Great Wall GW491QE Service Manual Download Page 25

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EF.1-7

United Electronic engine management system-Analysis of function /principal /

failure for system parts &components

ProCarManuals.com

Summary of Contents for GW491QE

Page 2: ...or exhausts of pollutants from light vehicles at phase III IV in China equivalent to European Class III standard To meet the needs from numerous maintenance technical management personnel we prepare this GW491QE Petrol Engine Service Manual based on the latest technical materials All contents specifications and data stated in this manual are the latest information before printing and this service ...

Page 3: ...data United Electronic engine management system Delphi engine management system Engine body Cylinder head Valve mechanism Cooling system Lubrication system Ignition system Starting system Charge device Clutch G1 EF 1 EF 2 EM 1 EM 2 EM 3 CO LU IG ST CH CL ProCarManuals com ...

Page 4: ...nical parameters for model GW491QE petrol engine Specification adjustment parameters for key components Technical data for maintenance Tightening torque for fastening elements Troubleshooting Engine service maintenance data Page ProCarManuals com ...

Page 5: ... closed loop control 16 Piston average velocity 13 18m s 17 Average valid pressure 874kpa 18 Compression pressure of cylinder when at 250r min 1128kpa European class II 1350kpa European class III 19 Ignition sequence 1 3 4 2 20 Ignition control pattern Without ignition distributor and direct ignition under an electronic control 21 Spark plug clearance 1 0 1 2mm 22 Model of spark plug F6RTC 23 Valv...

Page 6: ...G B 18285 2005 38 E mission control level when under operating condition W ith a three way catalytic converter and a closed loop control for air fuel ratio and the with light duty vehicle satisfies requirements from G B 18352 2 2001 and G B 18352 3 2005 standards 39 D ifference between cylinders 98 kpa 40 Vacuum inside air intake pipe when at idle speed 53 3 kpa 41 Temperature of outlet cooling wa...

Page 7: ...Unit mm Name Test items Standard value Use limit Cylinder head Planeness on the contact surface of body Planeness on the contact surface of manifold pipe Slope angle of valve seat A ir intake A ir exhaust Contact angle Contact width 0 05 0 05 30 45 60 30 45 60 45 1 2 1 6 0 15 0 10 Valve guide Inner diameter E xterior diameter Increased size 0 05 Temperature when changing on the side of cylinder he...

Page 8: ... 0 10 0 30 Cylinder block Planeness Diameter of bore hole increased size 0 50 increased size 0 75 increased size 1 00 91 0 05 91 24 91 74 91 99 92 24 Piston and piston ring Piston diameter increased size0 50 increased size0 75 increased size1 00 Clearance of piston Side play of annular groove Opening gap of piston ring First gas ring Second gas ring Oil ring 90 938 90 968 91 425 91 455 91 675 91 7...

Page 9: ...engine 7 9L Radiator Pressure when the pressure relief valve of cover is opened 73 6 103 kpa Min value not less than 58 9kpa Thermostat Temperature when valve is opened Lift distance of valve 95 80 84 8mm 76 8mm Transmission belt Bending deflection of transmission belt when a 98N force is applied New belt Used belt 5 7 mm 7 8 mm 3 Lubrication system Name Test items Standard value Use limit Capacit...

Page 10: ...lue Use limit Battery Density of electrolyte for battery When full charge of battery at 20 1 25 1 27 AC generator Resistance of rotor coils Diameter of slip ring Exposed length of electric brush 4 0 32 3 32 5 mm 12 5mm 32 1mm 5 5mm Regulator Adjustment voltage at20 13 95 14 4 V Driving belt A 98N bending deflection force is applied to driving belt between AC generator and water pump New belt Used ...

Page 11: ...der block Drain plug of oil pan 40 18 18 50 80 160 85 13 40 12 20 25 2 Standard bolt tightening torque Tightening torque Grade diameter mm screw pitch mm hexagonal headed bolt N m hexagonal flange bolt N m 4T 6 8 10 12 14 16 1 1 25 1 25 1 25 1 5 1 5 5 12 5 26 47 74 115 6 14 29 53 84 5T 6 8 10 12 14 16 1 1 25 1 25 1 25 1 5 1 5 6 5 15 5 32 59 91 140 7 5 17 5 36 65 100 6T 6 8 10 12 14 16 1 1 25 1 25 ...

Page 12: ...x to the thermal baffle of solenoid valve is leaking air 1 1 Charge with power 2 Clean wiring terminals and tighten battery line 3 Change the fuse 4 Repair or change starter 5 Repair or change ignition switch 2 1 Change the high tension resistance line 2 Change the ignition coil 3 Adjust the clearance between both electrodes 4 Have it baked or clear away the carbon deposit 5 Change the spark plug ...

Page 13: ...ations 5 Check the intake manifold pipe and gasket 6 1 Wash the cover and clean the filtration core by purging 2 Repair and adjust its control mechanism 7 Refer to the methods of elimination in case of failure engine too hot 4 Engine is backfired or deflagrated Cause of failure Methods of elimination 1 Failure in ignition system 1 Joint on the ignition line is loose 2 Spark plug not working well 3...

Page 14: ...he bushing of connection rod abraded too much 5 Main bushing abraded too much 6 Thrust piece of crankshaft abraded too much 7 Much clearance between camshaft and the thrust plate of camshaft 8 Timing chain and timing chainwheel abraded too much 9 Chain tensioner null and void 10 Too much carbon deposit in the combustion chamber of cylinder 11 Petrol is not consistent to the specification 1 Check a...

Page 15: ...g bolt or change the gasket 2 Change the combined piston oil rings 3 Sent it on service 4 Change the valve oil seal 5 Change the valve and guiding rod 6 Check clean and make it through 7 Avoid the engine running with small load and at high speed when possible 9 Engine not flame our after the ignition switch is closed Cause of failure Methods of elimination 1 Engine too hot 2 Spark plug too hot 3 T...

Page 16: ...sh clean and tighten the connector 7 Change the oil filter 8 Change the oil pressure sensor 9 Change the bushing or bearing 10 Change the machine oil manometer 11 Check repair and fix it Engine service maintenance data 1 SST special maintenance tools Note sort A used in the routine repair during the inspection of vehicles or used as general tools B used in the overhauling as to dismantle component...

Page 17: ...ft Tools used to change the oil seal after the co axis Spanner for oil filter Tools used to repair radiator Spanner used to adjust idle speedscrews Rocker supporttools Valve pushrodtools Cone shaped tools used for the crankshaft bearing on injection pump Tools used to dismantle the splined shaft from injectionpump Oil seal remover Tools usedtofix flanges inpairs Universal remover Belt pulley for c...

Page 18: ...ta Name of material Product No Usage etc 1282B sealant 1282B Three bond or similar products 08823 00100 Cooling water bypass flange Rear end cover plate for cylinder 1324 bond 1324 Three bond or similar products 08833 00070 Thermostat for manifold pipe Bolts for flywheel or driving plate Fixing screws for induction coil 1324 bond 1324 Three bond 242 Letai or similar products 08833 00080 Cooling fl...

Page 19: ...for system parts components General troubleshooting and steps to engine Criterion to flashing code mounting torque of components within M1 5 4 system Description of the diagnosis function on M7 9 7 system failure M7 9 7 system service diagnosis flow process based on fault code United Electronic engine management system ProCarManuals com ...

Page 20: ... sensor phase sensor actuator idle speed adjustor EWD3 oil injector EV6 electrical fuel pump fuel pressure adjustor DR carbon canister control valve TEV and ignition coil ZSK and ECU electronic controller BOSCH Motronic7 9 7 engine management system for electric injection The key feature of M7 9 7 engine electronic control management system is the application of a control strategy based on torque ...

Page 21: ... b Connection between torque and exterior system eg transmission mechanism or vehicle dynamic control c Control over several types of engine parts and components d Provide a matching interface across EOL programming tool and maintenance tools 3 Online diagnosis OBD a Fulfill a series of OBD function b A management system used for diagnosis function UASE Electronic Control Engine Management System ...

Page 22: ...EF 1 4 cases Precautions to the maintenance of electric injection system UAES Electronic Control Engine Management System Notes for Electronic Injection System Service ProCarManuals com ...

Page 23: ... do not start the engine immediately instead open the ignition switch before wait for ten seconds to restart the engine Following a successful starting process perform a ECU self learning as per following sequence Have the engine running at idle speed for at least ten minutes Flameout for at least ten minutes Open the ignition switch rather than an immediate starting process and wait for at least ...

Page 24: ...tem parts components 1 System circuit diagram and the definition of ECU Pins a United Electronic M1 5 4 system circuit diagram United Electronic engine management system Analysis of function principal failure for system parts components ProCarManuals com ...

Page 25: ...EF 1 7 United Electronic engine management system Analysis of function principal failure for system parts components ProCarManuals com ...

Page 26: ...depending on the type of vehicle Input 14 Ground of driving stages for oil injector and carbon canister control valve Ground 41 Signal o A C switch Input 15 Function reserved 42 Idle pin 16 Oil injector pin 2 for cylinder 2 Output 43 Idle pin 17 Oil injector pin 2 for cylinder 1 Output 44 Signal of air inlet temperature sensor pin 2 Input 18 8A fuse accumulator voltage Power supply 45 Engine water...

Page 27: ...ing speed sensor A Input 56 16 Throttle position sensor Input 57 Air conditioner compressor switch Input 17 Sensor ground 1 Ground 58 18 Oxygen sensor Input 59 Vehicle speed signal Input 19 K nock sensor A Input 60 20 K nock sensor B Input 61 Power ground 1 Ground 21 62 22 63 Intermittent power supply Input 23 64 Phase D on step motor Output 24 65 Phase A on step motor Output 25 66 Phase B on step...

Page 28: ...zed air to impact vacuum elements Whereby the sensor needs to be changed in case of failure check whether the output voltage and current from generator is under a normal condition g Simple measurement method Temperature sensor part after disconnection of joint Have digital multimeter adjusted to the ohm position and connect two pens with Pin 1 and Pin 2 of sensor respectively And the rated resista...

Page 29: ... etc e Cause of general failures artifical failure f Precautions to maintenance take note of the installation position g Simple measurement method after disconnection of joint Have digital multimeter adjusted to the ohm position connect two pens with Pin 1 and Pin 2 of sensor respectively And the resistance value at room temperatrure shall be 2k 20 Connect two pens with Pin 1 and Pin 3 of sensor r...

Page 30: ...e body may be transmited via mass block inside the sensor Under the vibration stress of mass block a voltage will be produced on two pole faces of piezoelectric crystal to converse the vibration signal into voltage signal d Mounting torque e Symptom Bad acceleration etc f Cause of general failur The sensor might be corroded when contacting with various liquids for long term period such as machine ...

Page 31: ...sured from the characteristiccurve shown above A simulation method may be applied during measurement details as shown below have the working zone of sensor submerged into boiled water ensure the submerge is with sufficient time then observe the change of sensor resistance and the resistance shall be decreased to an extent within 300 400 Specific value depends on the temperature of boiled water h T...

Page 32: ...e inside to the outside and the output voltage will be high close to 900mV And a relatively thin gas mixture results in a smaller difference of density for oxygen ion inside and outside the ceramic pipe and a smaller difference of potential as well that a small number of oxygen ions will move from the inside to the outside and the output voltage will be low close to 100mV c Installation position o...

Page 33: ...f ceramic pipe 100 K s Allowable temperature on ceramic elements when condensed water is produced on the exhausted side 350 random vibration peak value 800 m s2 simple harmonic vibration vibration displacement 0 3 mm Allowable vibration on shell simple harmonic vibration vibration acceleration 300 m s2 Uninterrupted DC current at 350 Absolute value 10 μA Interrupted Max AC current when the exhaust...

Page 34: ...350 850 350 850 Voltage mV of sensing element whenλ 0 91 co 1 840 70 710 70 840 80 710 70 Voltage mV of sensing element whenλ 1 10 20 50 50 30 20 50 40 40 Inner resistance of sensing element kΩ 1 0 1 0 1 5 0 3 Response time ms 600mV 300mV 200 200 400 400 Response time ms 300mV 600mV 200 200 400 400 ProCarManuals com ...

Page 35: ...age sustaining for 75 seconds at most exhausted gas temperature 350 24 V Power of the connector Testing voltage 13 V Heating power under a heat balance at working voltage 13V When the exhausted gas is at a temperature of 350 and a flow rate of approx 0 7m s 12 W Heating current under a heat balance at working voltage 13V When the exhausted gas is at a temperature of 350 and a flow rate of approx 0...

Page 36: ...age on coil used for arotating speedsignaloutput c Installation position above the cover of chainwheel chamber M1 5 4 and on the same plane of rear flywheel of engine d Mounting torque e Symptom unable to start etc f Cause of general failures artifical failure g Precautions to maintenance Check whether the clearance betweensensor and the signal tooth on belt pulley is within mm it may be adjusted ...

Page 37: ...life period 1130 hours 130 Coil zone 40 150 Transition zone Blended blended Lead wire zone 40 130 Storage temperature 20 50 Ambient temperature when not starting 40 130 Long term ambient temperature when starting 40 130 Short term ambient temperature when starting 150 500 hours 150 Tolerable temperature for H S lead wire induced type of rotating speed sensor Lead wire zone within the whole service...

Page 38: ...nnect with lead wire Open the ignition switch rather than to start the engine have digital multimeter adjusted to the DC voltage position connect two pens with the red black lead wire of sensor respectively and ensure a 5V reference voltage is provided And a voltage output shall be available between green lead wire and black lead wire while the engine is running It s recommended to apply a vehicle...

Page 39: ...s the opening degree of bypass air duct depends on the angle position of slide block which is controllable by the electrical pulse occupation rate output from the electronic controller c Installation position on the throttle valve unit d Symptom too much high idle speed idle speed flameout etc e Simple measurement method after disconnection of joint Have digital multimeter adjusted to the ohm posi...

Page 40: ...low capacity VS step length shows a linear correlation And there one spring behind choke plug on the end of screw rod as shown in the figure above The size of utilizable force along the extension direction of choke plug is equal to the force of step motor plus the spring force while the size of utilizable force along the retracted direction of choke plug is equal to the spring force reduced by the...

Page 41: ... bad acceleration unable to start start with difficulty etc e Precautions to maintenance The injector may have various types During maintenance Part No of injector to be re installed shall be consistent to the original one as injectors looking alike and able to be installed might be inappropriate For an easy installation it recommended to apply clean silicon free machine oil to the surface of orin...

Page 42: ... etc e Cause of general failures The use of inferior fuel might result in An insulation layer formed by accumulative colloid A dead hug of bearing bush with armature of oil pump Corrosion of oil level sensor components V alue M easurement M in T ypical M ax U nit S torage temperature when with original package 40 70 A llowable temperature of injector inside vehicle when not working 140 C ontinuous...

Page 43: ...haust point kPa A mbient temperature applicable to storage and transport A llowable fuel temperature A llowable vibration acceleration m s2 13 Fuel pressure adjustor DR Principal The pressure adjustor is of a membrane typed overflow valve Once the system fuel pressure is increased to a degree that the fuel pressure inside oil inlet mouth is greater than a resultant force of the pre tensioned sprin...

Page 44: ...ave the carbon canister control valve handged installed onto hose f Simple measurement method after disconnection of joint Have the digital multimeter adjusted to th ohm position and connect two pens with two pins of carbon canister control valve respectively And the rated resistance when at 20 shall be P denotes the difference between atmospheric pressure Pu and the inlet air pressure Ps 1 fuel g...

Page 45: ...ously on secondary windings to provide spark plug with energy for discharge process Different from ignition coils installed with ignition distributor the ignition coil ZSK2 2 has both ends of its secondary windings connected with one spark plug respectively to perform two ignitions simultaneously c Installation position on engine d Symptom unable to start etc e Cause of general failures burning da...

Page 46: ...by accumulator via Pin 18 Power supply via Pin 37 when main relay has been connected Power supply via Pin 27 when ignition switch has been connected c Ground Pin 2 10 14 19 24 30 48 Failure diagnosis interface Includes Pin 55 and engine data line K Using line K the record of failure information inside ECU may be called out or some commands may be manually input such as elimination of the record of...

Page 47: ...engine rotating speed sensor Receive the engine load signal etc b Symptom Unstable idle speed bad acceleration unable to start too much high idle speed tail gas out of limit start with difficulty air conditioner failed the oil injector control failed flameout etc c Cause of general failures The electrical overload on peripheral units results in a burning damage or failure of parts and components i...

Page 48: ...egarding the system pressure refer to the characteristic parameter for pressure adjustment valve Regarding the requirement for fuel refer to the characteristic parameter for injector Regarding the sealability it s required to have no fuel leakage under working pressure The inner diameter of fuel rubber hose shall be 7 9 0 3 mm2 European Measurement Value Min Typical Max Unit Working temperature wh...

Page 49: ...lubricating oil and gear box oil No Repair or change the timing belt 2 The hot vehicle is starting with difficulty S N Operation steps Check result Follow up steps Yes Clear the displayed failure away 1 Place ignition switch to the ON position A fault diagnosis instrument may be used to check whether there s any record of failure information No Next step Yes Next step 2 Connect the fuel manometer ...

Page 50: ...alve and idle speed passage 4 Observe whether it s easy to start by gently stepping on the throttle valve No Next step Yes Next step 5 Connect the fuel manometer valve And have the Pin 30 of fuel pump relay short circuit connected with the Pin 87 and check whether the fuel pressure is within 250kpa and 300kpa while the fuel pump is working No 9 Yes 8 6 Check whether the oil injector is working aft...

Page 51: ...r No Change the sensor Yes Next step 3 After the connection of ignition switch connect a commutator between ECU and wiring harness and check whether respective voltage on following pins of ECU is normal Whether the accumulator voltage on Pin 27 is at about 12V and whether respective voltage on Pin 14 19 is 0V No Check the wiring harness and socket connector Yes Next step 4 Check whether the passag...

Page 52: ...ange the idle speed actuator 2 Check whether the idle speed actuator has got stuck No Next step Yes Check the wiring harness and socket connector 3 After the connection of ignition switch connect a commutator between ECU and wiring harness and check whether respective voltage on Pin 14 45 the signal output end for air inlet temperature sensor and cooling fluid temperature sensor respectively of EC...

Page 53: ...er a closed loop control No Check the oxygen sensor and wiring harness Yes Settle the leakage 19 Check whether the engine air inlet system has leakage No Next step Yes Next step 20 Check whether the pressure of engine cylinder is normal No Clear the failure away 6 The idle speed during vehicle heating process is unstable S N Operation steps Check result Follow up steps Yes Clear the displayed fail...

Page 54: ...ether the oil injector is able to work normally after it has been washed No Change the oil injector Yes Change the fuel 8 Check whether fuel contains water or has deteriorated No 14 Yes Next step 9 Check whether the fuel pressure is below 250kpa No 13 Yes Next step 10 Close the fuel manometer valve and re connect the electric spark switch to have oil pump working for three seconds then check wheth...

Page 55: ...le Another self learning is needed after a power cut to ECU S N Operation steps Check result Follow up steps Yes Clear the displayed failure away 1 Place ignition switch to the ON position A fault diagnosis instrument may be used to check whether there s any record of failure information No Next step Yes Next step 2 Check whether the passage of air filter is free No Change it Yes Next step 3 Check...

Page 56: ...al when vacuum hose is being clamped No Next step Yes Change the PVC valve 6 Observe whether the running at idle speed is normal when the forced ventilation vacuum pipe on crankshaft box is being clamped No Next step Yes Change the carbon canister control valve 7 Observe whether the running at idle speed is normal when the hose of control valve on carbon canister is being clamped No Next step Yes ...

Page 57: ...return barrier to stop oil return check whether it s able to produce oil pressure rapidly No Repair or change the oil injector or oil pipe Yes Repair or change the oil inlet pipe 13 Check whether the oil inlet pipe has any leakage or has been blocked No Change the oil pump Yes Repair or change the oil return pipe 14 Check whether the oil return pipe has been bent or blocked No Change the fuel pres...

Page 58: ...to produce an oil pressure No 14 Yes Change the fuel pressure adjustor 13 When the valve on fuel meter is opened before oil return pipe is being clamped by oil return barrier to stop oil return check whether it s able to produce oil pressure rapidly No Repair or change the oil injector or oil pipe Yes Repair or change the oil inlet pipe 14 Check whether the oil inlet pipe has leakage or has been b...

Page 59: ... normal No Change the sensor Yes Next step 16 Check whether spark plug high voltage line and ignition coil are under a normal condition No Change or adjust it Yes Check air conditioner system 17 Check whether the failure is caused by air conditioner system No Change ECU 14 Failure with the air conditioner system S N Operation steps Check result Follow up steps Yes Repair it 1 Check whether system ...

Page 60: ...e loop with rotating speed sensor Yes Next step 3 Pull out the division line from one of cylinders before it s connected with spark plug and keep the electrode of spark plug about 5mm away from engine body and check whether blue white high voltage fire is produced while the engine is running No Check and repair the ignition system Yes Settle the mechanical failure on engine 4 Check and observe whe...

Page 61: ...Next step Yes Change the failed components 5 Remove the oil injector and check whether it has any leakage or has been blocked using a special washing analyzer instrument No Next step Yes Change the fuel 6 Check the fuel condition and observe whether the symptom is caused by the filling with petrol No Next step Yes Settle the mechanical failure on engine 7 Check and observe whether the pressure ins...

Page 62: ... time S N Operation steps Check result Follow up steps Yes Check and repair the air inlet system 1 Check the air filter for blockage and the air inlet passage for air leakage No Next step Yes Wash or change it 2 Check whether the idle speed adjustor has got stuck No Next step Yes Next step 3 Check and observe whether the model and clearance of spark plug on each cylinder is in compliance with the ...

Page 63: ...ndition No Check and repair relevant loops 8 Despite of a normal starting process the idle speed is unstable after the vehicle heating process is ended S N Operation steps Check result Follow up steps Yes Check and repair the air inlet system 1 Check the air filter for blockage and the air inlet passage for air leakage No Next step Yes Next step 2 Check and observe whether the model and clearance ...

Page 64: ...k and repair the air inlet system 2 Check whether there s any air leakage with air inlet system and its connected vacuum pipes No Next step Yes Wash relevant parts and components 3 After a removal of idle speed adjustor check whether any carbon deposit is produced on the throttle valve unit and the idle speed adjustor or inside the idle speed bypass air duct No Next step Yes Check and repair relev...

Page 65: ...ning at idle speed and whether the fuel pressure keeps at about 300kpa after vacuum pipe has been pulled away from the fuel pressure adjustor No Check and repair the oil supply system Yes Next step 3 Check and observe whether the model and clearance of spark plug on each cylinder is in compliance with the specification No Adjust or change it Yes Wash relevant parts and components 4 After a removal...

Page 66: ... with the specification No Adjust or change it Yes Wash relevant parts and components 6 After a removal of idle speed adjustor check whether any carbon deposit is produced on the throttle valve unit and the idle speed adjustor or inside the idle speed bypass air duct No Next step Yes Next step 7 Check whether the inlet air pressure sensor throttle position sensor and its loops are under a normal c...

Page 67: ...25 1 1 15 The air fuel ratio and the control repair coefficient are unreliable 31 2 0 16 The engine is running out of Max rotating speed 33 2 0 17 Failure with the electronic control unit 34 2 1 18 The air fuel ratio to control the addition modification coefficient The scope of idle speed plays a role 35 2 0 19 The air fuel ratio to control the multiplication modification coefficient The scope of ...

Page 68: ...a flashing fault indicator lamp d Each flashing code is composed of two digits and each is made up of one number within 0 and 9 e The digit 0 will flash for ten times and any digit within 1 9 will flash as per its literal meaning The flashing will be stopped instantaneously for one second between two digits forming a flashing code and will be stopped for a long term period between f An identical f...

Page 69: ...t up the fault indicator lamp Condition as to eliminate the fault indicator lamp fault code When the fault indicator lamp is lighting have vehicle running without failure for one driving cycle to settle the failure and the fault indicator lamp will be closed As for verified failure the fault code will be cleared away after 40 continuous trouble free preheating cycles from the time of failure settl...

Page 70: ... pressure sensor signal voltage for Pin 1 of knock sensor and signal voltage for Pin 2 of knock sensor b The displayed status for electronic injection system covers Status of theft prevention system safety status editing status status of cooling system status of stable working condition status of dynamic working condition exhaust control status status of oxygen sensor idle speed status status of f...

Page 71: ... the control loop of oil pump Class31 20 P0324 Failure with the processing chip of knock signal and its loops Class5 21 P0325 Failure with the loop of knock sensor Class31 22 P0335 Failure with the signal of crankshaft position sensor Class33 23 P0336 The failure is caused by an inappropriate signal of crankshaft position sensor Class33 24 P0340 Failure with the signal of phase sensor Class31 25 P...

Page 72: ...nd Pin 1 of plug is about 5V No Next step Yes Repair or change the wiring harness 4 Check whether respective loops between Pin 17 33 37 of ECU and the connection Pin 1 3 4 of sensor are short circuit to power supply No Next step Yes Diagnosis help 5 Start the engine and have it running at idle speed Step on the gas slowly until it s full opened and observe the change of value at item inlet air pre...

Page 73: ...r from wiring harness and a multimeter may be used to check whether the resistance between Pin 1 and Pin 2 of sensor is fit for the temperature No Change the sensor Yes Continue to proceed until step 6 4 Pull out the plug of inlet air temperature sensor from wiring harness and a multimeter may be used to check whether the voltage between Pin 1 and Pin 2 of sensor is about 5V No Next step Yes Repai...

Page 74: ...alue of item absolute opening degree of throttle valve in data stream is increased to a degree of 85 95 when the opening degree of throttle valve is being increased No Continue to proceed until step 5 Yes Change the sensor 4 Repeat step 3 to observe the item absolute opening degree of throttle valve in data stream and whether any abrupt change exists during the change of value No Next step Yes Rep...

Page 75: ...diagnosis instrument and place the ignition switch to the ON position Yes Next step Yes Diagnosis help 2 Start the engine and have it running at idle speed until the cooling fluid temperature reaches its normal value Observe the change of value at the item oxygen sensor voltage on diagnosis instrument and whether the displayed value makes a rapid change within 100mV 900mV No Next step Yes Repair o...

Page 76: ...resistance of fire division line is too big E Whether the clearance of air valve is too big So on and so forth No Diagnosis help Fault code P0172 The self adaptive value for a closed loop control of air fuel ratio is beyond the lower limit Note The diagnosis flow process below is applicable to cases excluding that fault codes are produced simultaneously on inlet air pressure sensor carbon canister...

Page 77: ...xt step Yes Next step 4 A multimeter may be used to check whether the resistance between Pin 1 and Pin 2 of fuel injector for cylinder 2 is within 11 17 Ω when at 20 No Change the fuel injector Yes Diagnosis help 5 A multimeter may be used to check whether the voltage between Pin 2 of fuel injector for cylinder 2 and the negative electrode of power supply is about 3 7V No Next step Yes Repair or c...

Page 78: ...86 of fuel pump relay is about 12V No Next step Yes Repair or change the wiring harness 3 Check whether the loop on the power supply end of relay is a broken loop or short circuit to ground No Next step Yes Change the fuel pump relay 4 A multimeter may be used to check whether the resistance between Pin 1 and Pin 2 of fuel injector for cylinder 1 is within 11 17 Ω when at 20 No Next step Yes Diagn...

Page 79: ...r it based on diagnosis Fault code P0340 Failure with the signal of phase sensor S N Operation steps Check result Follow up steps 1 Connect with the diagnosis instrument and place the ignition switch to the ON position Next step Yes Continue to proceed until step 4 2 Pull out the plug of phase sensor from wiring harness and a multimeter may be used to verify whether the voltage between Pin 1 and P...

Page 80: ...her the loop between the connection Pin 2 of carbon canister control valve and the Pin 46 of ECU is short circuit to ground No Diagnosis help Fault code P0445 The voltage in the control loop of driving stage for carbon canister control valve is too high S N Operation steps Check result Follow up steps 1 Connect with the diagnosis instrument and place the ignition switch to the ON position Next ste...

Page 81: ...upply or ground No Diagnosis help Fault code P0506 The rotating speed under an idle speed control is lower than the desired idle speed value S N Operation steps Check result Follow up steps 1 Connect with a diagnosis instrument and place the ignition switch to the OFF position Next step Yes Next step 2 Check whether adjusting screws of throttle valve pulling line of gas pedal and throttle valve ar...

Page 82: ...ion switch to the ON position Next step Yes Next step 2 Pull out the plug from idle speed adjustor and a multimeter may be used to verify whether the resistance values between Pin A and D and between Pin B and C are about 53 5 3 Ω when at 20 No Change the step motor Yes Repair or change the wiring harness 3 Check whether respective loops between the connection Pin A B C D of idle speed adjustor an...

Page 83: ...ment and place the ignition switch to the ON position Next step Yes Next step 2 Clear away any fault code and re verify whether the failure is of a stable failure No System is normal 3 Change ECU END Fault code P0602 The diagnosis data ID code of electronic controller has not been programmed yet S N Operation steps Check result Follow up steps 1 Connect with the diagnosis instrument and place the ...

Page 84: ...f air conditioner compressor relay and Pin 70 of ECU is a broken loop No Next step Yes Diagnosis help 6 Check whether the electromagnetic clutch for air conditioner compressor is working in a normal way No Repair or change the electromagnetic clutch Fault code P0647 The voltage in the control loop of air conditioner compressor relay is too high S N Operation steps Check result Follow up steps 1 Co...

Page 85: ...air conditioner is opened observe the change of value corresponding to the item temperature of evaporator on a diagnosis instrument and the displayed value shall be decreased accordingly when the temperature of evaporator is reduced No Change the sensor Fault code P1651 Failure with the control loop of engine fault indicator lamp SVS S N Operation steps Check result Follow up steps 1 Connect with ...

Page 86: ...stem control EF 2 4 Determination on the principal utility failure of key system parts EF 2 9 Methods for failure diagnosis fault codetospareparts EF 2 23 Precautions to the use service troubleshooting of electrical injection system EF 2 26 Troubleshooting EF 2 27 ProCarManuals com ...

Page 87: ...ch receives appropriate signals from each sensor eg intake pressure temperature sensor crankshaft position sensor throttle position sensor etc and by an ECU internal control program which calculates the best The engine management system for electric injection is mainly composed of three parts sensor electronic control module ECU and actuator The basic structure of ITMS 6 system is as shown in the ...

Page 88: ...ontrol when a flooded engine is produced step on the gas to a Max extent to stop fuel injection based on a computer control The fuel cut control when decelerating saves fuel and decreases the exhaust cooling system control temperature signal for 2nd evaporator evaporating exhausting diagnosis request signal Diagnostic theft preventionsignal theft detector control signal EGR feedback signal signal ...

Page 89: ...eds to be closed as required by the theft detector the fuel pump will stop running Start pre injection the start pre injection only acts once during a normal starting process Initial stage of starting process The inner pressure of inlet manifold is shown as ambient atmospheric pressure When throttle is closed the idle speed adjustor will have a fixed parameter changeable by the starting temperatur...

Page 90: ...stion condition and to optimize the dynamic performance of engine and the cost effectiveness of fuel MT20U system is competent to provide a separate knock control over various cylinders inside engine Work condition for knock control Engine shall be running and the running time must exceed two seconds Engine rotating speed 800r min Absolute pressure of inlet manifold40 kPa K nock control mode Stabl...

Page 91: ...ic performance air conditioner will be cut off when TPS is greater than 90 or the engine is with heavy load C arbon canister solenoid valve control logic Fuel tank is with exterior heat radiation and fuel return heat transfer fuel inside fuel tank shall be heated to form a fuel evaporation which will be collected into an activated carbon canister And the carbon canister solenoid valve may be used ...

Page 92: ...ere s any failure with vehicle speed sensor or its connection loop system will cut fuel supply to protect the engine and the engine rotating speed is unallowable to exceed 2500 r min to limit thevehicle driving speed and vehicle users will be urged to clear the failure away The speed limiting function will fail when the overall accumulative mileage is greater than 70 000km 12 Theft detector contro...

Page 93: ...stic method by the speed change of crankshaft ºAny missed fire may be diagnosed by the speed change of crankshaft Ionic current diagnostic method ºAny missed fire may be diagnosed by observing the ionic current inside cylinder Deterioration diagnosis on catalytic converter ºAs required by EOBD the indicator light shall be lighted and the fault code must be recorded when the deterioration of cataly...

Page 94: ...S 6 engine control module ECU a F unction principal Engine control module is one microprocessor based on a single chip device And its function is to process sensor data coming from different positions of vehicle to determine the working status of engine and to exactly control the engine via an actuator Auxiliary system control function theft prevention system fan cooling system air conditioner sys...

Page 95: ...orking status of engine and to exactly control the engine via an actuator Auxiliary system control function theft prevention system fan cooling system air conditioner system etc Installation It shall be installed inside the engine chamber and better not have steel part overlapping on exterior cover b Failure determination Important note Either of following determinations may be concluded based on ...

Page 96: ...hall be consistent to the actual value When exterior cover is damaged or there s air leakage the pressure will be a fixed value Converter GND Sensor 4 Inlet temperature sensor MAT ITMS 6 a Function principal The inlet temperature sensor is used to test and measure the temperature of air inside the engine cylinder As any change of air temperature will directly influence the density it s regarded as...

Page 97: ...eristics of pressure sensor Pressure kPa Output voltage V Characteristics of temperature sensor Working voltage 5 V DC Working temperature 40 135 6 Engine rotating speedsensorcrankshaftpositionsensor a Function principal Being one type of magnetoelectric sensor the engine rotating speed sensor crankshaft position sensor shall be installed nearby the crankshaft and shall work with 58x gear ring on ...

Page 98: ...olved in engine combustion becomes thin the accumulative oxygen content in exhaust gas will be increased while the output voltage of oxygen sensor will be decreased On the contrary the output voltage value will be increased In such way information concerning the air fuel ratio may be feedbacked to ECM The main sensitive material of oxygen sensor is zirconia When zirconia is activated by the heat e...

Page 99: ...ge 80 000 kilometers Limitation of engine rotating speed when sensor fails 2500r min Expiration for engine rotating speed limit When exceeding 70 000 kilometer c Characteristics of product Working temperature 40 150 Working voltage 4 3 13 V Working clearance 0 3 2 mm 11 Knock sensor KS MT20U a Function principal The knock sensor is a piezoelectric type of vibrating sensor installed at a sensitive ...

Page 100: ...her system parts components are normal in function Failure diagnosed by the system may be read out from a Diagnosis Instrument The signal in wire harness has not adopted shielded wire or its shielded layer has not been well grounded air inlet control system throttle valve unit valve unit throttle sensor idle speed control valve 13 Throttle valve assembly a Function principal The function of thrott...

Page 101: ...n between the wiring terminal of idlespeed valve and ECM wiring terminal via wire harness 15 Throttle position sensor TPS MT20U a Function principal Throttle position sensor has the same structure as linearly variable resistor and its sliding terminals are driven by throttle shaft A different opening degree of throttle will result in a different response of resistance signal from its sensor to ECU...

Page 102: ...e upper compression stop point has gas mixture which is with higher density and pressure and a greater amount of energy is needed for the ignition of cylinder spark plug and the gas mixture will be rapidly ignited to do work the ignition for this cylinder is called valid ignition Wiring terminal ITMS6 drive the cylinder A 2 3 B 12V drive the cylinder C 1 4 wiring terminal MT20U drive the cylinder ...

Page 103: ...lug on each cylinder shall be consistent as we b High tension wiring As system will be supported by a high energy voltage ignition and the high tension wiring shall have appropriate impedance able to withstand sufficient voltage and constrain the radio interference wave released by ignition system during a high energy ignition process Function principal The function of ignition system is to ignite...

Page 104: ...le resistor Wiring terminal MT20U A fuel pump positive B sensor positive C sensor negative D fuel pump negative Wiring terminal ITMS 6 A fuel pump positive B fuel pump negative Installation It shall be installed inside the fuel tank c Characteristics of product b Failure determination Any failure on fuel pump and its related loops may be determined by driving the fuel pump relay to act with a Diag...

Page 105: ...he vacuum degree of exterior inlet manifold and will always keep a constant oil pressure difference across fuel rail and inlet manifold Excessive fuel having been adjusted by adjustor will return to oil tank via fuel return pipe Installation the fuel pressure adjustor is installed on oneend offuel rail b Failure determination Important note Either of following determinations may be concluded based...

Page 106: ...n Damaged sealing ring cause an air or oil leakage Connectors loosened and wire harness damaged Broken coil loop leads to a non oil injection c Characteristics of product Working temperature 30 125 Min working voltage 6 V Coil resistance 12 0 0 6 Delphi engine management systm Determination on the principal utility failure of key system parts 23 I njector a Function principal The injection nozzle ...

Page 107: ...rincipal The function of three way catalytic converter is to converse harmful gas exhaust having combusted in engine into nonharmful gas discharge to atmosphere The internal structure of three way catalytic converter is of honeycomb pipe design whose pipe wall is with noble metal elements like Pt rhodium Pd coated layer used as catalytic reaction medium The power loss of three way catalytic conver...

Page 108: ...t up to remind vehicle driver of check and maintenance in time b When under an emergency some special operations may be performed to activate the stroboflash of engine fault indicator light so as to read engine fault code And this is most cost effective way to acquire fault code 3 Code reading method by the stroboflash of engine fault indicator light a That the fault indicator light is on while en...

Page 109: ...on vehicle and to test and check the system status 6 Fault code checklist for fault code reader a Fault code checklist for ITMS 6 fault code reader F ault code checklist for fault code reader F ault code D escription of failure F ault code D escription of failure 0105 F ailure with the loop of inlet manifold pressure sensor 0443 F ailure with the loop of carbon canister solenoid valve 0110 F ailur...

Page 110: ...of oxygen sensor is too long The carbon canister solenoid valve is short circuit to accumulator The communication between ECM and theft detector has anerror The thin time of oxygen sensor is too long The carbon canister solenoid valve is short circuit to ground or in an open circuit Thetemperature of front evaporator is too high The loop of fuel injector A cylinder 1 has an error Fan 1 is short ci...

Page 111: ...ree method is applied to wash injector ensure that additive to be used contains no materials harmful to oxygen sensor and three way catalytic converter i When performing an inspection on dual idle speed exhaust remember to sufficiently preheat the engine and three way catalytic converter and to measure the high idle speed first before the low idle speed 2 Precautions during installation of accesso...

Page 112: ...s amiable and attentive in listening The query shall be made from an integral view and focus on key points and you need to further understand the history and the frequency of symptom Based on the symptom known from vehicle owner when some failure is produced an analysis judge and initial determination may be concluded b Observe diagnostic method The observation shall be based on the symptom and co...

Page 113: ...plain area about 100kPa 7 Work range of throttle position sensor 0 99 6 8 Oxygen sensor 200 mV heating type 450 10 mV non heating type 9 Idle speed control valve 40 159 steps step Step II Idle speed check Preheat the engine to a normal water temperature after it s starting at low idle speed Test item System status and Limit value 1 Engine fault indicator light Off 2 Display of fault code None 3 Co...

Page 114: ...g electrode determine the working status of each cylinder Subject to above inspections a basic determination may be made to judge whether each relevant component within the fuel system is working in a normal way Place a group of new spark plugs After starting observe the engine running at an idle speed Take out spark plug again and determine the working status of each cylinder Subject to above ins...

Page 115: ...n controller the unselected no key may be seen which indicates that the password key does not have a valid password repeater That the selected theft detector no response is seen indicates that the communication between the electrical injection controller and the theft detector has not been connected When the electrical injection control has mated with the theft detector it will be flashing at 2Hz ...

Page 116: ...rive B 1ignition fuse1 fuel pump relay ignitionfuse2 battery fuse4 carbon canister wash solenoid valve serial data diagnosis request engine fault indicator light engine rotating speed signal fault diagnosis socket fuse checklist ignition fuse1 15A fuse2 10A fuse3 10A fuse4 10A fuel pump injection nozzle ECU ignition carbon canister wash solenoid valve theft detector ignition electronic ignition co...

Page 117: ...oolant temperature signal manifold air temperature signal vehicle speed signal vehicle speed sensor coolant temperature sensor manifold air tem perature sensor manifold absolute pressure sensor throttle position sensor oxygen sensor battery air blow motor switch air conditioner request switch high temperature switch for air compressor air conditioner pressure switch airconditioner clutchrelay 58 g...

Page 118: ...k and the motorized seat connected to the sensor for speed indicator connected to the sensor for vehicle speed odometer connected to the three air conditioner status switch permanently closed blue white idle speed control valve connected to air conditioner electromagnetic clutch for compressor green black red black white brown red red blue red purple red brown blue red blue purple black red yellow...

Page 119: ...ed to the front oxygen sensor connected to the machine oil pressure switch connected to the air inlet temperature pressure sensor connected to the air conditioner clutch connected to the knock sensor connected to the idle speed control valve throttle position sensor c o n n e c t e d t o t h e crankshaft position sensor connected to the carbon canister control valve shielding ground connected to t...

Page 120: ...EF 2 35 attached figure V Delphi engine management system troubleshooting and common failure ProCarManuals com ...

Page 121: ...EF 2 36 Attached figure VI Delphi engine management system troubleshooting and common failure ProCarManuals com ...

Page 122: ...EF 2 37 Attached figure VII Delphi engine management system troubleshooting and common failure ProCarManuals com ...

Page 123: ...EF 2 38 Attached figure VIII Delphi engine management system troubleshooting and common failure ProCarManuals com ...

Page 124: ... EM 1 4 Inspection on engine body EM 1 9 Inspection on camshaft components EM 1 10 Disassembly of piston and connection rod components EM 1 12 Inspection on piston and connection rod components EM 1 13 Assembly of piston and connection rod components EM 1 18 Installation of engine body EM 1 20 Assembly of engine body EM 1 22 Engine body ProCarManuals com ...

Page 125: ...ction rod bearing bush sealing gasket rear oil seal cover timing chainwheel chamber timing chain and chainwheel timing chainwheel chamber cover crankshaft pulley sealing gasket sealing gasket crankshaft oil pump crankcase oil tray crankshaft main bearing crankshaft thrust washer main bearing cover ProCarManuals com ...

Page 126: ...g the oil filter Bolts nuts and brackets connecting the oil filter shall be dismantled f The engine installation bracket on the left right side shall be removed g Remove the cooling fluid release valve namely water drain switch from engine h Dismantle the oil pressure switch Preparations before and key points to the disassembly of engine body 1 Preparations before the disassembly of engine body a ...

Page 127: ...nts particularly main bearing cover of crankshaft bearing thrust washer shall be placed in order as per the sequence for a correct easy re assembly restoration to place 2 Measure the oil clearance of connection rod a A punch head or number punch head may be used to make match marks on the connection rod and its cover to assure acorrectreassembly b A twelve edge socket spanner may be used to unscre...

Page 128: ...llation of connection rod cover shall be subject to marks made on the connection rod and its cover Nuts on the connection rod cover shall be tightened as per specified tightening moment and steps Remark Do not rotate the crankshaft Prior to the installation a thin layer of oil must be applied to the threaded part of nut and to the lower part of nuts as well j Removal of the connection rod cover k ...

Page 129: ...he upper bearing bush from the top of the engine body by pushing Remark Always keep the connection rod bush and the connection rod cover as an integral part Piston and the connection rod cover shall be put in order as per a correct sequence 4 Measure the axial clearance of crankshaft Its axial clearance may be measured by a micrometer when prizing the crankshaft with a screwdriver on front and bac...

Page 130: ...al and the bearing bush e Check whether the main neck journal and the main bearing bush has any scratch or exfoliation If the main neck journal and the main bearing bush has some damages the crankshaft shall be abraded repaired or changed and the main bearing bush shall be changed f Place the crankshaft onto the engine body g Place a piece of plastic feeler gauge horizontally onto each main neck j...

Page 131: ...the contacting surface between the cylinder and the cylinder cover And standard bearing bush is available with three size which may be indicated by relevant marks including 1 2 or 3 S N D iameter of main bearing on crankshaft D iameter of main journal on crankshaft C learance M ax abrasion clearance 1 58 036 0 022 0 58 0 015 0 0 022 0 053 2 58 037 0 022 0 58 0 015 0 0 022 0 052 3 58 036 0 021 0 58...

Page 132: ...sts on the surface where the spacer of cylindercoveris installed Max flexural deflection 0 05 mm b If the actual flexural deflection is greater than Max value the enginebodyshall be changed 5 Measure the diameter of cylinder a A bore gauge may be used to measure the diameter of cylinder at axial point A B and C of push force Standard diameter 91 91 03 mm M ax diameter 91 24 mm If the actual diamet...

Page 133: ... be changed 2 Check the length of timing chain Using measurement methods given in the figure a spring balance may be used to verify the Max length of chain 291 4mm when a 49N pulling force is applied And two or three points may be selected anddeterminedasmeasure ment point If Max length of chain exceeds the limit value the chainshall be changed C heck the diameter of timing chainwheel a Using meas...

Page 134: ...e abraded and repaired using oilstone And a micrometer shall be used to measure the height of convexity on camshaft and Min height of convexity may be measured at the big end on the slope of cam If the height of convexity is less than Min value the camshaft shall be changed A ir inlet cam 38 720 0 620 0 mm A ir exhaust cam 38 729 0 629 0 mm b Check the abrasion situation of plunger piston on chain...

Page 135: ...mbly of piston and connection rod components 1 Check the mating situation between the piston and the piston pin Pull the piston installed on piston pin back and forth If it feelsloose the piston and the piston pin shall be changed 2 Removal of piston ring a The first and second piston ring may be removed using a expander b Manually remove the retaining ring and the oil piston ring on two sides of ...

Page 136: ...cable to piston ring groove or broken piston ring may be used to clear all contaminants away from the ring groove c Piston may be thoroughly washed using solvent and soft brush Note Do not use steel wire brush 2 Measure the clearance of piston a A micrometer may be used to measure the diameter of long piston shaft at a place 24mm away from the top of piston Standard piston diameter 90 938 90 968 m...

Page 137: ...f stroke by piston then a measurement may proceed using chock gauge c A feeler gauge may be used to measure the clearance ofopening If the actual opening clearance is greater than Max value thepiston ring shall be changed If the actual opening clearance is still greater than Max valueafter a replacement with new piston ring the cylinder shall be rebored and piston ring with an increased size shall...

Page 138: ...eter 7 2 mm If the measured value is less than Min value nuts on bearing cover for connection rod and connection rod bolt shall be changed c Measure the oil clearance between the lining on small end of connection rod and the piston pin A caliper gauge shall be used to measure the inner diameter of lining on small end of the connection rod Standard diameter 24 008 24 009 mm A micrometer is used to ...

Page 139: ... oil clearance is within a standard scope Standard oil clearance 0 005 0 011 mm Check the mating of piston pin under a normal room temperature Piston pin will be applied with appropriate amount of oil and be pushed by thumb into lining on small end of the connection rod 7 Inspection on crankshaft a Measure the radial runout of crankshaft Place the crankshaft on a V shaped piece A micrometer may be...

Page 140: ...ness and cylindrictiy is greater than Max value c Main neck journal or and the connection rod neck journal may be abraded and repaired when necessary Main neck journal or and the connection rod neck journal may be abraded and repaired to a reduced diameter R educed size of the bearing bush hole U S 0 25 mm Final diameter of main neck journal 57 485 57 500 mm Final diameter of connection rod neck j...

Page 141: ...ng amount 0 02 mm Note Excessive honing will damage the precisely made roundness Assembly of piston and connection rod components 1 Assembly of piston and connection rod component a Pre matching between piston and cylinder Four pistons having the same No as cylinder holes must be kept into a special work place tool chest in accordance with the sequence for cylinder b Selection and match making of ...

Page 142: ...alled onto E uropean device but these two parts must be interchanged simultaneously E uropean piston and piston ring may not be installed onto E uropean device or air valve will strike against the piston E uropean piston ring may not be installed onto E uropean piston or it will lead to a series of trouble eg burning of oil abnormal sound produced on engine etc 3 Assembly of the connection rod bus...

Page 143: ...priate amount of oil may be applied to the surface where the thrust washer is connected on two sides of main bearing hole in the middle of engine body followed by an installation of two upper thrust washers onto the engine body During installation the oil groove surface shall face outward 3 Put the crankshaft into engine body Note During the installation the crankshaft shall be handled with care t...

Page 144: ...o have any foreign material used as gasket material between bush back and bush seat d Each main bearing cover shall be subject to a correct installation sequenceand direction 8 Installation of piston and connection rod a To prevent crankshaft from damage the connection rod bolt shall be installed with a short hose sleeve b Clean oil may be used to lubricate the inner wall of cylinder and the neck ...

Page 145: ...l seal lip And it may be fixed onto the rear end of engine body using five M8 22 bolts with flat washer and standard spring washer and bolts shall be tightened to a specified moment using a fixed torque wrench T ightening moment 12 2 N m SST 09223 61010 2 I nstallation of AC generator bracket The generator bracket may be fixed onto the cylinder using two M10 1 2 35 bolts T ightening moment 25 2 N ...

Page 146: ...y at the camshaft hole using two M8 16 bolts with flat washer and standardspring washer Tightening moment 18 3 N m Remark The thrust collar of camshaft shall make the side having pit mark face outward b Manually rotate the camshaft and its rotation shall be flexible Thenthe woodruff key of camshaft must be turned to an upward position c Assembly of chain shock absorber Using brush a layer of clean...

Page 147: ...erconnection surface b Sealing material will be filled into the oil dish as indicated in the figure When oil sump on the oil dish is facing downward and when eighteen installation holes on the oil dish are facing exactly the installation holes of dish gasket and the installation holes on the lower surface of the engine body the oil dish may be fixed using eighteen M8 16 bolts with flat washer and ...

Page 148: ... figures for cylinder head EM 2 2 Dismantle of cylinder head EM 2 3 Disassembly of cylinder head EM 2 4 Clean up inspection on each spare part EM 2 5 Assembly of cylinder head EM 2 12 Installation of cylinder head EM 2 15 ProCarManuals com ...

Page 149: ...neral description is provided as below for dismantle inspection maintenance of cylinder head Disassembly figures for cylinder head valve spring upper seat air exhaust valve chamber cover rocker shaft and spring spark plug spark plug sleeve water outlet pipe front warm air water pipe engine hook engine front fender hydraulic tappet push rod rocker shaft valve guide engine rear fender cylinder head ...

Page 150: ...the fuel distributor assembly 3 Piston for cylinder No 1 will be placed to thetopdead center of compression stroke Rotate the crankshaft pulley to have its groove facing exactly to mark 0 made on the timing chaincover 4 Dismantle of inlet outlet manifold a Have the cooling water bypass hose removed from theinlet manifold b A torque wrench will be used to unscrew eight fixing nutson inlet outlet ma...

Page 151: ...ylinder head may be lift up from the connection surface of device unit and put onto a wood block onsaddle piece which has been provided in advance Note Do not damage cylinder head and the surface of device unit on one side having cylinder cover spacer Remark If the cylinder head is hard to be lifted up a screwdriver may be used to prize the middle of convexity on cylinder head c Sealing ring will ...

Page 152: ...p of piston and device unit a Carbon deposits on the top of piston may be scraped awaywhen the piston inside each cylinder has been lifted respectively to the upper stop point while the crankshaft isrotating b All spacer materials must be cleared away from the top of device unit and carbon deposits and oil contaminants shall beblown off as well from bolt holes Note Take care of your eyes when comp...

Page 153: ...ad shall be 0 05mm c The planeness on the contact surface between cylinder head and inlet outlet manifold shall be 0 10mm d The cylinder head shall be changed if the measured planeness is greater than the foresaid value 7 Check for cracks on the cylinder head a Using color penetrating fluid check whether there s anycrack on combustion chamber at air inlet outlet hole and atthe surface or on the to...

Page 154: ...ed when necessary a Heat the cylinder head to approx 90 b The valve guide may be struck out using SST and hammer SST 09201 60011 c A caliper gauge may be used to measure the diameter of installation hole for valve guide on cylinder head Diameter of installation hole for standard valve guide 13 000 13 018 mm External diameter of standard valve rod Standardclearance Max clearance Engine model Air in...

Page 155: ...valve 0 030 0 065 mm 11 Check and abrade the valve a An abrading method will be applied to clear away any indent or carbon deposit from the valve b Check whether the cone angle on valve surface has been abraded to a correct angle Cone angle on valve surface 44 5 Note The abraded amount shall be decreased to a Min degreewhen possible yet sufficient to remove any damage remainedon the surface c Insp...

Page 156: ...dicates that the valve guide and the valve seat are homocentric if not the valve seat needs to be abraded and repaired Check whether the contacting width between valve seat and the middle of valve surface is within 1 2 1 6 mm If not a modification to the valve seat shall be made as per methods stated below If the valve seat is much higher than the valve surface 30 and 45 carbide tools shall be use...

Page 157: ...c A spring tester will be used to check the tensile force for each spring having specified installation length Installation length 40 6 mm Standard installation tensile force 345 N M in installation tensile force 282 N The spring shall be changed if the installation tensile force is less than Min installation tensile force 14 Inspection on rocker and rocker shaft a Inspection on rocker shaft Verif...

Page 158: ... between valve and rocker shaft as been much abraded oil stone provided for valve refacer may be used for abrading or they may be changed SST 09207 71010 15 I nspection on hydraulic tappet and push rod a Inspection on hydraulic tappet A micrometer will be used to measure the external diameter of hydraulic tappet then an inner diameter amesdial will be used to measure the diameter of installation h...

Page 159: ...hall be changed if the actual runout is greater than 030mm Check whether the oil hole on push rod has been blocked if so compressive air may be applied to blow off any blocked material When hydraulic tappet is submerged in light oil push the plunger piston for several times to discharge air insidethe hydraulic tappet SST 09276 71010 Assembly of cylinder head Assembly of cylinder head 1 Check After...

Page 160: ... b After air inlet exhaust valve is removed kerosene will be used to wash residual abrasive sands on valve in the valve seat hole inside the combustion chamber or inside the air inlet exhaust duct Remark Valves after an abrasion are not interchangeablewhen washing the removed valves they shall be placed in order by sequence to avoid any mis installation and misdetermination at a later stage 5 Pres...

Page 161: ...T ightening tor que 12 2 N m 8 Installation of rear fender onto cylinder head a A layer of varnish shall be applied evenly onto both sides of sealing spacer for rear fender which will be adhered to the surface where the rear fender is linked with cylinder head And make them facing four installation holes exactly b Four M8 14 bolts with standard spring washer may be used to fix the rear fender onto...

Page 162: ... backward SST 09207 71010 c Two M8 nut with flat washer may be manually screwed onto stud bolt Screw the short threaded end ofthree bolts fixing the rocker shaft into the fixed seat for rocker shaft followed by a tightening made progressively in two steps as from the middle to two sides as shown in the figure Tightening torque 18 3 N m d After a layer of clean machine oil has been applied to the b...

Page 163: ...xactly to relevant spacers and to six holes on the low part Six M8 30 hexagonal socket head bolts with flat washer and standard spring washer will be used for fixing purpose and shall be tightened as per the sequence from the middle to two ends a pre tightening may be made using a pneumatic wrench before a re tightening to specified torque using a fixed torque wrench Tightening torque 16 3 N m g I...

Page 164: ...ness will be inserted into relevant sockets provided for four fuel injectors 8 Installation of ignition coil components Using three M6 35 bolts with flat washer and light type spring washer ignition coil may be fixed on relevant supporting frame flat washer shall be applied to one side close to the ignition coil and light type spring washer shallbe applied to one side close to the supporting frame...

Page 165: ...m for valve mechanism EM 3 2 Disassembly of timing chain camshaft EM 3 3 Inspection repair for timing chain camshaft components EM 3 5 Replacement of front oil seal on crankshaft EM 3 8 Installation of timing chain camshaft EM 3 9 ProCarManuals com ...

Page 166: ...assembly push rod tappet camshaft vibration absorber thrust disk tensioner cam chainwheel cam chainwheel bolt timing chain cover crankshaft pulley bolt crankshaft pulley front oil seal of crankshaft sealing ring crankshaft chainwheel timing chain Those with mark refer to spare parts which have been used and can not be re used ProCarManuals com ...

Page 167: ...d push rod 1 Removal of valve tappet Eight tappets will be removed using a steel wire or magnet Note Always keep tappets in an upright array as per a correct sequence 2 Removal of crankshaft pulley a Removal of pulley bolt using SST SST 09213 70010 and 09330 00021 b Even removal of crankshaft pulleys using SST Valve mechanism Disassembly of timing chain camshaft ProCarManuals com ...

Page 168: ... be checked in accordance with Max allowable tension degree 13 5mm when applied with a 98N pulling force If it exceeds Max allowable value the timing chainwheel shall be changed 5 Removal of chair tensioner 6 Removal of timing chainwheel a To loosen the fixing bolts on camshaft chainwheel crankshaft pulley needs to be installed b After unscrewing the fixing bolt SST may be used to have camshaft ch...

Page 169: ...ut 0 06 mm The camshaft needs to be changed if the runout exceeds Max value b Measure the height of convexity of camshaft using amicrometer Standard height of convexity Air inlet port 38 620 38 720 mm Air exhaust port 38 629 38 729 mm M in height of convexity Air inlet port 38 26 mm Air exhaust port 38 27 mm The camshaft needs to be changed if the height of convexity is less than Min value c Measu...

Page 170: ...lar measurement may be performed on three pointsormore having been random selected Max stretched length of chain 291 4mm when a49N stretching force is applied The chain needs to be changed if the read value of stretched length exceeds Max value c Measure the diameter of chainwheel installed with chain using callipers Min diameter of chainwheel with chain Crankshaft 59 mm Camshaft 114 mm The chain ...

Page 171: ...g and chain tensioner column installed on the chain tensioner unit e Install the side plate to place Note Installation direction f Strike the plate into place using hammer and socket spanner 5 Inspection on the chain shock absorber Measure the thickness of shock absorber using callipers Standard thickness 6 6 mm M in thickness 5 mm If the thickness is less than Min value the shock absorber needs t...

Page 172: ...nap ring and push rod seat may be installed using a presser applicable to sealing test SST 09276 71010 8 Sealing drop test check Using a presser applicable to sealing test with stress set to196 2N measure the time it takes to drop for 1mm after it has dropped for about 2mm Sealing drop time 7 50 s mm when at 20 Replacement of front oil seal on crankshaft Method I Provided that the timing chain cov...

Page 173: ... new oil seal c Strike new oil seal into place using SST and hammer until the surface of oil seal reaches the same height as the edge of timing chain box SST 09223 22010 Method II a Dismantle the oil seal using SST SST 09308 10010 b Strike new oil seal into place using SST and hammer until the surface of oil seal reaches The same height as the edge of timing chain cover SST 09223 22010 c MP multi ...

Page 174: ...tallation of timing chain and chainwheel a The set key of crankshaft chainwheel must be installedupward b Have the set key on camshaft chainwheel matching well with the mark made on the thrust disk 2 Installation of shock absorber The shock absorber may be fixed using two bolts Tightening torque 18 5 N m set key of crankshaft setting of camshaft mark Valve mechanism Installation of timing chain ca...

Page 175: ...allation of new sealing ring and timing chain cover may proceed Tightening torque 6N m 4 Installation of chain tensioner The chain tensioner will be fixed using two bolts Tightening torque 18 5N m e Have the crankshaft pulley installed on crankshaft f A thin layer of engine oil will be applied to the top screwed parts of camshaft chainwheel bolts g The camshaft chainwheel bolts may be installed us...

Page 176: ...t hole carefully Installation at a later stage a Installation of the assembly for push rod and rocker shaft b Installation of water pump pulley and fan c Installation and adjustment of driving belt d Start the engine and check for leakage e Check the engine oil Valve mechanism Installation of timing chain camshaft ProCarManuals com ...

Page 177: ...CO 1 Cooling system Composition characteristics of cooling system CO 2 Inspection change of coolant for engine CO 2 Cooling water pump CO 3 Thermostat CO 5 Radiator CO 6 ProCarManuals com ...

Page 178: ...pressure inside the cooling system slightly higher than atmospheric pressure so as to raise the boiling point of coolant when the pressure inside the cooling system is too high or too low the valve will be opened making the cooling system ventilated with the atmosphere Structure schematic diagram for cooling system as shown below Inspection change of coolant inside engine 1 Check the level of cool...

Page 179: ...ed from the radiator and the exhaust valve of engine the exhaust valve is onthe left front side ofengine c Screw down the exhaust valve d Fill the system with coolant Cooling water pump Part drawing cooling water pump pulley silicone oil clutch fan cooling water pump sealing ring fan transmission shaft fan without silicone oil clutch The one with mark refer to spare part which has been used and ca...

Page 180: ...g water pump a Rotate the belt pulley seat and check whether the bearingof water pump is rotating smoothly and free from noise b Water pump may be changed when necessary 4 Dismantle the cooling water pump a Dismantle the adjustment rod of transmission belt from water pump after the belt has been dismantled b Dismantle the nuts four bolts water pump and sealing ring Disassembly of Cooling water pum...

Page 181: ...antle the outlet hose of radiator from the inlet of water tank 3 Dismantle the thermostat and the inlet of water tankTwo nuts the inlet of water tank sealing ring and the thermostat shall bedismantled from the timing chain box 2 Installation of cooling water pump pulley and fan Using four nuts the water pump pulley and the assembly of silicone oil clutch and fan may be installed 3 Check if there s...

Page 182: ... go down sharply when it s lower than 58 9 kPa c The cover shall be changed if any failure has been found in either of above articles 2 Check the leakage of coolant system a Fill the radiator with coolant and press the manometer b Increase the temperature of engine c After an increment of pressure to 117 72kPa observe whether the pressure is going down If it does occur check if there s any leakage...

Page 183: ...LU 1 CH ST Page Lubrication system Composition function of lubrication system LU 2 Inspection on machine oil pressure LU 2 Change of engine oil oil filter LU 3 Oil pump LU 4 LU ProCarManuals com ...

Page 184: ...ck whether machine oil has deteriorated has water content changes color or becomes thin Machine oil shall be changed if the quality is too bad It s allowed to use machine oil stated below SG grade petrol machine oil with viscosity coefficient API 10W 40 GB11121 1995 or better than SG grade or machine oil with recommended viscosity 2 Inspection on the level of engine oil The level of liquid shall b...

Page 185: ...Using SST oil filter may be dismantled SST 09228 22020 b Check and wash the installation ring for machine oil filter c Clean engine oil shall be applied to the seal gasketof new machine oil filter d Screw up the oil filter gently until someresistances are met e Screw it up by 3 4 round using SST SST 09228 22020 3 Fill engine with machine oil a After a washing the oil drain plug shall be installed ...

Page 186: ... not use SST when on the side of timing chain cover or screwdriver may be used when necessary Do not damage the flange of the oil pan during the dismantle of oil pan 5 Dismantle of oil filter screen Four bolts O ring and screen shall be dismantled successively 6 Dismantle of oil pump Oil pump may be pulled out after bolts have been dismantled SST SST oil pump body safety valve spring safety valve ...

Page 187: ...e shaft of oil pump in a similar way stated above when the machine oil outlet has been blocked by finger and the shaft of oil pump shall be difficult to rotate 1 Check whether oil pump is working normally a Have the filter screen submerged in oil using a screwdriver and rotate the shaft of oil pump in a clockwise direction and machine oil is supposed to discharge from the oil outlet Disassembly of...

Page 188: ...ng Standard clearance 0 03 0 07 mm M ax clearance 0 15 mm The rotor shall be changed if the actual clearance exceeds Max value And the oil pump assembly may be changed when necessary Assembly of oil pump Installation of oil pump 1 Installation of oil pump a Align the convex of propeller shaft on oil pump with thelocating slot on the driving rotor of oil pump b Oil pump may be installed using bolts...

Page 189: ... using non residual solvent Note Do not splash solvent onto the painting surface b Fill the bottom oil cover with sealing materials as indicated in the figure Sealing material Product part No 08826 00080 or counterparty product Nuzzle whose opening section area is 3mm must beapplied during the installation Note ºAvoid filling in too much sealing materials on the surface particularly at rear oil ho...

Page 190: ...IG 1 Ignition system ProCarManuals com ...

Page 191: ...e the engine working The preventive measures are given below 1 If the engine can not be started do not have the ignition key being connected for over ten minutes 2 During the connection between system and the tachometer the test line of tachometer shall be connected to the negative terminal of ignition coil 3 To prevent any damage on igniter or ignition coil do not have the terminal of tachometer ...

Page 192: ...t you can you can you can you can Check the resistance of high voltage damping wiring You can t you can t You can t Change the high voltage resistance line Check the power supply to ignition coil 1 Place the ignition switch to position ON 2 check whether an battery voltage exists on the positive connection line of ignition coil Check the line between spark plug and ignition coil Check the resistan...

Page 193: ...ually Check whether the electrode of spark plug has been abraded whether screw thread or insulator has been damaged Spark plug needs to be changed whenever there s any abnormality Recommended spark plug F6RTC 4 Adjust the clearance of electrodes Following a careful bending of bypass electrode correct electrode clearance may be acquired by adjustment Correct electrode clearance 1 0 1 2 mm 5 Install...

Page 194: ...ST 1 Starting system Structure circuitdiagramofstarter ST 2 Disassemblyofstarter ST 3 Inspectiononstarter ST 4 Assemblyofstarter ST 7 Testing on starter ST 9 ProCarManuals com ...

Page 195: ... staring current and subject to an intermittent operation Structure circuit diagram of starter The structure of starter as shown in the figure below Starting system Structure circuit diagram of starter end cover brush bracket excitation winding excitation frame armature front bearing rear bearing brush spring solenoid switch release spring steel ball idler wheel bearing clutch assembly starter she...

Page 196: ... need to be taken out c Take out the excitation frame together with the armature d Remove the felt sealing gasket 2 Removal of starter shell clutch assembly and gear a Remove two screws b Following spare parts shall be removed from the solenoid switch a Starter shell b Idler wheel and bearing c Clutch assembly d Release spring Starting system Disassembly of starter ignition switch f u s e terminal...

Page 197: ...nd brush holders Inspection on starter Armature winding 1 Check whether the rectifier is in an opened loop Use an ohmmeter to check whether conduction exists on the discofrectifier The armature needs to be changed if the conduction fails 2 Check whether the rectifier has been grounded Use an ohmmeter to check whether noncon duction exists between rectifier and the core of armature windings The arm...

Page 198: ...he excitation frame The excitation frame needs to be repaired or changed if the conduction works non conduction conduction Rectifier 1 Check whether the surface of rectifier has been contaminated or damaged by burning If it does occur sand paper No 400 or lathe may be used for a repair or correction purpose 2 Check the circumferential radial runout of rectifier Max circumferential radial runout 0 ...

Page 199: ...damage is found In case of any damage check whether the gear ring of flywheel has been abraded or damaged 2 Check the small gear on clutch Have the small gear rotating in clockwise direction to check Bearing 1 Check bearing Manually push each bearing inward and have it rotating at the same time The bearing may be changed if any resistance has beenmet or the rotation is not flexible Starting system...

Page 200: ...orm a holding power winding test in an open circuit An ohmmeter may be used to check whether conduction exists between terminal 50 and the switch unit The solenoid switch needs to be changed if non conduction exists Assembly of starter Note During the assembly of starter bearings and gears may be lubricated using high temperature grease 1 Installation of armature into the excitation frame After th...

Page 201: ...e installed using two screws 3 Installation of steel ball into the axle hole of clutch a Grease needs to be applied to steel ball b Steel ball shall be installed into the axle hole of clutch 4 Installation of clutch assembly a Grease needs to be applied to the release spring b Release spring shall be installed into the hole of solenoid switch c Following spare parts shall be installed into the sta...

Page 202: ... due to burning the test must be completed within 3 5s 1 Perform a pull in test a Remove the lead wire of excitation winding from terminal C b Connect the battery onto solenoid switch as shown in the figure and check while small gear is moving outward The solenoid switch assembly needs to be changed if small gear does not move 2 Perform a holding power test Subject to above wire connection remove ...

Page 203: ...oes not return to the inside 4 Perform a zero load performance test a As indicated in the figure have the battery and armature connected respectively with the starter b Check whether the rotation of starter is smooth or flexible when small gear goes out and whether the current value is within the limit of specification Specified current 90A when at 11 5V terminal 50 terminal 30 Starting system Tes...

Page 204: ...ture drawing electrical schematic diagram of generator CH 2 Inspection on vehicle CH 5 Disassembly of AC generator CH 7 Inspection on AC generator CH 9 Assembly of AC generator CH 12 Charging device ProCarManuals com ...

Page 205: ...ectifier bridge for a power supply to electrical devices on vehicle 2 Structure drawing of generator Structure drawing electrical schematic diagram of generator Name of spare parts indicated in the drawing is given below 1 nut 2 spring washer 3 belt pulley 4 through bolt 5 limiter ring 6 driving end cover 7 bearing 8 bearing cove 9 limiter ring 10 rotor 11 stator 12 adjustor 13 insulation bush 14 ...

Page 206: ... diagram stator coil excitation coil stator coil excitation coil I C adjustor I C adjustor Structure drawing electrical schematic diagram of generator a Circuit schematic diagram for 90A internally adjusted generator b Circuit schematic diagram for 90A externally adjusted generator ProCarManuals com ...

Page 207: ... d circuit schematic diagram for 65A externally adjusted generator Electrical schematic diagram Electrical schematic diagram stator coil excitation coil I C adjustor stator coil excitation coil Structure drawing electrical schematic diagram of generator ProCarManuals com ...

Page 208: ... the bonding positionbetween upper lower interlayer has any crack or damage whether any crack broken core rupture scratch or abrasion is produced on the edge of belt or whe ther any damage is produced on the internal convexity side of reinforced rib b Check the bending deflection of belt by applying a 98N stress to the position indicated in Stressdiagram Bending deflection of driving belt New belt...

Page 209: ...t having worked for five minutes or above on the rotating engine F ollowing the installation of belt check whether the belt is matching with wheel groove appropriately 6 Check the charging loop when under zero load Note If accumulator AC generator test meter is applicable the meter shall be connected into the charging loop in accordance with the description provided by the manufacturing plant a If...

Page 210: ... is increased from idle speed to 2000r min check the read value on ammeter and voltmeter standard current 10A standard voltage 13 9 15 1 V when at 25 13 4 14 4 V when at 11 5 If the voltage value is greater than standard value IC adjustor needs to be changed 7 Check the charging loop when under load a Open the front headlight when engine is at a rotatingspeed as 2000 revolutions minute and place t...

Page 211: ...tud bolt on rectifier support d Remove the insulation washer from the electrical brush frame 3 Removal of rotor Use a press tool to press out the rotor 2 Removal of belt pulley and fan a Fix the rotor onto a soft jaw vice b Remove nuts and spring washers c Remove the belt pulley fan and spacer bush b When the end shell is prized up by a screwdriver have it removed simultaneously with the rotor Not...

Page 212: ...slip rings Standard resistance 4 The rotor needs to be changed if non conduction exists 2 Check whether the rotor has been grounded Use an ohmmeter to check the non conduction between slip ring and the rotor The rotor needs to be changed if conduction exists 3 Check the slip ring a Check whether the surface of slip ring is rough or has been scratched or damaged If it does occur the rotor needs to ...

Page 213: ...e exposed length of electrical brush Standard exposed length 12 5 mm M in exposed length 5 5 mm The electrical brush needs to be changed if the exposed length is less than Min value 2 The electrical brush may be changed when necessary a Remove the electrical brush and spring by welding b Have the electrical brush line inserted via spring c Connect the electrical brush onto the electrical brush fra...

Page 214: ...meter connect one end of the test head with the rectifier terminal and connect the other end with the negative terminal b Exchange the test joint and repeat the above step c Check its conduction or non conduction covered in above two steps d The rectifier support shall be changed when its conduction or non conduction does not conform to relevant stipulations Bearing 1 Check the front bearing Check...

Page 215: ... the rectifier support onto the stator Clamp the rectifier terminal using nipper pliers and weld the wiring terminal Note the heat shall be prevented from transmission to rectifier insulation washer soft cushion Assembly of AC generator 3 Installation of the rectifier end shell onto rectifier support a Put the insulation washer on the positive stud bolt of the rectifier frames b Put two soft cushi...

Page 216: ... shell lead wire grip 5 Installation of fan and belt pulley a Fix the rotor onto soft jaw vice b Insert spacer ring into the rotor shaft c Insert the fan belt pulley and spring washer successively into the rotor shaft d Install and tighten the nut Tightening moment 62 5N m Assembly of AC generator b Use press tool to press rotor into the shaft 4 Installation of rotor a Insert spacer ring into the ...

Page 217: ...r rotorshaft into the rectifier end shell the rectifier shell for driving end shell may be assembled 6 Assembly of the driving end shell and rectifier end shell a Have the rotor exposed by bending the wiring head of rectifier b Bending tools may be used to push the electrical brush to the end then one hard steel wire shall go through the manhole of rectifier end shell and the electrical brush will...

Page 218: ...CL 1 C l u t c h ProCarManuals com ...

Page 219: ...utch friction disk needs to be changed if any failure occurs 2 Check the radial run out tolerance on end surface of the clutch driven disk Check the radial run out tolerance on end surface of the clutch driven disk using an amesdial Max radial run out tolerance 0 8 mm The clutch driven disk needs to be changed whereby the radialrun out tolerance exceeds Max value 3 Check the guide bearing Manually...

Page 220: ...it can t be rotated or is rotating with great resistance Note T his bearing needs no lubrication or cleanup as it s subject to a permanent lubrication Installation of clutch components 1 Install the clutch driven disk onto flywheel The clutch driven disk may be installed onto flywheel using SST SST 09301 20020 2 Installation of clutch pressure plate a Have the clutch pressure plate pointed to the ...

Page 221: ...tourance 0 5mm 4 Supramoly lithium base grease shall be applied tofollowing parts a Contact point between the release shifting fork and the bearing bush b Contact point between the release shifting fork and the pushrod c Supporting point of the release shifting fork d Spline of clutch disk e Internal groove of the release bearing shell f MP multi purpose lubricant shall be applied to the front par...

Page 222: ...ProCarManuals com ...

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