
59 Unused 60 Unused
61 Front oxygen sensor heating Input 62 Front oxygen sensor signal (high Input
control level)
63 Canister solenoid valve control Input 64 Rear oxygen sensor heating control Input
65 Unused 66 Unused
67 Fan low speed control Input 68 Unused
69 Knock sensor signal Input 70 Injector 3# Input
71 Injector 4# Input 72 Unused
73 Ground Ground None
7. Electric fuel pump (PUMP) Composition and principle:
Purpose: The electric fuel pump is composed of DC motor,

blade pump and end cover (integrated with check
To deliver fuel from fuel tank to engine fuel supply
EC-22
main pipe at certain fuel pressure and flow, and keep valve, pressure relief valve and anti-electromagnetic
the fuel pressure stable (realized through fuel pressure interference component) and installed coaxially with
regulator). motor, and enclosed in the same casing. The
maximum pressure at outlet of the electric fuel pump
is determined by pressure relief valve, which is 450 ~
650kPa. However, the pressure of the whole fuel
system is determined by the fuel pressure regulator,
normally 350kPa for MT20U electrojet system.
Note:
If the vehicle fuel tank is in the state of lacking of

fuel or short of fuel for a long time, the fuel pump
cannot be well lubricated, which would lead to the
fuel pump sintered; especially for engines using
CNG and LPG, the fuel tanks of such kind of
engines are normally in the state of lacking of fuel
or short of fuel for a long time; the fuel pump runs
for a long time, but cannot be well lubricated,
which would cause the fuel pump to be burnt out.
The fuel temperature has relatively great influence

on the fuel pump performance; when it runs at
high temperature for a long time and the fuel
temperature gets higher than certain temperature,
the pumping pressure of the fuel pump drops
down rapidly, therefore, when the engine of hot
vehicle cannot be started, please check carefully
whether the high temperature operation
performance of the fuel pump is not good.
The lubrication and cooling of the fuel pump is

realized through the gasoline in the fuel tank.
The fuel tank of this vehicle is in saddle shape,

having two fuel pump ports.
Pressure relief pressure: <900 kPa
Operation voltage: 8～16V
Fuel pump resistance value: <130Ω
The injection pump in the auxiliary fuel tank is

responsible for pumping back the return fuel to
the main fuel tank.
Picture of electric fuel pump

EC-23
Picture of electric fuel pump
Circuit diagram of electric fuel pump
main power
power relay
Fuel pump control
Circuit diagram of electric fuel pump

Pins:：
The electric fuel pump has two pins, connected to the

fuel pump relay. On the fuel pump casing near the
two pins is carved with sign “+”, “－”, indicating
respectively connected to positive pole and negative
pole. ECU 47# pin controls the fuel pump relay.
Trouble shooting:
Failure of fuel pump normally is expressed with

insufficient fuel pressure, not pumping, etc. When
getting rid of the fault, check whether the system fuel
pressure is within the specified range, and whether the
pipeline is leaking. Besides, positive pressure or
negative pressure of the fuel tank would also affect
the fuel system.
EC-24
8. Electromagnetic injector (INJ)
Purpose:
MT20U adopts sequential fuel injection technique.

The sequential injection signal is supplied by the
intake pressure sensor (TEMP); if the intake pressure
sensor (TEMP) is damaged, follow the ignition
sequence and adopt grouped injection method to
control; the injector injects fuel within the specified
time according to the ECU instruction and supplies
fuel to the engine and makes it atomized.
ECU sends out electric pulse to the injector coil to

form a magnetic field force. When the magnetic field
force rises to resultant force that is strong enough to
overcome the return spring pressure, gravity and
friction force of needle valve, the needle valve starts
rising, and the fuel injection starts. When the fuel
injection pulse is stopped, the pressure of the return
spring makes the needle valve closed again.
Assembling:
Definite injector must use definite plug, never get

mixed. For convenience of assembling, it is
recommended to apply silicon-free clean oil to the
“O”ring surface on the top, which is connected with
fuel distribution pipe. Note that never let the oil
pollute interior of the injector and the injection hole.
When assembling, do keep the lower nozzle of the
injector sealed, otherwise intake system leakage may
be caused. Assemble the injector to the injector seat
with it perpendicular to the injector seat, then use
clamp to fix the injector on to the injector seat.
Note:
For the vehicle not used for a long time and unable
to be started normally due to sticking of gasoline
in the injector, please check carefully whether the
injector is stuck.
Fault diagnosis:
MT20U electrojet system does not make fault

diagnosis for the injector itself, but make fault
EC-25
diagnosis for the injector drive stage. When the
injector drive stage is short-circuited or overloaded to
the battery, short-circuited to ground and open
circuited, the fault sign position is set. At this time,
turn off the oxygen sensor closed-loop control and its
self-learning pre-control, the last self-learning data
are effective. After the fault is eliminated, the fault
sign can be reset.
Operation pressure: 350 kPa
Injector resistance: 11-16Ω
Operation temperature: -40～130℃
Picture of electromagnetic injector
Circuit diagram of electromagnetic injector
Electromagnetic injector
main relay
Pins: injector group
1# 1-cylinder injector gate electrode (connecting to Circuit diagram of electromagnetic injector

ECU 55#)
2# 2-cylinder injector gate electrode (connecting to

ECU 70#)

ECU 56#)
EC-26
ECU 71#)
Another wire of the four injectors is connected

together; the engine main relay supplies power to
ECU to control injector earth.
Trouble shooting:
Too long service time of the engine may lead to block

of the nozzle or bad atomization, the nozzle must be
cleaned periodically.
Coil short-circuited and open circuited inside the
nozzle may also lead to fault of injection system.
Whether the system line is short-circuited, open
circuited.
Fuel stuck in the injector hole due to using
unqualified fuel for a long time is liable to lead to
unstable idle speed.
9 Idle actuator stepping motor (IDLE)
Functions:
To control the air flow area of the bypass channel
inside the throttle valve body, thus the air input of the
engine is controlled; ECU can control the engine
speed within the target range according to the signal
sent by each sensor, the target speed can be calibrated
according to the coolant temperature.
The essence of the stepping motor is just a miniature
motor, since the motor is fed with current of different
direction, it can rotate according to the different
direction, the rotating shaft of the motor drives the
lead screw to move to control indirectly the valve
opening; MT20U sends out digital square wave to
control positive and negative rotation of the motor,
and then proceeds to control the travel of the stepping
motor.
Fault diagnosis:
ECU is able to monitor short-circuit, open-circuit of
the two coils of the stepping motor and switch on the
engine fault-indicating lamp in case such fault occurs,
then the engine enters fault mode.
Monitor whether there is short-circuit, open-circuit
phenomenon in between the four wires of the sensor
and ECU.
ECU is unable to monitor the fault caused by
mechanical part of the motor itself.
EC-27
Trouble shooting:
Connect the four wires between the stepping motor
and ECU and check for short-circuit, open-circuit.
Whether the stepping motor is jammed.
Whether there is short-circuit, open-circuit
phenomenon inside the stepping motor.
Take off the stepping motor and check whether the
stepping motor telescopes freely after supplied with
power.
Carbon deposit or dirt in the intake system would
affect the operation performance of the stepping
motor.
Motor coil resistance: 58.3～47.7Ω
Operation voltage: 7.5～12V
Picture of idle actuator stepping motor
air
idle control valve
throttle valve body
Idle actuator stepping motor

Circuit diagram of idle actuator stepping motor
EC-28
Pins:
1# (B) Idle stepping motor control (connecting to

ECU 33#)
2# (A) Idle stepping motor control (connecting to

ECU 34#)
3# (C) Idle stepping motor control (connecting to

ECU 54# )
4# (D) Idle stepping motor control (connecting to

ECU 53#)
10. Ignition coil (COIL)
Function:
The ignition coil converts the LV power of primary
winding to HV power of secondary winding, and
generates spark through discharging of the spark plug
to ignite the fuel-air mixture in the cylinder.
MT20U adopts grouped ignition technique, using the
principle that magnet coil mutual inductance can
produce high energy to control the power On time,
power Off time of the primary coil, using the HV
power generated at the coil secondary pole to break
down the spark plug clearance to generate strong
spark to ignite the mixture. When the engine is at
exhaust stroke, the air ionization is very high and the
resistance is very low; only very low voltage is
required to breakdown the spark plug clearance,
therefore, the grouped ignition technique adopted by
this system will not waste energy, but will save cost.
Fault diagnosis:
ECU does not have the function to implement fault
diagnosis for the ignition coil; therefore, in case the
ignition coil is fault, it does not have fault code; only
by checking the ignition coil resistance, can the
ignition coil be judged whether it operates normally.
The heating value is quite high when the ignition coil
is operating under normal operation condition, but too
high ignition coil temperature would lead to
increasing of resistance value of the ignition coil, and
will cause such problems as unstable operation or
EC-29
automatic shutdown of the engine. However, ECU
can monitor the control line of the ignition coil:
Control line short-circuited to ground
Control line short-circuited to power supply
Control line open-circuited
Strategy to deal with the faults:
When an ignition coil fault is detected, the
corresponding cylinder injector will be turned off.
Note: Too high temperature of the ignition coil
may lead to bad operation of the engine ignition
system.
Ignition coil primary resistance: O.55～0.4 5 KΩ
Ignition coil secondary resistance: 5.6～4.8 KΩ
Circuit diagram of ignition coil
HV terminal connecting to
power
positive pole
secondary
primary
coil
coil
connecting to
control pole
HV terminal LV terminal
Trouble shooting: socket
Short-circuit, open-circuit inside the coil
Coil leaking, casing cracked
Coil aged, leading to insufficient electricity for
ignition
11. Steel fuel distribution pipe assembly
Purpose:
To store and distribute the fuel from the fuel pump
and provide a relatively stable pressure environment
for the fuel injection system, which make the fuel
supply pressure and flow equal and the engine
running stable.
Composition:：
The fuel distribution pipe assembly is composed of
fuel distributor, injector.
Assembling requirement:
The quick release coupling of the fuel inlet/outlet pipe
and the fuel supply pipe must be connected securely;
after the fuel system is repaired, make trial run of the
vehicle at the spot, and the vehicle cannot be handed
EC-30
over until no leakage in the fuel system is ensured.
Fault diagnosis:
Normally, the probability of fuel supply main pipe
fault is very low; fuel leaking in most cases is due to
improper assembling, therefore, pay attention to the
following when assembling: never use again the used
oil seal, and apply properly some lube oil when
assembling.
Note: Before repairing the fuel system, relieve the
pressure first and make sure there is no pressure
fuel inside the fuel pipeline. Take off the fuel pump
plug, and then ignite the engine to run idly until it
shuts off automatically.
At this time, there must be no pressure oil in the
system. After repair, pump oil into the system
when starting up for the first time.
Method:
Switch the ignition key on, and switch it off after

self-checking, repeat the operation for 3 ~ 4 times.
Fuel distribution pipe assembly
Fuel distribution pipe assembly
12. Crankshaft position sensor (speed sensor

CKPS)
Purpose:
Crankshaft position sensor is used to provide ECU

with signals of the engine speed, angle, and upper
dead center; and is used for the engine ignition,
injection and timing system.
MT20U electrojet system adopts magnetic induction

EC-31
coil speed sensor, using rotary cutting magnetic force
line to generate alternating current and voltage
signals; ECU then converts, through shaping, such
alternating signals to digital signals that can be
recognized by the engine ECU, which are used to
control the engine system. The flywheel rim and the
signal wheel are installed together; 58X gear type is
adopted on the signal wheel to provide the ECU with
speed, angle, upper dead center, the upper dead
center of a cylinder is at the continuous notch.
Fault diagnosis:
ECU carries out real-time monitoring of the sensor

and line
Sensor has no signal output
Outputted signal distorted
Sensor signal line short-circuited
Sensor signal line open-circuited
Trouble shooting:
Check whether the sensor line is normal; whether

there is earth short-circuit in the line
Use Tee to connect the connector of the sensor and

the wiring harness and check whether the connections
of the power, grounding wire and signal wire are
normal.
Clearance between sensor and gear ring: 0.3— 1.5 mm
Sensor resistance value: 616～504Ω

EC-32
Circuit diagram of crankshaft position sensor
Pins:
#l (A) sensor signal line high level (connecting to
ECU l2#)
#2 (B) sensor signal line low level (connecting to
ECU 28#)
#3 (c) sensor grounding (connecting to ECU 73#)
13. Canister solenoid valve (EVAP)
Purpose:：
To control the cleaning air flow from the canister to
the intake main pipe. The adsorption quantity of the
canister is limited, if the evaporated gasoline
adsorbed on the canister is not consumed, the gasoline
will be volatilized to outside, which will cause
pollution to atmosphere, and the unsafe factor
increased.
Inside the canister solenoid valve is a solenoid valve
structure; the solenoid valve opening is controlled by
digital control pulse square wave sent by ECU, the
solenoids valve opening varies as the engine
operation condition varies; when the engine is at high
load, idle speed, to guarantee the engine’ s output
power, the canister solenoid valve is not in operation.
Fault diagnosis:
Sensor line short-circuited to ground
EC-33
Sensor line short-circuited to power
Sensor line open-circuited
Trouble shooting:：
Check whether the sensor line is short-circuited,
open-circuited
Check for any crossover wiring between the wiring
harnesses
Check whether the sensor line is short-circuited to
power supply
Check if the inside of the canister solenoid valve is
blocked and if airing is normal.
Coil resistance value: 19~22Ω
Operation voltage: 8~16V
Rated operation voltage: +12V
Picture of canister solenoid valve
Canister solenoid valve

Circuit diagram of canister solenoid valve
main relay
EC-34
Circuit diagram of canister solenoid valve
Pins:：
#l (A) solenoid valve control (connecting to ECU63#)
#2 (B) connecting to main relay power
14. Air conditioning control system (A／C)
Control principle:
When the air conditioning switch is switched on, the

air conditioning pressure is normal, and the data
detected by the evaporator temperature sensor is
normal, the air conditioning request signal is sent to
ECU through these switches; After ECU detected this
signal, it controls the air conditioning relay to operate,
and at the same time, sends signal to the stepping
motor to accelerate, and switches on the fan, thus the
air conditioning system operates.
Air conditioning cut-off conditions:
Throttle position sensor fault
Speed sensor fault
Engine heavy load
Evaporation tank temperature sensor fault
Evaporation tank temperature lower than 1.5℃
Engine speed overrunning
Coolant temperature higher than 108℃, refuel is

urgently needed.
Fault diagnosis:
Air conditioning relay line short-circuited to ground
Air conditioning relay line short-circuited to power
Air conditioning relay line open-circuited
Evaporator temperature sensor temperature too low
Evaporator temperature sensor temperature too high
Trouble shooting:
Check air conditioning system line
Check whether the air conditioning evaporator

EC-35
temperature sensor is damaged
Check whether there is crossover wiring inside the

wiring harness
Circuit diagram of air conditioning control

power
air
conditioning
request signal
Pins:
air conditioning compressor clutch
#l air conditioning request signal (connecting to ECU
39#)
#2 air conditioning relay control (connecting to ECU Circuit diagram of air conditioning control
46#)
15. Fan control (FAN)

MT20U controls high/low speed of the fan. The
control system controls high/low speed running of the
fan according to the signals of water temperature and
air conditioning; when the condition is proper, it
controls delay of the fan system.
Control mode:
First gear to start at 98℃ and stop at 94℃
Second gear to start at 105℃ and stop at 101℃
If the water temperature is higher than 101℃ after
stopping, the fan continues running for 1min.
If the water temperature is higher than 94℃ after
stopping, the fan continues running for 0.5min.
If the water temperature is lower than 85℃ after
stopping, the fan stops running.
Fault diagnosis:
High speed relay line short-circuited to power
High speed relay line short-circuited to ground
High speed relay line open-circuited
Low speed relay line short-circuited to power
Low speed relay line short-circuited to ground
EC-36
Low speed relay line open-circuited
Trouble shooting:
Check whether the line is short-circuited or
open-circuited according to the pins shown in the left
side diagram on ECU side.
Circuit diagram of fan control
main power
high speed fan relay
low speed fan relay two-speed fan
The high speed and low speed pins in the above

diagram comply with the reality, but there is
difference between the actual circuit and the circuit Circuit diagram of fan control
diagram. This diagram is for reference only.

1. Fault information record 6. Fault alarm
MT20U electronic control unit monitors continuously MT20U electrojet has fault-indicating lamp. When
the sensor, actuator, related circuit, fault-indicating some essential parts (e.g. ECU intake manifold
lamp and battery voltage, etc., and even the electronic absolute pressure sensor, throttle position sensor,
control unit itself, and makes detection of the sensor coolant temperature sensor, knock sensor, oxygen
output signal, actuator drive signal and internal signal sensor, injector, two drive stages of idle actuator
(e.g., oxygen closed-loop control, knock control, idle stepping motor, air conditioning relay, fan relay, etc.)
speed control and battery voltage control, etc.) for are fault and the corresponding fault position is set,
their reliability. Once fault is found in certain link, or ECU will warn the driver the vehicle is in fault mode
a signal value is not reliable, the electronic control through luminescent alarm by fault-indicating lamp
unit will set immediately fault information record in until this fault is reset.
RAM fault memory. The fault record is stored in the
7. Fault readout
form of fault code and is displayed in the order of the
fault occurrences. Engine fault-indicating lamp:
The fault can be divided into “steady state fault”and When engine is running, and fault occurs on the
“by-chance fault” (e.g. caused by temporary wiring system or part, the engine fault-indicating lamp will
harness broken or poor contact of connector). be on automatically to prompt the driver to inspect
and repair the vehicle immediately.
2. Faulty condition
When handling emergency failure, it is also possible
If the duration of an identified fault occurrence
to let the engine fault-indicating lamp flash frequently
exceeds the set stabilized time for the first time, ECU
by special operation, so as to read out the engine fault
will confirm it as a stable fault and store it as the
code, this is the most economic way to obtain the
“steady state fault”. If this fault disappears, it is stored
fault code. The operation method is as follows:
as the “by-chance fault” and “non-existent”. If this
fault is identified again, it is still the “by-chance Check and confirm:
EC-37
fault”, but the “existent”historical fault will not affect
Battery voltage is able to ensure startup speed of the
the normal operation of engine.
engine
3. Fault type
The engine and complete vehicle accessories are in
Short-circuited to power positive pole Off state
Short-circuited to ground Throttle is completely closed
Open-circuited Gearbox is set to neutral
Signal not reliable Ignition switch is switched off
4. There are four types of faults (faults of almost all Short circuit the diagnosis request terminal 1 in the
the electrojet vehicles are defined in this way) fault diagnosis by using guide line to ground terminal
4 or 5:
Most serious fault: signal exceeds upper limit of the
normal range Set the ignition switch to ON, but do not start the
engine.
Least serious fault: signal exceeds lower limit of the
normal range At this time, if there is fault in the system currently or
the historical fault code is not deleted after the fault is
Signal fault: no signal
cleared, the engine fault-indicating lamp will flash
Unreasonable fault: there is signal, but not reasonable according to certain patterns, outputting the code
detected by the system; (while reading out the fault
5. Limp home
code, the idle speed control valve will act for reset).。
For some identified serious faults, when their duration
After the fault code is read out, switch off the ignition
exceeds the set stabilized time, ECU will take proper
switch and plug out the diagnosis request short-circuit
software countermeasure to maintain running of the
guide wire.
engine, and not let the vehicle break down on its way
home.
Pattern of the lamp flashing to report the fault is:
Report the fault according to the sequence memorized

by the fault code;
There is a pause of 3.2s between the fault codes, the

digits flashes with a frequency of 0.4s on and 0.4s off,
and there is a pause of 1.2s between the digits.
Digit 0 flashes 10 times, other digits are in

correspondence with the flashing times.
Take the fault code 0110 and 0443 as an example:
Diagnosis request short-circuited to Indicating lamp flashes

ground Switch on ignition switch for 1 time at beginning Pause for 3.2s
10 times Pause for 1.2s 1 time Pause for 1.2s 1 time
Pause for 1.2s

10 次 Pause for 3.2s
10 次 Pause for 1.2s

4次 Pause for 1.2s 4次 Pause for 1.2s
EC-38
3times Pause for 3.2s If the diagnosis request does not stop, it will start to report 0110 fault code again … …
Note:
After the fault is cleared, it is suggested to use

faultfinder to clear the fault code, so as to avoid
affecting the fault locating during next repairing.
8. Clearing of fault information record
After the fault is eliminated, the fault information

record in the memory must be cleared.
The fault information that occurs when the ignition is

switched on but fails to last to the end of the
stabilized time is not recorded.
After the engine has been started successfully for

certain number of times, the fault code will be cleared
automatically.
ISO 9141— 2 standard diagnosis connector
Use faultfinder to clear the fault information record
by using the instruction “Fault memory zero
clearing”.
Pull out ECU connector or remove the battery wire to

clear away the fault information record in RAM.
9. Fault location diagnosis

interface
After the fault information record is obtained by the
above means, the possible fault position is known, but
it does not mean the fault has been located. Therefore,
EC-39
a cause led to fault information may be the electronic
element (e.g., sensor or actuator or ECU, etc.)
damaged or the wire broken, or the wire is
main power
short-circuited to ground or to battery positive pole,
or, likely, mechanical failure.
The fault is intrinsic, and its external expressive

results are various symptoms. After the symptom is
found, first of all, check whether there is fault record
by using faultfinder or the flashing code, and exclude
the related fault according to the fault information;
and then find out the fault according to the engine
symptom.
List of engine fault code

List of fault code of Delphi MT20(u) engine management system
Fault Fault
Fault description Fault description
code code
P0105-1 Intake manifold absolute pressure P0443-1 Canister solenoid valve line short-circuited to
sensor signal too high power positive pole
P0105-2 Intake manifold absolute pressure P0443-2 Canister solenoid valve line open-circuited or
sensor signal too low short-circuited to ground
P0110-1 Intake temperature sensor signal too P0480-1 Water tank low speed fan relay drive circuit
low short-circuited to power positive pole
P0110-2 Intake temperature sensor signal too P0480-2 Water tank low speed fan relay drive circuit
high open-circuited or short-circuited to ground
P0115-1 Coolant temperature sensor signal too P0481-1 Water tank high speed fan relay drive circuit
low short-circuited to power positive pole
P0115-2 Coolant temperature sensor signal too P0481-2 Water tank high speed fan relay drive circuit
high open-circuited or short-circuited to ground
P0120-1 Throttle position sensor signal too P0482-1 Air conditioning cooling fan relay drive circuit
high short-circuited to power positive pole
P0120-2 Throttle position sensor signal too low P0482-2 Air conditioning cooling fan relay drive circuit
open-circuited or short-circuited to ground
P0130-4 No oxygen sensor signal P0500-0 No speed sensor signal
P0135-1 Oxygen sensor heating circuit P0505-0 Idle speed control error
short-circuited to power positive pole
EC-40
P0135-2 Oxygen sensor heating circuit P0560-1 System voltage too high
open-circuited or short-circuited to
ground
P0170-1 Time indicating oxygen sensor air-fuel P0607-0 Knock control system failure
ratio concentrated too long
P0170-2 Time indicating oxygen sensor air-fuel P0650-1 Fault-indicating lamp line short-circuited to
ratio thinned too long power positive pole
P0201-0 Injector A (1-cylinder) circuit fault P0650-2 Fault-indicating lamp line open-circuited or
short-circuited to ground
P0202-0 Injector B (3-cylinder) circuit fault P1230-1 Main relay line short-circuited to power
positive pole
P0203-0 Injector C (4-cylinder) circuit fault P1230-2 Main relay line open-circuited or
P0204-0 Injector D (2-cylinder) circuit fault P1530-1 Air conditioning relay line short-circuited to
power positive pole
P0230-1 Fuel pump relay short-circuited to P1530-2 Air conditioning relay line open-circuited or
power positive pole short-circuited to ground
P0230-2 Fuel pump relay open-circuited or P1604-0 EEPROM error
P0325-0 Poor connection of knock sensor P1610-0 Anti-theft controller error
P0335-0 No 58x crankshaft position sensor P1610-8 ECM and anti-theft controller communication
signal error
P0335-8 58x crankshaft position sensor signal P2000-1 Front air conditioning evaporator temperature
error too high
P0342-0 Camshaft position signal low P2000-2 Front air conditioning evaporator temperature
too low
P0343-2 Camshaft position signal high P2001-1 Rear air conditioning evaporator temperature
too high

1. Element fault
a. Intake pressure/temperature sensor
intake pressure/temperature
sensor
EC-41
Intake pressure/temperature sensor
Fault
P0105-1 Intake manifold absolute pressure sensor signifying too high
code:
To set up emergency ● Light-up the fault-indicating lamp until the fault disappeared
control scheme: ● When engine stops: 90kPa
● When engine is at idle: =45kPa
● When engine is running: manifold pressure changes as the throttle opening
changes
● If cylinder pressure cylinder-judgment technique is used, the injection sequence
will have 50% probability of dislocation by 3600.
Connection terminal: MT20U Pressure/temperature Normal measuring
sensor signal
5V reference voltage: 04 B 5V
Manifold pressure 42 A 0.5～4.5V
signal:
Sensor signal ground: 21 D 0V
Judgment conditions Possible cause Refer to trouble
shooting scheme
Engine running 1） Wiring harness pressure signal is 1） Repair the harness
No TPS fault short-circuited to 5V reference voltage or power
MAP＞98.117kpa positive pole
TPS＜19.141% 2） Sensor damaged 2） Replace the sensor
Fault duration＞2.5s 3） ECM pressure signal input interface fault 3）Replace ECM
Fault
P0105-2 Intake manifold absolute pressure sensor signal too low
code:
To set up emergency ● Light-up the fault-indicating lamp until the fault is disappeared
control scheme: ● When engine stops: 90kPa
● When engine is at idle: =45kPa
● When engine is running: manifold pressure changes as the throttle opening
changes
● If cylinder pressure cylinder-judgment technique is used, the injection sequence
will have 50% probability of dislocation by 3600.
Connection terminal: MT20U Pressure/temperature Normal measuring signal
sensor
5V reference voltage: 04 B 5V
Manifold pressure signal: 42 A 0.5～4.5V
Sensor signal ground: 21 D 0V
Judgment conditions Possible causes Refer to trouble shooting
scheme
No TPS fault 1） Connector not secured 1） Connect again
MAP＜14.017kpa 2） Wiring harness pressure signal line 2） Repair the harness
PRM＜1050rpm open-circuited
EC-42
TPS＞18.75% 3） Wiring harness pressure signal line 3） Repair the harness
Fault duration ＞2.5s short-circuited to ground
4） 5V reference voltage line open-circuited 4） Repair the harness
5） Sensor signal grounding wire open-circuited 5） Repair the harness
6） Wiring harness 5V reference voltage reversed 6） Repair the harness
with reference grounding wire (this fault may lead
to sensor damage)
7） Sensor damaged 7） Replace the sensor
8） MAP signal interface fault on ECM 8）Replace ECM
Fault
P0110-1 Intake temperature sensor signal too low
code:
To set up emergency ● Lightup the fault-indicating lamp until the fault is disappeared
control scheme: ● Intake temperature is equal to coolant temperature, but not exceeding 44.25℃
Connection MT20U Pressure/temperature Normal measuring
terminal: sensor signal
Intake 27 C 0.5～4.5V
temperature
signal:
Sensor signal 21 D 0V
ground:
Judgment conditions Possible causes Refer to trouble
shooting scheme
Engine running time ＞120s 1） Connectors not connected securely 1）Re-connect
MAT＜-38.25℃ 2） Temperature signal line open-circuited 2）Repair harness
Fault duration ＞2s 3）Sensor signal open-circuited to ground 3） Repair harness
4）Temperature signal line short-circuited to power 4） Repair harness
positive pole
5）Sensor damaged 5） Replace sensor
6）ECM signal input interface fault 6）Replace ECM
Fault
P0110-2 Intake temperature sensor signal too high
code:
control scheme: ● Intake temperature is equal to coolant temperature but not exceeding 44.25℃
Connection Intake temperature Pressure/temperature Normal measuring
MT20 MT20U
terminal: sensor sensor signal
Intake 35 27 B C 0.5～4.5V
temperature
sensor:
Sensor signal 28 21 A D 0V
ground:
shooting scheme
Engine running time＞60s 1）Temperature signal line short-circuited to ground 1） Repair harness
MAT＞148.5℃ 2）Sensor damaged 2） Replace sensor
Fault duration ＞2s 3）ECM signal input interface fault 3）Replace ECM
b. Water temperature sensor

EC-43
to instrument
Water temperature sensor
Fault code: P0115-2 Coolant temperature sensor too high

control scheme: ● Use intake temperature when starting, and fix after increasing to 79.5℃ with
the time
Connection terminal: MT20 MT20U Coolant temperature sensor Normal measuring
signal
Coolant temperature 34 43 B 0.5～4.5V
signal:
Sensor signal ground: 37 05 A 0V
shooting scheme
Engine running time＞2s 1）Temperature signal line short-circuited to 1) Repair harness
CTS＞135℃ ground
Fault duration ＞2s 2）Sensor damaged 2) Replace the sensor
3）ECM signal input interface fault 3) Replace ECM
Fault code: P0115-1 Coolant temperature sensor too low
control scheme: ● Use intake temperature when starting, and fix after increasing to 79.5℃ with
the time
Connection terminal: MT20U Coolant temperature sensor Normal measuring
signal
Coolant temperature 43 B 0.5～4.5V
signal:
Sensor signal 05 A 0V
ground:：
shooting scheme
Engine running time＞10s 1）Connectors not connected securely 1) Re-connect
CTS＜-38.25℃ 2) Temperature signal line open-circuited 2) Repair harness
Fault Duration＞2s 3）Sensor signal open-circuited to ground 3) Repair harness
4）Temperature signal line short-circuited to 4) Repair harness
EC-44
power positive pole
5）Sensor damaged 5) Replace sensor
c. Throttle position sensor
Throttle position sensor
Fault code: P0120-1 Throttle position sensor signal too high

control scheme: ● When at idle speed, set the opening of throttle position sensor 0%; At other
speed, the opening of the throttle position sensor changes as the speed changes.
●Throttle position sensor automatic zero check function paused.
●Flooding clearing function paused
Connection MT20U Throttle position sensor Normal measuring signal
terminal:
5V reference 20 A 5V
voltage:
Throttle position 24 C 0.5～4.5V
signal:
Sensor signal 05 B 0V
ground:
EC-45
Judgment conditions Possible causes Refer to trouble shooting scheme
Engine running but speed 1) Sensor signal line short-circuit to power 1) Repair the harness
＜3000rpm positive pole or reference voltage circuit
No MAP fault and 2) Sensor damaged 2) Replace the sensor
MAP70kPa 3) ECM signal input interface fault 3) Replace ECM
Fault duration＞2s
Fault code: P0120-2 Throttle position sensor signal tool low

control scheme: ● When at idle speed, set the opening of throttle position sensor 0%; At other
speed, the opening of the throttle position sensor changes as the speed changes.
●Throttle position sensor automatic zero check function paused
●Flooding clearing function paused
Connection terminal: MT20 MT20U Throttle position sensor Normal measuring
signal
5V reference voltage: 36 20 A 5V
Throttle position 26 24 C 0.5～4.5V
signal:：
Sensor signal ground: 37 05 B 0V
shooting scheme
Fault duration ＞2s 1) Connectors not connected securely 1) Re-connect
2) Sensor signal line open-circuited 2) Repair harness
3) Sensor signal line short-circuited to ground 3) Repair harness
4) Sensor damaged 4) Replace sensor
5) ECM signal input interface fault ECM 5) Replace ECM
d. Oxygen sensor
main relay
EC-46
Oxygen sensor
Fault code: P0130-4 No oxygen sensor signal

control scheme: ● Air-fuel ratio cannot be controlled in closed-loop
Connection terminal: MT20U Heated oxygen Normal measuring
sensor signal
System main power \ C 12V
supply:
Heating drive: 61 D 0V
Oxygen sensor high 62 B 0～1000mV
signal: fluctuation
Oxygen sensor low 06 A 0V
signal:
shooting scheme
360.24mV＜oxygen sensor signal ＜538.19 1）Connectors not connected securely 1) Re-connect
mV 2）Sensor signal line open-circuited 2) Repair harness
Engine running time＞40s 3）Sensor poisoned or failed due to 3) Replace sensor
No TPS and MAP fault Coolant temperature overheat
＞72℃ 4）ECM signal input interface fault 4) Replace ECM
Entering closed-loop fuel control status
TPS＞10.156%
Fault duration＞15s
Fault code: P0170-2 Time indicating oxygen sensor air-fuel ratio thinned too long
Connection terminal: MT20U Heated Normal measuring
oxygen sensor signal
supply:
Oxygen sensor high 62 B 0～1000mV fluctuation
signal:
signal:
EC-47
shooting scheme
Oxygen sensor signal ＜52.083 mV 1）Sensor signal line ground short-circuited 1) Repair harness
Engine running time ＞40s 2）Sensor high low signal lines reversed 2) Repair harness
No TPS and MAP fault Coolant 3）Sensor damaged 3) Replace sensor
temperature ＞72℃ 4）ECM signal input interface fault 4) Replace ECM
Entering closed-loop fuel control
status
TPS＞10.156%
Fault duration ＞15s
Fault code: P0130-4 No oxygen sensor signal

supply:
signal:
Oxygen sensor low signal: 06 A 0V
shooting scheme
360.24mV ＜ oxygen sensor signal ＜ 1）Connectors not connected securely 1) Re-connect
538.19 mV 2）Sensor signal line open-circuited 2) Repair harness
Engine running time＞40s 3）Sensor poisoned or failed due to 3) Replace sensor
No TPS and MAP fault overheat
Coolant temperature ＞72℃ 4）ECM signal input interface fault 4) Replace ECM
Entering closed-loop fuel control status
TPS＞10.156%
Fault duration ＞15s
Fault code: P0135-1 Oxygen sensor heating circuit short-circuited to power positive pole
To set up emergency ● Lightup the fault-indicating lamp until the fault is disappeared and turn off the
control scheme: ignition switch
● Postpone the system closed-loop operation time
sensor signal
supply:
signal:
EC-48
signal:
shooting scheme
Fault duration＞1s 1）Heating drive line short-circuited to power 1) Repair harness
positive pole
Fault code: P0135-2 Oxygen sensor heating circuit open-circuited or short-circuited to ground
To set up emergency ● Lightup the fault-indicating lamp until the fault is disappeared and turn off the
control scheme: ignition switch
● Postpone the system closed-loop operation time
supply:
signal:
signal:
shooting scheme
1）Connectors not connected securely 1) Re-connect
No main relay fault
2 ） Wiring harness heating drive line 2) Repair harness
Duration ＞1s
open-circuited
3 ） Wiring harness heating drive line 3) Repair harness
Fault code: P0170-1 Time indicating oxygen sensor air-fuel ratio concentrated too long
sensor signal
supply:
signal:
EC-49
signal:
shooting scheme
Oxygen sensor signal ＞998.26 mV 1）Sensor signal line short-circuited to 5V 1) Repair harness
Engine running time ＞40s or 12V
No TPS and MAP fault 2）Sensor damaged 2) Replace sensor
Coolant temperature ＞72℃ 3）ECM signal input interface fault 3) Replace ECM
Entering closed-loop fuel control
status
TPS＞10.156%
Duration＞15s
Fault code: P0170-2 Time indicating oxygen sensor air-fuel ratio thinned too long
oxygen signal
sensor
supply:
signal:
signal:
shooting scheme
Oxygen sensor signal ＜52.083 mV 1 ） Sensor signal line ground 1) Repair harness
Engine running time ＞40s short-circuited
No TPS and MAP fault 2）Sensor high low signal lines reversed 2) Repair harness
Coolant temperature ＞72℃ 3）Sensor damaged 3) Replace sensor
Entering closed-loop fuel control status 4）ECM signal input interface fault 4) Replace ECM
TPS＞10.156%
Fault duration＞15s
e. Injector
main relay
EC-50
Injector
Fault code: P0201-0 Injector A (1-cylinder) circuit fault

P0202-0 Injector B (3-cylinder) circuit fault
P0203-0 Injector C (4-cylinder) circuit fault
P0204-0 Injector D (2-cylinder) circuit fault
To set up emergency control scheme: ● Lightup the fault-indicating lamp until the fault is disappeared
● None
Connection terminal: MT20U Injection nozzle Normal measuring signal
System main power \ A 12V
supply:
Injector A (1-cylinder): 55 B 0-12V approximate square wave
Injector B (3-cylinder): 56 B 0-12V approximate square wave
Injector C (4-cylinder): 71 B 0-12V approximate square wave
Injector D (2-cylinder): 70 B 0-12V approximate square wave
Judgment conditions Possible causes Refer to trouble shooting scheme
Ignition switch 1） Corresponding nozzle line short-circuited 1） Repair harness
switched on to power positive pole or ground 2） Repair harness
Fuel pump operation 2） Corresponding nozzle circuit switch 3） Re-connect
normal 3） Connectors not connected securely 4） Replace damaged nozzle
Ignition voltage＞10V 4） Nozzle circuit damaged 5） Replace ECM
5） ECM signal output control interface fault
f. Fuel control pump

EC-51
main power
power relay
fuel control pump
Fuel control pump
Fault code: P0230-1 Fuel pump relay short-circuited to power positive pole
control scheme: ● None
Connection terminal: MT20U Fuel pump relay Normal measuring signal
System main power \ Refer to electrical 12V
supply: system instructions
Relay drive: 47 Refer to electrical 0V(running), 12V(stopped)
system instructions
scheme
Duration＞1.5625s 1 ） Relay drive line short-circuited to 1) Repair harness
system power positive pole
2）Relay damaged 2) Replace relay
Fault code: P0230-2 Fuel pump relay open-circuited or short-circuited to ground

Connection terminal: MT20U Fuel pump relay Normal measuring signal
System main power \ Refer to electrical 12V
supply: system instructions
EC-52
Relay drive: 47 Refer to electrical 0V(running), 12V(stopped)
system instructions
scheme
Duration＞1.5625s 1） Connectors not connected securely 1） Re-connect
2） Circuit connecting the system main 2） Repair harness
power open-circuited
3） Relay drive line short-circuited to 3） Repair harness
system power negative pole
4） Relay drive line open-circuited 4） Repair harness
5） Relay damaged 5） Replace relay
6） ECM signal input interface fault 6) Replace ECM
g. Knock sensor
Knock sensor
Fault code: P0325-0 Poor connection of knock sensor

control scheme: ● Adopt safety ignition advance angle table
Connection terminal: MT20U Knock sensor Normal measuring signal
EC-53
Knock signal: 69 0～1V
Sensor signal ground: 05 0V
scheme
Engine running speed＞2000rpm 1） Connectors not connected securely 1） Re-connect
MAP＞50kPa 2） Knock signal line open-circuited 2） Repair harness
Duration＞5s 3） Sensor signal short-circuited to ground 3） Repair harness
4） Knock signal line and other lines 4） Repair harness
short-circuited
5） Sensor damaged 5） Replace sensor
6） ECM signal input interface fault 6) Replace ECM
Fault code: P0607-0 Knock control system failure

control scheme: ●Ignition advance angle will be postponed (adopt safety ignition advance control)
Connection terminal: 69# MT20U ECM Normal measuring signal
ECM： ESM internal fault \
scheme
1）ECM fault 1）Replace ECM
h. Crankshaft position sensor

Fault code: P0335-8 58x crankshaft position sensor signal error
Connection terminal: MT20U Crankshaft position sensor Normal measuring
EC-54
signal
Crankshaft signal 12 A ＞400mV sine wave
high: (and sensor B)
Crankshaft signal 28 B ＞400mV sine wave
low: (and sensor A)
System grounding 73 C 0V
wire:
shooting scheme
Number of teeth entering ECM not equal 1）Poor signal line screen 1）Adopt screened line
to 58 after engine running for 5 cycles in 2 ） 58x gear ring has metal foreign 2）Clear 58x gear ring
succession matters
Fault code: P0335-0 No 58x crankshaft position sensor signal

●Engine unable to start
Connection terminal: MT20U Crankshaft position sensor Normal measuring
signal
Crankshaft signal 12 A ＞400mV sine wave
high: (and sensor B)
Crankshaft signal 28 B ＞400mV sine wave
low: (and sensor A)
System grounding 73 C 0V
wire:
shooting scheme
Start engine 1）Connectors not connected securely 1) Re-connect
No engine speed signal 2）Signal high low connected in reverse 2) Repair harness
MAP dropped to 2.9509kPa 3）Signal line open-circuited 3) Repair harness
System voltage drops 0.8V 4）Signal line and other line short-circuited 4) Repair harness
Speed ＜4km/h 5）Sensor damaged 5) Replace sensor
Duration ＞2s 6）ECM signal input interface fault 6) Replace ECM
i. Ignition coil
EC-55
main relay
HV coil
Ignition coil
Fault code: P0351-1 Ignition coil 1-4 cylinders drive line short-circuited to power positive pole
control scheme: ● Stop fuel injection to 1- 4 cylinders
● Increase the target idle speed to 1200rpm
Connection terminal: MT20U Ignition coil Normal measuring signal
System main power \ B 12V
supply:
1-4 cylinder drive: 32 C 0-12V approximate square
wave signal induction
peak value＞300V
2-3 cylinder drive: 52 A 0-12V approximate square
peak value＞300V
scheme
Duration: 1.25s 1）1-4 cylinder drive circuit and power 1) Repair harness
positive pole short-circuited
2）Ignition coil damaged 2) Replace ignition coil
3）ECM fault 3) Replace ECM
Fault code: P0351-2 Ignition coil 1-4 cylinder line open-circuited or short-circuited to ground wire
EC-56
control scheme: ● Stop fuel injection to 1-4 cylinders
supply:
1-4 cylinder drive: 32 C 0-12V approximate square
peak value＞300V
peak value＞300V
scheme
Duration: 1.25s 1）Connectors not connected securely 1) Re-connect
2）1-4 cylinders drive line short-circuited to 2) Repair harness
3）1-4 cylinders drive line open-circuited 3) Repair harness
Fault code: P0352-1 Ignition coil 2-3 cylinders drive line short-circuited to power positive pole
● Increase the target idle speed to 1200rpm
supply:
1-4 cylinders drive: 32 C 0-12V approximate square
peak value＞300V
2-3 cylinders drive: 52 A 0-12V approximate square
peak value＞300V
scheme
Duration: 1.25s 1）2-3 cylinders drive circuit short-circuited 1) Repair harness
to power positive pole
EC-57
Fault code: P0352-2 Ignition coil 2-3 cylinders drive line open-circuited or short-circuited to
grounding wire
supply:
1-4 cylinders drive: 32 C 0-12V approximate square
peak value＞300V
peak value＞300V
scheme
Duration: 1.25s 1）Connectors not connected securely 1) Re-connect
2）2-3 cylinders drive circuit short-circuited to 2) Repair harness
the system power negative pole
3）2-3 cylinders drive circuit open-circuited 3) Repair harness
j. Canister solenoid valve
main relay
Canister solenoid valve

EC-58
Fault code: P0443－1 Canister solenoid valve line short-circuited to power positive pole
To set up emergency control scheme: Lightup the fault-indicating lamp until the fault is disappeared
Turn off the canister solenoid valve
Canister Normal measuring
Connection terminal: MT20U
solenoid valve signal
System main power supply: \ B 12V
63 A 0~12V square wave
shooting scheme
Duration >2s 1) Solenoid valve drive circuit short-circuited 1) Repair harness
to power positive pole 2) Replace solenoid
2) Solenoid valve damaged valve
3) ECM fault 3) Replace ECU
Fault code: P0443-1 Canister solenoid valve line short-circuited to power positive pole
control scheme: ● Turn off the canister solenoid valve
Connection terminal: MT20U Canister solenoid valve Normal measuring signal
supply:
Solenoid valve drive: 63 A 0-12V square wave
scheme
Duration ＞5s 1）Connectors not connected securely 1) Re-connect
2）Solenoid valve drive circuit short-circuited to 2) Repair harness
3）Solenoid valve drive circuit open-circuited 3) Repair harness
4）Circuit connected with the system main power 4) Repair harness
open-circuited
5）Solenoid valve damaged 5) Replace ignition coil
EC-59
k. Fan relay
main power
high speed fan

relay
two-speed
low speed fan relay fan
Fan relay
Fault code: P0480-1 Water tank low speed fan relay drive circuit short-circuited to power positive
pole
● Fan does not run until water temperature rises to 98℃, then it turns On
Connection terminal: MT20U Low speed fan relay Normal measuring signal
Battery: \ Refer to electrical system 12V
instructions
Relay drive: 67 Refer to electrical system Running=0V,
instructions Stopped=12V
scheme
Duration ＞3s 1 ） Relay drive circuit short-circuited to power 1) Repair harness
positive pole
EC-60
Fault code: P0480-2 Water tank low speed fan relay drive circuit open-circuited or
To set up emergency control ● Lightup the fault-indicating lamp until the fault is disappeared
scheme: ● None
● Fan does not run (open-circuited), until water temperature rises to 98℃,
then it turns On
● Fan running constantly (short-circuited to ground)
Connection terminal: MT20U Low speed fan relay Normal measuring signal
Battery: \ Refer to electrical 12V
system instructions
Relay drive: 67 Refer to electrical Running=0V,
system instructions Stopped=12V
scheme
Duration＞3s 1）Connectors not connected securely 1) Re-connect
2）Relay drive circuit short-circuited to system 2) Repair harness
power negative pole
3）Relay drive circuit open-circuited 3) Repair harness
4）Open-circuited to battery connection circuit 4) Repair harness
Fault code: P0481-1 Water tank high speed fan relay drive circuit short-circuited to power
positive pole
Connection terminal: MT20U High speed fan relay Normal measuring signal
system instructions
Relay drive: 50 Refer to electrical Running =0V, Stopped=12V
system instructions
scheme
Duration＞3s 1）Relay drive circuit short-circuit to power 1) Repair harness
positive pole
Fault code: P0481-2 Water tank high speed fan relay drive circuit open-circuited or
● Fan running constantly (short-circuited to ground)
Connection terminal: MT20U High speed fan relay Normal measuring signal
system instructions
Relay drive: 50 Refer to electrical Running =0V, Stopped=12V
system instructions
scheme
Duration ＞3s 1）Connectors not connected securely 1) Re-connect
2）Relay drive circuit short-circuited to system 2) Repair harness
power negative pole
3）Relay drive circuit open-circuited 3) Repair harness
EC-61
4）Open-circuited to battery connection circuit 4) Repair harness
l. Speed sensor
Speed sensor
Fault code: P0500-0 No speed sensor signal

● May adopt driving limit measures
Connection MT20U Speed sensor Normal measuring signal
terminal:
Sensor signal 03 / 0-12V square wave
ground:
scheme
Engine running 1）Connectors not connected securely 1）Re-connect
Speed ＜2kph 2 ） Signal line from gearbox to 2 ） Replace flexible shaft or
MAP＜25.82Kpa instrument interrupted signal wire
1200rpm ＜ engine speed ＜ 3）Wiring harness from instrument to 3）Repair harness
5000rpm ECM interrupted
Throttle closed 4）Speed sensor damaged 4）Replace speed sensor
fault Duration ＞5s 5）Instrument fault 5）Tidy up or replace instrument
6）ECM fault 6）Replace ECM
EC-62
m. Idle speed stepping motor
Idle speed stepping motor
Fault code: P0505-0 Idle speed control error

control scheme: ● Pause idle adjustment
Connection terminal: MT20U Idle control valve Normal measuring signal
Idle valve A-Hi: 54 D 0-12V square wave
(and idle valve C)
Idle valve A-Lo: 53 C 0-12V square wave
(and idle valve D)
Idle valve B-Hi: 33 B 0-12V square wave
(and idle valve A)
Idle valve B-Hi 34 A 0-12V square wave
(and idle valve B)
scheme
Engine idle running 1） Connectors not connected securely 1） Re-connect
Water temperature reached normal 2） Any one of lines of idle valve 2） Repair harness
value open-circuited
No TPS and VSS fault 3） Corresponding relationship of the 3） Repair harness
Deviation from the target speed idle valve connector and ECM
EC-63
＞180rpm connector wrong
Duration ＞15s 4） Intake manifold leaking 4） Clear the leaking
5） Idle control valve damaged 5） Replace idle control valve
6） ECM fault 6） Replace ECM
Fault code: P0560-1 System voltage too high
control scheme: ● Stop system fuel injection
Connection terminal: MT20U Ignition switch Normal measuring
signal
Ignition switch: 01 Refer to electrical system 12V
instructions
shooting scheme
Switch on the ignition switch 1）Generator regulator damaged 1）Replace the damaged
System voltage ＞17.2V voltage regulator
Duration ＞5s 2）HV battery is used by mistake 2）Use correct battery
n. Fault-indicating lamp
fault-indicating lamp
Fault code: P0650-1 Fault-indicating lamp line short-circuited to power positive pole
To set up emergency ● Not lit
control scheme:
Connection terminal: MT20U System fault-indicating lamp Normal measuring
signal
Ignition switch: \ Refer to electrical system 12V
instructions
Indicating lamp 31 Refer to electrical system Off=12V, On=0V
drive: instructions
EC-64
shooting scheme
Duration ＞2s 1）Wiring harness J1 –31 line short-circuited to 1）Repair harness
system power positive pole
Fault code: P0650-2 Fault-indicating lamp line open-circuited or short-circuited to ground

To set up emergency ● Not lit (open-circuited)
control scheme: ● Constantly lit (short-circuited to ground)
Connection terminal: MT20U System fault-indicating lamp Normal measuring
signal
instructions
Indicating lamp 31 Refer to electrical system Not lit=12V, lit=0V
drive: instructions
shooting scheme
Duration ＞2s 1）Poor installation of the fault bulb 1）Re-install the bulb
2）Line to ignition switch fault 2）Repair harness
3）Drive circuit line short-circuited to power 3）Repair harness
negative pole
4）Fault bulb damaged 4）Replace the bulb
Fault code: P1230-1 Main relay line short-circuited to power positive pole
control scheme: ● Unable to start
Connection terminal: MT20U Main power relay Normal measuring signal
instructions
Relay drive: 58 Refer to electrical system Operating=0V,
scheme
Duration ＞1s 1）Relay drive line short-circuited to power 1）Repair harness
positive pole
Fault code: P1230-2 Main relay line open-circuited or short-circuited to ground

control scheme: ● Unable to start (open-circuited)
● Able to start normally (short-circuited to ground)
Connection terminal: MT20U Main power relay Normal measuring signal
instructions
Relay drive: 58 Refer to electrical system Operating =0V,
scheme
EC-65
Duration ＞1s 1）Poor installation of relay 1）Re-install the relay
2）Line to ignition switch open-circuited 2）Repair harness
3）Relay drive line open-circuited 3）Repair harness
4 ） Relay drive line short-circuit to power 4）Repair harness
negative pole
5）Relay damaged 5）Replace the relay
o. Air conditioning compressor relay
power
air conditioning
request signal
air conditioning
compressor clutch
Air conditioning compressor relay
Fault code: P1530-1 Air conditioning compressor relay line short-circuited to power positive pole
control scheme: ● Air conditioning not operating
Connection terminal: MT20U Compressor relay Normal measuring signal
instructions
scheme
EC-66
Air conditioning system detected 1）Repaired harness line short-circuited to 1) Repair the harness
Duration ＞3s power positive pole
2）Relay damaged 2) Replace the relay
3）ECM fault 3) Replace the ECM
Fault code: P1530-2 Air conditioning compressor relay line open-circuited or short-circuited to
ground
control scheme: ● Air conditioning not operating (open-circuited)
● Air conditioning operating constantly (short-circuited to ground)
Connection terminal: MT20U Compressor relay Normal measuring signal
instructions
scheme
Air conditioning system 1） Connectors not connected securely 1) Re-connect
detected 2） Line to battery open-circuited 2) Repair harness
Duration＞3s 3） Repaired harness short-circuited to power 3) Repair harness
negative pole
4） Repaired harness line open-circuited 4) Repair harness
5）Relay damaged 5) Replace the relay
Fault code: P1604-0 EEPROM error

To set up emergency ● Lightup the fault-indicating lamp
control scheme: ● Engine of vehicle with thief-proofer unable to start
● Mileage accumulation function failed
Connection terminal: MT20U ECM Normal measuring signal
ECM： ECM internal fault \
scheme
Fault exists 1）ECM fault 1）Replace ECM
Fault code: P2000-1 Air conditioning evaporator temperature too high

Connection terminal: MT20U Front evaporator Normal measuring signal
temperature sensor
EC-67
Temperature signal: 26 Refer to electrical system 0.5～4.5V
instructions
Sensor signal ground: 05 Refer to electrical system 0V
instructions
scheme
Temperature indication＞144℃ 1） Temperature signal line short-circuited to 1) Repair harness
Duration ＞3s power negative pole
2）Sensor damaged 2) Replace the sensor
Fault code: P2000-2 Air conditioning evaporator temperature too low
Connection terminal: MT20U Front evaporator Normal measuring signal
temperature sensor
Temperature signal: 26 Refer to electrical system 0.5～4.5V
instructions
Sensor signal ground: 05 Refer to electrical system 0V
instructions
scheme
Temperature indication＞-36℃ 1） Connectors not connected securely 1) Re-connect
Duration ＞3s 2） Temperature signal line short-circuited to 2) Repair harness
power positive pole
3） Temperature signal line open-circuited 3) Repair harness
2. When starting, the engine itself not running or running slowly, problem of the starter itself (jammed,
internally short-circuited), engine resistance too high, circuit system (voltage earth).
No. Operation steps Checking result Subsequent step

Use universal meter to check whether there is Yes Next step
1 voltage of approx. 10 ~ 12.5V between two Repair or replace battery
No
wiring terminals of the battery.
Set the ignition switch to “ON”. Use universal Yes Next step
meter to check whether there is battery voltage Repair wiring terminal or
2 of approx. 10~12.5V on the wiring terminal replace wire
No
connecting the battery positive pole on the
ignition switch.
3 Maintain the ignition switch at start gear, use Yes Next step
EC-68
universal meter to check whether there is over Repair or replace the
8V voltage on the wiring terminal connecting the ignition switch
No
starter motor operating coil on the ignition
switch.
Use universal meter to check whether the engine Repair or replace the
Yes
4 is open-circuited or short-circuited. starter motor
No Next step
Check whether the engine is jammed due to poor Yes Eliminate the trouble
5
lubrication. No Next step
If in winter, check whether the resistance of Change with proper lube
Yes
starter motor is too high due to improper oil
6 selection of engine lube oil and gear case oil Check the others
(engine’s resistance becomes high as the oil No
viscosity is high).
3. When starting, engine can run by trailing, but cannot start successfully
Checking
No. Operation steps Subsequent step
result
Set the ignition switch to “ON”. Use faultfinder to check Clear the displayed
Yes
1 whether there is fault information record. fault
No Next step
Pull out the cylinder-split wire and connect the spark plug, Yes 8
make the spark plug electrode 5 ~ 10mm away from the engine
2
body, use the starter motor to trail the engine to run, check No Next step
whether there is blue white high tension spark.
Check whether the high tension wire resistance value is normal Yes Next step
3 (not lower than 4K ohms)
Repair or replace high
No
tension wire
Check whether the cylinder-split high-tension wire, spark plug Yes Replace
4 is damaged.
No Next step
Check whether crankshaft position sensor is damaged. Yes Replace

5
No Next step
Check whether the ignition coil is normal. Yes Next step

6
No Replace
Check whether the intake pressure sensor connectors are Yes Next step
7 securely connected (MT20U has intake pressure
Connect securely the
cylinder-judgment technique). No
plug
8 Set the ignition switch to “ON”. Check whether the fuel pump Yes Next step
EC-69
Checking
result
relay and fuel pump are able to operate.
Repair the fuel pump
No.
circuit
Connect the fuel pressure gauge valve. Short-circuit #30 and Yes Next step
9 #87 pins of the fuel relay and let the pump run; check whether
the fuel pressure is at 350kPa. No 13
Pull out the fuel distribution pipe together with the injector and Yes 12
pull out one-by-one the injector connector on the harness and
10
supply 12V voltage directly from the battery to injector, and No Next step
check whether the injector can inject fuel.
Check again whether the injector can inject fuel after it is Yes Next step
11 cleaned.
No Replace injector
Check whether the fuel is deteriorated or moisture contained. Yes Replace the fuel
12
No 18
Check whether the fuel pressure is lower than 350kPa. Yes Next step
13
No 17
Close the fuel valve, switch on the ignition switch again and Yes Next step
14 make the fuel pump run again, and check whether the fuel
pressure can be established. No 16
Open the fuel gauge valve and clamp tightly the fuel return Replace the fuel
Yes
pipe with fuel return interceptor and make it no return fuel. pressure regulator
15 Check whether it can establish fuel pressure (the fuel pump
aging and operation capability decreasing must also be Repair or replace the
No
considered). injector or fuel pipe
Check whether the fuel inlet pipe is leaking or blocked. Repair or replace the
Yes
16 inlet pipe
No Replace the fuel pump
Check whether the fuel return pipe is blocked or bent. Repair or replace the
Yes
fuel return pipe
17
Replace the fuel
No
pressure regulator
Connect an adaptor between ECU and harness, check whether Yes Next step
there is voltage on pins 1, 17 and 18 of ECU, whether the
18 positive power wire connecting the above-mentioned ECU pins
Repair or replace the
and the grounding wire connecting the pin 73 of the ECU are No
harness
normal.
EC-70
Checking
result
Check whether there is leakage in the components of the intake Yes Repair
19 system.
No Next step
Check whether the intake manifold absolute pressure and Yes Repair or replace
20 temperature sensor is blocked.
No Next step
Check whether the coolant temperature sensor is normal. Yes Next step
21
No Repair or replace
Check whether the unsuccessful startup is due to mechanical Remove the mechanical
Yes
22 problem such as, too big clearance between the piston and trouble
cylinder, cylinder leaking.
No Replace ECU
Note:
When carrying out this test, do disconnect the injector control coil so as to prevent too much fuel from
entering the 3-way catalytic reactor to burn out the 3-way catalytic reactor after the engine is started
successfully.
4. Difficult startup of hot vehicle

No. Operation steps Checking Subsequent step
result
Set the ignition switch to “ON”. Use faultfinder to check Yes Clear the displayed fault
1 whether there is fault information record.
No Next step
Connect the fuel pressure gauge valve. Short-circuit the pins Yes Next step
2 #30 and #87 of the fuel pump relay and make the fuel pump
No 9
run, and check whether the fuel pressure is at 350kPa.
Disconnect the connection pipe, turn off the ignition switch, Yes Next step
observe whether the pressure of the fuel system can still be
3 No Repair fuel system
maintained at 250 ~ 300kPa in one hour (whether there is
system internal leakage). leakage
Connect the connection fuel pipe and intercept the return fuel Yes Replace fuel pressure
pipe with return fuel interceptor, and close the fuel pressure regulator
4 valve at the same time. Turn off the ignition switch and
No
observe whether the pressure of the fuel system can still be Next step
maintained at 250 ~ 300kPa in one hour.
Check whether there exists fuel leakage in injector and pipe. Replace the injector and
Yes
5 fuel pipe
No Next step
Pull out water temperature sensor connector and start the Yes Check coolant
6
engine. Observe whether it can start successfully. temperature and line
EC-71
No Next step
Connect an adaptor between ECU and harness, check Yes Next step
whether there is voltage on pins 1, 17 and 18 of ECU,
7 whether the positive power wire connecting the No
above-mentioned ECU pins and the grounding wire Repair or replace harness
connecting the pin 73 of the ECU are normal.
Replace the fuel, carry out hot startup again, and observe Yes End
8 whether it can be started successfully.
No Replace ECU
Check whether the fuel pipe is blocked or bent, whether the Yes Next step
9 fuel pump pressure regulation valve is operating normally.
Use universal meter to check whether there is battery voltage Yes Next step
10 on both ends of the fuel pump connector.
No Repair or replace fuel
pump relay and wire
Use universal meter to check whether the fuel pump Yes Next step
11 resistance value is correct.
Check whether the fuel pump is jammed. Yes Replace the fuel pump
12
No Replace ECU
5. Speed is normal, but always difficult to start

Checking
result
Set the ignition switch to “ON”. Use faultfinder to check whether Yes Clear the displayed fault
1
there is fault information record. No Next step
Check whether the air filter is free. Yes Next step
2
No Replace
After successful startup, check whether the intake manifold Yes Next step
3 pressure at idle is between 35 ~ 55kPa. No Clear intake system
leakage
Step on the throttle gently and observe whether the startup is Replace and check the
4 Yes
easy. throttle and idle channel
Connect the fuel pressure gauge valve. Short-circuit the pins 30 Yes Next step
5 and 87 of the fuel pump relay and make the fuel pump run, and No
check whether the fuel pressure is at 350kPa. 9
Use special connector to supply 12V voltage directly from battery Yes 8
6 to injector to check whether the injector operates normally. No Next step
Check again whether the injector can operate normally after it is Yes Next step
7 cleaned. No Replace the injector
8
No 14
9 No 13
Close the fuel gauge valve, switch on again the ignition switch Yes Next step
10 and let the pump run again, check whether the fuel pressure can No
be established. 12
EC-72
Open the fuel gauge valve, use fuel return interceptor to clamp Yes Replace the fuel
tightly the fuel return pipe and make it no return fuel, and check pressure regulator
11
whether the fuel pressure can be established quickly. No Repair or replace
injector or fuel pipe
Check whether the fuel inlet pipe is leaking or blocked. Yes Repair or replace the
12 fuel inlet pipe
Check whether the fuel return pipe is blocked or bent. Yes Repair or replace the
fuel return pipe
13
No Replace the fuel
pressure regulator
Pull out the idle actuator connector on the harness before the Yes Next step
14 engine coolant temperature reaching 35℃, and observe whether
the engine speed is dropped (engine enters fault mode). No Repair or replace idle
actuator
Set the ignition switch to “ON”. Check whether the voltage of the Yes Next step
15 following pins of the ECU is normal: approx. 12V battery voltage
for pins 1, 17 and 18, and 0 for pin 73. No Check the harness and
connectors
Make the engine run at idle speed, and check whether the ignition Yes Next step
16 advance angle is normal after the coolant temperature reaches No Check the harness and
normal value. connectors
Check whether the cylinder pressure of the engine is normal. Yes Next step
17
No Clear the trouble
18
temperature sensor is blocked. No Next step
Check whether the coolant temperature sensor is normal. Yes Replace ECU
19
6. Difficult startup of cold vehicle
Checking
result
Set the ignition switch to “ON”. Use faultfinder to check Yes Clear the displayed
1 whether there is fault information record. fault
No Next step
Use universal meter to check whether the coolant Yes Next step
temperature sensor is normal. Or connect in series a 15k
ohm between the pins 43 and 05 of ECU to start the No
2
engine instead of the coolant temperature sensor. If the
Replace the sensor
engine can be started, it indicates the coolant temperature
sensor is abnormal.
Switch on the ignition switch. Connect an adaptor Yes Next step

between ECU and harness, and check whether the
3 No Check the harness and
voltage of the following pins of ECU is normal: approx.
12V battery voltage for pins 17, 18, and 0V for pin 73. connectors

4
No Replace
EC-73
Checking
result
After successful startup, check whether the intake Yes Next step
5 manifold pressure at idle speed is between 35 ~ 55kPa.
No Eliminate intake
system leakage
Step on the throttle gently and observe whether the Yes Check the throttle and
6 startup is easy. idle channel
No Next step
Pull out the idle actuator connector on the harness before Yes Next step
the engine coolant temperature reaching 35 ℃ , and
7 No Repair or replace idle
observe whether the engine speed is dropping (engine
enters fault mode). actuator
Connect the fuel pressure gauge valve (the connecting Yes Next step
point depends on vehicle model). Make the pins 86 of the
fuel pump relay grounded directly. Switch on the ignition No
8
switch and make the fuel pump relay and the fuel pump
12
operate, and check whether the fuel pressure is at approx.
350kPa.
Use special connector to supply 12V voltage directly Yes 11

9 from the battery to injector, and check whether the
No Next step
injector is operating normally.
Check again whether the injector can operate normally Yes Next step
10 after it is cleaned.
No Replace injector
Check whether the fuel is deteriorated or moisture Yes Replace the fuel
11 contained.
No 17
12
No 16
Close the fuel gauge valve, switch on again the ignition Yes Next step
13 switch and let the pump run again, check whether the
No 15
fuel pressure can be established.
Open the fuel gauge valve, use fuel return interceptor to Yes Replace the fuel
clamp tightly the fuel return pipe and make it no return pressure regulator
14
fuel, and check whether the fuel pressure can be No Repair or replace
established quickly. injector or fuel pipe
EC-74
Checking
result
Yes Repair or replace the

15 Check whether the fuel inlet pipe is leaking or blocked. fuel inlet pipe

fuel return pipe
16 Check whether the fuel return pipe is blocked or bent.
No Replace the fuel
pressure regulator
Check whether the cylinder pressure of the engine is Yes Next step
17
normal. No Clear the trouble
Check whether the intake system of the engine is leaking Yes Repair
18
or blocked. No Next step
19
temperature sensor is blocked. No Replace ECU
EC-75
7. Idle unstable at any time

Checking
result
Yes Clear the displayed
Set the ignition switch to “ON”. Use faultfinder to check whether
1 fault
there is fault information record.
No Next step
2 Check whether the idle actuator of stepping motor is jammed. idle actuator
No Next step
Switch on the ignition switch. Check whether the connection Yes Check the harness
3 wire between the water temperature sensor, idle stepping motor and connectors
and ECU is normal. No Next step
Make the engine run at idle speed, cut fuel of the cylinders Yes 8
4 one-by-one, and observe whether the engine speed is dropping or No
Next step
fluctuating.
Yes Next step
Check whether the operation of the injector of each cylinder is
5 No Check the injector
normal.
and harness
Check whether the resistance value of high-tension wire of each Yes Next step
6
cylinder is normal. No Replace
Yes Replace
7 Check whether the ignition coil is damaged.
No Next step
Yes Next step
8 Check whether the spark plug is normal. No Replace the spark
plug
9 and 87 of the fuel pump relay and make the fuel pump run, and
No 13
check whether the fuel pressure is at 350kPa.
Use special connector to supply 12V voltage directly from the Yes 12
10 battery to injector, and check whether the operation of injector is No
Next step
normal.
11
cleaned. No Replace injector
Yes Replace fuel
12 Check whether the fuel is deteriorated or moisture contained.
No 18
Yes Next step
13 Check whether the fuel pressure is lower than 350 kPa.
No 17
14 and let the pump run again, check whether the fuel pressure can No 16
be established.
15
EC-76
Checking
result
whether the fuel pressure can be established quickly. No Repair or replace the
injector or fuel pipe
16 Check whether the fuel inlet pipe is leaking or blocked. fuel inlet pipe
No Replace fuel pump
fuel return pipe
17 Check whether the fuel return pipe is blocked or bent.
No Replace the fuel
pressure regulator
Check whether the detection hole of the intake manifold pressure Yes Clear it
18 and intake temperature sensor is blocked. No Next step
Make the engine run at idle speed, and observe whether the Yes Next step
operation of oxygen sensor is normal after the coolant No
19 Check the oxygen
temperature reaches the temperature activated by closed-loop
sensor and harness
control. (Fluctuated between 0-1V)
Check whether the engine intake system is leaking. Yes Eliminate the leakage
20
No Next step
21
Make the engine run at idle speed. Check whether the ignition Yes Replace ECU
22 advance angle is normal after the coolant temperature reaches the No Check others
normal value.
8. Idle unstable during warming up

Checking
result
Yes Clear the displayed
Set the ignition switch to “ON”. Use faultfinder to check whether
1 fault
there is fault information record.
No Next step
Yes Next step
2 Check whether the air filter is free.
No Replace
Yes Next step
Make the engine run at idle speed, and check whether the intake
3 No Eliminate the intake
manifold pressure during warming up is between 35 ~ 55kPa.
system leakage
Turn off the engine, and switch on the ignition switch. Connect Yes
Next step
an adaptor between ECU and harness and check whether the
4
voltage of intake temperature, water temperature sensors and pins No
4, 20 of ECU (used as 4.5~5V sensor power) is normal. Repair
Pull out the idle actuator connector before end of warming up, Yes Next step
5 and observe whether the engine speed is changed (engine enters No Replace the idle
fault mode). actuator
Yes Next step
6 Check whether the coolant temperature sensor is normal.
No Replace
EC-77
Make the engine run at idle speed. Check whether the ignition Yes Replace ECU
7 advance angle is normal after the coolant temperature reaches the No
normal value. Check others
9. Idle unstable at end of warming up

Checking
result
Set the ignition switch to “ON”. Use faultfinder to check whether Yes Clear the displayed
1 there is fault information record. fault
No Next step
Set the ignition switch to “ON”, connect an adaptor between Yes
ECU and harness and check whether the voltage of ECU intake Next step
manifold absolute pressure sensor output, intake temperature
2 No
sensor output, coolant temperature sensor output, oxygen sensor Repair or replace the
output pins and the voltage outputted to the idle actuator pins by harness and related
ECU are normal. parts
Turn off the engine and chemical whether the air filter is free. Yes Next step
3
No Replace
Check whether the intake manifold pressure at idle speed is Yes Next step
4 between 35 ~ 55kPa. No Eliminate intake
system leakage
Connect fuel pressure gauge valve (connecting point depends on Yes Next step
vehicle model). Short-circuit the pins 30 and 87 of the fuel pump No
5
relay and make the fuel pump run, and check whether the fuel 9
pressure is approx. 350kPa.
6 battery to injector, and check whether the injector is operating
No Next step
normally.
7
8
No 14
9
No 13
12
be established.
11
injector or pipe
12 fuel inlet pipe
13
fuel return pipe
EC-78
Checking
result
No Replace the fuel
pressure regulator
Make the engine run at idle speed. Check whether the ignition Yes Next step
14 advance angle is normal after the coolant temperature reaches the No Adjust ignition
normal value. advance angle
Pull out coolant temperature sensor and observe whether the Yes Replace the coolant
15 engine is normal. temperature sensor
No Next step
16
Check whether the resistance value of high-tension wire of each Yes Next step
17 cylinder is normal.
No Replace
Check whether the ignition coil and high-tension wire is damaged Yes Replace
18
or cracked. No Next step
Check whether the spark plug is normal. Yes Replace ECU
19 No Replace the spark
plug
10. Idle unstable or fire cut-off when using load (air conditioning)
Checking
result
No Next step
Switch on the air conditioning switch. Connect an adaptor Yes Next step
2 between ECU and harness and measure whether there is signal No Repair air
input for ECU air conditioning switch and pressure signal. conditioning circuit
Check whether the air-conditioning system pressure, Yes Next step
3 electromagnetic clutch of the compressor and the air conditioning No
Repair or replace
pump are normal.
Set the ignition switch to “ON”. Check whether the voltage of Yes Next step
4 pins 33, 34, 53 and 54 (output to idle actuator) of ECU is normal. No Check the control
circuit
Take off the stepping motor and check whether the stepping Yes Repair or replace the
5 motor is jammed or failure to run. stepping motor
No Next step
Start the engine and switch on the air conditioning, use Yes Replace ECU
faultfinder to check whether the operation of the idle actuator at No
6 Replace the idle
this time is normal by checking the number of steps of the
actuator
stepping motor.
EC-79
11. Periodically unstable (Self-learning must be carried out after ECU power off)
Checking
result
No Next step
2
No Replace
Make the engine run at idle speed and check whether the intake Yes Next step
3 pressure is at 35 ~ 55kPa.
No Repair intake and
leakage
Make the engine run at idle speed, cut fuel of the cylinders Yes 7
4 one-by-one, and observe whether the engine speed is dropping or
No Next step
fluctuating.
Set the ignition switch to “ON”. Connect an adaptor between Yes
ECU and harness and check whether the voltage of ECU’ s intake Next step
manifold absolute pressure sensor output, intake temperature
5
sensor output, coolant temperature sensor output, oxygen sensor
output, electronic ground, ignition switch pin and ECU’
s pins 33, No Repair or replace the
34, 53 and 54 (output to idle actuator) is normal. harness
Make the engine run at idle speed. Check whether the ignition Yes Next step
6 advance angle is normal after the coolant temperature reaches the
No Check others
normal value.
Check whether the detection hole of the intake manifold pressure Yes Clear
7 and intake temperature sensor is blocked.
No Next step
8
No Next step
Use special connector to supply 12V voltage directly from the Yes
Next step
battery to injector, and check whether the operation of injector is
9 normal.
No Repair the injector
and corresponding
harness
Check whether the resistance value of the high-tension wire of Yes Next step
10 each cylinder is normal.
No Replace
11 Check whether the ignition coil and high-tension wire is damaged Yes Replace
EC-80
Checking
result
or cracked, etc.
No Next step
Check whether the spark plug is normal. Yes Replace ECU
12 No Replace the spark
plug
EC-81
12. Too high idle speed (self-learning must be carried out after ECU power off)
Checking
result
1 Set the ignition switch to “ON”. Use faultfinder to check whether Yes Clear the displayed
there is fault information record. fault
No Next step
2 Check whether the cable connected with accelerator pedal is Yes Adjust or replace
jammed or too tight.
No Next step
3 Check whether the canister solenoid valve, fuel pressure Yes Repair or replace
regulator, crankcase forced-draft vacuum tube, brake system
vacuum booster hose are installed reliably or damaged.
No Next step
4 Make the engine run at idle speed, shift into neutral, step on the Yes Next step
brake pedestal, and observe whether the idle speed is too high.
No 6
5 Clamp the vacuum booster hose and observe whether the idle Yes Repair or replace the
becomes normal. vacuum booster
No Next step
6 Clamp the crankcase forced-draft vacuum tube and observe Yes Replace PCV valve
whether the idle becomes normal.
No Next step
7 Clamp the canister control valve hose and observe whether the Yes Replace the canister
idle becomes normal. control valve
No Next step
8 Check whether the idle actuator is not free or jammed. Yes Repair or replace
No Next step
9 Check whether there is leakage in other part of the intake pipe Yes Repair or replace
No Next step
10 Check whether the sealing ring of the injector is perfect. Yes Next step
No Replace the sealing

ring
11 Check whether the intake manifold absolute pressure and intake Yes Replace ECU
temperature sensor is perfect.
No Replace the sensor
EC-82
13. Speed cannot be increased or fire is cut-off when accelerating

Checking
result
1 Set the ignition switch to “ON”. Use faultfinder to check Yes Clear the displayed fault
whether there is fault information record. No Next step
2 Check whether the air filter is free. Yes Next step
No Replace
3 Make the engine run at idle speed, and check whether the Yes Next step
speed is normal at idle.
No Maintenance according to
idle fault items
4 Make the engine run at idle speed, and check whether the Yes Next step
intake pressure is 35 ~ 55kPa.
No Repair
5 Make the engine run at idle speed, and check whether the Yes
Next step
ignition advance angle is normal after the coolant
temperature reaches normal value. No Adjust the ignition advance
angle
6 Connect the fuel pressure gauge valve. Short-circuit the Yes Next step
pins 0 and 87 of the fuel pump relay and make the fuel
No 10
pump run, and check whether the fuel pressure is at
350kPa.
7 Use special connector to supply 12V voltage directly from Yes 9
the battery to injector, and check whether the injection is No
normal. Next step
8 Check again whether the injector can operate normally Yes Next step
after it is cleaned. No Replace injector
9 Check whether the fuel is deteriorated or moisture Yes Replace the fuel
contained. No 15
10 Check whether the fuel pressure is lower than 350kPa. Yes Next step
No 14
11 Close the fuel gauge valve, switch on again the ignition Yes Next step
switch and let the pump run again, check whether the fuel No 13
pressure can be established.
12 Open the fuel gauge valve, use fuel return interceptor to Yes Replace the fuel pressure
clamp tightly the fuel return pipe and make it no return regulator
fuel, and check whether the fuel pressure can be No Repair or replace the
established quickly. injector or pipe
13 Check whether the fuel inlet pipe is leaking or blocked. Yes Repair or replace the fuel
inlet pipe
14 Check whether the fuel return pipe is blocked or bent. Yes Repair or replace fuel return
pipe
No Replace fuel pressure
regulator
15 Set the ignition switch to “ON”. Connect an adaptor Yes Next step
between ECU and harness, and check whether the voltage No Repair or replace harness
of the output signal terminal of ECU throttle position
sensor and pins 4, 20 (used as 4.5 ~ 5V sensor power) is
normal.
16 Check whether the ignition coil, high-tension wire and Yes Replace ECU
EC-83
Checking
result
spark plug are normal. No Repair the related parts and
components
14. Reacting slowly when accelerating
Whether the fuel is up to the standard, whether the intake pressure sensor, throttle position sensor is
fault.
Checking
result
1 Set the ignition switch to “ON”. Use faultfinder to check whether Yes Clear the displayed
there is fault information record. fault
No Next step
2 Turn off the engine, and check whether the air filter is free. Yes Next step
No Replace
3 Make the engine run at idle, and check whether it is normal at Yes Next step
idle speed.
No Repair according to
idle fault items
4 Make the engine run at idle speed, and check whether the intake Yes Next step
pressure is 35 ~ 55kPa.
No Repair
5 Switch on the ignition switch. Connect an adaptor between ECU Yes
Next step
and harness, and check whether the voltage of the output signal
terminal of ECU throttle position sensor, grounding terminal and No Repair or replace the
pins 4, 20 (used as 4.5 ~ 5V sensor power) is normal. harness
6 Make the engine run at idle speed, and check whether the ignition Yes Next step
advance angle is normal after the coolant temperature reaches No Check others
normal value.
7 Connect the fuel pressure gauge valve. Short-circuit the pins 30 Yes
Next step
and 87 of the fuel pump relay and make the fuel pump run, and
check whether the fuel pressure is between 350kPa. No 11
8 Use special connector to supply 12V voltage directly from the Yes 10
battery to injector, and check whether the operation of the
injector is normal. No Next step
9 Check again whether the injector can operate normally after it is Yes Next step
cleaned.
No Replace injector
10 Check whether the fuel is deteriorated or moisture contained. Yes Replace the fuel
No 16
11 Check whether the fuel pressure is lower than 350 kPa. Yes Next step
No 16
12 Close the fuel gauge valve, switch on again the ignition switch Yes
Next step
and make the pump run again, check whether the fuel pressure
can be established. No 14
13 Open the fuel gauge valve, use fuel return interceptor to clamp Yes Replace the pressure
tightly the fuel return pipe and make it no return fuel, and check regulator
whether the fuel pressure can be established quickly. No Repair or replace
injector or pipe
14 Check whether the fuel inlet pipe is leaking or blocked. Yes Repair or replace the
fuel inlet pipe
No Replace the fuel
pump
EC-84
Checking
result
15 Check whether the fuel return pipe is blocked or bent. Yes Repair or replace the
fuel return pipe
No Replace the pressure
regulator
16 Check whether the exhaust system and 3-way catalytic reactor is Yes Replace or clean
blocked.
No Replace ECU
15. Performance is poor, asthenic when accelerating

Confirm whether the fuel is up to the standard, whether hand brake, brake is dragging.
Checking
result
Check whether there exist such troubles as clutch slip, tyre Yes Repair
1 pressure low, brake dragging, tyre dimension not right, and No
Next step
four-wheel positioning incorrect.
Check whether the throttle can be fully opened. Yes Next step
2 No Repair or replace
throttle
No Next step
Make the engine run at idle speed, and check whether the ignition Yes Next step
4 advance angle is normal after the coolant temperature reaches No
normal value. Check others
Set the ignition switch to “ON”. Connect an adaptor between Yes Next step
ECU and harness, and check whether the voltage of ECU’ s intake No
manifold absolute pressure sensor, throttle position sensor, intake
5 Repair or replace the
temperature sensor, coolant temperature sensor pin, ECU’ s
harness
oxygen grounding terminal and signal output terminal pins, and
ECU pins 4, 20 (used as 4.5 ~ 5V sensor power) is normal.
Make the engine run at idle speed, and check whether the intake Yes Next step
6
pressure is 35 ~ 55kPa. No Repair
7 and 87 of the fuel pump relay and make the fuel pump run, and No
11
check whether the fuel pressure is at approx. 350kPa.
8 battery to injector, and check whether the operation of injector is No
Next step
normal.
9
10
No 16
Check whether the fuel pressure is lower than 350 kPa. Yes Next step
11
No 15
14
be established.
Open the fuel gauge valve, use fuel return interceptor to clamp Yes Replace pressure
13
tightly the fuel return pipe and make it no return fuel, and check regulator
EC-85
Checking
result
injector or pipe
14 fuel inlet pipe
fuel return pipe
15
No Replace pressure
regulator
Check whether the data of the intake manifold absolute pressure Yes Next step
16
and intake temperature sensor is normal. No Replace the sensor
16. Air conditioning system trouble

Checking
result
1 Check whether the system has sufficient coolant, whether the air Yes Next step
conditioning belt is normal, and whether the air conditioning No Clear the trouble
clutch, pressure switch are normal.
2 Make the engine run at idle speed and switch on the air Yes Clear the displayed
conditioning switch. Use faultfinder to check whether the air fault
conditioning thermistor is fault. No Next step
3 Switch on the air conditioning switch. Connect an adaptor Yes Next step
between ECU and harness to measure whether there is signal No Check the harness
input for ECU’ s air conditioning switch, air conditioning
pressure.
4 If this vehicle adopts low level control, check whether the air Yes Repair the harness
conditioning is still working when it is switched off. No Next step
5 Check whether there is low level output at the grounding terminal Yes Repair the air
of the operating coil of ECU’ s air conditioning relay. conditioning relay
and harness
No Replace ECU
Electrojet system fault diagnosis:
Troubles in engine electrojet system are normally

caused by the following problems:
1 Matching of the engine electrojet system. This

problem often occurs when the vehicle comes into the
market at initial stages. For example: idle unstable,
fire cut-off, and these problems are in batches. Such
problems basically cannot be solved through
maintenance. Therefore, in case such problem is
encountered, make an active contact with the
after-sale department.
2 Most of the problems in electrojet system are

caused by poor contact of the connectors, many
troubles can be eliminated simply by replacing some
EC-86
parts, and when the replaced part is installed to other
vehicle, the other vehicle still can run normally,
therefore, it is suggested to check first whether the
related connectors of the electrojet system are well
connected when the similar problems occur.
3 The electrojet system parameters, data flow are

extremely essential during maintenance, therefore, it
is suggested not only rely on the fault code to locate
the problem during the maintenance, but make
comprehensive use of the data flow in locating and
solving the problems.
Engine Mechanical System EM-1
Chapter 4 Engine Mechanical System

Timing system
Components......................................................................................................................................EM-3
Disassembling...................................................................................................................................EM-4
Inspection.........................................................................................................................................EM-6
Assembling........................................................................................................................................EM-7
Oil sump and filter
Assembling......................................................................................................................................EM-11
Components....................................................................................................................................EM-11
Inspection........................................................................................................................................EM-13
Assembling......................................................................................................................................EM-16
Components....................................................................................................................................EM-18
Inspection........................................................................................................................................EM-19
Assembling......................................................................................................................................EM-20
Valve mechanism
Inspection........................................................................................................................................EM-22
Assembling......................................................................................................................................EM-24
Components....................................................................................................................................EM-26
Inspection........................................................................................................................................EM-27
Assembling......................................................................................................................................EM-30
Components....................................................................................................................................EM-31
Inspection........................................................................................................................................EM-32
Assembling......................................................................................................................................EM-33
Cooling system
Components....................................................................................................................................EM-35
Inspection .......................................................................................................................................EM-36
Assembling......................................................................................................................................EM-36

Components....................................................................................................................................EM-37
Inspection........................................................................................................................................EM-38
Assembling......................................................................................................................................EM-38
Radiator cover
Components....................................................................................................................................EM-39
Inspection........................................................................................................................................EM-40

Components....................................................................................................................................EM-40
Inspection........................................................................................................................................EM-41
Assembling......................................................................................................................................EM-42
Thermostat
Components ...................................................................................................................................EM-43
Inspection........................................................................................................................................EM-44
Assembling......................................................................................................................................EM-44
Intake system
Components....................................................................................................................................EM-45
Inspection.......................................................................................................................................EM-47
Assembling.....................................................................................................................................EM-47
Exhaust system
Components...................................................................................................................................EM-48
Disassembling................................................................................................................................EM-48
Assembling.....................................................................................................................................EM-48

Assembling......................................................................................................................................EM-49
Timing system
Components
Timing belt
timing belt upper cover
engine cooling pump generator support
engine cooling pump pulley
timing belt rear left cover (top)

drive belt (air conditioning,
power steering)
shock absorber belt

timing belt rear left cover (bottom)
balance shaft sprocket wheel
camshaft sprocket wheel
crankshaft sprocket wheel “B”

Timing belt “B”
tensioner arm Tensioner “B”
tensioner
induction piece
automatic tensioner idler wheel
oil pump chain
crankshaft sprocket wheel
special washer
torque
Disassembling:
1. Loosen the fastening bolts on the timing belt upper
cover, and take off the timing belt upper cover.
2. Remove the fastening bolts of crankshaft belt

pulley, and take off the belt pulley.
3. Loosen the fastening bolts on the lower cover of

timing belt, and take off the timing belt lower cover.
4. Turn the engine crankshaft clockwise to make the

cylinder 1 piston reach the compression upper dead
center and align with the timing mark.
Note:
Now, the camshaft toothed wheel just aligns with

the timing mark on the cylinder head cover; and
the position pin of the camshaft-toothed wheel
must be on the upper side.
5. Loosen the two fastening bolts of the auto
tensioner, and take off the tensioner.
6. Take off the loosened timing belt.
Note:
If the timing belt will be used again, in order to

ensure the stress direction will not be changed
when revolving, mark an arrow on the belt
indicating the revolving direction of the belt.
7. Unscrew the fastening bolts of the camshaft timing

gear, and take off the timing gear.
8. Loosen the two fastening bolts of the crankshaft

position sensor, and take off the crankshaft position
sensor.
9. When disassembling oil pump gear, take off the

observation plug on the left side of the engine body
first, then inert a screw driver with a diameter of
approx. 8mm, its depth of insertion is approx. 60mm,
so as to hold stable the left balance shaft.
10. Unscrew the fastening bolts of the oil pump gear,
and take off the oil pump driving gear.
11. Loosen the fastening bolts of the right balance

shaft timing gear, loosen the bolts of the balance shaft
belt tensioning wheel, and take off the eccentric
tension wheel.
12. Take off the driving belt of the right balance shaft,
and remove the right balance shaft driving gear.
13. Take off the crankshaft driving gear and signal

panel.
Inspection:
1. Inspect whether the camshaft gear, crankshaft gear,

tension pulley and idler pulley have any abnormal
worn-out, cracks, and damage; if any, replace them
timely when necessary.
2. Inspect the turning resistance and moving noise of

the tension pulley and idler pulley; if abnormal,
replace them timely.
3. If the tension pulley and idler pulley have grease
leakage, replace them timely.
4. Inspect wear of tappet and damage of tensioner; if
serious, replace them timely.
5. Measure the exposed length of the tensioner tappet;
if larger than the standard value, replace it.
Standard value: 14.5mm
6. Use the bench vice to press slowly the auto
tensioner; if the tappet is easily retracted, the
tensioner must be replaced.
Warning: cushion
The tensioner must be placed horizontally on the
bench vice; and both ends of the tensioner must be
cushion
cushioned with something to prevent it being
damaged.
Assembling:
plain washer
1. Assemble the timing gear in the crankshaft signal
panel, turn the crankshaft gear to align it to the timing
mark on the cylinder block, and make sure cylinder 1
piston stay at compression upper dead center.
2. Assemble the right balance shaft gear, and align it

with the timing mark on the cylinder block.
3. Assemble the timing belt and eccentric tensioner,

press the tensioner with hand, and tighten the
fastening bolts (tightening torque：43－55N•m).
Note:
When assembling eccentric wheel, the flange must
face forward. When tightening the fastening bolts,
do not turn the balance shaft, otherwise the belt
would be too tight.
4. Check the tension of belt: when pressing the belt
with fingers, the belt’
s slippage should be 5-7mm;
when measuring the tensioning force with measuring
tool, the standard values are as shown in the table
below.
Measurement range Pressure Torque
139mm 0.42kg/C ㎡ 50— 100N•m
5. Tighten the fastening bolts of right balance shaft

gear.
6. Assemble the crankshaft position sensor signal

panel and timing belt pulley.
Note:
Do not assemble the sensor blades in reverse, or it

would cause the belt to break up accidentally.
7. Assemble the crankshaft timing gear stopper and

bolts, and tighten the bolts (tightening torque：
110~130N•m).
8. Assemble the crankshaft position sensor, and
tighten the two fastening bolts.
9. Assemble the camshaft belt gear, align it with the

timing mark on the cylinder head cover, tighten the
bolts （tightening torque：80~100N•m）.
Note:
Now, the position pin of camshaft gear is at the due

up-position.
10. Assemble the oil pump drive gear and align it with
the timing, insert a screw driver into the observation
hole to lock the balance shaft, tighten the driving gear
bolt (tightening torque：50— 60N•m).
11. Use the bench vice to press slowly the automatic
tensioner until the hole on the outer cover aligns with
the hole on the plunger, insert a dog catch to lock it.
Assemble the tensioner onto the body (tightening
torque: 43— 45N•m).
12. Wind the belt according to its running direction

onto the timing wheel and tensioner in the following
order: crankshaft timing gear— oil pump gear— idler
pulley— exhaust camshaft gear— air intake camshaft
gear— tensioner.
13. Pull out the dog catch of the auto tensioner, take
out the screwdriver from the balance shaft hole, and
assemble the plug screw (applying some sealant
THREE BONDNO. 121B).
14. Turn the crankshaft several turns, check whether

the timing mark is right, and measure the distance
protruding from the tensioner crown bar top.
Standard value: 5.5— 9mm
15. Assemble the timing belt lower cover and upper

cover, and tighten the bolts (A tightening torque:
8-10N, B tightening torque：8-10N).
Oil sump and oil strainer

Disassembling:
1. Open the engine oil cover, loosen the oil bolts on

the oil sump, drain out the engine oil.
2. Remove the 19 fastening bolts on the oil sump in

the order as indicated in the picture.
Note:
There are long and short bolts.
oil seal cover
torque
3. Remove the two fastening bolts on the strainer, and

take off the strainer.
4. Remove the four fastening bolts on the oil flow
deflector, and take off the flow deflector.
Assembling:
1. Clean off the colloidal residues on the joint face of

the oil sump, assemble the oil deflector and strainer.
2. Apply sealant in the groove along the edge of the

oil sump. Tighten the fastening bolts of the oil sump oil seal cover
in the order as indicated in the picture (tightening
torque: 10— 12N·
m).
Note:
The thickness of the sealant is 3mm; the oil sump

assembling must be finished within 15 minutes
after the sealant is applied. torque

Components
front bearing
rear bearing
right balance shaft
gasket
left balance shaft
front cap
driving gear bolt
oil pump cover

driven gear bolt driven gear oil sump top
gasket
O ring
oil strainer
oil filter
gag oil sump bottom
washer
oil drain plug
torque
Disassembling:
1. Turn engine to cylinder 1 piston upper dead center,

disassemble the engine timing belt.
2. Disassemble the engine left balance shaft

observation hole, and insert a screwdriver of about
8mm diameter into about 60mm depth to lock the left
balance shaft.
screwdriver
plug
3. Loosen the fastening bolts of oil pump gear, and

take off the oil pump gear.
4. Use special tool to disassemble the left balance

shaft outer cover on the oil pump assembly casing,
disassemble the fastening bolts fastening the balance
shaft and oil pump driven gear.
5. Disassemble the fastening bolts of right balance

shaft, disassemble the eccentric tensioner to take off
the driving belt, and take off the right balance shaft
gear and shaft.
6. Drain the engine oil, and disassemble the oil sump.
7. Remove the fastening bolts of oil pump assembly.

8. Disassemble the oil pump casing assembly and
gasket.
9. Take out the left and right balance shaft.
10. Dismantle the fastening bolts on the oil pump

casing, and take off the oil cover and oil pump gear.
Inspection:
1. Inspect whether all the oil holes on the oil pump

casing are blocked; clean the oil holes when
necessary.
2. Inspect whether the front sleeve of balance shaft is

worn out, damaged and jammed with the balance
shaft.
3. Inspect whether there is any crack and other

damage on the oil pump casing, if any, replace it.
4. Inspect whether the oil seal is worn out, damaged

or aged; if it is, replace it.
5. Assemble oil pump gear into the oil pump, turn the
gear under close fitting state to see if it moves freely.
Check whether there is any channel-like wear on the
joint area between oil pump body and oil pump cover
gear surface.
6. Assemble the oil pump drive gear and driven gear
in the oil pump casing, measure the top clearance of
tooth of the gear.
Reference value: drive gear: 0.16-0.21mm
Driven gear: 0.18-0.21mm
Limit value: drive gear: 0.25mm
Driven gear: 0.25mm
7. Check the side play of the oil pump gear.
Standard value: drive gear: 0.08-0.14mm
Driven gear: 0.06-0.12mm
Limit value: drive gear: 0.25mm
Driven gear: 0.25mm
Replacement of bush of balance shaft:
1. Use special tool to dismantle the front bush of right

balance shaft from the cylinder block
front bush
rear bush
2. Use special tool to dismantle the rear bush of right
balance shaft from the cylinder block.
rear bush
3. Use special tool to dismantle the rear bush of left
balance shaft from the cylinder block. Now, use
special tool to fix the bush detacher on cylinder block
front side.
4. Use special tool to assemble the rear bush of left
balance shaft onto the cylinder block rear
Note: bush
The rear bush of left balance shaft does not have

oil hole; when assembling, apply engine oil on the
outer surface of the rear bush and on the surface
of the bush mounting hole on the cylinder block.
5. Use special tool to assemble the bush of right

balance shaft onto the cylinder block.
Note:
Be sure to align the oil hole on bush with the oil

hole on the cylinder block, and apply engine oil on
the outer surface of bush.
6. Use special tool to assemble the front bush of right

balance shaft onto the cylinder block.
bush
cylinder block
Note:
Be sure to align the oil hole on bush with the oil main oil duct
hole on the cylinder block.
oil hole
Assembling:
1. Apply engine oil on oil pump gear, and align the

two timing marks.
2. Tighten the bolts to assemble the oil pump casing

onto the oil pump casing assembly.
3. Assemble the left and right balance shaft to their

positions.
4. Use special tool, that is, the crankshaft front oil seal
oil pump
erector, to assemble the crankshaft oil seal into the oil
oil seal casing
pump casing assembly.
5. Put the special tool at the front end of crankshaft,

and apply a thin layer of engine oil on the outer
surface of the special tool to facilitate assembling the
oil pump casing; assemble a new oil pump casing
gasket on the oil pump casing assembly, tighten all
the bolts with stipulated tightening torque (tightening
torque：20-27N•m).
6. Assemble the left balance shaft onto the oil pump
driven gear fastening nuts, screw in stop piece, and
tighten it with special tool.
7. Insert a screw driver into a bolt hole on the left side

of cylinder block, check whether the balance shaft is
in the right position, then assemble oil pump drive
gear belt pulley, and replace the fastening bolts and
tighten them.
8. Assemble the right balance shaft drive gear,

eccentric wheel and crankshaft inner timing gear,
align the timing marks, assemble the right balance
shaft timing belt, press tight the eccentric wheel
tightening belt, and tighten the fastening bolts.
9. Align the timing mark, assemble the timing belt;

pull out the screwdriver on the cylinder block side
and assemble the bolts applied with sealant.
Components
with new part loosened

without new part
cylinder head bolt retainer lock

valve spring upper seat
valve oil seal
retainer lock washer
valve spring
valve spring upper seat
valve oil seal valve spring lower seat
valve spring Intake valve guide
valve spring lower seat
Intake valve guide
cylinder head
intake seat ring exhaust valve seat ring
intake valve exhaust valve
Cylinder head gasket
cylinder block
Torque
Disassembling:
1. Disassemble the fastening bolts of the cylinder
head cover, and take off the head cover.
2. Disassemble the ignition coil and high-tension

wire.
3. Disassemble the fastening bolts of the valve

chamber cover, and take off the valve chamber cover
and gasket.
4. Disassemble the timing belt cover, and take off the

timing belt.
5. Use special tool to disassemble the bolts of

cylinder head in the order as indicated in the picture. Camshaft pulley side
6. Take off the cylinder head assembly carefully, and

take off the head gasket.
Inspection:
1. Inspect carefully whether the cylinder head has any

crack, damage or leakage; if any, the cylinder head
assembly must be replaced.
2. Clean thoroughly the foreign matters, sealing

residues and accumulated carbon; after the oil duct is
cleaned, use compressed air to blow the oil duct to
make certain the oil duct unblocked.
3. Inspect the planeness of the cylinder head surface.
If the planeness exceeds the maintenance limit,
replace the cylinder head or machine precisely the
surface.
Planeness of cylinder head:
Standard tolerance: less than 0.05mm
Maintenance limit: 0.2mm
4. Inspect whether the head gasket has any ablation,

erosion or damage; if any, replace it.
Note:
The head gasket must be replaced with the head

gasket of the original manufacturer; otherwise
there would be the faults like incorrect
compression ratio caused.
Assembling:
Camshaft pulley side
1. Put the marked side of head gasket directing to the
cylinder head.
2. Align the cylinder head carefully to the position pin

of the cylinder block, and place it onto the cylinder
block.
3. Tighten the cylinder head bolts to the specified

torque in the order as shown in the picture.
Tightening torque:
Old bolts: 20N.m+90°+90°
New bolts: 63 N.m+ loosening+20 N.m+90°+90°

Valve mechanism
Disassembling:
1. Use a wrench to block the hexagonal fastening part

of the camshaft, use another wrench to disassemble
camshaft toothed wheel fastening bolts, and take off
the toothed wheel.
2. Loosen the fastening bolts of camshaft bearing

cover, take off the bearing cover, camshaft, rocker
arm, and valve lash regulator, and put them in the
order of direction.
3. Use special tool to press down the valve spring

seat, take out the valve lock; while taking out the
valve lock, do not over-press the spring, only press it
until there is the space enough for the lock clip sliding
out of the slot; otherwise, the valve stem might
become bent.
4. If the valve lock clip will not come off while

pressing the spring, dismantle the pressing device, put
a suitable tube onto the spring seat, which is to protect
the valve lock clip from impact. Put a piece of wood
on the valve head (with the cylinder head combustion
chamber side facing the workbench), and then strike
the tube part with hammer.
5. Reassemble the special pressing tool to press the

valve spring, take off the lock clip; after taking off the
valve lock, loosen the bolts slowly, and take off the
pressing tool.
6. Disassemble the valve spring seat and valve spring,

and take off the valve from below.
7. Put each set of valve, valve lock clip, valve spring
and spring seat into a plastic bag, and mark the No.,
so as to facilitate the reassemble.
8. Use pliers to take off the valve oil seal.
Note:
Never re-use the valve oil seal.
Inspection:
1.Valve
Clean the valve with hairbrush. Inspect if there is any

wear or deform at end B of each valve; if any, replace
it; the damage at end A should also be repaired or
corrected. If the dimension exceeds the limit value,
replace the valve.
Standard value
Intake valve: 1.0mm
Exhaust valve: 1.5mm allowance
Maintenance limit:
Intake valve: 0.7mm verticality

Exhaust valve: 1.0mm
2. Valve spring
Inspect the free height of each valve spring; if

free height
necessary, replace it. Use a ruler to measure the

verticality of each valve spring; if the verticality of
valve spring exceeds the limit, replace it.
Standard value
Free length: 48.82mm
Load-on: 25.3kg/40mm
Verticality deviation: 1.5°or less.

Maintenance limit:
Free length: 44.82mm
Verticality deviation: 4°
3. Valve guide
Inspect the clearance between the valve stem and

valve guide; if the clearance exceeds the limit, replace
it with a new valve guide whose dimension has been
enlarged.
Clearance between valve stem and valve guide:
Standard value:
Intake valve: 0.020-0.047mm
Exhaust valve: 0.050-0.085mm
valve stem
Maintenance limit:
stem dia.
Intake valve: 0.1mm
stem inner dia.
Exhaust valve: 0.15mm
Repair of valve seat ring:
1. Inspect if the valve guide is worn out through

sizing; if it is, replace it, and correct the seat ring.
milling cutter
stem
exhaust valve intake valve

seat ring seat ring
2. Use the valve seat guide rod and reamer to correct

the valve seat.
3. After correction, the valve and valve seat must be

ground with abrasive paste carefully.
Replacement of valve seat ring:
1. Cut the valve seat from inside to the dimension of

new hole
the replacement, make its wall thin, and replace the
valve seat ring. cut old hole
2. Re-bore the valve seat hole on the cylinder head to
the diameter of the valve seat of larger dimension.
3. Before matching the valve seat, or heat the cylinder

head to about 250℃ or cool the valve seat in liquid
nitrogen oxide, take care not to scrape cylinder head
seat hole.
4. After assembling, repair the valve seat again.
Valve seat ring contact width: 0.9～1.3mm
Replacement of valve guide
1. Use special tool to press out the old guide toward

the cylinder head bottom.
cylinder
head
valve guide
2. Repair and grind the valve guide hole to enable it

to match the valve.
3. Use special tool to press in the valve guide; the intake exhaust
valve guide should be pressed in starting from the
cylinder head top; note that the intake guide and
exhaust guide are not of the same length.
4. After pressing in the valve guide, assemble in the

valve, and check if it can move smoothly.
Assembling:
1. Clean all the parts; oil the rotation and moving

sealing member
valve guide
parts.
2. Use special tool to press in the new valve oil seal

into its required position.
3. Apply every valve with oil, insert the valve into the
guide, insert the valve into valve oil seal with valve spring seat
moderate strength; after inserting, check if the valve
can move smoothly.
4. When assembling valve spring, put the painted end
directing toward the valve spring upper seat.
porcelain spring upper
enamel seat
plated side
spring stem
sealing
member
spring
seat
5. Use special tool or suitable tool to press the spring

and assemble the lock clip. After assembling the
valve, determine if the lock clip is correctly
assembled.
6. Clean the sealing surface connecting the cylinder

block and cylinder head.
7. Inspect the cylinder gasket mark, assemble the

cylinder gasket with the marked side directing toward
the cylinder.
8. Tighten in turn the cylinder head fastening bolts.

camshaft pulley side
Components
fly wheel
fly wheel baffle

plate
rear oil seal bracket crankshaft rear
oil seal
cover plate
crankshaft bushing
upper bearing bush
thrust piece
crankshaft
adapting disc
driving disc
lower bearing bush

thrust piece
main bearing cover
Disassembling:
1. Disassemble the engine timing system, cylinder
head, oil sump, flying wheel, front cover plate and oil
pump assembly.
2. Disassemble the rear baffle plate and rear oil seal.
3. Disassemble the piston connecting rod cap bolt,
take off bearing cap of connecting rod big end, and
press the piston out of the cylinder top.
Note:
Mark the piston connecting rod cap to facilitate its
reassembling to ensure correct position and
direction; when pushing the connecting rod piston,
it is strictly forbidden to strike the connecting rod
bearing part with steel or hard things, so as to
prevent it from damage or deforming.
4. Loosen and remove the bolts of crankshaft main
bearing cover in the order indicated; take off the
bearing cover and crankshaft, and put bearing bushes
in the order of the cylinder block number.
Inspection:
1.Crankshaft
Inspect if the crankshaft main journal and connecting
rod journal are damaged, uneven worn out and
cracked, and also inspect the oil hole. Inspect the
bevel and outer diameter of crankshaft journal.
Standard value:
Outer diameter of main journal: 56.982— 57.000mm
Outer diameter of connecting rod journal:
44.980— 45.000mm
2. Inspect carefully if there is breaking-off, melting,
pull-damage, and abnormal contact in the main
bearing bush and connecting rod bearing bush. If any,
replace bearing bush.
Measurement of oil film clearance:
Oil film clearance is obtained through measuring the
outer diameter of crankshaft main journal and the
inner diameter of bearing bush and comparing the
measurements.
Standard value:
Crankshaft main bearing bushes 1, 2, 4 and
5:0.018— 0.036mm
Main bearing bush 3 of crankshaft: 0.024— 0.042mm
Connecting rod bearing bush: 0.015— 0.048mm
Limit value: 0.1mm
Use of plastic gauge
Usually, we use plastic gauge to measure oil film
clearance. Firstly, wash off oil, grease and other
foreign substance on bearing bush and main bearing
journal, put in the plastic gauge of the same width as
that of the main bearing bush and make it parallel to
bearing journal and avoid it from the oil hole.
Assemble the crankshaft, main bearing bush and main
bearing cover, and tighten them to the required
torque. During this process, do not turn the
crankshaft. Disassemble the main bearing cover,
measure its width at the widest part according to the
trace left on the plastic gauge. If the measured oil film
clearance exceeds the limit value, it is necessary to
replace the bearing bush or select to use bearing bush
of smaller dimension. When installing new
crankshaft, be sure to use bearing bush of standard
dimension. If it still cannot reach the standard film
clearance after replacing the bearing bush, it is
necessary to grind the main bearing journal and
connecting rod journal to a smaller dimension; at the
same time, select to use bearing bush of
corresponding dimension.
3. Oil seal
Check whether the front and rear oil seal is damaged
or surface damaged; if it is, replace it.
4. Main bearing cover
After assembling the main bearing cover, make sure
that the crankshaft can move smoothly and the axial
clearance is correct. If the axial clearance exceeds the
limit value, replace the bearing bush.
Standard value: 0.05— 0.25mm
5. Flywheel
Check whether the contact surface of the flywheel
and clutch disk is damaged or worn out; if the damage
or wear is serious, replace the flywheel.
Check the separation clearance of the contact surface
of flywheel and clutch: the limit value is 0.13mm.
Check whether the flywheel gear ring is damaged,
cracked and worn out; if necessary, replace the gear
ring.
6. Cylinder block
a. Check whether the cylinder hole has any scratch,
rust or erosion.
b. Use cylinder gauge to measure the cylinder hole at
A and B position indicated in the picture.
Position 1: The first air ring position
Position 2: Central position of the cylinder hole
Position 3: Bottom end position of the cylinder hole
c. If the cylinder hole exceeds the cylindericity
requirement, or the cylinder wall is seriously worn out
or scraped, the cylinder hole should be re-bored and
re-ground; then assemble with enlarged piston and
piston ring.
Standard value:
Cylinder hole: 86.5+0.03mm
Cylinder hole cylindericity: maximum 0.01mm
d. If there is any protruding matter on cylinder block,
remove it on machine tool.
Piston work size and marking: mm
Same marking: 0.50
Size: 0.50 0. S.
e. Re-bore to expand the cylinder hole; make sure
there is certain play between the enlarged piston and
cylinder hole, and ensure all the used pistons have the
same enlarging amount. The standard measurement
method of the piston outer diameter is to measure the
diameter at 23mm from the piston skirt section. The
play between piston and cylinder hole is:
0.02— 0.04mm.
f. Inspect the planeness of cylinder block topside. If it
exceeds the limit value, machine it to the minimal
limit or replace it.
Standard value: the maximum planeness of cylinder
block: 0.05mm
Limit value: planeness of cylinder block topside:
0.1mm
Note: When assembling cylinder head, it is
permissible to have a wear of less than 0.2mm.
g. For selection of the enlarged piston due to cylinder
hole boring, it must be selected based on the
maximum cylinder hole.
Same marking: 0.50
Size: 0. 50mm
Note: The piston dimension is carved on the top of
the piston.
h. Measure the outer diameter of the piston to be
used, and then calculate the new size of the cylinder
hole.
New size of cylinder hole = piston outer diameter +
0.02~0.04mm (play between piston and cylinder hole)
–0.02 (grinding allowance)
Note: To prevent cylinder hole being deformed due
to temperature rising, drill, bore and grind the
cylinder hole in the sequence of ignition.
i. Inspect the play between piston and cylinder hole.
Note: When drilling cylinder block, all the four
cylinders must be drilled, never drill only one
cylinder.
Assembling:
1. Insert a main bearing bush with groove into the
cylinder block side (upper bearing bush).
2. Insert a main bearing bush without groove into the
main bearing side (lower bearing bush). without groove with groove
3. Assemble the thrust piece.

lower bearing
bush with groove upper bearing bush
thrust bearing (central)
4. Apply lube oil on the main journal and connecting

rod journal, and then assemble the crankshaft.
5. Assemble the main bearing cover, make sure the
arrow mark toward the engine side. The number on
the cover must be correct.
6. Tighten the main bearing cover bolts to the
specified torque (25Nm+90°).
7. Turn the crankshaft, make sure the crankshaft
moving freely and check the crankshaft axial
clearance.
8. Use special tool to fit the new oil seal into the oil
oil
seal bracket. oil seal separation
bracket piece
Note: After the oil seal is disassembled, do replace
it with a new one. When fitting the oil seal into the
oil seal bracket, make sure the oil hole of the oil
seal facing downward.
oil hole
oil dish device
surface
9. Insert in new oil seal bracket gasket and oil seal

bracket device (tightening torque: 10— 12N· m).
10. Assemble the rear baffle plate onto the block.
Assemble the flywheel assembly, and tighten the
flywheel bolts to the specified torque (130-140 N·
m).
Components
first piston ring
second piston ring
oil ring
piston
piston pin
bolt
connecting rod
upper bearing bush
lower bearing bush
connecting rod bearing cover
plastic locking bolt
torque
Disassembling:
1. Disassemble the fastening bolts from the
connecting rod bearing cover to the crankshaft, and
take off the lower bearing bush, and place them
according to their order and direction.
2. Push the connecting rod and take the piston out
from the cylinder top, take out the upper bearing
bush, and place them according to their order and
direction.
3. Place the connecting rod bearing covers and
connecting rod according to their order and direction.
4. Use special tool to press out the piston pin. detacher
support
supporting
5. Use piston ring caliper to take off the piston ring.
fork
Inspection:
1. Piston and piston pin
a. Inspect every piston to see if there is any scrape,
worn-out and other defects; if any, replace the piston;
the piston ring must be replaced together with the
piston.
b. Inspect the matching of the piston pin inside the
pinhole. Under room temperature, the piston pin can
be pushed smoothly inside the pinhole by hand.
2. Measurement of piston ring side play
Measure the piston ring side play as shown in the
picture; if the measured value exceeds the limit value,
replace it with a new piston ring, and then measure its
side play again. If the measured value still exceeds
the limit value, replace the piston and the piston ring
at the same time; if the measured side play is smaller
than the limit value, only the piston ring has to be
replaced.
Standard value of piston ring side play
First piston ring: 0.03— 0.07mm
Second piston ring: 0.02— 0.06mm
Oil ring: 0.06— 0.15mm
3. Piston ring end gap
Put the piston ring in the block cylinder hole, and use
the piston to press down lightly the piston ring to the
correct position. Measure the end gap with gauge; if
the gap exceeds the limit value, replace the piston
ring.
Standard value of piston ring gap
Press down the
First piston ring: 0.25— 0.35 mm ring with piston
Second piston ring: 0.40— 0.55 mm

Oil ring film ring: 0.10— 0.40mm
Limit value of piston ring gap
Second piston ring: 0.8mm
Oil ring film ring: 1.0mm
4. Connecting rod
Gap
Inspect if the connecting rod is worn out; if its
mounting surface is damaged or worn out, replace the
connecting rod.
Assembling:
1. Insert in the bushing ring of the piston ring.
2. Assemble the upper and lower film ring of the
piston ring.
Note:
When assembling the upper film ring, put one end
of the film ring in between the piston ring groove
and the bushing ring first, then press down part of
Inner chamfer
the lower film ring with finger and make it enter type
the ring groove as shown in the picture. When
assembling the film ring, do not use piston ring
tensioner. Use the above method to assemble the Down cutting
lower film ring. type
3. Apply lube oil around the piston and piston ring, The first
and then use piston tensioner to insert in the second Upper film ring piston ring
gap gap
piston ring and the first piston ring
Engine
front
Second piston
ring gap and
bushing ring Lower film
tension gap
4. Use special tool to assemble the piston pin, ring gap
connecting rod and piston together, pay attention to
the front, rear direction.
5. Use piston compression device to compress the
piston ring, install the piston and piston ring into the
cylinder block.
6. Make sure the forward identification mark on
piston and connecting rod pointing to the engine front
side.
7. When installing the connecting rod big end, make
sure the side marking of the connecting rod and the
cap is on the same side. Tighten the connecting rod
nut (tightening torque: 20Nm+90°).
Engine
block No.
cut
8. Inspect the connecting rod side play.
Standard value: 0.10— 0.25mm
Limit value: 0.4 mm

Cooling system
Water pump
Components
Disassembling:
1. Drain the engine cooling water; dismantle the inlet
pipe of the cooling water pump.
2. Loosen the generator’ s fastening bolts and the
adjusting bolts, push upward the generator to loosen
the driving belt, and take off the driving belt.
3. Dissemble the bolts of water pump belt pulley and
take off the pulley.
water pump
4. Dissemble the generator bracket and the tension pulley
pulley of automatic tensioner.
generator
pulley crankshaft
pulley
5. Disassemble the fastening bolts of water pump

casing, and take off the water pump.
Inspection:
1. Inspect whether the belt has any cracks, ageing,
and damage phenomena.
2. Inspect whether the water pump has any cracks,
warn out, and damage; if necessary, replace water
pump parts.
3. Inspect the water pump bearing for any damage,
abnormal noise, and slow rotation; when necessary,
replace water pump parts.
4. Inspect whether sealing members have any
leakage; when necessary, replace the water pump
parts.
5. Inspect whether the engine cooling water is
leaking; if any, replace the water pump sealing
member.
Assembling:
1. Clean the engine cooling water pump casing and
cylinder block sealing plate surface.
2. Install new “O”sealing ring into the groove at the
front edge of engine cooling pipe; then wet it with
water, do not use oil or grease.
3. Install a new engine cooling water pump sealing
plate and a new engine cooling water pump part, and
tighten the bolts with the specified torque (tightening
torque: 20— 27Nm).
4. Assemble the timing belt and timing belt cover.
5. Assemble the engine cooling water pump belt

pulley and driving belt, and tension the generator
bracket.

Radiator
Components
radiator top water pipe radiator fan motor radiator fan
protection
cover
clamp
radiator bottom water

pipe
air conditioning fan
expansion tank
Inspection:
1. Inspect whether there is any foreign matter in
between the radiating fins.
2. Inspect whether the radiating fins are damaged; if
necessary, have them repaired.
3. Inspect whether the radiator is eroded, damaged,
rusted or scaled.
4. Inspect whether the radiator hose is cracked,
damaged or aged.
5. Inspect whether the expansion water tank is
damaged.
Assembling:
1. Pour clean mixed coolant into radiator and
expansion water tank.
2. Run the engine until the coolant is heated to high
enough to switch on the thermostat valve, then stop
running the engine.
3. Take off the radiator cap; fill coolant into radiator
from the filler port. Fill water into the expansion tank
till the upper stop level.
4. Inspect whether the radiator, hose or connecting
joint is leaking.
Note:
When the radiator is hot, do not open its cap;
Only the coolant designated by the original
manufacturer can be filled;
Water temperature can become too high due to
dust or foreign matters deposited on the radiator;
so it should be taken off for cleaning.
Disassembling:
1. Disconnect the grounding wire from the battery
connectors.
2. Disconnect the fan motor connectors.
3. Loosen the radiator drain plug to drain coolant.
4. After the radiator hose and the clamp are simply
marked, open the upper and lower hoses and overflow
device.
5. Dismantle the radiator assembling bolts.
6. Dismantle the radiator and fan motor.

7. Take off the radiator fan motor and condenser fan
motor from the radiator.
Radiator cover
Components
radiator cap spring
HP valve
flexural valve vacuum spring

valve
Pressure Pressure
Pressure：
Inspection:
1. Inspect whether the radiator cap is damaged,
cracked or weakened.
weakened
2. Connect tester onto the radiator cap. weakened
3. Increase pressure until the pointer stops moving.
4. If the reading cannot keep stable for about 10s,

replace the radiator cap.

Components
radiator
fan assembling clamp
fan
cover radiator fan motor
Torque
Inspection:
Radiator fan motor and condenser fan motor
1. Connect power to the motor terminal, and check

the rotation of fan motor.
2. Check whether there is abnormal stray noise when

the motor is running.
Radiator fan motor relay
1. Dismantle the radiator fan relay (high terminal and

low terminal) from the relay box inside the engine
compartment.
2. Inspect the conduction between the terminals.
Current Terminal No. Conducted or not
On Terminals 1-3 Conducted
Off Terminal 1-3 Interrupted
Terminal 2-4 Conducted
Radiator fan
1. Check whether the fan blades are damaged or

cracked.
2. Check whether the bolt hole on the fan central shaft

hub is cracked or damaged.
Assembling:
Assembling order is opposite to the disassembling

order.
Note:
1. When assembling, do not let the fan blades

touch the fan housing.
2. After assembling, make sure the fan does not

have any abnormal noises or vibration while
running.
Disassembling:
2. Disconnect the wiring harness of the fan motor

connector and the fan housing.
3. Dismantle the four mounting bolts on the fan

housing.
4. Take off the fan motor housing.
5. Dismantle the fan mounting clamp to separate the

fan motor and the fan.
6. Dismantle the three screws, and take off the fan

motor.
Thermostat
Components
radiator water outlet pipe
radiator water inlet device
Gasket thermostat
Components
coolant outlet device
gasket
coolant inlet device

thermostat
coolant temperature sensor
coolant hose
gasket
Inspection:
1. Heat the thermostat as shown in the picture. thermostat

Gasket
2. Inspect whether the valve works normally.
3. Measure the temperature when valve starts to open.
Temperature when opening valve: 80-84°C

water
Temperature when full open: 95°C
Assembling:
1. Inspect whether the thermostat flange is correctly

fixed into the thermostat housing sleeve.
2. Assemble the inlet device.
Tightening torque
Bolts for engine coolant inlet device:
10-15Nm
3. Re-filling coolant.
Disassembling:
1. Drain the coolant until the level is lower than the

thermostat
2. Disassemble the inlet device and washer.
3. Disassemble the thermostat.

Intake system
Components
air filter assembly
intake guide A
intake pipe
intake guide B
air outlet 
Note:
connected with
engine.
air inlet
injector
gasket
surge tank
intake manifold
absolute pressure
and intake
power transistor temperature sensor
idle actuator throttle intake manifold

valve body
torque
Disassembling:
1. Disassemble air filter, intake hose, vacuum hose,

and throttle valve body.
2. Disassemble accelerating pedal pull cable.
3. Disconnect the wiring harness of the fuel injection

nozzle, and remove the water pipe tension bolts on
intake manifold.
4. Loosen the two hold-down bolts of oil rail, take off
the wiring harness bracket, and pull outward the oil
rail and injector unit.
Note:
When disassembling and assembling, take care not

to let the injection nozzle washer fall off; if the
injection nozzle washer dismantled, it must be
replaced.
5. Turn and pull out the injector from the oil rail.
Note:
When assembling, the injector sealing rubber ring

must be replaced with a new one.
6. Loosen the fastening bolts connecting the intake

manifold assembly onto the cylinder block, and take
off the intake manifold assembly and gasket.
Inspection:
1. Inspect whether the nozzle has any accumulated

carbon, sinter and coke-like matter; if any, clean it or
replace it.
2. Inspect whether the intake manifold has any

cracking and leaking places.
3. Inspect whether the intake manifold gasket is

cracked or damaged; if it is, replace it.
Assembling:

order.
Exhaust system
Components
heat protection cover locking nut: 25-30
locking nut
exhaust manifold gasket
25-35
Torque: Nm
Disassembling:
1. Loosen the three fastening bolts of the exhaust 4. Loosen the bolts fixing the exhaust manifold to the
manifold cover, and take off the cover. cylinder block; and take off exhaust manifold and
gasket.
Assembling:

order.
2. Loosen the three fastening bolts from the front

exhaust pipe to the front catalyst; disconnect the front
exhaust pipe.
3. Disconnect the wiring harness plug of the front and

rear oxygen sensors.
Disassembling: 2. Drain the engine coolant and oil, and disassemble
the cooling system pipe from the air-conditioning
1. Disassemble the accessories, wiring harness and
compressor.
pipelines around the engine block.
3. Disassemble the four fastening bolts from the
engine bracket cross-member to the chassis.
4. Take off the gearbox shifting rod, clutch slave

cylinder, back-up lamp switch connector, and speed
sensor connector.
5. Disassemble the four fastening bolts from the

gearbox bracket cross-member to the chassis.
6. Disassemble the lower swinging arm connection

bolts assembly, lift the engine gearbox assembly
upward and take it off.
Assembling:

order.

4-2.0L Gasoline Engine

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Refine MPVWorkshop Manual 2.

Chapter 1 General Description of Engine

Chapter 2 Engine Electrical System

Chapter 3 Engine Control System

Speed density type air flow meter....................................................................................................EC-5

Chapter 4 Engine Mechanical System

Radiator and thermostat

Radiator fan motor assembly

Engine and gearbox assembly

Chapter 1 General Description of Engine

Specifications and parameters....................................................................................GI-5

Tightening torque ........................................................................................................GI-9

Special tools ...................................................................................................................GI-12

Gasoline engine (2.0 L4)

Series HFC4GA3 gasoline engine is a multipoint

Engine identification number

The engine identification number is stamped on the

Explanation of the engine identification number

Engine model composition is as follows:

3. Engine fuel type code

5. Engine displacement volume

Engine ex-works number

The engine ex-works number is composed of 8 digits.

Year Engine Ex-works number

Year Code Year Code Year Code Year Code

2001 1 2009 9 2017 H 2025 S

Engine type Code

Description Specifications and parameters Limit value

Description Specifications and parameters Limit value

Valve head thickness (edge)

Valve stem and valve guide clearance

Phenomena Possible causes Repair

Cylinder head gasket damaged Replace the piston

Phenomena Possible causes Repair

Coolant leaking Fill to specified level

Tool Picture Purpose

To disassemble balance shaft front

To disassemble balance shaft rear

To erect balance shaft front/rear

Guide plate To disassemble and erect balance

To disassemble and erect front nut

Camshaft front oil seal

To erect camshaft oil seal

Used as guide when pressing in

Tool Picture Purpose

To disassemble and install cylinder

To disassemble and erect front nut

Valve spring compressor

Valve guide mounting

Crankshaft rear oil seal 1. To erect engine rear oil seal

Tool Picture Purpose

To disassemble and erect

Cross-member stud bolt To disassemble and erect

Chapter 2 Engine Electrical System

Ignition system (DOHC)

Camshaft position sensor

2. Measuring of secondary coil resistance

Disassembling and assembling

8. Remove the lower cover.

9. Disconnect the connector and remove the multi-function switch.

Terminal Door alarm switch

Test of spark plug wire

With engine at idle speed, check whether there is any