Motor j3 Vvt a137.PDF

Maintenance Manual of Tojoy Sedan

Contents

Engine Volume Chapter 1

Mechanical Part of Engine .......................... ........................................ ........................... ............. 33

Section 1

Engine Body .......................... ............. .......................... .......................... .......................... ........................... ........................... ............... .. 33

I.

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

III.

Preparation ................................................................................................................36 ................................................................................................................36

IV.

Engine Assembly ....................................................................................................... .......................................................................................................39 39

V.

Drive Belt ...................................................................................................................43 ...................................................................................................................43

VI.

Air Filter and Air Duct ...................... ..................... ...................... ...................... ..........45 ..........45

VII.

Intake Manifold and Exhaust Manifold ....................................................................... .......................................................................47 47

VIII.

Exhaust System .........................................................................................................51 .........................................................................................................51

IX.

Timing sprocket mechanism ...................................................................................... ......................................................................................53 53

XI.

Cylinder head .............................................................................................................60 .............................................................................................................60

XII.

Valves ........................................................................................................................ 65

XIII.

Cylinder Body Assembly ................... ..................... ..................... ..................... ..........70 ..........70

XIV.

Diagnosis of Common Troubles ................................................................................. .................................................................................83 83

XV.

Parameters for Maintenance ...................................................................................... ......................................................................................85 85

Section II

Engine Lubrication System ......................... ............ .......................... .......................... .......................... .................... ....... 89

I.

Precautions ................................................................................................................ ................................................................................................................89 89

II.

Preparation ................................................................................................................90 ................................................................................................................90

III.

Lubrication system schematic diagram ......................................................................91 ......................................................................91

IV.

Engine Oil .................................................................................................................. ..................................................................................................................91 91

V.

Oil Pan and Engine Oil Pump ....................................................................................95 ....................................................................................95

Section III

Cooling System of Engine ......................... ............ ........................... ........................... .......................... .................... ....... 99

I.

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

II.

Engine Coolant ........................................................................................................100 ........................................................................................................100

V.

Radiator Cooling Fan ............................................................................................... ...............................................................................................104 104

V.

Water Pump ............................................................................................................. .............................................................................................................104 104

VI.

Thermostat Sub-assembly .......................................................................................106 .......................................................................................106

VII.

Water Piping Sub-assembly .....................................................................................108 .....................................................................................108

VIII.

Trouble Analysis ...................................................................................................... ......................................................................................................109 109

IX.

Parameters for Maintenance ................... .................... ..................... .................... ....110 ....110

Section IV

Fuel Supply System of Engine Engine .......................... ............. .......................... ........................... ........................ .......... 111

I.

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

II.

Preparation .............................................................................................................. ..............................................................................................................112 112


Contents

III.

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

IV.

Fuel Injector and Guide Rail ....................................................................................113 ....................................................................................113

V.

Fuel Filter ................................................................................................................. .................................................................................................................116 116

VI.

Fuel Pump Assembly ...............................................................................................119 ...............................................................................................119

VII.

Fuel Tank Assembly ................................................................................................ ................................................................................................123 123

Section V

Emission Control System of Engine........................................................ Engine........................................................ 125

I.

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

II.

Forced Ventilating System of Crankcase .................... ..................... ...................... ..129

Chapter 2

Electrical Part of Engine.............. Engine............................ ........................... ........................... .............. 132

Section 1

Ignition System................. .......................... ............. .......................... .......................... .......................... ................... ...... 132

I.

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

II.

Diagnosis of Common Troubles Troub les...................... ...................... ...................... ............. 134

III.

Parameters for Maintenance .................................................................................... ....................................................................................134 134

Section 2

Starting Starting and Charging System ......................... ............ ........................... ........................... ......................... ............ 135

I.

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

II.

Battery ..................................................................................................................... .....................................................................................................................135 135

III.

Starting System ....................................................................................................... .......................................................................................................138 138

IV.

Charging System ..................................................................................................... 146

Chapter III

Electronic Control Control System of Engine............................. ................................. .... 152

Section I

Precautions ......................... ............ .......................... .......................... .......................... .......................... .......................... ................. .... 152

I.

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

II.

General Precautions ................................................................................................ ................................................................................................152 152

III.

Precautions in Maintenance .....................................................................................152 .....................................................................................152

IV.

Common tools for diagnose .....................................................................................154 .....................................................................................154

V

Precautions for On-board diagnose (OBD) system of engine ................... ............... 157

Section II Structural Structural Principle and Inspection of Engine Control System ................. ............... .. 160 I.

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

II.

Multiple-point Fuel Injection System ........................................................................ ........................................................................160 160

III.

On-board Diagnosis System ....................................................................................164 ....................................................................................164

IV.

Engine Trouble Diagnosis ........................................................................................170 ........................................................................................170

Section III

Structural Principle and Inspection Inspection of Engine Electronic Components ... 176

I.

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

II.

Coolant Temperature (ECT) Sensor ........................................................................ ........................................................................179 179


Contents

III.

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

IV.

Hall sensor ............................................................................................................... ...............................................................................................................184 184

IV.

Oxygen sensor................... ..................... ...................... ..................... ..................... .186

VII.

Fuel Injector (INJ) .................................................................................................... ....................................................................................................189 189

VIII.

Air-conditioning switch and relay ..................... ...................... ..................... ............. 192

X.

Canister solenoid valve .................... .................... ..................... .................... ...........194 ...........194

XII.

Electric Fuel Pump ................................................................................................... ...................................................................................................199 199

XIII.

Electronic Control Module (ECM) of Engine ...... ...................... ...................... .......... 200

Section IV

Trouble Diagnosis Procedures Procedures for Engine Engine Control System System .................... ............... ..... 205

I.

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

II.

Diagnosis by Trouble Phenomena ...........................................................................222 ...........................................................................222


Mechanical Part of Engine

Chapter 1 Mechanical Part of Engine Section 1 Engine Body I.

General Precautions

1.

Precautions on Discharging Engine Coolant

Discharge coolant after engine has cooled down. 2.

Precautions on Disconnecting Fuel Pipeline

1)

Before the operation, ensure that the operating area is free of objects which may cause combustion or sparks.

2)

Disconnect the piping, plug openings to prevent leakage of fuel.

3.

Precautions on Dismantlement and Disassembly

1)

Use special tools as required in Instruction. Always operate safely; any forcible operations and operations other than that specified in Instructions are forbidden.

2)

Take particular care not to damage the matching face or the sliding face.

3)

Use the adhesive adhesive tape or equivalent to cover the opening of engine system so as to prevent the entry of foreign bodies, if necessary. necessary.

4)

For the purpose of troubleshooting and reassembly, reassembly, methodically mark and neaten the disassembled parts.

5)

When loosening the bolts and nuts, follow this basic principle: “outmost ones first, diagonal ones second, and so on”. Conduct the operation in compliance with the loosening sequence, if specified.

4.

Precautions on Check, Repair and Replacement

Thoroughly check the parts before repair or replacement. Check the substitutive parts by the same means, and then replace as required. 5.

Precautions on Assembly and Installation

1)

Use the torque torque spanner spanner to tighten tighten the nuts and bolts. bolts.

2)

When tightening the nuts and bolts, bolts, follow this basic principle: screw up the central nuts and bolts with the same torque in steps, and then carry out the same operation with the internal and external diagonal ones. Perform the operation in accordance with the tightening sequence, if it is specified.

3)

Replace gaskets, oil seal or O-ring with new ones.

4)

Thoroughly rinse, clean and dry every part. Carefully Carefully check the engine oil pipeline or engine coolant pipeline for obstruction.

5)

Never damage the sliding face and the matching face. Completely eliminate the foreign bodies such as cloth scraps or the dust. Before assembly, paste the sliding face with engine oil.

6)

When refilling engine coolant after draining completely, completely, release air from the pipes at first.

7)

After repair, repair, start the engine and run with high speed to check for any leakage of the engine coolant, fuel, engine oil and exhaust gas.

33



6.

Parts Needed to Be Tightened with Specified Angle

1)

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

-

Cylinder head bolt

-

Bolt of main bearing cap

-

Connecting rod bolt

2)

Please follow the specified tightening methods.

3)

Make sure that the surfaces of threads and pedestal are clean and coated with engine oil.

II.

Precautions on Sealant

1.

Removal of Sealant

Fig.1.1.001 JAC-T1F017

After dismounting fixing nuts and bolts, use the scraper to detach the matching faces and remove old sealant. Knock

Attention: ■

Do not damage the matching faces.

■

Insert the scraper, and then knock its side

Slide

to slide it as shown in the figure. ■

For the positions where it is difficult to use scraper,

lightly

knock

the

parts

to

dismount them with a plastic hammer. ■

Fig.1.1.002 Scraper

If you have no choice but to use the tools such as a screwdriver, be careful not to damage the matching faces.

2.

Application Steps of Sealant

1)

Remove the attached old sealant from the application and matching faces of liner with scraper.

Attention: ■

Thoroughly remove the old sealant from the groove on surfaces, fixing bolts and bolt holes where the sealant was applied.

2)

Wipe sealant surface and matching surface clean with a special cleaner, remove water drops, grease and foreign substances.

34


3)


Position sealant with the specified size. Fig.1.1.003

■

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

■

Generally, the sealant is put inside the bolt hole; however, it is occasionally put outside the bolt hole.

■

Install the matching part in a certain period of time after applying sealant.

■

Eliminate any dirt from the sealant.

■

Do not re-tighten the bolts or nuts after installation in order to avoid failures of bolts or nuts.

■

Add engine oil and coolant 30min after the installation has been finished.

Attention: ■

Conduct the operation in accordance with the instructions specified in this manual.

35



III. Preparation 1.

Tools for Maintenance List of Special Tools No.

Tool

Appearance

Code

Description

Fix camshaft 1

End forked clamp

timing sprocket JAC-T1D001

Used together 2

Pin

with the end forked clamp

3

Used to install

Locating tool for

and dismantle

piston pin

the piston pin JAC-T1F005

Used together 4

with the

Guide sleeve

locating tool for piston pin

5

Flywheel chock

JAC-T1F011

Used to fix the flywheel

Used to 6

compress the

Valve spring

JAC-T1F012

compressor

valve spring Install valve cotter

36



Used to install 7

Oxygen sensor

JAC-T1F015

socket

and dismantle the oxygen sensor

8

9

Used to

Dismantlement

JAC-T1F017

tool for oil pan

dismantle the oil pan

Used to install

Installer for valve

JAC-T3F001

oil seal

the valve oil seal

Functioning as Guide for front oil 11

a guide during

seal of

JAC-T3F003

crankshaft

the installation of front oil seal of crankshaft

Used to install

Installer for front 12

oil seal of

JAC-T3F004

crankshaft

of engine crankshaft

Installer for rear 13

the front oil seal

Used to install

oil seal of

JAC-T3F005

crankshaft

the rear oil seal of crankshaft

37


Maintenance Manual of Tojoy Sedan 2.

List of Auxiliary Materials for Assembling Engine List of Auxiliary Materials for Assembling Engine

No.

Name

Application

Specification and Grade Factory filled oil: SAE10W-30 Ambient temperature: -25℃-35℃

Engine

1

Used during filling and assembly

oil

User

must

select

the

appropriate

oil

according to the local temperature Quality level: SJ or above

2

Silica

Engine oil pump, water pump, oil pan

gel

and rear oil seal housing of crankshaft

3

Sealant

4

Sealant

5

Petrol

6

Sealant

3.

Oil pressure switch, draining screw plug and flywheel bolt Coolant temperature sensor and water temperature alarm switch

LT5699 or equivalent LT243 or equivalent LT648 or equivalent 93# unleaded petrol or above

Stud bolt

LT271 or equivalent

List of Auxiliary Materials for Assembling Cylinder head List of Auxiliary Materials for Assembling Cylinder head

No.

Name

Present Material and Model

Assembly Position

5W-30 (winter) 15W-40 1

Engine oil

(summer),with SJ-class quality

Valve head, camshaft and camshaft oil seal

level and above 2

Sealant

LT271 or equivalent

3

Sealant

LT962T or equivalent

38

Stud bolt Guide sleeve of spark plug, bowl patch of cylinder body/cover, connecting pipe nozzle



IV. Engine Assembly 1.

Precautions on Installation and Dismantlement

Caution: Operation in violation of the following instructions may incur personal injury! ■

Park the vehicle on flat and firm ground.

Attention: ■

Always pay attention to safe operation, and do not conduct any forcible operations or operations other than that specified in Instructions.

■

Do not start before the exhaust system and engine coolant have completely cooled down.

■

If the necessary items or operations are not mentioned in the sections of Engine, see relevant chapters.

■

Use the specified lifting points all the time and select appropriate lifters according conditions.

2.

Preparation for Dismounting Engine and Transmission Assembly

1)

General

Dismount the engine and transmission assembly from the vehicle, and then detach the engine from transmission. 2)

Preparation

①

Discharge the engine coolant from the radiator. See “Change Engine Coolant”.

②

Discharge the engine oil, transmission oil and clutch oil. See "Engine Oil", “Transmission Oil” and “Clutch Pipeline”.

③

Collect the refrigerant in AC pipeline.

④

Discharge power steering fluid.

Attention: ■

Perform this step after the engine has cooled down.

■

Do not spill engine cooling fluid or brake fluid to the drive belt.

⑤

Dismount the following parts:

■

Engine trimming cover. See “Intake Manifold”.

■

Front wheels and tyres. See “Wheels and Tyres”.

■

Engine deflectors (left and right).

■

Air duct and air filter assembly. See “Air Duct”.

■

Battery, battery base and base support. See “Battery”.

■

Radiator assembly and radiator fan. See “Radiator”.

39


Dismantlement of Related Elements in Engine Compartment

①

Disconnect the following pipelines and put them aside.


Attention: Use plugs to prevent leakage when disconnecting the pipelines. ■

Inlet pipe of fuel injector. See “Fuel Injector”.

■

Vacuum hose of braking vacuum booster on engine side. See “Braking Vacuum Booster”.

■

PVC hose. See “Fuel Evaporation Control System”.

■

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

■

Oil inlet pipe and oil return pipe of power steering pump; fixing support of oil pipes. See “Power Steering Pump”.

■

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

②

Dismount the steering fluid reservoir.

③

Dismantling of shifting cable.

④

Disconnect the wire harness connectors and buckles of the following parts and then take them away:

■

Oxygen sensor

■

Engine coolant temperature sensor

■

Crankshaft position sensor

■

Camshaft position sensor

■

Speed sensor

■

VVT oil control valve harness

■

Throttle opening sensor

■

Absolute intake pressure sensor

■

Ignition coil

■

Fuel injector

■

Knock sensor

■

Generator

■

Starter

■

Air conditioner switch

4.

Dismantlement of Components of Chassis

①

Dismount the front drive shaft. See “Front Drive Shaft”.

②

Dismount the front exhaust pipe. See “Exhaust System”.

③

Dismount the engine supporting beam. See “Engine Supporting Beam”. 40


Dismantlement

①

Attach the lifting device hook to the hanging lug of the engine

Fig.1.1.004


Fig.1.1.005

②

Lift the engine and fix it in place.

③

Use the manual lifting stand or equivalent to firmly support the bottom of engine and transmission assembly; adjust the lifting tension.

Attention: ■

A soft pad may be placed on the supporting surface so as to ensure a totally stable state.

④

Detach left, right, front and rear suspensions of engine. See “Engine Suspension”.

⑤

Carefully lower the engine and transmission assembly. Be aware of following items during operation:

■

Make sure that the work will not affect the vehicle.

■

Make sure that all connecting parts have been disconnected.

■

In order to avoid falling due to changes of vehicle gravity, use the jack to support the rear lifting point.

6.

Detachment

①

Dismount the power steering pump assembly and air conditioner compressor assembly from engine and transmission assembly. See “Power Steering Pump”.

②

Dismount starter. See “Starter”.

③

Lift engine and transmission assembly with specified lifter, and then detach them.

Attention: ■

Before lifting, check whether each connection wiring harness has been disconnected.

7. Installation Be aware of following items to install with steps contrary to dismantlement. 1)

Do not damage the soft pad of engine suspension. Meantime, avoid spilling engine oil onto the soft pad.

2)

Make sure that all engine suspensions have been properly fixed. Then, tighten the nuts and bolts.

8. Check after Installation 41

Maintenance Manual of Tojoy Sedan 1)


Check for any leakage.

The steps for checking oil and fluid leakage, lubricating oil leakage and the exhaust leakage are as follows: ■

Before starting engine, check oil and fluid levels (including engine oil and coolant). Refill to specified level as required..

■

Check for fuel leakage with following steps：

-

With ignition switch turned to the “ON” position, check whether there is fuel leakage at the connecting positions.

-

With engine started, recheck whether there is fuel leakage at the connecting positions during engine increasing.

■

During running of engine, check for any abnormal noise and/or vibration.

■

With engine warmed up, verify that there are no leakage of fuel, exhaust gas or other oil and liquid (including engine coolant and oil).

■

Bleed air and replenish by using specified ports and hoses.

■

After engine cooled down, recheck oil and liquid levels (including engine oil and coolant). If necessary, refill them to the specified levels.

2)

General of Check Items List of Leakage Check Items Item

Before Startup

During Engine

After Engine

Operation

Stopped

Engine coolant

Level

Leakage

Level

Engine oil

Level

Leakage

Level

Transmission oil, brake fluid, power steering

Level

Leakage

Level

Fuel

Leakage

Leakage

Leakage

Exhaust

—

Leakage

—

fluid and clutch fluid

42



V.

Drive Belt

1.

Check Drive Belt

Warnings: ■

Be sure to operate only when engine stopped.

1)

Check belt for aging, crack, wear and oil stain. Replace as required.

2)

Check the belt tension at the mid-point between pulleys.

■

Inspection should be conducted with cold state of engine or when it has been stopped for at least 30min.

■

Tension range - Generator belt: 550 ± 50N; power steering pump belt: 475 ± 50N. Be aware that the tension of belt reused should be calculated by using the empirical formula: tension of new belt * 1.2/1.5.

■

Adjust if tension is out of range.

Attention: ■

When checking belt tension after installation, firstly to adjust tension to specified value. Then revolve the crankshaft for more than two laps to re-adjust in order to avoid tension between pulleys changes.

2.

Adjustment of Tension List of Tension Adjustment Part

Method

Generator belt

Screw adjusting bolt of generator

Belts of power steering pump

Screw adjusting bolt of power steering pump

Attention: ■

After replacing with the new belt, adjust the tension so as to meet the requirements

■

When installing the belt, ensure the proper engagement with the belt pulley groove.

■

Do not splash the engine oil or engine coolant onto the belt.

■

Do not over wind or bend belt; for worn belt, pay attention to mounting direction.

43



Generator Belt

1) Loosen the generator adjusting nuts and supporting nuts. Then adjust the tension by using the adjusting bolt. Fig. 1.1.006

Fig. 1.1.007

2)

Tighten generator adjusting and supporting nuts.

■

Tightening torque: Generator adjusting nuts: 22.5 ± 2.5 Nm Generator supporting nuts: 47±5 N.m

4.

Belt of Power Steering Pump

1)

Loosen the power steering pump adjusting and supporting bolts. Fig. 1.1.008

■

Fig. 1.1.0009

Tightening torque: Adjusting nuts: 4 - 6N.m Supporting nuts:20-25N.m

2)

Adjust tension with the adjusting bolt.

3)

Lock adjusting bolt and power steering pump fixing bolt.

5.

Dismantlement of Drive Belt

1)

Completely loosen all belts in accordance with the instructions in “Tension Adjustment”.

2)

Dismount the belt of power steering pump, and then the generator belt.

6.

Installation of Drive Belt

1)

Mount the belt onto the pulley with steps contrary to dismantlement.

Attention: ■

Make sure that the belt has properly engaged with the groove of pulley.

■

Make sure that no engine oil or coolant splashed onto any belt or pulley groove.

2)

Verify that the tension of every belt is within the standard range. See “Inspection of Drive Belt”. 44


Maintenance Manual of Tojoy Sedan VI. Air Filter and Air Duct 1.

Parts

4

2

1

3

Diagram of Positions 1- Front Intake Pipe; 2- PVC Hose; 3- Intake Hose; 4- Air Filter Assembly 2.

Intake Pipe

1)

Dismantlement

①

Dismount the fixing bolt of front intake pipe,

Fig.1.1.010

take off the front intake pipe assembly. ■

Tightening torque: 17-19 N·m

②

Dismount the locking bolt on upper cover of air Fig.1.1.011

filter. ■


45



③

Disconnect the locking clamp of intake hose, and then take off upper cover and intake hose.

■

Tightening torque: 6-9 N·m Fig.1.1.012

④

Fig. 1.1.013

Dismount the fixing bolt of air filter base, and Fig. 1.1.014

then take down the base. ■


2)

Check after Dismantlement

Check whether there is any crack or wearing on the air duct assembly. If any, replace. 3)

Installation

Install with steps contrary to dismantlement. Attention: ■

Properly mount every joint and tighten the clamp.

3.

Replacement of Air Filter element

1)

Dismantlement

①

Loosen the locking bolt on upper cover of air

Fig.1.1.015

filter and lift the upper cover.

46



②

Dismount air filter element.

2)


■

Periodically clean or replace the filter element with recommended period. See “Periodical

Fig. 1.1.016

Maintenance”. ■

Blow the filter element from its back side with compressed air, till nothing is blown off.

3)

Installation

■

Install with steps contrary to dismantlement.

VII. Intake Manifold and Exhaust Manifold

Decomposition Diagram of Intake and Exhaust Manifolds 1.

Intake Manifold

1)

Dismantlement

Caution: ■

Do not discharge the engine coolant when the engine is hot, otherwise you would be scalded.

47

Maintenance Manual of Tojoy Sedan ①

Discharge the engine coolant. See “Engine Coolant”.

②

Dismount the engine trimming cover.

■


③

Fig.1.1.017

Dismount the air filter assembly. See “Air filter Assembly”.

④

Disconnect the wire harness connectors of the following parts:

■


■

Fuel injector

■

Electronic throttle opening sensor

■

Carbon canister control solenoid

⑤

Disconnect the following hose joints:

■

Water hose joint (insert a plug to prevent the engine coolant leakage)

■

PCV hose

■

Vacuum hose of braking vacuum booster on intake manifold side

■

Vacuum hose on carbon canister solenoid side

■

Small circulating water hose for throttle valve body

⑥

Dismount fixing bolts and valve body, take off valve body assembly.

48

Fig.1.1.018



⑦

Dismount the fuel injector assembly. See “Fuel


Fig.1.1.019

Injector”. ■

Tightening torque: 18.4±1.4 N·m

⑧

Dismount the supporting bracket of intake manifold

Fig.1.1.020

and engine cylinder body. ■


⑨

Dismount the fixing bolt and nut of intake manifold.

■

Tightening torque: 18±1.0 N·m

⑩

Take off the intake manifold.

2)


Fig.1.1.021

Check whether there is any crack or other damage on intake manifold and whether the matching face is distorted. If this is the case, repair or replace the intake manifold. Check for any abnormal condition of rubber rings. 3)

Installation

■

Install with steps contrary to the dismantlement.

Attention: ■

Do not reuse the non-reusable parts.

■

Before starting the engine, check the level of engine coolant. If the level is lower, refill engine coolant as specified.

■

Carry out the following steps to check whether fuel leakage is present. 49

Maintenance Manual of Tojoy Sedan -


With ignition switch turned to the “ON” position, check whether there is fuel leakage at the connecting positions.

-

With engine started, recheck whether there is fuel leakage at the connecting positions during engine increasing.

■

With engine warmed up, verify that there is no fuel and/or coolant leakage.

■

After engine cooled down, recheck the level of engine coolant. Refill to specified level as required.

2.

Exhaust Manifold

1)

Dismantlement

Caution: ■

Perform this operation after the exhaust system has completely cooled down.

①

Disconnect the wire harness connectors of front

Fig.1.1.022

oxygen sensor. Special tools should be used if necessary. ■


Attention: ■

Do not damage the oxygen sensor.

■

It is forbidden to use any oxygen sensor which has dropped to the hard ground from a height above 0.5m. Such an oxygen sensor should be replaced.

②

Unscrew the fixing bolt for heat shield of exhaust manifold, and then take off heat shield.

■

Tightening torque: 5-10N·m

50

Fig.1.1.023


④

Unscrew bracket bolt to remove the exhaust manifold Fig.1.1.024

bracket. ■

⑤ ■


Tightening torque: 20±1.0 N·m

Unscrew fixing bolt to remove the exhaust manifold. Tightening torque: M8 35±2 N·m Fig.1.1.025

2)


Check whether the matching face of exhaust manifold is distorted. 3)

Installation

Install with steps contrary to the dismantlement. Attention: ■

Do not reuse the non-reusable parts.

■

Do not excessively tighten oxygen sensor, otherwise it may be damaged.

VIII. Exhaust System 1.

Parts

Diagram of Exhaust System 1- Rear muffler; 2- Lug; 3- Front muffler; 4- Front exhaust pipe; 5-Three-element Catalytic Converter; 6Bellow; 7-Rear oxygen sensor 51



Inspection of Exhaust System

Check whether the exhaust pipe, the three-way catalytic converter, the muffler and the fixing devices are properly installed and whether there is any leakage, crack, damage or aging. ■

Repair or replace the damaged part as required.

3.

Dismantlement and Installation

Attention: ■

Do not have you hand cut by the edge of heat shield.

■

Do use original exhaust system parts or equivalent products.

■

Perform the operation after the exhaust system has completely cooled down, for the temperature of exhaust system remains hot when the engine has just stopped.

1)

Dismantlement

Disconnect every joint and fixed part. 2)

Installation

■

Install with steps contrary to dismantlement.

■


■

Replace the exhaust pipe gasket when reassembling the exhaust system each time.

■

Repair or replace replace the seriously distorted heat shield. Eliminate Eliminate the accumulations from the heat shield.

■

When install install the heat shield, try to avoid wide clearance or blockage blockage and intervention between the heat shield and each exhaust pipe.

■

Eliminate the sediments from the sealed face of each joint. Such joints should be firmly connected to avoid gas leakage.

■

Pre-tighten the fixing nuts nuts and bolts on exhaust manifold side and those on vehicle side. Check whether there is any intervention between parts, and then tighten the parts to specified torque.

■

When install the fixing rubber, avoid excessive excessive upward/downward and leftward/rightward leftward/rightward twist or stretch.

3)

Check after Installation

■

Verify clearance between rear muffler and rear bumper.

■

WIth engine running, check the connecting position of exhaust pipe for air air leakage leakage and abnormal noise.

■

Ensure that the fixing support and the fixing rubber have been properly mounted. Do not subject them to excessive force. Improper installation may result in considerable noise and shake.

52

Maintenance Manual of Tojoy Sedan IX. Timing sprocket mechanism 1.

Parts

Timing sprocket mechanism diagram 2.

Dismantlement and Installation of Timing

chain 1)

Dismantlement

①

Dismount the fixing bolt of water pump belt

Fig.1.1.026

pulley. ■

Tightening torque: 7-8.2 N·m

Note: It is permissible to perform the dismantlement by means of the friction force of drive belt before drive belt is removed. b)

Dismantle drive drive belt to check whether the drive belt has wearing, aging, cracking, etc.; if any, any, replace drive belt.

c)

Dismantle oil gauge assembly

■

Tightening torque: 7-8.2 N·m

53

Fig.1.1.027



d)

Dismantle damping wheel

■


e)

Dismantle generators and power steering pump bracket

Fig.1.1.028

Fig.1.1.029

f)


Fig.1.1.030

Dismantle oil pan and cylinder head cover

Attention: Only when oil pan and cylinder head cover are disassembled can the oil pump assembly be dismantled. g)

Dismantle oil pump assembly

h)

Check timing

Fig.1.1.031

Check the timing point shown in the diagram for compliance.

54



Timing mark of sprocket




i)

Dismantle tensioner and set/dynamic tracks of the automatic timing chain. Check for any abnormalities.

■

Tightening torque: Automatic tensioner: tensioner: 9 - 11 N • m Set track: 10-12 N·m Dynamic track: 19-28 N·m Fig.1.1.032

j)

Dismantle exhaust camshaft sprocket bolt

■


Fig.1.1.033

Fig.1.1.034

55


k)

Dismantle intake cam timing controller

■

Tightening torque: 64.5±5.5 N·m


Fig.1.1.035

2） Installation Reverse the above steps for installation. Be aware of timing and tightening torque during installation. X.

Camshaft assembly

1. Parts

Camshaft decomposition diagram

56



Disassembly and installation

1） Disassembly

①

Remove cylinder cover. See "Intake Manifold."

②

Remove high-voltage ignition coil. See "Ignition Coil."

③

Disconnect PCV hose and air hose of respirator. respirator.

④

Remove the cylinder cylinder head cover from the cylinder head.

⑤

Remove camshaft camshaft timing timing sprocket. sprocket. Seethe "timing sprocket body." body."

⑥

Remove camshaft position sensor sensor from rear end of the cylinder head. Tightening torque: 9 - 11 N • m

Attention: ■

Handle with care to avoid collision or damage.

⑦

Remove the camshaft from cylinder head.

2） Inspection after removal

Fig.1.1.036

① Camshaft ■

Measuring camshaft base circle diameter and the maximum lifting strokes of intake and exhaust.

Base circle diameter: 36mm Maximum lifting stroke of intake：8.7054mm Maximum lifting stroke of exhaust：8.2836mm If specified value is exceeded, replace the camshaft.

②

Mechanical tappet

■

Measure the top thickness of the mechanical

Fig.1.1.037

tappet Measurement should be within: 2.70～2.30mm

3) Installation Assembly of camshaft machenism: All parts camshaft assembly should be assembled according to grouped drawings. 57



The mechanical tappet tappet at the intake intake side will be grouped grouped and assembled as per the following following table to ensure the intake valve clearance.

Distance between intake camshaft base circle

Top end thickness of

Mechanical tappet

Valve clearance

and valve tappet L1

mechanical tappet

label

(mm)

2.91＜ 2.91＜L1≤2.93

2.70

270

0.19-0.25

2.93＜ 2.93＜L1≤2.95

2.72

272

0.19-0.25

2.95＜ 2.95＜L1≤2.97

2.74

274

0.19-0.25

2.97＜ 2.97＜L1≤2.99

2.76

276

0.19-0.25

2.99＜ 2.99＜L1≤3.01

2.78

278

0.19-0.25

3.01＜ 3.01＜L1≤3.03

2.80

280

0.19-0.25

3.03＜ 3.03＜L1≤3.05

2.82

282

0.19-0.25

3.05＜ 3.05＜L1≤3.07

2.84

284

0.19-0.25

3.07＜ 3.07＜L1≤3.09

2.86

286

0.19-0.25

3.09＜ 3.09＜L1≤3.11

2.88

288

0.19-0.25

3.11＜ 3.11＜L1≤3.13

2.90

290

0.19-0.25

3.13＜ 3.13＜L1≤3.15

2.92

292

0.19-0.25

3.15＜ 3.15＜L1≤3.17

2.94

294

0.19-0.25

3.17＜ 3.17＜L1≤3.19

2.96

296

0.19-0.25

3.19＜ 3.19＜L1≤3.21

2.98

298

0.19-0.25

3.21＜ 3.21＜L1≤3.23

3.00

300

0.19-0.25

3.23＜ 3.23＜L1≤3.25

3.02

302

0.19-0.25

3.25＜ 3.25＜L1≤3.27

3.04

304

0.19-0.25

3.27＜ 3.27＜L1≤3.29

3.06

306

0.19-0.25

3.29＜ 3.29＜L1≤3.31

3.08

308

0.19-0.25

3.31＜ 3.31＜L1≤3.33

3.10

310

0.19-0.25

3.33＜ 3.33＜L1≤3.35

3.12

312

0.19-0.25

3.35＜ 3.35＜L1≤3.37

3.14

314

0.19-0.25

3.37＜ 3.37＜L1≤3.39

3.16

316

0.19-0.25

3.39＜ 3.39＜L1≤3.41

3.18

318

0.19-0.25

3.41＜ 3.41＜L1≤3.43

3.20

320

0.19-0.25

3.43＜ 3.43＜L1≤3.45

3.22

322

0.19-0.25

3.45＜ 3.45＜L1≤3.47

3.24

324

0.19-0.25

3.47＜ 3.47＜L1≤3.49

3.26

326

0.19-0.25

3.49＜ 3.49＜L1≤3.51

3.28

328

0.19-0.25

3.51＜ 3.51＜L1≤3.53

3.30

330

0.19-0.25

Table: Distance between intake camshaft base circle and top of valve tappet, top end thickness of the mechanical tappet grouping and assembly

58


Maintenance Manual of Tojoy Sedan ②

The mechanical tappet at the exhaust side will be grouped and assembled as per the following table to ensure the intake valve clearance.

Distance between exhaust camshaft base circle

Top end thickness of

Mechanical

and valve tappet L2

mechanical tappet

tappet label

2.99＜L2≤3.01

2.70

270

0.27-0.33

3.01＜L2≤3.03

2.72

272

0.27-0.33

3.03＜L2≤3.05

2.74

274

0.27-0.33

3.05＜L2≤3.07

2.76

276

0.27-0.33

3.07＜L2≤3.09

2.78

278

0.27-0.33

3.09＜L2≤3.11

2.80

280

0.27-0.33

3.11＜L2≤3.13

2.82

282

0.27-0.33

3.13＜L2≤3.15

2.84

284

0.27-0.33

3.15＜L2≤3.17

2.86

286

0.27-0.33

3.17＜L2≤3.19

2.88

288

0.27-0.33

3.19＜L2≤3.21

2.90

290

0.27-0.33

3.21＜L2≤3.23

2.92

292

0.27-0.33

3.23＜L2≤3.25

2.94

294

0.27-0.33

3.25＜L2≤3.27

2.96

296

0.27-0.33

3.27＜L2≤3.29

2.98

298

0.27-0.33

3.29＜L2≤3.31

3.00

300

0.27-0.33

3.31＜L2≤3.33

3.02

302

0.27-0.33

3.33＜L2≤3.35

3.04

304

0.27-0.33

3.35＜L2≤3.37

3.06

306

0.27-0.33

3.37＜L2≤3.39

3.08

308

0.27-0.33

3.39＜L2≤3.41

3.10

310

0.27-0.33

3.41＜L2≤3.43

3.12

312

0.27-0.33

3.43＜L2≤3.45

3.14

314

0.27-0.33

3.45＜L2≤3.47

3.16

316

0.27-0.33

3.47＜L2≤3.49

3.18

318

0.27-0.33

3.49＜L2≤3.51

3.20

320

0.27-0.33

3.51＜L2≤3.53

3.22

322

0.27-0.33

3.53＜L2≤3.55

3.24

324

0.27-0.33

3.55＜L2≤3.57

3.26

326

0.27-0.33

3.57＜L2≤3.59

3.28

328

0.27-0.33

3.59＜L2≤3.61

3.30

330

0.27-0.33

Valve clearance (mm)

Table: Distance between the exhaust camshaft base circle and top of valve tappet, top end thickness of mechanical tappet assembly grouping and assembling

59



Installation precautions: ■

Mechanical tappet should be applied with proper amount of oil evenly; after the cylinder head is assembled, it should turn flexibly without sticking or other abnormalities.

■

Before assembling camshaft, proper amount of oil should be evenly applied on each contact surface; after the camshaft bearing bolt is tightened, the camshaft should turn flexibly without sticking or other abnormalities; axial clearance should be: 0.05 - 0.15mm. (Measurement location)

③

Install the camshaft position sensor.

Attention: ■

Apply a film of sealant to the flange of rear end cover.

■

Tighten the fixing bolt after the support has been fully mounted.

④

Install camshaft timing sprocket

⑤

Be aware of following items to install with steps contrary to dismantlement.

■

Before installing cylinder head cover, clear any sealant on cylinder head.

■

Make sure that cylinder head cover gasket is put into the installation slot.

4)


■

Check for proper position of all parts installed.

■

Check the level of engine oil before starting the engine. If the engine oil is less than the required volume, replenish to specified level.

■

With engine running, check for abnormal noise and vibration.

■

Be sure that there is no oil leakage after engine warmed-up thoroughly.

■

Recheck the level of engine oil with engine cooled down. Replenish the engine oil to the specified level as required.

XI. Cylinder head 1.

On-vehicle Maintenance

1)

Inspect the cylinder pressure:

①

Thoroughly warm up the engine and then stop it.

②

Release the fuel pressure. See “Release of Fuel Pressure”.

③

Disconnect the fuse of fuel pump, otherwise the fuel may be sprayed out during measurement.

④

Use special ignition coil and spark plug removal tool. See "Ignition Coil" and the "Spark Plug."

⑤

Dismantle engine trimming cover. See “Intake manifold”.

⑥

Install a cylinder pressure gauge (with joint) on the spark plug hole.

⑦

Push the accelerator pedal to the end, then turn the ignition switch to the “START” position to start the engine. After the instrument finger appears stable, read compression pressure and engine speed. Perform these steps to check other cylinders. 60

Maintenance Manual of Tojoy Sedan ■

Standard pressure: 1500kPa

■

Minimum pressure: 1200kPa

■

Tolerable pressure difference between cylinders: ≤150kPa


Attention: ■

It is required to obtain the specified engine speed always by the battery which is fully charged.

■

Inspect valve clearance and other relevant parts (such as valve, valve seat, piston, piston ring, cylinder bore, cylinder head and gasket) if the compression pressure is less than the minimum value. Repeat measurement of compression pressure after the check. If the pressures in some cylinders are low, add some engine oil to the spark plug holes of such cylinders and then inspect again.

■

The piston ring may be worn or damaged if the cylinder pressure rises after the engine oil is added. Check the piston ring and replace if necessar y.

■

The valve may have faulty if the compression pressure is still low after the adding of engine oil. Check whether the valve is damaged. Replace the damaged valve or valve seat.

■

The cylinder gasket must be leaky if the compression pressures in two neighboring cylinders are low and even keep low after adding engine oil. Replace cylinder gasket.

⑧

After inspection, remount the dismounted parts.

⑨

Start engine, confirm that the engine runs smoothly.

2.

Parts

Diagram of Cylinder head 3.


1)

Dismantlement 61



Discharge engine coolant and oil. See “Change Engine Coolant” and “Change Engine Oil”.

Attention: ■

Perform these steps after engine cooled down.

■

Do not splash engine coolant or oil onto the drive belt.

②

Dismount the following elements and the relevant parts:

■

Engine trimming cover. See “Intake Manifold”.

■

Drive belt. See “Drive Belt”.

■

Cylinder head cover. See "Camshaft Assembly."

■

Intake manifold. See “Intake Manifold”.

■

Exhaust manifold. See “Exhaust Manifold”.

■

Oil gauge tube.

■

Oil pump body assembly and timing mechanism. See the "Timing Sprocket Mechanism."

③

Loosen the cylinder head bolts with special tool.

④

Remove the cylinder gasket.

2)


①

Cylinder head Bolt

Measure the length of cylinder head bolt. ■

Limit: 143.5±0.7mm. Replace the cylinder head bolt if this Limit is exceeded.

②

Cylinder head

■

Check whether there are cracks or other damages on the cylinder head.

■

Check whether there is any blockage in the coolant gallery and oil passage. If any, clean the coolant gallery and oil passage.

■

Check planeness of cylinder head.

Note: Check the planeness of cylinder body as well when performing this check. a.

Wipe off the engine oil from the cylinder head, remove any sealant and the carbon deposit.

Attention: ■

Be careful to prevent impurities from falling into coolant gallery and oil passage of cylinder head.

62



b.

Measure the planeness in six directions at

Fig.1.1.38

several positions on bottom surface of cylinder head. Standard value: below 0.03mm Height of cylinder head (new): 113±0.1mm If the the standard value is exceeded, grind or replace the cylinder head according to the specification. Attention: ■

The total grindable margin of matching surface between cylinder head and cylinder body should not be greater than 0.2mm.

3)

Installation

①

Install new cylinder gasket.

②

Follow the numerical order as shown in the

Fig.1.1.039

diagram to tighten the cylinder head bolt and follow the given steps to install cylinder head . A:

Intake side

B:

Exhaust side : Front end of engine

a.

Install washer.

b.

Apply a film of engine oil onto washer, which is at the threaded portion of bolt.

c.

Tighten cylinder head bolts in sequence, until each bolt torque is 24.5 ± 2 N • m.

d.

Fully unscrew bolts.

e.

Tighten the bolts until the torque of each bolt is 24.5 ± 2N • m.

f.

Paint marks on the bolt head and the cylinder

Fig.1.1.040

head (see Fig.1.1.040). g.

Screw each bolt for more 90° with to the tightening sequence.

h.

Re-tighten each bolt by 90°.

Attention: ■

Painting Mark

When the two tightening angles are below 180 °, tightening performance can not be assured; be sure to reach 180 ° when tightening.

63



When the two tightening angles are above 184 °, completely loosen the bolt and re-tighten per the initial sequence.

i.

If the old cylinder head bolts are replaced during the maintenance, operation should be performed in sequence from “a” to “h”.

j.

If the old cylinder head bolts are not replaced during the maintenance, operation should be performed in sequence “a, b, e, f, g and h”.

③

Then, perform the installation steps which are just contrary to dismantlement.

4)


The steps for checking oil leakage, lubricant leakage and tail gas leakage are as following: ■

Before starting the engine, check the engine oil/coolant level. If the level is lower, replenish the engine oil/coolant till the specified level is reached.

■

Perform the following steps to check whether the oil leakage occurs:

-

Turn the ignition switch to the “ON” position (when engine is stopped). With the oil pressure acting on the oil pipe, check whether there is fuel leakage at the joint.

-

Start the engine. With the engine accelerating, recheck whether there is fuel leakage at the joint.

■

Run the engine to check whether the abnormal noise or vibration appears.

■

With engine warmed up completely, verify that there is no fuel leakage, tail gas leakage or any oil/fluid (including engine oil and coolant) leakage.

■

After engine cooled down, recheck oil/fluid (including engine oil and engine coolant) level. Replenish the oil/fluid to the specified level as required.

64



XII. Valves 1.

Parts

Diagram of Valve parts 1 - cylinder head bolts 2 - cylinder head bolt washer 3 - cylinder head assembly 4 - Cylinder gasket 5 – intake valve cotter 6 - intake valve spring upper seat 7 - intake valve spring 8 - intake valve 9 - exhaust valve cotter 10 - exhaust valve spring upper seat 11 - exhaust valve spring 12 - exhaust valve 13 - intake valve oil seal 14 - intake valve spring lower seat 15 - exhaust valve seal 16 - exhaust valve spring lower seat

17 - intake valve guide 18 - exhaust valve guide 19 -intake valve seat 20 - exhaust valve seat 21 cylinder head

2.

Disassembly and Assembly

Fig.1.1.041

1)

Disassembly

①

Dismount the spark plug with the special socket.

②

Dismount the valve cotter, valve spring and spring seat.

■

Compress the valve spring with the special compressor.

Attention: ■

Pay attention to the position of upper dead point of piston. 65

JAC-T1F001


■

Label the dismounted valve, valve spring and other parts, and write down their corresponding

cylinder

numbers

Fig.1.1.042


JAC-T1F012

and

positions ■

Store the parts reliably.

③

Dismount the valve oil seal.

④

See “Replacement of Valve Seat” to replace

Fig.1.1.043

the valve seat, if required.

⑤

See “Valve Guide” to replace the valve guide, if required.

2)

Assembly

①

Install valve guide if it has been dismounted. See “Valve Guide”.

②

Install valve seat, if it has been dismounted. See “Valve Seat”.

③

Install valve oil seal.

a.

Install the valve spring seat.

b.

Install the new valve oil seal with the special

Fig1.1.044

tool shown in Fig.1.1.044

JAC-T3F001

Attention: ■

The valve oil seal should not be reused.

■

The valve oil seal must be installed with the proper special tool.

④

Install valve.

⑤

Install valve spring.

Note: The parts with paint mark should be installed upwards.

⑥

Install retaining seat for valve spring.

⑦

Install valve cotter.

■

Use the valve spring compressor during the installation. 66



After installation, lightly knock the edge of valve stem with a rubber hammer to check the mounting condition.

⑧

Install spark plug with the spark plug socket.

3)

Check after Disassembly

1.

Valve

■

Check whether the contact between valve

Fig.1.1.045

Good

surfaces is proper. Renew the surface of valve seat if the contact is uneven or incomplete.

Bad

■

Inspect thickness of valve edge. Replace the valve if the measurement is less than the

For intake valve: 1.35-1.65mm， For exhaust valve: 1.85±0.15mm

■

Fig.1.1.046 Contact (required to be at the center of surface)

specified value.

Bad

Thickness of edge

Inspect the total length of valve. Replace the valve if the measurement is less than specified value. For intake valve: 89.51-90.01mm， For exhaust valve: 90.69-91.19mm

2.

Valve Spring

■

Check free height of valve spring. Replace the valve spring if the measurement is less than specified value.

■

Check perpendicularity of valve spring. Replace the valve spring if the measurement is out of Standard value: 2° Limit: 4°

67

limit.


3.

Valve guide

■

Check the gap between the valve guide and


Fig.1.1.047

the valve stem. Replace the corresponding parts if the measurement is out of limit.

Valve guide

Valve guide Standard value: 0.020-0.036mm Outer Diameter of Valve Stem Inner Diameter of Valve Conduit

Limit: 0.10mm

■

Replacement of Valve guide

a.

Push out the valve guide towards the cylinder side by the press.

b.

Rebore mounting hole on the valve guide of cylinder head to make it match increased size of valve guide to be installed.

Attention: ■

Do not install the valve guides with the same sizes of old ones. Re-boring mounting hole on the valve guide of cylinder head

Outer diameter of valve guide: Fig.1.1.048

For the hole with diameter of 10.605-10.615mm, extend the size of valve guide by 0.05mm. For the hole with diameter of 10.805-10.815mm, extend the size of valve guide by 0.25mm. For the hole with diameter of 11.055-11.065mm,

Protrusion Height

extend the size of valve guide by 0.50mm. c.

Press the valve guide till its protrusion height reaches the specified value.

Standard value: 23.0mm Attention: ■

Use cold pressing method to install valve guide from upper side of cylinder head. Check whether there are cracks after press fitting.

■

After valve guide pressed in, insert a new valve to check for smooth sliding of valve.

4.

Valve Seat

■

Check the valve protrusion height between the end face of valve stem and the surface of valve spring seat. Replace the valve seat if the limit is exceeded.

68


Standard values:

Fig.1.1.049


End Face of Valve Stem

For intake valve: 53.21mm Valve Protrusion Height

For exhaust valve: 54.10mm Limits:

Surface of Valve Spring Seat

For intake valve: 53.71mm For exhaust valve: 54.60mm

■

Renew valve seat.

a.

Before renewing the valve seat, check the clearance between valve guide and valve. Replace the valve guide if necessary.

b.

Resurfacing the valve seat by the proper special tool or the valve seat grinder till specified seat surface width and angle are met.

c.

After renewing the valve seat, grind the valve and the valve seat by the grinding cream. Then, check the protrusion height of valve stem (refer to the above mentioned check steps of valve seat)

■

Replacement of Valve Seat

a.

Cut away the replaced valve seat from its

Fig.1.1.050

inner side in order to decrease the wall thickness. Then remove the valve seat. Cut Away

b.

Rebore the valve seat hole on cylinder head

Fig.1.1.051

till the hole matches the selected valve seat with a extended diameter. See “Parameters for Maintenance” for the detailed size. c.

Valve Seat Height

Do not have the cylinder head hole scratched by the valve seat cooled by the liquid nitrogen before it is pressed.

d.

Renew the valve seat till its width and angle meet the specifications (see the operation instruction of valve seat correction).

e.

leak

testing

must

be

conducted

for

disassembly of valve related components.

69

Inner Diameter of Extended Hole


XIII. 1.


Cylinder Body Assembly Parts

Disassembly Diagram of Cylinder Body Assembly 1 - flywheel bolt 2 - signal wheel screw 3 -flywheel 4 - crankshaft oil seal bolt 5 - crankshaft oil seal housing 6 - bearing cap bolt 7 - bearing caps 8 – upper main bearing shell 9 - crankshaft 10 - lower main bearing shell 11 - crankshaft thrust 12 - crankshaft signal wheel 13 - cylinder block 2.


1)

Disassembly

①

Dismount the engine assembly from the vehicle, and then detach the transmission from engine. See “Engine Assembly” for detailed dismantlement steps.

③

Fix whole engine.

④

Discharge engine oil. See “Change Engine Oil”

⑤ ■

Dismount following engine accessories. See relevant chapters for detailed dismantlement steps. Drive belt 70


Generator, power steering pump, compressor and related supports

■

Intake and exhaust manifolds

■

Water pump and its components

■

Ignition coil

■

Cylinder cover, damping wheel, oil pan

■

Engine timing sprocket mechanism

⑥ ■


Dismount the flywheel assembly. Fix the flywheel by the special tool to dismount the fixing bolt. Tightening torque:

For flywheel: 95-105N·m

Attention: ■

Fixing bolts should be loosened in the diagonal orders.

⑦

Disassemble knock sensor, crankshaft position sensor, oil pressure switch.

■

Tightening torque: Knock sensor: 16 - 24 N • m Crankshaft position sensor: 7.8 - 9 N • m Oil pressure switch: 8 - 12 N • m

Attention: ■

Do not drop or knock the sensor.

⑧

Remove crankshaft rear oil seal bracket

■

Tightening torque: 7.0-8.2N·m

■

Insert the screwdriver between the crankshaft and the rear oil seal housing to dismantle.

Attention: ■

Once dismounted, the rear oil seal must not be reused. It should be replaced by a new one.

⑨

Dismount the piston and connecting rod assembly:

Before dismounting the piston and connecting rod assembly, check the gap at the big end of connecting rod. See “Check after Disassembly” below. a.

Rotate the crankshaft to place the journal side of crankshaft which is corresponding to the connecting rod to be dismounted at the center of bottom.

b.

Dismount the connecting rod cover.

■

Tightening torque: 13±1N·m + 90°-94°

Be aware that when tightening the "5Nm → 10Nm → 13Nm +45 ° +45 °" alternate methods should be followed to tighten. c.

Push out the piston and connecting rod assembly from the cylinder body by the rubber hammer or equivalent.

71



Attention: ■

Be careful not to damage the big bonnet and connecting rod fitting surface

■

Do not damage the cylinder wall and the crankshaft journal with the big end of the connecting rod.

■

Maintain the connecting rod big end and the connecting rod body match sequentially and maintain the connecting rod big end serial number in consistency

⑩ Dismount bearing shell from the connecting rod and the connecting rod cover. Attention: ■

Identify their mounting positions, and properly place them to avoid confusion.

⑪ Dismount ring from the piston. Check the side clearance of piston ring before dismounting. See “Check after Disassembly” below. Attention: ■

Fig.1.1.052

Use the piston ring expander. Piston Ring Expander

⑫ Dismount the piston ring from the connecting rod with method below: a.

Insert the push rod (special tool) from the front side with a arrow mark, and then install the guide sleeve D.

b.

With the front mark of piston face upwards, install piston and connecting rod assembly on Fig.1.1.053

the mounting base of piston pin (special tool). c. d.

Push out the piston ring by the press.

Front Mark Front Mark

Detach the connecting rod from piston.

Attention: ■

Push Rod

Guide Sleeve D

After dismounting piston pin, place it

Base

together with the piston pin and the connecting rod. ■

It is forbidden to place the pistons, piston pins and connecting rods of different cylinders together.

⑬ Dismount the crankshaft bearing cap. Before loosening the crankshaft bearing cap, measure axial clearance of crankshaft. See “Check after Disassembly” below.

72


Loosen the bolts of crankshaft bearing cap in the following sequence. ■

Fig.1.1.054


Number of Bearing Cap

Tightening torque: 35±2 N·m＋60°～64° Be aware of the number and forward mark of bearing cap.

■

In Fig.1.1.065: For the upper row, 4→8→10→6→2 For the lower row, 1→5→9 →7→3

During the dismantlement, it is allowable to jiggle the

crankshaft

bearing

cap

forwards

Fig.1.1.055

and

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

⑭ Dismount the crankshaft. 2)

Check after Disassembly

①

Axial clearance of Crankshaft

Fig.1.1.056

Detection methods are as shown in the figure Standard value: 0.09-0.27mm

If measurement is not within the standard range, re place the thrust washer and repeat measurement. If it is still over limit, replace the crankshaft.

②

Big End Clearance of Connecting Rod

Measure the gap between the connecting rod and the crankshaft by using feeler gauge. Standard value: 0.10-0.3mm Limit: 0.4mm If the limit is exceeded, replace the connecting rod and measure again. Replace the crankshaft if measurement is still out of the limit.

73

Fig.1.1.057


③

Side clearance of Piston Ring


Fig.1.1.058 Bad

Measure the side clearance between piston ring and piston ring groove top land by the feeler gauge. Feeler Gauge

Standard values:

Good

st

For 1 piston ring, 0.03～0.07mm For 2nd piston ring, 0.04～0.06mm

Feeler Gauge Piston Ring

Limits: st

For 1 piston ring, 0.1mm nd

For 2 piston ring, 0.1mm If the measurement exceeds the limit, replace the piston ring, and then remeasure the gap. Replace the piston if the measurement is still out of the limit.

④

End Gap of Piston Ring

Ensure that the inner diameter of cylinder stays

Piston Pressed and Fixed

within the specified range. See "Cylindricality of Cylinder"

Fig.1.1.059 Feeler Gau e

Piston Rin

Lubricate the piston and the piston ring with new engine oil, then insert the piston ring till the piston reaches the middle part of cylinder, measure end Piston Ring

gap of piston ring by the feeler gauge.

Measured Point

Standard values: For 1st piston ring, 0.20-0.35mm nd

For 2 piston ring, 0.35-0.50mm Limits: For 1st piston ring, 0.8mm nd

For 2 piston ring, 0.8mm If the measurement exceeds the limit, replace the piston ring, and then measure again. Extend cylinder bore through grinding and use the corresponding piston and piston ring if the measurement is still over the limit.

⑤

Planeness of Cylinder Body

Remove any gasket material and eliminate the engine oil, sediment, carbon or other contaminants on surface of cylinder body.

74



Attention: ■

Be careful to prevent gasket materials from falling into the engine oil or coolant.

■

Measure

planeness of

cylinder

body in

Ruler

Fig.1.1.060

different directions at six positions using ruler and feeler gauge. Standard values: below 0.05mm Limits: below 0.1mm Feeler Gau e

If the limit is exceeded, replace cylinder body.

⑥

Cylindricality of Cylinder

Measure the cylinder degree at 6 different points per cylinder by using micrometer. Standard values: For cylinder bore: 75.0mm For cylindricality: below 0.07mm

⑦

Diameter of Piston Skirt

Fig.1.1.061

Use outside micrometer to check whether the piston skirt is distorted. Standard values:74.973mm

Dial Indicator

⑧

Clearance between Piston and Cylinder Bore

Calculate per the actual measurement of piston skirt and cylinder bore. (Gap) ＝ (inner diameter of cylinder) － (diameter of piston skirt) Standard value: 0.02-0.04mm If the calculated value exceeds the limit, replace piston a nd piston ring assembly.

⑨

Boring Cylinder

a.

The piston with extended size to be used should be determined in accordance with the cylinder which has the highest bore.

Pistons of the following extended sizes, i.e. 0.25mm, 0.50mm, 0.75mm and 1.00mm, are applicable. b.

Measure the diameter of piston to be used.

After boring cylinder, clearance between piston and cylinder bore must be within standard range. The 75



piston diameter should be measured at the position shown in Figure. c.

Calculate the boring size based on the piston diameter.

[Boring size] ＝ [outer diameter of piston] ＋ [clearance between piston and cylinder (0.02-0.04mm)]

－ [grinding margin (0.02mm)] d.

Boring each cylinder till it obtains the calculated boring size.

Attention: ■

To avoid the distortion due to heat during the boring course, bore the cylinders in following sequence: Cylinder 2 → Cylinder 4 → Cylinder 1 → Cylinder 3

e.

Grind the cylinder till it meets the final processing size (outer diameter of piston ＋ clearance between piston and cylinder)

⑩ Diameter of Main Crankshaft Journal Measure the main crankshaft journal b y the outside micrometer. Standard value: 46.0mm If it exceeds the standard, please follow the rules of selection to replace.

⑪ Diameter of Main Journal of Connecting Rod Measure

the

diameter

of

main

journal

of

Fig.1.1.062

connecting rod by using outside micrometer.

Dial Indicator

Standard values:43.0mm Replace the connecting rod bearing shell if measurement exceeds standard value.

⑫ Gap of Connecting Rod Bearing Shell Note: Use the plastic divider to perform the measurement. a.

Clean any engine oil from the connecting rod journal and connecting rod bearing shell.

b.

Put the plastic divider on the connecting rod journal, and asset it to a length equal to

Fig.1.1.063

bearing shell width. The plastic divider must be placed at the center of connecting rod journal and be parallel with the axial line of connecting rod. c.

Lightly put the connecting rod cover to specified place, and screw the bolt to specified torque.

d.

Dismount the bolt, then take off the connecting rod cover slowly.

e.

Measure the pressed portion of plastic divider at the widest point by the scale which is printed on the plastic divider bag.

76


Maintenance Manual of Tojoy Sedan Standard value: 0.02 - 0.04mm + (0.01mm) expansion Limit:0.1mm

⑬ Roundness and Cylindricality of Crankshaft Measure sizes of each main crankshaft journal and main connecting rod journal at four different

Fi .1.1.064

positions as shown in the figure. ■

The difference between “X” and “Y” of “A” and “B” represents the roundness.

■

The difference between “A” and “B” of “X” and “Y” represents the cylindricality.

Limits: For roundness: equal to or less than 0.05mm For cylindricality: equal to or less than 0.05mm Calibrate or replace the crankshaft if the measurements exceed the limits.

⑭ Clearance of Crankshaft a.

Wipe off oil from the crankshaft journal and the inner surface of bearing shell.

b.

Mount the bearing shell.

c.

Set the plastic divicer till its width equals to the width of bearing shell. Then put them on the journal along the axial line of journal.

d.

Lightly mount the crankshaft bearing shell cover, and screw the bolt till to specified torque.

e.

Dismount the bolt and lightly take off the crankshaft bearing shell cover.

f.

Measure the pressed portion of plastic divider Plastic Wire Gauge

at the widest point by the scale which is

Fig.1.1.065

printed on the plastic wire gauge bag. Standard values: 0.02-0.04mm Limit:0.1mm

Attention: ■

Fig.1.1.066 Round-angle Rolling Area

The connecting rod journal and main journal of crankshaft should be rolled but needn't to be machined to the reduced size.

77



⑮ Flywheel Check whether the flywheel and the signal disk are distorted or cracked. Attention: ■

Do not disassemble the flywheel.

⑮

Crankshaft signal wheel

Fig.1.1.067

Check whether the crank signal wheel has distortions, cracks and other anomalies. Check whether the bolts are loose

3)

Assembly

①

Blow away any oil and coolant from the cylinder body, the cylinder bore and the crankcase. Remove any foreign bodies.

Attention: ■

Use goggles to protect your eyes.

②

Install the upper and lower main bearings shells.

Attention: ■

Select the bearing shells by using the identification marks of crankshaft (See the table below). If the crankshaft can not be identified, measure the diameter of crankshaft, and then select the corresponding bearing shell to match the crankshaft.

Crankshaft group marking Main bearing Hole group marking 0 (up / down)

1

2

3

4

5

Black／Black

Black／Yellow

Black／Red

Black／White

Black／Purple

1 (up / down)

Yellow／Black

Yellow／Yellow

Yellow／Red

Yellow／White

Yellow／Purple

2(up / down)

Red／Black

Red／Yellow

Red／Red

Red／White

Red／Purple

a.

Remove any dust, dirt and oil from the matching surfaces of cylinder body and main bearing cap.

b.

Install intermediate and upper bearing shells on the cylinder body

c.

Be aware of direction of bearing shell during the installation.

■

Bearings shells with oil holes and slots should be installed at block side; other shells should be installed at the main bearing cap side.

■

For installation of bearings, clean before installation. Please apply engine oil to the bearing surface. Do not use oil on the back, but to thoroughly clean it.

■

During installation, align the extrusion on bearing shell with the cut of cylinder body and main bearing cap.

78


Maintenance Manual of Tojoy Sedan ③

Add oil to bearing surface

Install crankshaft on cylinder block. When rotating the crankshaft by hand, check whether the rotation of crankshaft is smooth.

④

Install main bearing cap.

■

The main bearing cap can be identified through

Arrow Points to Timing Belt Side

Bearing Cap No

Fig.1.1.068

mark. ■

Install the main bearing cap starting from the front of the engine according to the ordering numbers.

■

Arrow must point to engine front.

⑤ Screw the bolts for main bearing cap in numerical sequence shown in right figure. a.

Apply new engine oil onto the thread and fixing surface of bolts of main bearing cap.

b.

Tighten bolts for main bearing cap in steps.

■

Tightening torque: 35±2N·m

c.

Screw all bearing cap bolts by 60-64° clockwise.

■

After installation of bolts of main bearing cap, verify that the crankshaft can be rotated smoothly by hand.

■

Check the axial clearance of crankshaft. See “Axial clearance of Crankshaft”.

⑥

Install piston onto the connecting rod with following instructions.

a.

Fig.1.1.069

Measure the following lengths (See right Figure).

A： Distance from piston flange to piston flange outside B： Distance from piston flange to piston flange inside

P i s t o n

Connecting Rod

P i s t o n

C： Length of piston pin. D： Thickness of small end of connecting rod. b.

Introduce

the

measurements into

following

formula: L ＝ [(A-C)-(B-D)] ／2 c.

Insert push rod (special tool) into the piston pin, and then install guide sleeve.

d.

When mounting the piston and the connecting rod, keep the front marks at same side.

e.

Apply the engine oil onto the outer circle of piston pin.

f.

Starting from the guide sleeve, press the guide sleeve, piston pin and push rod into the piston front mark side. 79


Maintenance Manual of Tojoy Sedan g.

Screw

in

the

guide

sleeves,

clearance

Fig.1.1.070

between the two sleeves should be 3mm plus the calculated L in Step 2. h.

With the front mark facing downwards, install piston and connecting rod on mounting base of piston pin.

i.

Install piston pin by the press. Guide Sleeve A

Guide Sleeve B

Attention: ■

If the pressing load exceeds specified value, replace the piston pin and piston assembly and/or the connecting rod.

Standard value: 108±54N·m

⑦

Install piston pin.

Attention: ■

When mounting the piston ring, do not damage the piston.

■

Do not damage the piston ring due to the excessive expansion.

a.

Install oil ring

a)

Install oil ring lining ring into the piston ring groove. Then install the upper and lower blades.

Attention: ■

Lining ring and blade can be installed in two directions

There is no difference between

upper and lower blades. ■

Lining ring and blade size coloring scheme. Table of lining ring and blade size coloring scheme

b)

Size

Color

Standard

Colorless

Extended by 0.50mm

Blue

Extended by 1.00mm

Yellow

To install the blade, install one end of blade into the groove (as shown in the diagram) before pressing the other areas to place.

Attention: ■

Fig.1.1.071

Do install blades by using piston ring expander, otherwise, they may break.

c)

After installation of the blades, check whether they can move smoothly in both directions. Piston Ring Expander

80


b.


Install first and second piston rings.

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

Opening direction of combined oil ring lower blade

Opening direction of lining ring of combined oil ring

Opening direction of second gas ring

Opening direction of combined oil ring upper blade Engine front-end

⑧

Install bearing shell onto the connecting rod and the connecting rod cover.

■

Apply engine oil onto bearing surface of shells before installation. Do not use engine oil on the back but to thoroughly clean it.

⑨

Install piston and connecting rod assembly onto the crankshaft.

■

Place the crankshaft journal which is corresponding to the connecting rod to be mounted at the just center of bottom.

■

Apply sufficient engine oil onto cylinder bore, piston and crankshaft journal.

■

Align air ring opening with oil ring opening. See Fig.1.1.097. Schematic Diagram for Piston Ring Location Opening direction of first gas ring

Opening direction of combined oil ring lower blade

Opening direction of lining ring of combined oil ring

Opening direction of second gas ring Opening direction of combined oil ring upper blade Engine front-end

■

Install piston rod assembly in corresponding cylinder according to marks on connecting rod.

■

Make sure that the front mark on piston top faces to timing belt, and then press the piston and connecting rod assembly into the cylinder from the cylinder upside.

81


Make the piston ring with front mark facing the front


Fig.1.1.072

end of engine by the piston ring compressor or other suitable tool, then install piston ring onto piston head. Attention: ■

Do not damage cylinder wall or crankshaft journal by the big end of connecting rod.

■

Do not to damage big bonnet and connecting rod fitting surface

⑩ Install connecting rod cover. During installation, first use high pressure gas for Fig.1.1.073

blowing the expansion sections. When tightening connecting rod bolt, the order of “5Nm→10Nm→13Nm+45°+45°”alternate methods should be followed. After piston connecting rod assembly is installed, verify that clearance for the connecting rod big end is 0.10 - 0.30mm.

Attention: Connecting rod bolts can only be used once.. Before installing nut, apply engine oil on its thread and seat.

⑪

Install rear oil seal housing of crankshaft with rear oil seal assemble to the cylinder block.

⑫

Installation of knock sensor, Hall sensors, oil pressure switch.

Attention: ■

Do not screw the nut when grasping the joint.

■

If the knock sensor is shocked, replace with a new one.

Note: Be sure that there is no foreign body at the matching surface of cylinder body or the back side of knock sensor.

⑬ Be aware of following to install with steps contrary to dismantlement. ■

Flywheel

Alternately tighten bolts to specified torque.

82



XIV. Diagnosis of Common Troubles Diagnosis List of Common Troubles Trouble

Low cylinder pressure

Low oil pressure

High engine oil pressure

Engine quiver

Noise of valve Noise from connecting rod bearing shell and the main bearing shell

Poor cooling performance

Jam in radiator

High temperature of coolant

Possible Cause

Resolution

The cylinder gasket is leaky.

Replace cylinder gasket.

The piston ring is damaged or worn.

Replace the piston ring.

The cylinder or the piston is worn.

Repair or replace the piston or the cylinder body.

The valve seat is worn or damaged.

Repair or replace the valve seat.

The volume of engine oil is insufficient.

Check oil level.

The engine oil pressure sensor failed.

Replace sensor.

The engine oil filter is blocked.

Replace filter.

Oil pump rotor or cover damaged

Replace.

The viscosity of engine oil is low.

Check. Change oil as required.

The plunger of engine oil pressure switch is constantly open.

Repair.

The bearing gap is high.

Replace.

The plunger of engine oil pressure switch is constantly closed.

Repair.

The engine supporting bolt loosened

Tighten

The transmission mounting support loosened.

Tighten

The engine support loosened

Tighten

The heat shield for engine is damaged.

Replace.

The engine support heat shield is damaged.

Replace.

The heat shield for transmission is damaged.

Replace

The engine oil is thin (low oil pressure).

Change oil.

The valve or the valve guide is damaged or worn.

Replace.

The oil is insufficient.

Check the level of engine oil.

The engine oil is thin (the oil pressure is low).

Change oil.

The bearing gap is wide.

Check and then determine the cause.

The radiator or the radiating pipe is leaky.

Repair or replace.

The water tank cover is not sealed.

Tighten or replace the cover.

The thermostat is leaky.

Replace the thermostat pad.

The radiator is leaky.

Repair or replace.

The water pump is leaky.

Replace.

The coolant contains the impurities.

Replace the coolant.

The water tank cover is not strictly sealed.

Replace.

The cooling system is jammed.

Rinse or replace.

The thermostat is at fault.

Replace.

The belt skids.

Adjust or replace.

The water pump is at fault.

Replace.

83

Maintenance Manual of Tojoy Sedan Trouble

Low temperature of coolant Ineffective fan

Exhaust system leaks

Abnormal noise


Possible Cause

Resolution

The sensor is at fault.

Repair or replace.

The fan is at fault.

Repair or replace.

The coolant is insufficient.

Replenish

The thermostat is at fault.

Replace.

The sensor or the wire harness is at fault.

Repair or replace.

The sensor or the starter is at fault.

Repair or replace.

The fan relay or the wire harness is damaged.

Repair or replace.

The joint loosened.

Tighten it

The exhaust pipe or the muffler is damaged.

Repair or replace.

Exhaust pipe gasket damaged

Replace.

The muffler loosened

Tighten it

The rubber pad cut off

Replace.

The exhaust pipe or muffler contacts vehicle body.

Correct

The exhaust pipe or the muffler is damaged.

Repair or replace.

84



XV. Parameters for Maintenance 1.

List for Technical Parameters of Engine Technical Parameters list of Engine Item

Standard Value

Limits

Camshaft base circle diameter (mm)

36

—

Diameter of camshaft journal (mm)

32.033-32.082

—

Planeness of cylinder gasket surface (mm)

＜0.03

0.1

Total height of cylinder head (mm)

112.9-113.1

—

1.35

0.85

0.85

1.85

1.35

1.35

Φ5

—

Camshaft

Cylinder head and valve

Thickness of valve edge (mm) Diameter of valve stem (mm) Clearance between valve stem and

Intake valve

0.020-0.047

0.10

valve guide (mm)

Exhaust valve

0.030-0.057

0.15

45°-45.5°

-

Intake valve

53.21

53.71

Exhaust valve

54.10

54.60

Intake valve

89.61

89.11

Exhaust valve

90.94

90.44

43.1

42.7

152/33.4

-

310/25.2

-

Perpendicularity of valve spring

＜2°

4°

Contact width of valve seat (mm)

0.9-1.3

-

Inner diameter of valve guide (mm)

Φ5

-

Protrusion of valve guide (mm)

23.0

-

φ10.655-10.665

-

φ10.855-10.865

-

φ11.105-11.115

-

Conical angle of valve Protrusion of valve stem (mm)

Total length of valve (mm)

Free height of valve spring (mm) Load / mounting height of valve spring (N)/(mm)

Diameter of size-extended valve guide on cylinder head (mm)

Intake Diameter of size-extended valve seat ring hole (mm) Exhaust

Extended by 0.05mm Extended by 0.25mm Extended by 0.50mm Extended by 0.3mm Extended by 0.6mm Extended by 0.3mm Extended by 0.6mm

85

Φ31.925-31.945

-

Φ32.225-32.245

-

φ28.425-28.445

-

φ28.725-28.745

-


Item


Standard Value

Limits

Addendum gap of oil pump

0.06-0.18

—

Side clearance of oil pump(mm)

0.04-0.11

—

Clearance of oil pump housing

0.10-0.18

0.35

75.0

—

0.03-0.07

0.1

piston ring

0.02-0.06

0.1

1 piston ring

0.15-0.30

0.8

piston ring

0.30-0.50

0.8

Oil ring

0.20-0.50

1.0

Outer diameter of piston pin (mm)

18.0

—

Pressing load on piston pin (under room temperature) (N)

4900-14700

—

Oil gap of crankshaft pin (clearance of connecting rod journal) (mm)

0.014-0.059

0.1

Side clearance of big end of connecting rod (mm)

0.10-0.35

0.4

Axial clearance of crankshaft (mm)

0.09-0.27

0.25

Diameter of main journal of crankshaft (mm)

46.0

—

Diameter of connecting rod journal (mm)

40.0

—

Clearance of main journal of crankshaft (mm)

0.014-0.034

0.1

Plainness of surface of cylinder body gasket (mm)

0.05

0.1

Total height of cylinder body (mm)

280

—

Cylindricality of cylinder body (mm)

<0.007

—

—

-

0.01-0.035

—

Oil pump and oil pan

Piston and connecting rod Reference outer diameter of piston (mm) st

Side clearance of piston ring mm)

1 piston ring nd

2

st

Gap of piston ring opening (mm)

nd

2

Crankshaft and cylinder body

Reference cylinder bore (mm)

75.0

Clearance between piston and cylinder (mm)

86



Tightening Torques List of fastener tightening torque Name

Specification

Qty.

Tightening Torques (Nm)

High strength bolt Main bearing cap bolt

M9×1.25×74.5

10

35±2Nm +60°-64° (Synchronous fastening machine) 5Nm → 13Nm +90 ° - 94 °

Connecting rod bolts tightening M6×0.75×33 torque

8

Camshaft bearing cap bolt

M6×1×35

16

11±1

Front camshaft bearing cap bolt

M8×1.25×30

3

20±1

Cylinder head bolt

M9×1.25×143.5

10

24.5±2Nm +180°-184°

Crankshaft pulley bolt

M14×1.5×54

1

50Nm±2Nm+60°±2°or165 Nm±5 Nm

Flywheel bolt

M11×1.25×25

6

100±5

Exhaust camshaft sprocket bolt

M12×30

1

88±10

Valve timing adjuster bolt

M10×41

1

64.5±5.5

(Manual) 5Nm → 10Nm → 13Nm +45 ° +45 ° alternate tightening

E-type bolt Crankshaft rear oil seal bolt

M6×10 E8

6

7.6±0.6

Rear lug blot

M8×20 E10

2

18.4±1.4

Intake manifold bolt

M8×40 E10

5

18±1.0

Oil pan bolt

M6×12 E8

14

7.6±0.6

Sprocket cover bolt I

M10×90 E14

2

39.5±3.0

Sprocket cover bolt II

M10×50 E14

2

39.5±3.0

Sprocket cover bolt III

M6×30 E10

2

8.4±0.6

Bolt M6×20 E10

M6×20 E10

2

8.4±0.6

Bolt M6×12 E10

M6×12 E10

3

8.4±0.6

Bolt M6×45 E10

M6×45 E10

2

8.4±0.6

Bolt M6×25 E10

M6×25 E10

7

8.4±0.6

Bolt M6×12 E8

M6×12 E8

1

8.4±0.6

Bolt M6×25 E10

M6×25 E10

2

8.4±0.6

Cylinder head cover bolt

M6×27 E10

10

9±1.0

Oil filter bracket bolt

M8×30 E12

3

20±1

Heater water returning pipe bolt

M6×20 E8

2

7.6±0.6

Hydraulic oil rail bolt

M8×35 E12

2

18.4±1.4

Plug Main oil passage plug I

Inner hex M20

2

60±5

Main oil passage plug II

Inner hex M12

1

35±5

Water drainage plug

Inner hex M12

1

25±5

Oil passage plug

Inner hex M10

1

20±2

VVT oil passage plug

M14×1.5×14

1

44±5

Oil drainage plug

M14×1.5×14

1

39±5

87



Other bolts Set track bolts

M6×1×12

2

10±2

Dynamic track bolts

M8×1.25×15

1

23.5±4.5

Starter bolt

M8×55

2

24±3

Oil pressure switch

R 1/8

1

10±2

Spark plug

M14

4

34±4

Exhaust manifold stud

M8×1×12

6

22±2.5

2

See "Standard parts and threaded connections not mentioned in table above"

3

10±1

Q2580614 (crank signal wheel bolt) M6

3

12.5±2.5

Water temperature sensor

1

20±4

Q1840830 (exhaust bracket bolt)

manifold M8×30

Catalytic gas shroud nut

M6×1

Hall sensor bolt

Inner hex M6×1×16

2

8.4±0.6

Knock sensor bolt

Inner hex M8×1.25×30

1

20±4

Exhaust manifold nut

M8

5

35±2

4

6±0.5

Throttle self-tapping screw Absolute pressure self-tapping screw

sensor

9.0±1

Square head bolt

M10×1.25×90

1

47±5

Idle wheel bolt

M10×1.25×38

1

49±9

2

35±5

1

After contact mounting surface, turn by 3 / 4 laps or 11 ± 1Nm

Oxygen sensor Oil filter

Standard parts and threaded connections not mentioned in table above M6

9-11

M8

20-25

M10

30-50

M12

60-80

88



Section II Engine Lubrication System I.

Precautions

Application Steps of Sealant: 1. Remove any old sealant on the seal gasket by using scraper. Fig. 1.2.001 Scraper

Attention: ■

Thoroughly remove old sealant from grooves, fixed bolts and bolt holes on sealant application surface.

2. Wipe sealant surface and matching surface clean with special cleaner, remove water drops, grease and foreign substances. 3. Set the sealant with specified type completely on appointed position. 1)

Install the matching parts in a certain period of time after sealant applied.

2)

If there is any dirt on sealant, remove immediately.

3)

Do not retighten the bolt and nut after installation.

4)

Fill oil and coolant 30min after installation.

89

Maintenance Manual of Tojoy Sedan II.

Preparation

1.

Repair Tools


List of repair tools No.

Tool

1

Oil pressure gauge

Outline Drawing

Explanation

Measure oil pressure

Connect oil pressure 2

Hose

gauge to cylinder body

3

Oil pressure switch

Dismount and mount

socket

oil pressure switch

90


Maintenance Manual of Tojoy Sedan III. Lubrication system schematic diagram Lubrication System Diagram of 1.3L Engine Main oil gallery Main oil gallery of cylinder head Filter

VVT screen

Bearing hole of first air intake camshaft

Main bearing

OCV (Oil control valve)

C3 oil gallery of air intake camshaft Pressurelimiting valve

Main shaft journal of crankshaft

Oil pump valve Connecting rod journal of crankshaft

Oil pickup

e l z z o n n o i t a c i r b u l n i a h c g n i m i T

r e n o i s n e t c i t a m o t u A

Air intake camshaft

Oil gallery of first camshaft bearing cap

C1 cylinder head gallery (right side)

C1 oil gallery of first camshaft bearing cap

C2 oil gallery of first camshaft bearing cap

Exhaust camshaft C1 oil gallery of air C2 oil gallery of air intake camshaft intake camshaft Air intake camshaft bearing hole 2, 3, 4, 5

Connecting rod bearing

C1 cylinder head gallery (left side)

Air intake cam with mechanical tappet

Exhaust camshaft bearing hole 2, 3, 4, 5 Exhaust cam with mechanical tappet

VVT (valve timing adjuster) Remarks: 1. Splashing means is used for lubrication of cam and tappet 2. Oil returning of VVT is achieved through OCV internal valve plug. 3. Oil ports at front air intake camshaft are defined respectively as C2, C1 and C3.

Oil pan IV. Engine Oil 1.

Check

1)

Engine oil level

Note: Before starting the engine, park the vehicle steadily to check oil level. If engine has been started, stop engine and check it after 10min.

① ②

Pull out the oil gauge and clean it .

Fig. 1.2.002

Insert the gauge; confirm that the oil level in engine is between the two marks as shown.

③

Please adjust the oil level if it is out of range.

2)

Appearance of engine oil

①

Check the engine oil for any white turbidity and/or severe pollution.

②

If the oil is turbid or polluted, it may be caused by engine coolant. Please repair or replace the damaged parts.

3)

Leakage of engine oil

Check the following areas for oil leakage. ■

Oil pan 91


Oil drainage bolt on oil pan

■

Oil pressure switch

■

Oil filter

■

Matching surface of cylinder body and cylinder head

■

Front and rear oil seals of crankshaft

■

Matching surface of oil pump and cylinder body

4)

Inspect oil pressure


Attention: ■

As the temperature of engine oil is high, please prevent yourself from being hurt.

■

Check oil pressure after vehicle parked.

①

Check oil level. Please refer to “Engine oil

Fig. 1.2.003

level”.

②

Lift the vehicle, disconnect harness connector at oil pressure switch and remove the oil pressure switch.

③

Install oil pressure gauge and hose.

④

Start engine and warm up to normal working temperature.

⑤

Inspect oil pressure when engine operates with no load.

Fig. 1.2.004

Note: The engine pressure will increase when the temperature of engine oil is low. ■

If there is obvious difference, please inspect oil circuit and oil pump for leakage.

⑥

Install the pressure switch in accordance with the following steps after inspection:

a.

Remove any used sealant attached on pressure switch and engine.

b.

Apply sealant as specified and tighten the pressure switch.

■

Please use the specified sealant: LT5699 or equivalent. 92



■


c.

After the engine is warmed up, make sure there is no oil leakage during normal operation of engine.

2. Change Oil Attention: ■

As the temperature of engine oil is high, please protect yourself from being hurt.

■

Avoid direct contact of your skin with waste oil for a long time. If contact has taken place, wash thoroughly with soap or detergent as soon as possible.

①

Warmup the engine to check engine compartment for oil leakage. Please refer to “Leakage of engine oil”.

②

Stop the engine and wait for 10min.

③

Loosen engine oil filler cap and remove the oil drain bolt.

④

Discharge the engine oil.

⑤

Install the oil drain bolt with new washer.

Attention: ■

Be sure to clean oil drain bolt and install with new gasket.

■

Tightening torque of oil drain bolt: 34-44N·m

⑥

Fill new oil.

Please refer to “Maintenance” for specification and viscosity of oil. ■

Oil volume: 4L

Attention: ■

Do not pull out oil gauge when filling oil.

■

The oil filling volume varies with oil temperature and oil drainage time, thus the above data are only for reference.

■

Always use oil gauge to check oil filling volume.

⑦

Warm up engine and check the oil drain bolt and oil filter for oil leakage.

⑧

Stop engine and wait for 10min.

⑨

Check the oil level. Please refer to “Engine Oil Level”.

93


V.

Oil Filter

1.


1)

Dismantlement


Fig. 1.2.005

Dismount the oil filter with an oil filter spanner.

Attention: ■

Use original oil filter provided by JAC or equivalent.

■

As the temperatures of engine and engine oil are high, please proetct yourself from being hurt.

■

During dismantlement, prepare a cleaning cloth to absorb leaked or splashed oil.

■

Do not make the engine oil stick on drive belt.

■

Thoroughly wipe and dry the engine oil splashed on the engine and vehicle.

2)

Installation

①

Remove any foreign substances attached on mounting surface of oil filter.

②

Fig. 1.2.006

Apply a film of engine oil on oil seal surface of new oil filter.

③

Tighten the oil filter until the O-ring seating on the installation surface; tighten the oil filter by more 0.75 lap or get the tightening torque to 11 ± 1N • m.

Attention: ■

The oil filter must be tightened with filter spanner.

■

If the filter is tightened by hand, oil leakage may occur due to inadequate tightening torque.

2.


1)

Check oil level. Please refer to “Engine Oil”.

2)

Start engine to check whether there is oil leakage.

3)


4)

Check oil level and fill as required. Please refer to “Engine Oil”.

94


Maintenance Manual of Tojoy Sedan V.

Oil Pan and Engine Oil Pump

1.

Parts

12

1 13 6 14

10

7

8

2

9 5

11 15

4

3

Breakdown drawing of oil pan and oil pump 1 - oil filter bracket gasket 2 - oil filter bracket bolt 3 - oil filter 4 - oil pan bolt 5 – oil pan assembly 6 - oil pickup 7 - oil pickup bolt

8 - oil filter bracket 9 – oil drainage bolt 10 – oil drainage bolt washer 11 -

water pump seal 12 - oil pump assembly 13 - automatic tensioners observation manhole cover 14 crankshaft front oil seal 15 - Pump 2.

Dismantlement

Caution: ■

Do not discharge engine oil when engine is hot so as to avoid being hurt.

1)

Remove external mounted generator, power steering pump, cylinder head cover and other parts to the oil pump assembly.

2)

Discharge engine oil. Please refer to “Change Engine oil”.

95


3)

Dismount oil pan.

a.

First, use loosening agent for sealants in order


Fig. 1.2.007

to prevent oil pan sealing surface from deformation. b.

Loosen the fixed bolts according to following sequence: center-both sides.

■

Tightening torque:7.6±0.6 N·m

c.

Knock the special tool into the space between

Fig. 1.2.008

oil pan and cylinder body as shown in Fig. 1.2.008. d.

Slightly knock the side of special tool, in order to make the tool move along the sealing surface of oil pan/cylinder body, and then dismount the oil pan.

Attention: ■

Do not damage the matching surface.

4)

Dismount oil pump housing assembly. assembly.

5)

Dismount oil pickup.

Fig. 1.2.009

Attention: ■


3.


1)

Oil pickup

■

Remove any attached foreign bodies of oil pickup.

2)

Oil pump housing assembly

■

Check the oil hole of oil pump casing assembly for blockage, and clean it if necessary. necessary.

■

Check the oil pump casing assembly assembly for crack or other damage. If there is any, any, please replace.

4.

Installation

1)

Install oil filter set.

96



2)

Install pump housing assembly. assembly.

3)

Install external generator, power steering pump, cylinder head cover and other parts parts on the oil pump

assembly. 4)

Install oil filter.

■

Clean the oil filter mounting surface on oil pump housing.

■

Apply some oil on O-ring of oil filter.

■

Tighten oil filter filter until the O-ring seating on the installation surface; re-tighten the oil filter by 0.75 lap or get the tightening torque to 11 ± 1N • m.

Attention: ■

The oil filter must be tightened with filter spanner. spanner. If the filter is tightened by hand, oil leakage may occur due to inadequate tightening torque.

5)

Install oil pan.

■

Clean cylinder cylinder block and oil pan mating surface to ensure that there are no oil and other impurities.

■

Apply sealant as shown in diagram below. Fig. 1.2.010

Oil pan

Apply sealant as shown in figure.

■

Specified sealant: LT5699 or equivalent.

97


7)

Install oil drainage bolt on oil pan

Fig. 1.2.011

■ The oil drainage bolt gasket for the oil pan is a one-time product, new one should be used after removal. bolt washer of oil pan ■ Install the oil drainage bolt shown in the figure. Attention: ■

After the installation of oil pan, wait at least 30min before filling engine oil.

5.


1)

Check the oil level and fill as required. Please refer to “Engine Oil”. Oil”.

2)

Start engine and make sure sure there is no oil oil leakage.

3)


4)

Recheck the oil level. Please refer to “Engine Oil”.

98



Maintenance Manual of Tojoy Sedan Section III I.

Cooling Circuit

1.

Cooling Circuit Diagram

y e l l u p p m u p t n a l o o c f o s t l o b g n i x i F

r e l l u p p m u p t n a l o o C

p m u p r e t a w r o f s t l o B

y l b m e s s a p m u p r e t a W

p m u p r e t a w f o g n i r l a e S

Cooling System of Engine

I s t l o b e p i p g n i n r u t e r r e t a w r e t a e H

Heater water returning pipe bolts II

Heater water returning pipe

Spacer of heater water returning pipe

Thermost subassembly

Water pump feeder

Water pump inlet bolt

e s o h t e l t u o g n i t a e h e r p e l t t o r h T

Cooling circuit diagram 2.

Principle Diagram of Cooling Radiator

Expansion tank

Thermostat Thermostat casing W e a x r c m h a a n i r g h e e r a t

Water pump

Thermostat on

Cylinder body

Thermostat off

Cylinder cover

Basic diagram of cooling

99

A i r t h r o t t l e b o d y

e s o h t e l t u o g n i t a e h e r p e l t t o r h T


II.

Engine Coolant

1.

Check

1)

Level check


After the engine cooled, check whether coolant level in reservoir is between MIN and Max marks. ■ Adjust level if necessary.

2)

Fig. 1.3.005

Leakage check

Apply pressure to cooling system with leak detector of radiator cap to detect any leakage.

3)

Fig. 1.3.006

Test pressure

Caution: ■

Please do not dismount radiator cap when engine is very hot, otherwise the high-pressure engine coolant overflowing from radiator will cause severe burns.

Attention: ■

Test pressure over specified value may cause radiator damaged.

■

When it is detected that the engine coolant is insufficient, fill engine coolant into radiator. If any parts are damaged, please repair or replace.

2.

Change Coolant

Caution: ■

To avoid being burned, please do not change coolant when engine is hot.

■

Wrap up the radiator cap with thick cloth, and turn to open it carefully. Release the pressure in radiator first, and then fully remove cap. 100



■

Be careful not to splash engine coolant onto the drive belt.

1)

Discharge engine coolant

①

Dismount the deflector on right side of engine.

②

Open the water drain plug at the bottom of radiator, and then open the radiator cover.

③

If necessary, remove coolant reservoir to discharge coolant and clean the reservoir before reinstallation.

④

Check the discharged engine coolant for rust or other impurities or discoloration.

■

If it is polluted, please wash the engine cooling system. Refer to “Wash Cooling System”.

2)

Refill coolant

①

Install removed coolant reservoir and water drain plug of radiator.

Attention: ■

Be sure to clean the water drain plug and install with new O-ring.

②

Make sure all the hose clamps have been tightened firmly.

③

Dismount the air filter upper cover and air intake hose. Please refer to “Air Filter Assembly”.

④

Disconect the outlet pipe of warm water pipe. Please lift the hose as high as possible.

⑤

Fill coolant into radiator and reservior until specified level is achieved. The coolant should be filled slowly allowing air in system can be bleed gradually.

Attention: ■

The original engine coolant provided by JAC must be used. Please refer to “Recommended Oil and Lubricant”.

■

Disconnect when engine coolant overflows from warm water pipe, and then reconnect and continue to fill engine coolant.

⑥

Install air filter upper cover and air intake hose. Please refer to “Air Filter Assembly”.

⑦

Install radiator cap.

⑧

Warm up engine until the thermostat is turned on.

Touch the lower water pipe of radiator to detect whether there is any warm water flows out, so as to verify that the thermostat has been turned on. Attention: ■

Check the engine water temperature indicator to avoid overheating of engine.

⑨

Stop engine to lower the engine temperature.

■

Cooling time can be reduced by using fan.

■

Fill coolant in radiator through the filler if necessary. 101



⑩

Fill engine coolant in reservoir to the MAX position.

⑪

Install the radiator cap and repeat steps ③-⑨ more than twice until the engine coolant level does

not lower any more.

⑫

Run the engine to check the cooling system for leakage.

3)

Wash cooling system

①

Install the dismounted radiator water drainage plug and reservoir.

Attention: ■

Be sure to clean the water drainage plug and mount the new O-ring.

②

Dismount air filter upper cover and air intake hose. Please refer to “Air Filter Assembly”.

③

Remove outlet pipe of warm water pipe. Please lift the hose as high as possible.

④

Fill engine coolant into radiator and coolant reservoir, and install radiator cap.

Remove connection when engine coolant overflows from warm water pipe, and then reconnect and continue to fill engine coolant.

⑤

Install the air filter upper cover and air intake hose. Please refer to “Air Filter Assembly”.

⑥

Run engine to warm it up to normal working temperature.

⑦

Increase engine speed for several times with no load applied to the engine.

⑧

Stop engine and wait for it to cool.

⑨

Discharge the water in system. Please refer to “Discharge engine coolant”.

⑩

Repeat steps ①-⑨ until the radiator begins to discharge the cleared water.

III. Radiator 1.


Caution: ■

Please do not dismount radiator cover when engine is very hot, otherwise the high-pressure engine coolant will cause severe burns. Wrap up the radiator cover with thick cloth and slowly turn it to discharge the air pressure inside. Turn and open the radiator cover and take it off carefully after the pressure is fully released.

1)

Dismantlement

①

Dismount engine deflector. Please refer to “Deflector”.

②

Discharge engine coolant in radiator. Please refer to “Replace Engine Coolant”.

Attention:

■

Operate after engine is cooled.

■

Please do not make the engine coolant splash onto the drive belt.

③

Dismount air intake pipe and take it off.

④

Disconnect the harness connector of radiator fan motor and move it aside. 102



⑤

Dismount the inlet and outlet hoses of radiator and returning hose of coolant reservoir.

⑥

Dismount bracket of radiator and take off the radiator and fan subassembly.

Attention: ■

Please do not damage or scratch the radiator core during dismantlement.

⑦

Disassemble cooling fan sub-assembly from radiator.

2)

Installation

Install in the reverse order with dismantlement. 3)


■

Check if there is any engine coolant leakage with leak detector for radiator cover. Please refer to “Leakage Check”.

■

Start and warm up the engine. Visually inspect whether there is any coolant leakage.

2.

Inspect Radiator Cap

1)

Pull out the negative pressure valve and open it. Check if it can be fully closed after pressure release.

■

Make sure there is no dirt on or damage to negative pressure valve seat of radiator cover.

■ Make sure the opening and closing operations Fig. 1.3.007

of negative pressure valve are normal.

2)

Inspect relief pressure of radiator cap.

Standard value: 78-98KPa

Fig. 1.3.008

Limit: 59KPa Connect the radiator cap to the leak detector for radiator and apply engine coolant to sealing face of the cover. Replace radiator cap if operation of negative pressure valve is abnormal or the relief pressure decreases below limit. 3.

Inspect Radiator

■

Check the radiator for slurry or blockage. If necessary, wash the radiator surface with following methods.

■

Be careful not to bend or damage the radiating fin. 103



When washing the radiator without dismantling it, please dismount all accessories such as cooling fan, wind collection cover and horn. Then wrap up the harness connectors with adhesive tape to prevent water from flowing in.

1)

Wash back of radiator core from top to bottom with the water hose pointing to the radiator vertically.

2)

Wash each surface of radiator core every 1min.

3)

If no dirt is washed off radiator, washing must be stopped.

4)

Vertically blow the back radiator downwards with compressed air. Apply the compressed air with pressure lower than 490KPa and keep the distance above 30cm.

5)

Blow each surface of radiator core with compressed air every 1min until no water is blown out.

V.

Radiator Cooling Fan

1.


1)

Dismantlement

①

Dismount the air intake pipe and take it off.

②

Disconnect the harness connector of radiator fan motor and move it aside.

③

Dismount the radiator cooling fan sub-assembly.

Attention: ■

Do not damage or scratch radiator core during dismantlement.

2)

Installation

Install in the reverse order with dismantlement. 2.


1)

Disassembly

①

Dismount the cooling fan from fan motor.

②

Dismount the fan motor from wind collection cover.

2)

Check after disassembly

①

Cooling fan

Check the cooling fan for cracks or abnormal bend. If any, replace the cooling fan.

②

Fan motor

Check the motor for sticking. 3)

Assembly

Assemble in the reverse order with disassembly. V.

Water Pump

1.

Dismantlement and Installation 104



Attention: ■

Be careful not to splash the engine coolant onto the drive belt while dismantling the water pump.

■

If the water pump can not be disassembled, it should be replaced as a whole.

■

After the installation of water pump, connect the hose, fix it with clamping band, and then check if there is any leakage with leak detector for radiator cover.

1)

Dismantlement

Fig. 1.3.009

① Discharge the engine coolant in radiator. Please refer to “Replace Engine Coolant”.

② Loosen the fixed bolt for belt pulley of water pump.

③

Dismount the drive belt. Please refer to “Drive

Fig. 1.3.010

Belt”.

④

Dismount the fixed bolt for water pump.

Attention: ■


2)


■

Check the water pump body assembly for severe corrosion, leakage of water-seal and erosion.

■

Check the water pump bearing for jamming or other damages. Replace the bearing if necessary.

3)

Installation

①

Clean water pump installation seat.

②

Installation of pumps and replacement of the pump seals.

Attention: ■

Do not let the seal ring drop during installation.

■

Alternately and evenly tighten fixing bolts of water pump.

a.

Install belt pulley of water pump.

105



b.

Install drive belt and adjust it in accordance with specified tension. Please refer to “Drive Belt”.

c.

Fill engine coolant. Please refer to “Refill engine coolant”.

2.


■

Check if there is any coolant leakage with leak detector for radiator cap. Please refer to “Leakage Check”.

■

Start and warm up the engine. Visually inspect if there is any engine coolant leakage.

VI. Thermostat Sub-assembly 1.


1)

Dismantlement

①

Discharge the engine coolant through water drain plug of radiator. Please refer to “Replace Engine

Fig. 1.3.011

Coolant”. Attention: ■

Operate after the engine has cooled.

■

Please do not splash the engine coolant onto the drive belt.

② Disassemble water inlet pipe and heater returning pipe of radiator at thermostat side.

Fig. 1.3.012

③ Disconnect the harness connectors of coolant temperature sensor and water temperature alarm switch and fixed bolts for support racks of harness connectors of front and rear oxygen sensors, and then remove them.

④ Unscrew water pump inlet bolt,

remove the Fig. 1.3.013

thermostat.

106


2)


Fig. 1.3.014


① Thermostat ■ Inspect opening of thermostat valve at normal room temperature. Temperature of thermostat (ON): 82℃ (initially open) 95℃ (fully open)

Maximum lift of valve stem: ≥8mm Please replace the thermostat when the measurement exceeds the specified range.

②

Water pump inlet and thermostat housing

Check them for cracks and other damages. 3)

Installation

Be aware of following precautions to install with steps contrary to dismantlement.

①

Be careful not to splash engine coolant onto the engine and wipe and dry the engine coolant with cleaning cloth.

②

Replace the thermostat seal ring.

Attention: ■

Do not apply engine oil or other oil substances to the seal ring.

■

Water pipes on thermostat housing must be installed solidly.

③

When mounting thermostat, its poppet valve must be set at the highest position.

Fig. 1.3.015

Highest

④

If the water temperature alarm switch needs to be reused, apply specified sealant to its thread.

■


107

Fig. 1.3.016


⑤

If the engine coolant temperature sensor needs to be reused, apply specified sealant to


Fig. 1.3.017

its thread. ■


2.


■

Check for any coolant leakage with leak detector of radiator cap. Please refer to “Leakage Check”.

■

Start and warm up the engine. Visually inspect if there is any engine coolant leakage.

VII. Water Piping Sub-assembly 1.

Dismantlement

①

Discharge the engine coolant through water drainage plug at the bottom of radiator. Please refer to “Replace Engine Coolant”.

Attention: ■

Operate after the engine has cooled.

②

Dismount the air filter assembly. Please refer to “Air Filter Assembly”.

③

Dismount the upper and lower water hoses of radiator.

④

Dismount the warm water hose and minor cycle water piping.

⑤ Unscrew water inlet pipe bolt before disassembling the water inlet pipe from back of water pump. Attention: ■

Please dismount the negative terminal of battery before dismantlement.

2.

Installation

Be aware of following precautions and install with steps contrary to dismantlement. 1)

Firmly insert each hose. Mount the clamp properly so that it will not clamp the raised position of water piping.

2)

Replace the steel water returning pipe gasket of heater.

Attention: ■

Do not apply engine oil or other oil substances to the seal ring.

■

Water pipes on thermostat housing must be installed solidly.

3.


1)

Check if there is any engine coolant leakage with leak detector for radiator cap. Please refer to “Leakage Check”.

2)

Start and warm up the engine. Visually inspect if there is any engine coolant. 108



VIII. Trouble Analysis Table for Overheating Cause Analysis Symptom

Item should be inspected Water pump malfunction

Worn or loosening of drive belt

Stuck of thermostat at closed position Improper heat radiation

Radiator is damaged

Blockage due to dust or paper scraps

—

Mechanical damage

F a i l e d P a r t s o f C o o l i n g S y s t e m

The radiator cooling is blocked

Insufficient air flow

The cooling fan fails to work The resistance for fan rotation is too large

Excessive foreign substances (corrosion, pollutants, sand, etc.)

Fan assembly

—

—

—

—

—

—

—

—

Viscous engine coolant

The fan blade is damaged Damaged wind collection cover Incorrect blend ratio of coolant Poor quality of engine coolant

Coolant hose Water pump Insufficient engine coolant

Engine coolant leaks

Radiator cap

Loose clamp Broken hose Improper sealing Looseness Poor sealing Broken radiator coolant reservoir Broken radiator core

Coolant reservoir

— T r o u b l e o f P a r t s o f O t h e r S y s t e m s

The engine is overloaded

Abnormal driving

Breakage of stock solution tank Excessively high engine speed in the case of no-load Long-term traveling Driving at ultra high-speed

Drive train failure

Wheel and tyre with incorrect specifications mounted Braking drag Incorrect ignition timing The vent of bumper is blocked Poor ventilation

The radiator grill is blocked The radiator is blocked The condenser is blocked

109

—

— Cover mounted Blockage of slurry or paper scraps — Poor ventilation

—


Maintenance Manual of Tojoy Sedan IX. Parameters for Maintenance Technical specification for cooling system Temperature of thermostat opening

82℃ (Initially open) 95℃ (Fully open)

Maximum lift of thermostat valve stem

>8mm

110

Maintenance Manual of Tojoy Sedan Section IV I.


Fuel Supply System of Engine

General Precautions

Caution: The following rules should be complied with during the replacement of parts of fuel pipeline. ■

Set the mark “Attention: combustive” in workshop.

■

Be sure to operate in the well-ventilated area, and prepare C02 fire extinguisher in the operation workshop.

■

Do not smoke during the fuel system servicing. No fire in working area.

■

Hold the discharged fuel in the container and cover it. Put the container in safe area.

When disassembling the fuel pipe components, note the following: ■

Disconnect negative pole of battery.

■

Replace with new clips all the time.

■

Do not distort the fuel pipe during installation.

■

Please operate on level ground.

■

Connect the fuel pipe joint and make sure the joint has been fixed. Make sure the joint and resin pipe don’t contact any adjacent parts.

■

Do not excessively tighten the hose clips to prevent damage of hose.

■

Check each connection for fuel leakage according to following steps after installation of fuel pipe.

-

Set the ignition switch at “ON” position to apply fuel pressure on fuel pipeline (do not start the engine). Then check each connection for fuel leakage.

-

Start the engine, increase its speed and check each connection for fuel leakage.

■

Only the original fuel filler cap provided by JAC can be used.

■

Please refer to “Fuel Evaporative Emission System” for maintenance of parts of the system.

111



Preparation

The special tools are listed in the table below: List of Special Tools S.N.

Tool

1

Fuel pressure gauge

Outline Diagram

No.

Explanation

JAC－T1F018

Measure fuel pressure

III. Fuel System 1.

Check Fuel Pipe

Check the fuel pipeline, fuel filler cap and fuel tank for proper installation, leakage, crack, damage, loose connection, worn and aging. 2.

Inspect Fuel Pressure

Attention: ■

Always keep the joints of fuel hose sealed with O-ring.

■

Do not operate electrical system during inspection.

■

Prepare a container under the fuel pipe to be disconnect to avoid fuel splash.

1)

Fully release fuel pressure. Please refer to “Release Fuel Pressure”.

2)

Dismount the nut for fuel pressure inspection door on fuel injector guide rail.

3)

Connect fuel pressure gauge.

4)

Set ignition switch at “ON” position and check for fuel leakage.

5)

Start engine and check if there is fuel leakage.

6)

Obtain the reading shown in fuel pressure gauge.

■

Fuel pressure: 350KPa

Attention: ■

Do not check fuel pressure during system operation.

■

During the Inspection of fuel pressure, please always check the fuel piping for leakage.

7)

If the check result is not good, turn to the next step. 112


Check for the following matters.

-

Blockage of fuel hose and fuel pipe.

-

Blockage of fuel filter.

-

Fuel pump and its control circuit.


IV. Fuel Injector and Guide Rail 1.

Dismantlement

Caution: ■

Do read the “General Precautions” before dealing with fuel system. Please refer to “General Precautions”.

1)

Disconnect the PCV hose joint at intake manifold side.

2)

Disconnect

the

injector

wiring

harness

connector

3)

Disconnect the joint of fuel hose on fuel guide rail.

113

Fig. 1.4.001

Fig. 1.4.002

Fig. 1.4.003



Attention: ■

Please prepare the container and cleaning cloth in advance as fuel leakage may take place.

■

Avoid the naked flame and spark.

■

Please keep any parts away from heat source. Special attention must be paid when welding around them.

■

Do not expose the parts to the electrolyte of battery or other fluid.

■

Keep the connection clean and prevent damage and foreign substance, and properly cover the connection with plastic bag or equivalent.

4)

Dismount the fixing bolt for fuel guide rail.

5)

Take off the fuel guide rail with injector from intake manifold.

Fig. 1.4.004

Attention: ■

Avoid interference with fuel injector during removal.

■

Absorb the fuel leaked from fuel pipe with cleaning cloth.

6)

Dismount the fuel injector from fuel guide rail with following steps:

a.

Pry and dismount the snap-in.

b.

Straightly pull out the fuel injector from fuel pipe.

Attention: ■

Pay attention to the leakage of residual fuel in fuel pipe.

■

Do not damage the nozzle of fuel injector.

■

Do not make it fall off or knock it.

■

Do not disassemble it.

2.


1)

Fuel Injector

■

Check the upper and lower seal rings of fuel injector for crack, aging and breakage. If any, please replace. 114



Check the injection hole of fuel injector for blockage. If any, please wash or replace by using special instrument.

2)

Fuel Guide Rail

■

Check the fuel inspection hole for damage and jamming. If any, please replace.

■

Check if there is residuum in guide rail. If any, please clean.

3.

Installation

1)

Be aware of following precautions when mounting new O-ring on fuel injector.

■

As the upper and lower O-rings are different, do not confound them. Fuel pipe side: thick one Nozzle side: thin one

■

Please mount the O-ring by your hands.

■

Lubricate the O-ring with petrol.

■

Do not wash O-ring with solvent.

■

Verify that there is no foreign substance on O-ring and its matching part.

■

Make sure the O-ring will not be scraped by tool or fingernail, and it is not distorted or stretched during installation.

■

Insert new O-ring into fuel injector straightly.

Fig. 1.4.005

Do not deflect or distort it. 2)

Mount fuel injector ④ on fuel pipe ① with following steps.

③

: thick one

⑤

: thin one

a.

Insert the snap ② into the fixing groove on fuel injector. Insert the snap slice D into raised position F of fuel injector.

Attention: ■

Replace with the new snap every time.

■

Make sure there is no interference between the snap and O-ring.

b.

Insert fuel injector into fuel pipe where snap has been mounted.

Attention: ■

Make sure the direction of insertion aligns with the axis.

115



■

Insert the snap slice C into the raised position B of fuel pipe.

■

Make sure the flange A of fuel pipe is properly mounted in the fixing groove on snap flange.

c.

Make sure the fuel injector will not move or fall off. Installation is completed.

3)

Install fuel pipe guide rail and fuel injector assembly inside intake manifold.

Attention: ■

Be careful not to make fuel injector nozzle contact with other parts.

4)

For the following steps, install with steps contrary to dismantlement.

4. Check after Installation Check for fuel leakage with following steps. 1)

Set the ignition switch at “ON” position (when the engine stops), and then check the connection of fuel pipe for leakage.

2)

Start the engine, increase its speed and recheck the connection of fuel pipe for leakage.

V.

Fuel Filter

1.

Dismantlement

Caution: ■

Do read the “General Precautions” before dealing with fuel system. Please refer to “General Precautions”.

Attention: ■

The fuel filter should be periodically replaced in accordance with the maintenance instruction specified in “User’s Manual”.

1)

Open the fuel filler cap.

2)

Release the pressure in fuel tank.

3)

Dismount the rear seat cushion. Please refer

Fig. 1.4.006

to “Rear Seat”. 4)

Dismount the service lid for fuel tank.

■

Directly prize it up with flat end screwdriver.

116



5)

Disconnect the fuel pipe joint 1 (at fuel pump side), joint 2 (at fuel filter side) and grounding

Fig. 1.4.007

end 3 of fuel filter. Attention: 1

The fuel filter should be wrapped up with towel or equivalent, so as to avoid injection of residual fuel. Disconnect joint with following methods: ■

Hold the side edge of joint and press the raised position of joint to pull out the fuel pipe.

■

Fig. 1.4.008 3

If the joint attaches to the resin pipe, push and pull the joint for several times until it moves, and then pull out the joint.

Attention: ■

The joint can not be disconnected when

2

the raised position is fully pressed down. Do not excessively distort the joint. ■

Do not disconnect the joint with any tool.

■

Prevent the resin pipe from being heated. Special attention must be paid when welding around the resin pipe.

■

Prevent the resin pipe from contacting acidic fluid such as electrolyte of battery.

■

Do not bend or distort the resin pipe during installation and dismantlement.

■

To keep the connection clean and prevent from damage and foreign substance, please fully cover them with plastic bag or e quivalent.

6)

Take off the fuel filter and fuel pipe.

2.

Installation

Fig. 1.4.009

Be aware of following precautions to install with steps contrary to dismantlement. 117


Fuel filter

■

Be aware of correct installation direction of fuel filter.


Fig. 1.4.010

towards fuel inlet pipe side

2)

Connector

Connect the connector of fuel supply hose according to following methods:

①

Check the connection for foreign substance or damage.

②

Make the connector align with the resin pipe and insert the connector straightly until “click” is heard.

③

Check whether the connector is connected properly with following methods after connection.

■

Visually inspect that 2 raised positions have been connected to the connectors.

■

Stretch the resin pipe and its connector hard to verify that they have been firmly connected.

3.

Fig. 1.4.011


Check whether there is fuel leakage with following steps. 1)

Set ignition switch at “ON” position (when engine stopped), and then check the connection of fuel pipe for leakage.

2)

Start engine, increase its speed and recheck the connection of fuel pipe for leakage.

118



VI. Fuel Pump Assembly

Figure of fuel pump assembly 1.

Dismantlement

Caution: ■

Do read the “General Precautions” before dealing with fuel system. See “General Precautions”.

1)

Check fuel level indicated on fuel meter. If the meter indicates “full” or “to be full”, discharge the fuel from tank until the meter indicates that the fuel level is lower than position “E”.

Attention: If fuel level exceeds mounting surface of fuel level sensor, the fuel may overflow during the dismantlement of fuel level sensor. 2)

Open the fuel filler cap.

3)

Release the pressure in fuel tank.

4) Dismount the rear seat cushion. Please refer to “Rear Seat”. 5)

Dismount the service lid for fuel tank.

■

Directly prize it up with flat end screwdriver.

119

Fig. 1.4.012



Disconnect the harness connector of fuel pump and fuel pipe joint.

①

Fuel pipe joint of fuel pump

②

Harness connector of fuel harness

Fig. 1.4.013

1 2

Disconnect the joint with following methods: ■

Hold the side edge of joint and press the raised position of joint to pull out the pipe.

■

If the joint sticks on the resin pipe, push and pull the joint for several times until it moves, and then pull out the joint.

Attention: ■

The joint can not be disconnected until the raised position is fully pressed down. Do not excessively distort the joint.

■

Do not disconnect the joint with any tool.

■

Prevent the resin pipe from being heated. Special attention must be paid when welding around the resin pipe.

■

Prevent the resin pipe from contacting with acidic fluid such as electrolyte of battery.

■

Do not bend or distort the resin pipe during installation and dismantlement.

■

To keep the connection clean and prevent damage and foreign substance, please fully cover them with plastic bag or equivalent.

7) Loose and take off the locknut with special tool. ■


120

Fig. 1.4.014


8)


Fig. 1.4.015

Take off the Y-ring.

Attention: ■

Tilt the fuel pump when it is taken out, so as to avoid broken of fuel level sensor.

■

To avoid residual fuel from being polluted, wrap the Y-ring with cloth to pull it out straightly.

9)

Take off the fuel pump.

2.


1)

Fuel pump

①

Visual Inspection

■

Check for broken or fuel impurity. If any, please replace or wash it.

②

Inspect Fuel Pump Operation

■

Actuate the fuel pump with 12V regulated power supply directly and check if the operation is normal.

Fig. 1.4.016

Attention: ■

Do not make the fuel pump operation for a long time, so as to avoid damage of pump

plunger. 2)

Y-ring

■

Check it for material loss and broken.

3)

Locknut

■

Check for deformation, crack, material loss, broken, and damage at mounting thread.

4)

Fuel Level Sensor

■

Check the fuel float for interference and oxidation of its surface.

3.

Installation

Be aware of following precautions and install with steps contrary to dismantlement. 1)

Fuel pump assembly 121


The Y-ring must fully fit with fuel tank during installation.

■

Tilt the fuel pump to facilitate its installation and pay attention to its direction.

■

There should be no turn-up on Y-ring during the installation.

■

Pre-tighten the locknut during its installation, and then tighten it horizontally.

2)

Connector


Insert the connector of fuel supply hose with following methods:

①

Check the connection for any foreign substance and damage.

②

Make the connector align with the resin pipe and insert the connector straightly until “click” is heard.

③

Check whether the connector is properly connected with following methods after connected.

■

Visually check whether the 2 raised positions have been connected to the connectors.

■

Stretch the resin pipe and its connector hard and make sure they have been firmly connected.

4.


Check for fuel leakage with following steps. 1)

Set ignition switch at “ON” position (when engine stops), and then check the connection of fuel pipe for leakage.

2)

Start the engine, increase its speed and recheck the connection of fuel pipe for leakage.

122



VII. Fuel Tank Assembly

Breakdown diagram of fuel tank assembly 1-Filler cap

2-Filler tube

3-Fuel tank

4-Fastening band of fuel tank

8-Fuel pump

1.

5-Service lid

6-Locknut

7-Y-ring

9-Fuel filter 10-Thermal baffle


1） Dismantlement Caution: ■

Do read the “General Precautions” before dealing with fuel system. See “General Precautions”.

■

Discharge fuel tank if necessary. Please refer to “Fuel Pump”.

■

Please operate on level ground.

①

Carry out the dismantlement steps 1-6 of fuel pump. Please refer to “Fuel Pump”.

②

Disconnect fuel supply hose and vent hose.

③

Disconnect EVAP hose.

④

Support the fuel tank with special jack.

Attention:

■ The fastening band of fuel tank should not be blocked in supporting position. ⑤

Dismount the clamping bands of filler tube and fuel tank, and then disconnect the filler tube and fuel tank. 123

Maintenance Manual of Tojoy Sedan ⑥

Dismount fastening band of fuel tank.

■


⑦

Manually support the tank and carefully lower


Fig. 1.4.017

the jack to dismount fuel tank. Attention: ■

Make sure all connections have been disconnected.

■

Make sure there is no interference with vehicle.

2)

Check after dismantlement

①

Fuel tank

■

Check for impurity of fuel. If any, clean it with hot water.

■

Capacity of fuel tank: 45L

②

EVAP hose and clips

■

Check the hose for blockage, corrugation, deformation and breakage.

■

Check the clips for damage or breakage.

③

Reinforced plate and its backing plate

■

Check the surface of reinforced plate for scratch and deformation.

■

Check the backing plate for crack, material loss, deformation and breakage.

3)

Installation

Be aware of following precautions to install with steps contrary to dismantlement. ■

Firmly hold fuel supply hose to insert it.

■

Do not set the hose clamp in expansion area of fuel pipe.

■

Please refer to “Fuel Pipe Joint” for precautions of fuel pipe joint connection.

2.


Check for leakage with following steps.

①

Set ignition switch at “ON” position (when engine stops), and then check the connection of fuel pipeline for leakage.

②

Start the engine, increase its speed and recheck the connection between piping and fuel pipe of fuel system for leakage.

124


Maintenance Manual of Tojoy Sedan Section V

Emission Control System of Engine

I.

Fuel Evaporation Control System

1.

Description Intake manifold Air cleaner

EVAP

carbon

canister

solenoid valve

Fuel evaporation EVAP carbon

Air

canister

Fuel tank

Schematic diagram of fuel evaporation system The fuel evaporation system is used to reduce hydrocarbon compositions emitted into ambient air from fuel system. Reduction of hydrocarbon is achieved by using active carbon in EVAP carbon canister. When the engine is stopped or fuel is filled, the fuel evaporation from sealed fuel tank will be introduced into EVAP carbon canister with active carbon and stored there. During operation of engine, the fuel evaporation in EVAP carbon canister will be introduced into intake manifold through clean passage. EVAP carbon canister is controlled by ECM. With engine running, evaporation flow controlled by EVAP canister solenoid is adjusted with direct proportion of increased air flow. During deceleration and idling, the evaporation passage may be cut off by EVAP carbon canister solenoid.

125



Diagram of Fuel Evaporative Emission Pipeline

2 4

5

1 6

3

Diagram of fuel evaporative emission pipeline 1-Carbon canister assembly

2-Fuel inlet hose of engine 3-Pipe connecting carbon canister with solenoid valve

4-Hose connecting carbon canister with solenoid valve 5-Fuel inlet pipe of engine 6-Fuel filter

Note:

Fig. 1.5.001

Do not use soap water or any other detergent when installing vacuum pipe or cleaning pipeline. 3.

Inspection of parts

1)

EVAP carbon canister

①

Check EVAP carbon canister with following methods:

a.

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

b.

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

②

Dismount the vacuum hose

Loose the clamps between carbon canister and fuel tank and carbon canister solenoid valve with slip-joint pliers, pull out the vacuum hose. 126

Maintenance Manual of Tojoy Sedan ③

Dismount the carbon canister

Lift the carbon canister and dismount it from the bracket on inner lining of left fender.

2)


Fig. 1.5.002

Left front frame

EVAP carbon canister solenoid valve

The air flow rate is controlled by the opening of evaporation by-pass passage in EVAP carbon canister solenoid valve. The solenoid valve will repeat the operations of “ON” and “OFF” with signal from ECM to actuate the variation of valve opening, so as to optimize engine control. The optimum value memorized in ECM lies on the state of engine. When the engine operates, flow rate of fuel evaporation from EVAP carbon canister is adjusted along with the variation of air flow.

①

Instruction of parts

Flow rate of fuel evaporation from EVAP carbon canister is controlled by duty cycle of ON/OFF of the solenoid valve. The solenoid valve is actuated by ON/OFF duty cycle signal from ECM. The wider the pulse width in “ON” condition is, the more fuel evaporation will flow through the valve.

② Dismantlement a.

Fig. 1.5.003

Disconnect the vacuum hose of EVAP carbon canister solenoid valve.

127


b.

Disconnect the harness connector of EVAP carbon canister solenoid valve.

c.

Take off EVAP carbon canister solenoid valve from the bracket.

3)


Fig. 1.5.004

Fig. 1.5.005

Filler cap

Vacuum relief valve is mounted at the filler cap. When the pressure in fuel tank is high (more fuel evaporation), the vacuum relief will be closed, so as to avoid emission of fuel evaporation to ambient air. When the pressure in fuel tank is low (negative pressure), the vacuum relief valve will be opened, so as to enable the outside air to get into fuel tank.

128


Forced Ventilating System of Crankcase

1.

System Illustration


The forced ventilating system of crankcase is used to bring the cylinder blow-by gas in crankcase back to intake manifold. It is the forced ventilating valve (PCV) which brings the cylinder blow-by gas in crankcase back to intake manifold. With throttle partially opening, the intake manifold sucks blow-by gas of crankcase through PCV valve. In normal conditions, the ventilation volume of PCV valve is sufficient to suck all blow-by gas of crankcase and a little air. The vent air is brought into crankshaft through air intake pipe. Ventilation hose inhales fresh air from the rear end of the air filter to the crankcase to keep the crankcase pressure at a certain range. When the air throttle is fully open, the vacuum degree is not sufficient to open PCV valve and thus unable to suck blow-by gas of crankcase. The air flows through connecting hose in reversed direction. In vehicles with severe blow-by gas, PCV valve can not meet the requirements because part of air may get into the air intake pipe at any time during operation.

129



Inspection of Element

Check the PCV (forced ventilation of crankcase) valve as shown below: 1)

Operation principle Operation principle list of PAV valve

High vacuum

No vacuum

Valve chamber cover side


Operating state of engine

Out of work


Idling or deceleration

PCV valve

Out of work

PCV valve

Fully open

Variation of vacuum

Limited

Variation of vacuum

Slight

No

Moderate


Valve chamber cover side Improper acceleration and


Normal operation


PCV valve

Normal operation

PCV valve

Retardant operation

Variation of vacuum

Large

Variation of vacuum

Extremely large

130

high speed


2)



① Dismantlement a.

Disconnect the PCV valve hose from cylinder cover.

Fig. 1.5.006

b. Remove the PCV valve from cylinder

cover.

3)

Fig. 1.5.007


① PCV valve: Hissing may be produced during normal working of valve with air flows through.

Fig. 1.5.008

When finger touches the valve at the entrance, you can immediately feel a strong vacuum

VVT valve

pressure.

②

Vent hose of PCV valve

a.

Check the hose and joint for leakage.

b.

Disconnect all hoses and clean with compressed air. If the blockage in hose can not be cleared, replace.

131


Chapter 2

Electrical Part of Engine

Section 1 I.

Ignition coil

1.

Parts

Ignition System

Ignition coil 2.

Dismantlement & Installation

1)

Dismantlement

Attention: ■

Fig. 2.1.001

Be sure that the ignition switch is in the “OFF” position.

①

Dismount the trimming cover of engine. Refer to “Intake Manifold” section.

②

Disconnect the wiring harness connectors of the ignition coil from high voltage ignition coil.

132



③

Remove high-voltage ignition coil bolt to remove coil.

■


④

Dismount the spark plug with special socket.


Fig. 2.1.002

Tightening torque: 30-38N·m Attention: ■

Please do not drop or shake it.

2)


①

High-voltage ignition coil

■

Check the primary coil resistance between both terminals. Primary coil resistance: 0.77-0.95 Ω

■

Check the secondary coil resistances at the high voltage ends between No.1 cylinder and No.4 cylinder, and that between No.2 cylinder and No.3 cylinder. Secondary coil resistance: 7.75-10.23 KΩ

Attention: ■

The ignition coil harness connector must be disconnected for secondary coil resistance measurement.

②

Spark plug

Check the spark plug: ■

Check insulator of spark plug for damage and broken.

■

Check spark plug for carbon deposit. See the following table for causes of carbon deposit. Causes of Carbon Deposit Phenomenon

Black charcoal

Hard charcoal

Reason

Impurity in the fuel or high fuel-air ratio.

Impurities in the fuel; wrong ignition timing, or untight spark plug.

■

Check spark plug electrodes for damage.

■

Inspect clearance of spark plug. 133



Inspect clearance of spark plug by using feeler. Standard value: 0.7-0.8 mm If the clearance is beyond the standard value, replace. ■

Check sparking ability of spark plug.

a.

Connect spark plug to high voltage circuit.

b.

Keep the distance between edge of spark plug and the grounding metal at about 14 mm.

c.

Start the engine for about 3s, check whether there are sparks produced between the edge of spark plug and the grounding metal.

Attention: ■

During check, be careful not to get an electric shock.

■

If the clearance is less than 14 mm, the sparks may also be produced even though the high voltage wire has trouble.

■

If there are no sparks, replace spark plug.

3)

Installation

Install with steps contrary to dismantlement. II.

Diagnosis of Common Troubles Diagnosis Common Troubles Symptom

Possible causes

Solution

The engine can’t or is Trouble of ignition coil or ignition switch Check or replace the ignition coil or the difficult to start.

Unstable idle speed

ignition switch Trouble of spark plug

Check or replace spark plug

Disconnected high voltage wire

Check the high voltage wire

Trouble of high voltage wire or spark Check the high voltage wire or check or plug

Replace spark plug

Trouble of ignition coil

Check or replace the ignition coil

Engine surge or poor

Trouble of high voltage wire.

Check the high voltage wire

acceleration

Trouble of spark plug


Poor. fuel economy

Trouble of spark plug


III. Parameters for Maintenance Maintenance Specification of Ignition System High voltage

Primary coil resistance

0.77-0.95Ω

Ignition coil

Secondary coil resistance

8.7±0.87 KΩ

Spark plug

Spark plug clearance

0.7-0.8mm

134


Section 2 I.


Starting and Charging System

Principle Diagram of Starting and Charging System

Central electric box 120 A fuse

30 A fuse link

b a t t e r y

link

Ignition switch

Charging alarm light

Combined device

Anti-theft relay

Electric generator ETACS－low level effective

Rectifier

Starter

One-way clutch

Electric motor

Magnetic field winding

Stator winding

Solenoid switch

Principle Diagram of Starting and Charging System II.

Battery

1.

How to use battery

Attention: ■

If the engine is necessary to be started with auxiliary battery and jumper wire, 12 V auxiliary battery should be used.

■

When jumper wires are connected with battery, make sure that the jumper wires are clamped to the terminals of battery and have good contact.

2.

Methods to prevent excessive discharging of battery

The following precautions should be particularly emphasized to prevent excessive discharging of battery. ■

Always keep surface of battery (esp. the top) clean and dry.

■

The connecting part of the terminals should be clean and tightened.

135



■

If the vehicle is not used for a long time, the cathode terminal of battery should be disconnected.

■

Check charging condition of battery.

3.

Check

1)

Visual inspect

■

Check terminals of battery for damage and electrolyte leakage. If any, replace.

2)

Voltage inspection: Inspect batter for proper voltage. (The following parameters is for reference only)

①

If U>13.2V, inspect the electrical system.

②

If 12.5V
③

If 11V
④

If U<11V, the battery is damaged or the charging system has trouble. Please inspect charging system and battery.

4.

Dismantlement and installation

1)

Dismantlement

■ The ignition switch should be turned to the

Fig. 2.2.001

“OFF” position.

①

Disconnect the negative terminal.

②

Dismount the positive terminal of battery and the fixed bolts of battery pressure plate, and then take off the pressure plate.

③

Take off the battery.

④

Take off the bracket of battery.

136

Fig. 2.2.002


2)


①

Bracket of battery

■

Check for erosion. If there is, clean with warm clean water.

②

Battery harness

■

Check for erosion and damage. Replace if there is any.

3)

Installation



During connection, the anode terminal of battery should be connected first.

■

After installation, terminals may be smeared with mineral oil.

137



III. Starting System 1.

System Description

Closed solenoid switch of starter provides a closed circuit between battery and starter. The starter is connected with engine body for grounding. After the power supply and grounding are provided, the starter can turn the crankshaft, and thus engine is started. 2.


Components of Starter 1-M port 2-S port

1)

Dismantlement

①

Disconnect the negative terminal of battery.

3-B port

Fig. 2.2.003

Note: Before disconnecting the cathode terminal of battery, pull off the starter key first.

138


②

Disconnect the harness connector of starter.

③

Dismount the fixing bolts of starter, then take

Fig. 2.2.004 off the starter.

2)

Installation


Be sure to tighten the nut of “B” port.

139



Disassembly and Assemblage

1)

Disassembly


Exploded View of Starter 1-Screw

2-Front support 3-Stop ring

4-Snap ring

9-Planetary gear

11-Gasket 12-Stator 13-Rotor 14-Electric brush retainer 15-Rear support

10-Ball

5-Pinion

6-Gear ring

16-Fixing bolt

140

7-Solenoid switch

8-Plantery gear


Check

①

Solenoid switch

■

Before check, disconnect negative terminal of battery.

■

Disconnect the “M” port of starter.

a.

Test electrical connectivity between “S” port and switch body.

Fig. 2.2.005


Connecting from the power supply

“M”

■

Replace solenoid switch if opened.

b.

Test electrical connectivity between “S” port and “M” port.

■

Fig. 2.2.006

Connecting from the power supply

“M” end

Replace solenoid switch if opened.

② Pinion a.

Visual inspection of the meshing gear teeth

■

If the teeth are worn or damaged, replace meshing gear (check teeth of fly wheel in this step).

b.

Check the teeth of pinion

■

If the teeth are worn or damaged, replace pinion (check teeth of rotor shaft gear in this step).

c.

Check whether the pinion locks in one direction while turns smoothly in the other direction.

■

If it is able to lock or turnable in both directions, or if there is abnormal resistance, replace.

141


③

Electric brush

■

Check


Fig. 2.2.007 brush wearing

with

a caliper. if

excessive worn, replace.

Vernier caliper Electric brush

④ ■

Electric brush spring Depatch spring from the brush and use a

Fig. 2.2.008

spring tension gauge to check tension

Electric brush Electric brush

⑤

spring

Electric brush retainer

a. Test insulation voltage between brush retainer

Fig. 2.2.009

(positive) and bearings (negative) with an ohmmeter. If broken, replace electric brush retainer. b. Check for electric brush smoothly moving. ■ If electric brush bracket is bent, replace. If the sliding surface is dirty, clean.

⑥

Inspection of Stator

■ Check whether magnet is firmly fixed on the stator; check for crack. If the parts have any trouble, replace the assembly. Attention: ■

Please do not clamp the stator with a table vice, nor hammer it.

142

Fig. 2.2.010

Magnet


⑦

Inspection of Rotor

a.

Check connectivity between adjacent fillets


Fig. 2.2.011

with ohmmeter. ■

If open, replace.

b.

Check conductivity between each copper plate and shaft of commutator with ohmmeter.

■

If open, replace.

c.

Check surface of commutator.

■

If it is rough, use # 500 sandpaper to lightly

Fig. 2.2.012

sand with method shown in figure.

Sand paper

d.

Check diameter of commutator.

■

Check with a caliper; if it is less than the

Fig. 2.2.013

specified value, replace. Vernier caliper

Commutator

143



Assemblage

When assembling the starter, the bearing, the gear and the friction surface should be lubricated by adding high temperature grease. And then conduct the following operations.

① Gear clearance adjustment

Fig. 2.2.014

■ Push the pinion out with the magnetic switch energized, meanwhile check the clearance between the pinion and the thrust piece with a feeler. Stop block Gear clearance 0.5~1 mm Pinion

■

If the clearance is out of range, adjust by using spacer.

144

Fig. 2.2.015 Adjusting gasket


4.


Diagnosis flow chart of Common Troubles (if there is any abnormity found, disconnect negative pole of battery at once.) Inspection Flow Chart of Common Troubles of Starting System Replace the solenoid switch.

Starter fails to stop.

The engine fails to start.

Does engine run with revolving of crankshaft?

Yes

Does engine run normally?

Yes Inspect ignition/fuel system.

Yes

No

Inspect following items of Abnormal A

battery: 1. Charging condition

Normal

2. Connection of terminal 3.

Repair the starter.

Erosion of terminal. Yes

Yes Does the gear shaft run?

Does the starter run? No

Check pinion clutch.

No Check the reduction gear, armature and the gear shaft.

Abnormal Check the fuse and the fusible wire.

replace.

Normal Inspect following items of battery: 1. Charging condition Abnormal 1. 2. Connection of terminal 3. 2. Erosion of terminal. Normal

Charge battery. Repair poor connection and eroded terminal of battery.

A

Abnormal

Inspect circuitry of starting system.

Repair.

Normal Does magnet switch make noises during running?

No Repair the starter.

Yes Check the meshing condition of pinion and gear ring. Abnormal

If wired as follows with no load, does

Yes Replace solenoid switch.

starter run?

1. Adjust the displacement of pinion. 2. Inspect motion mechanism of pinion. 3. Check the gear ring.

No Repair the starter.

145



IV. Charging System 1.

System Description

The generator is used to provide DC voltage to vehicle electric system and keep charged condition of battery. The voltage output is controlled by IC adjuster. The “B” port supplies electricity to vehicle electric system and charging power supply to battery. The IC adjuster checks the input voltage at port 4 (“S” port) and thereby controls output voltage. After the powered and grounded, the charging alarm light will be lit. When generator provides sufficient voltage, the grounding circuit will be opened, while the charging alarm light will be turned off. If the charging alarm light is still on with engine running, it has troubles. 2.

Charging alarm light

If the following situations presents with generator working, the warming function of IC adjuster will be actuated, and the charging alarm light will be turned on. ■

No voltage is produced or the voltage is high.

3.


146


1)

Dismantlement

①

Disconnect the negative pole of battery.

②

Disconnect harness connectors of generator.


Fig. 2.2.016

Fig. 2.2.017

③

Loosen the adjusting supporting nut on generator. Then adjust tension with the tension adjusting bolt.

■

Tightening torque: generator adjustment nut: 22.5 ± 2.5 Nm Generator supporting nut: 47±5 N.m Fig. 2.2.018

Fig. 2.2.019

④

Dismount the belt of generator. Please refer to the “Drive Belt” section.

⑤

Take off the generator from the vehicle.

147



2)

Installation

■

Install with reversed order of dismantlement.

■

Before installing the generator, please inspect tension of generator belt. Please refer to the “Drive Belt”.

Attention: ■

Tighten the nut of “B” port. Tightening torque: 10-12 N·m

4.


Exploded View of Engine 1-Lock nut

2-Belt pulley 9-Rear bearing

3-Spacer 4-Front end cover 10-Stator 11- gasket

12- commutator

14-Guide sleeve of slip ring 148

5-Front bearing 6- Bearing cap 7-Bolt

15-Rear cover

13-Electric brush retainer

8-rotor



Disassembly

Disassemble in the following order.

①

Belt pulley

②

Rear cover

③

Commutator assembly

④

Separate front and rear cover assembly.

Attention: ■

Be careful to avoid damage of stator assembly.

2)

Check after disassembly

①

Inspect of rotor

a.

Resistance test

Fig. 2.2.020

Resistance: Approximately 2.0-2.5 Ω ■ If it is beyond the standard range, replace.

Slip ring

b.

Insulator test

■

If electrically continued, replace.

c.

Inspect wearing condition of slip ring.

■

If it is beyond the standard range, replace.

②

Carbon brush

a. Check carbon bush for smooth moving.

Fig. 2.2.021

■ If not, inspect carbon brush support and clean as required.

b.

Check wearing condition of carbon brush.

■

If Limit is exceeded, replace brush. 149

The mark line of wearing limit of electric brush



③ Stator a. Inspect continuity between terminals. ■

Fig. 2.2.022

If not, replace.

b. Grounding test ■

Lead

Fig. 2.2.023

Lead

If electrically continued, replace the stator.

Stator core

3)

Assembly

①

Rear bearing

Attention: ■

The rear bearing can not be reused after being taken off. Please with new one.

■

Lubrication of rear bearing out race is not permitted.

②

Installation of rear cover

a.

Mount the carbon brushes assembly, adjuster

Fig. 2.2.024

assembly and stator.

b.

Push the carbon brushes with fingers to install them on the stator.

Attention: ■

Be careful to avoid damage of slip ring surface. 150



Trouble Diagnosis for Charging System

Be sure that the battery has been sufficiently charged before test of generator. A 30 V volt meter and a proper test probe should be used in test. Inspection chart is helpful for inspection of generator. ■

Check the fusible wire before starting up.

■

Use a battery fully charged. Inspection Flow Chart of Charging System Disconnect the The ignition

The alarm

switch is on.

light is off.

connector, and

The alarm

ground the L-side

light is off.

Conduct following check: 1. Bulb of alarm light 2. Fuse of

harness.

alarm light .

The alarm light is

Perform following

on.

The alarm light is

inspection: 1. rotor 2. Slip ring of rotor 3.

on.

Electric brush.

The engine starts with a rev of 1500 rpm.

Change damaged IC regulator.

Conduct the The alarm light is

following check:

The engine

The alarm light

on.

1. Rotor

runs at idle

is off.

2. Slip ring of

speed.

rotor

Normal.

3. Electric brush

The alarm light is

The alarm light is

Normal.

on.

off. The engine rev is

More than 16.0 V.

2500 rpm. Measure the

Change the damaged IC regulator.

voltage of B port.

Less than 13.0 V.

Conduct the following check: 1. Rotor 2. Slip ring of rotor 3. Electric brush 4. Stator.

Change the damaged IC regulator or diode assembly.

Alarm light: the “charging” alarm light in the combined instrument. Attention: ■

If the charging system has trouble but the test results suggest normal, inspect connection of “B” port (Inspect tightening torque and v oltage drop).

■

Inspect conditions of rotor coil, rotor slip ring, electric brush and stator coil. Replace failure parts as required. 151


Chapter III

Electronic Control System of Engine Section I

I.

Electronic Control System of Engine

Precautions

Precautions of Supplemental Restraint System (SRS)

Using the SRSs including airbag and pretensioner of safety belt together with the front seat safety belt can contribute to reduction of the risk of injury and hazard severity of driver and front passenger in case of crash. For information of proper maintenance of the system, please refer to “Airbag” part of this manual. Caution: ■

All maintenance operation should be carried out by JAC authorized franchised stores in order to avoid increasing risk of personal injury and death due to the SRS system failure.

■

Improper maintenances, including incorrect dismantlement and installation of SRS system, may cause wrong action of the system resulting in personal injury and death.

For dismantlement methods bell spring (hair spring) and airbag controller, please refer to the airbag section. ■

Besides operations described in this manual, no electrically testing equipment should be used to test any circuit of airbag system. The air bag circuit harness can be identified by the yellow or orange harness or harness connectors.

II.

General Precautions

1.

Only digital electric meter should be used to inspect the electronic control system.

2.

JAC genuine components should be used during maintenance, otherwise it is impossible to guarantee the normal operation of system.

3.

Only unleaded gasoline should be used for maintenance and operation.

4.

Specified maintenance and diagnosis procedure should be followed to perform maintenance.

5.

The disassembly and dismantlement for the system components are prohibited during maintenance.

6.

During maintenance process, the electronic elements (electronic control modules and sensors) should be fetched and placed very carefully to avoid the falling down.

7.

Keep strong awareness of environmental protection to effectively deal with waste of the maintenance process.

III. Precautions in Maintenance 1.

Temperature of electronic control module should never be higher than 80℃ during hot working conditions simulation of trouble and other maintenance operations possibly resulting in the temperature rising. 152



The electronic controlled injection system operates with high fuel pressure (approximately 350kPa). Even with engine stopped, there is high pressure in fuel pipelines. Therefore, the fuel pipe should not be dismantled casually during the course of maintenance. In case that it is necessary to repair fuel system, pressure in fuel system should be released before dismantlement of fuel pipe.

3.

The dismantlement of fuel pipe and the replacement of fuel filter should be carried out by the special personnel in well-ventilated area.

4.

Power supply of electric fuel pump should be turn off before pump is removed from fuel tank in order to avoid sparks that may cause fire. The fuel injection pump should not be test with dry state or in water, otherwise its service life may be shortened. In addition, t he positive and negative poles of the fuel injection pump must not be reversed.

5.

During inspection of ignition system, the sparking should be detected only when it is necessary and the time should be as short as possible. The air throttle must not be opened during inspection; otherwise copious unburned full may flow into the exhaust pipe, accordingly leading to the damage of three-way catalyst.

6.

The manual adjustment is unnecessary because the idling regulation is completed solely by the electronic controlled injection system. The throttle limiting screw of throttle body has been adjusted by the manufacturer in factory; the initial position must not be changed by users arbitrarily.

7.

Terminals of battery must not be reversed, otherwise electronic components may be damaged. Negative grounding is used in this system.

8.

Battery cable should not be disconnected with engine running. Before welding on vehicle, cable on negative and positive poles of battery, and all electronic components should be removed.

9.

Do not test input and output signal of components by puncturing the insulator of wire.

153



IV. Common tools for diagnose ■

Description of tool: diagnose tool of electronic controlled injection system

Function: reading/clearing DTC of electronic injection system, view data flow, test actions of parts, etc..

Fig. 3.1.001

■

Description of tool: ignition timing indicator

Function: inspect ignition timing

Fig. 3.1.002

154


■


Description of tool: digital universal meter

Function: measure characteristic parameters such as voltage, current and resistance of electronic injection system

Fig. 3.1.003

■

Description of tool: vacuum gauge

Function: inspect air pressure of intake manifold

Fig. 3.1.004

155


■


Description of tool: cylinder pressure gauge

Function: inspect pressure in each cylinder

Fig. 3.1.005

■

Description of tool: fuel pressure gauge

Function: inspect pressure of fuel system, determine working states of fuel pump and fuel pressure regulator.

Fig. 3.1.006

156


V


Precautions for On-board diagnose (OBD) system of engine

The electronic control module (ECM) has an OBD system. The malfunction indicator lamp (MIL) of OBD system will be lit to indicate the driver that there is malfunction caused by aging of the exhaust system. Attentions: ■

Be sure to turn the ignition switch to OFF position and disconnect the cable of battery negative poles before any repairing or inspection. The open circuit or short circuit of related switch, sensor and solenoid valve may make the MIL lit. After the operation, be sure to insert connectors and lock them firmly. Loose (unlocked) connectors

■

may result in the open circuit, accordingly making the MIL lit. (Make sure that there is no water, grease and filth on the joint and port is not bent). ■

After the operation, be sure to route and fix the harness correctly. The interference between support and harness etc. may result in short circuit, accordingly making the MIL lit.

■

After the operation, be sure to connect the rubber pipe properly. The failed connection of the rubber pipe may cause lighting of MIL because of failure of the EVAP system and fuel injection system etc.

■

Be sure to clear any uneffective DTC from ECM before transferring vehicle to user (the repair is done).

■

Be sure to use the 12V battery as the power supply.

■

Never disconnect cable of battery with engine running.

■

Be sure to turn ignition to OFF position and disconnect cable of battery before connecting or disconnecting any ECM harness connectors. Otherwise the ECM may be damaged, because even if the ignition is turned to OFF position, the ECM still has 12V voltage. ■

Turn the ignition switch to OFF position and disconnect the connecting wire batterybattery cathode

cable of storage

before dismounting the any components.

Fig 3.1.007

Battery

■

Don’t disassemble the ECM.

■

If one of the battery cable is disconnected, memory of ECM will return to the initial value. And the ECM may start to control itself with initial value. When battery is disconnected, the engine will operate a little differently, which doesn’t mean any trouble. Don’t replace any components because 157



of a little change. ■

When connecting the ECM harness connectors, push the deflector rod (1) downward mostly to lock securely.

■

When Inserting the contact pin into the ECM or pulling it out, be aware to avoid damaging

Fig 3.1.008 Bent

contact pin port (bent or broken). When connecting the contact pin, make sure that the contact pin port of ECM is not bent or broken. ■

Connect the harness connectors of ECM firmly. Poor connection may cause extremely

Broken

high (fluctuation) voltage on the coil and capacitor, accordingly resulting in damage of IC. ■

The harness of the electronic control system of engine should be remained for a length of at least 10cm from the joint in order to avoid any trouble of the electronic control system of engine caused by receiving the exterior noise signal and decreasing the operation of IC etc.

■

Keep the parts and harness of the electronic control system dry.

■

Inspect ECM with port and reference value to assure the normal function of ECM before replacing.

■

Even the very little leakage in the intake system may lead to the severe trouble.

■

Don’t swing or vibrate the camshaft position sensor (phase) or the crankshaft position sensor (position).

■

Perform DTC validation procedures or the whole function inspection after conduction of trouble diagnosis. If repair is finished, DTC should not be seen in the validation procedures. Overall function inspection should obtain a good result after repair completed.

■

When measuring the ECM with the circuit tester, never make two measuring devices contacted. If the probes touch occasionally, the short circuit may be cause and the power transistor of ECM may be damaged.

■

During measurement of input/output voltages, the grounding port must not be used. Otherwise the transistor of ECM may be damaged. Ports other than the ECM may be used for gounding.

■

Fuel pump must not be used without fuel in pipes.

158


■ Tighten clamp of fuel hose to specified torque. Fig 3.1.009 ■

Don’t step on accelerator pedal when starting the vehicle.

■

Don’t

increase

the

speed

of

engine

immediately after starting the vehicle. ■ Don’t speed up before shutting down the engine.

159



Section II I.


Structural Principle and Inspection of Engine Control System

System Description

Engine Control System Diagram 1-Carbon canister 2-Carbon canister solenoid valve 3-Electronic throttle body assembly 4-Intake air temperature/pressure sensor 5-Injector 6-Camshaft position sensor 7-Ignition coil 8-Front oxygen sensor 9- Three-way catalyst 10-Rear oxygen sensor 11-Coolant temperature sensor 12-Crankshaft position sensor 13-Fuel filter 14-Electric fuel pump 15-Fuel tank 16- Diagnosis port 17-Engine control module

Note: This diagram is the control diagram, if the sensor location doesn’t match with physical parts, actual conditions should prevail. II.

Multiple-point Fuel Injection System

1. System Description Multiple-point fuel injection (MPI) system comprises of the sensor detecting engine operation and the electronic control module (ECM). The system is controlled based on signals from these sensors; actuators operate under control of the ECM. ECM functions include fuel injection control, idle control and ignition timing control etc. and some trouble diagnosis means for simplifying the troubleshooting in case of trouble.

160



Input/Output Signal List of Input/Output Signal Sensor Hall sensor

Input Signal of ECM

Actuator

Control fuel injection and mixing

Fuel injector

Engine speed Piston position


Intake quantity

Oxygen sensor

Oxygen concentration in exhaust

3.

ECM Function

Throttle opening sensor

Throttle opening

Knock sensor

Knock of engine

Air conditioner switch

Air conditioner pressure

Wheel speed sensor

Vehicle speed

Coolant temperature sensor

Coolant temperature

Starting Control

Special measures should be used to control the air flow, fuel injection and ignition timing during starting. At the beginning of starting, air in the intake manifold is still and the internal pressure of the intake manifold is ambient air pressure. Throttle closed and the electronic throttle is designated as a fixed parameter depends on temperature. In similar process, a specific "injection timing" is designated as the initial injection pulse. Fuel injection amount varies according to engine temperature in order to promote fuel film formation on intake manifold and cylinder walls; thus, when the engine reaches a certain speed, mixture should be thicker. Once the engine starts to run, the system immediately begin to reduce the mixture concentration At end of starting cycle, the starting enrichment function will be completely cancelled. In starting work conditions, spark advance are also adjusted and vary with the engine temperatures, intake air temperatures and engine speeds. 4.

Warming-up and Heating Control of Three-way Catalyst

With engine started at low ambient temperature, intake quantity of cylinder, fuel injection and electronic ignition are all adjusted to compensate the higher requirement of the engine torque; this process continues until the temperature is proper. During this stage of running, the most important factor is the quick heating of the three-way catalyst, for fast transition to the three-way catalyst functioning can markedly reduce the emission. Under this operation condition, the “heating three-way catalyst” may be performed by postpone the ignition advance angle properly to take advantage of the exhaust gas. 5.

Acceleration/Deceleration and Back-tow Fuel Cut Control

Part of the fuel injected to the intake manifold will not reach the cylinder in time to participate follow-up combustion stroke. Instead, it forms a film on intake manifold wall. With increasing of load and injection duration extension, fuel stored in the film will build up dramatically. When the throttle opening increases, 161



part injected fuel will be absorbed by the film. Therefore, corresponding amount of fuel must be added for compensation and to prevent the mixture from thinning during acceleration. Once load factor is reduced, the additional fuel contained in the fuel film on intake manifold wall will be re-released, and then it is necessary to reduce the injection duration accordingly during acceleration course. Back-tow and towing operation condition refers to conditions that the power supplied by the engine at the fly wheel is negative value. In this case, the engine friction and pumping gas loss can be used to make vehicles slow down. In back-tow or towing operation condition, fuel injection is cut off in order to reduce the fuel consumption and the emission, more importantly, the three-way catalyst can be protected correspondingly. Once engine speed decreases to the specific fuel supply recovery speed above idling, the fuel injection system will re-supply. In fact, ECM program has a rotation speed recovery range which depends on the changes of such parameters as engine temperature, dynamic change of engine speed, which can also prevent the engine speed from dropping to the specified minimum through calculation. Once the fuel injection system re-supplies fuel, the supplemental fuel will be supplied by using the initial injection pulse and the fuel film on the intake manifold wall will be formed. After resumption of fuel injection, torque-based control system makes the increase of engine torque slow and steady (smooth transition). 6.

Idle Control

At idle speed, the engine does not provide torque to the fly wheel. To ensure the engine running stably at the lowest possible idle speed, the closed-loop idle speed control system should keep the balance between the generated torque and the "power consumption" of engine. The necessary power should be generated with idling speed to meet the load requirements of all aspects, including those come from internal friction from the engine crankshaft and valve mechanism, as well as the auxiliary components, such as coolant pump. The system is based on the torque-based control strategy, which determines required output torque of engine to maintain the required idle rotation speed under any operating conditions with a closed-loop idle speed control strategy. The output torque increases with decreasing of engine speed and decreases with rising of engine speed. The system request greater torque to response to the new "disturbance factors", such as the switch of the air-conditioning compressor. With low engine temperature, it is necessary to increase the torque to compensate the greater internal friction loss and/or maintain higher idling speed. Sum of all these required output torque is delivered to the torque coordinator to carry out the calculation to get the corresponding intake density, gas mixture composition and ignition timing. 7.

λClosed-loop Control

Post treatment of three-way catalyst is an effective way to decrease the concentration of hazardous substance in the exhaust gas. The three-way catalyst can decrease the HC, CO and NO X by 98% or more and transform them into H2O, CO2 and N2. However this high efficiency can only be achieved in a very narrow range near the excessive air factor of engine λ=1. The objective of the λ closed-loop control is to ensure the gas mixture concentration at this range, thus, the closed-loop control system is used to get this target. λ closed-loop control system functions only with oxygen sen sor equipped. Oxygen sensor can detect oxygen content of the exhaust gas at three-way catalyst side. Rarefied gas mixture (λ> 1) produces a sensor voltage of about 100mV and the concentrated gas mixture (λ <1) produces a sensor voltage of about 900mV. In case of λ=1, the sensor voltage has a jump. λ closed-loop control responds to

162



the input signal (λ>1= too thin mixture, λ<1= too thick mixture) to revise the control variable and produc e a correction factor as a multiplier to correct the fuel injection duration. 8.

Evaporation Emission Control

Due to transfer of the external radiation heat and oil return heat, the fuel in tank is heated to form vapor. According to limit of evaporative emission regulation, it is not permitted to exhaust the vapor containing large quantity of HC composition directly into the atmosphere. The fuel vapor in the system is collected with an active carbon canister through the conduit and flushed into the engine at appropriate time to participate combustion. Flushing flow is controlled by the carbon canister control valve of ECM. The control functions only when the λ closed-loop control system is running under the closed-loop condition. 9.

Fuel Injection Control

The fuel injection timing and impulse width is controlled to provide the best mixing of air/fuel corresponding to the ever-changing operation condition of engine. The fuel injector is installed at the inlet of every cylinder. The fuel is drawn from tank by fuel pump and delivered to each fuel injector. Normally, each cylinder has one fuel injection operation with two revolutions of crankshaft. Injection sequence of cylinders is 1-3-4-2. 10. Ignition Timing Control The primary current to the ignition coil is controlled by connecting and disconnecting the power transistor of primary ignition circuit to regulate the ignition timing so that the best ignition timing can be provided according to operating conditions of engine. Ignition timing is determined by the ECM according to the engine speed, intake quantity, coolant temperature and atmospheric pressure. 11. Self-diagnosis Function When abnormal situation is detected by the sensor or actuator related to the exhaust control, the alarm lamp of engine (inspection lamp of engine) lights up to inform the driver. DTCs (diagnose trouble code) corresponding of this abnormal situation will be set in these conditions. The RAM data inside the ECM related to the sensor and actuator can be read with the diagnosis apparatus, and the actuator may be driven forcibly in some cases. 12. Other Control Functions 1)

Fuel Injection Pump

With relay connected, the fuel injection pump will be energized when the crankshaft starts to rotate or with engine running. 2)

Fan Relay Control

The speeds of the radiator fan and condenser fan is controlled with the engine coolant temperature, vehicle speed and air conditioner switch signal (AC).

163



III. On-board Diagnosis System 1.

Description

On-board diagnosis system (hereinafter referred to as OBD system) is the diagnosis system integrated in the engine control system to monitor the trouble components affecting the emission as well as the main function state of the engine. It is capable of identifying, storing and showing the trouble information through the self-diagnosis malfunction indicator lamp (MIL). 2.

Trouble Information Record

Electronic control module constantly monitors the sensor, actuator, associated circuit, malfunction indicator lamp (MIL) and battery voltage etc. as well as even the electronic control module itself, and carries out the credibility detection for the output signal of sensor, the drive signal of actuator and the internal signal (such as λ closed-loop control, coolant temperature, idling speed control and battery voltage control etc.). Once a trouble is found in some link or a signal value is incredible, the electronic control module immediately sets the trouble information record in RAM memory. Trouble information record is stored in form of DTC and shown based on the order in which the troubles present. The troubles can be divided into “steady-state trouble" and "sporadic trouble" according to their occurrence frequencies (for example, because of short term open circuit of harness or poor contact of connector). 3.

Malfunction Indicator Lamp (MIL) Instruction and Its Control Strategy

1)

Malfunction indicator lamp (MIL): the indicator required by the regulation for the emission-related components or system failure. Generally, MIL is an indicator lamp can display on the console with shape in line with the requirements of regulation and standard.

2)

MIL should be activated following the principles below:

①

In case of ignition switch in "ON" position (non-starting), MIL is continuously bright.

②

Within 3s after engine started, if there is no requirement in the trouble memory to light up the MIL, MIL would extinguish.

③

When there is requirement to light up the MIL both in the trouble memory and the outside of the ECM, MIL is lit.

④

When there is the requirement outside the ECM or in the trouble memory or due to the fire to blink the MIL, MIL would blink with frequen cy of 1Hz.

4.

Inspection steps

1)

For the vehicles with OBD function, inspection should be carried out always with steps below:

164


Maintenance Manual of Tojoy Sedan OBD Inspection Steps

1. Connect the diagnosis equipment to the diagnosis connector to put through it.

2. Turn on “ignition switch”.

3. Read the trouble information (trouble code, freeze frame): inquire in maintenance manual to confirm the trouble component and type: draw up maintenance solution with trouble information and experiences.

4. Remove the trouble.

5.

Clear

memory: run

the

vehicle

properly

following the corresponding trouble diagnosis conditions: read trouble related information and confirm the clearing of the trouble. 2)

Connection of Diagnosis apparatus:

The “K” line protocol and ISO9141-2 standard diagnosis joint are adopted for the system as shown in the figure.

Standard Diagnosis Connector

165



This standard diagnosis joint is connected on the harness of engine steadily. The pins 4, 7 and 16 of the standard diagnosis joint are used for engine electronic control system. The pin 4 of the standard diagnosis joint is connected to the grounding wire: pin 7 is connected to the pin 57 of ECM, that is, the “K” data line of the electronic control system of engine; pin 16 is connected to battery negative pole. 5.

ECU control system common DTCs and Explanation

Modern engine management system divides the control system failures into the faults related to emission control components and the failures not related to emission control components. Failures related to the emission control are often indicated with malfunction indicating light (MIL) while those h ave nothing to do with the emission control are usually indicated with the SVS indicator.

●

Activation rule of MIL of emission control related components failures:

Category A: As long as failures occur, system will light up the MIL light and record the DTC Category B: In 2 continuous emission monitoring processes, failures occur in each process and then system will light up the MIL light and record the DTC Category E: In 3 continuous emission monitoring processes, failures occur in each process and then the system will light up the MIL light and record the DTC Precautions: An emission monitoring process is one work cycle in which all the OBD functional tests can be completed. For OBD, National III emissions testing program can be used as reference. ●

Fault indicator SVS not related to the emission control components activation rules:

Category C: When fault occurs, DTC is set and SVS lights up, but the MIL is not lit up Category Z: The fault diagnosis system does not make any diagnosis for category Z failures

MT60 ECU common DTCs DTC

Explanation Information

Default type

P0011

Slow response of VCP intake phase response

B

P0012

Large error of VCP intake camshaft phase

A

P0016

VCP intake cam tooth learning deviation out of range

Ｂ

P0026

Clogged hydraulic control valve of VCP intake

Ａ

P0068

ETC air flow control failure

Ａ

P0106

Rationality diagnosis of intake pressure / throttle position

Ｅ

P0107

Low voltage or open circuit of Intake pressure sensor circuit

Ａ

166



DTC


Default type

P0108

High voltage of intake pressure sensor circuit

Ａ

P0112

Low voltage of intake air temperature sensor circuit

Ｅ

P0113

High voltage or open circuit of intake air temperature sensor circuit

Ｅ

P0117

Low voltage of coolant temperature sensor circuit

Ａ

P0118

High voltage or open circuit coolant temperature sensor circuit

Ａ

P0122

Low voltage of ETC throttle position sensor # 1 circuit

Ｅ

P0123

High voltage or open circuit of ETC throttle position sensor #1 circuit

Ｅ

P0131

Short circuit to low voltage of front oxygen sensor

E

P0132

Short circuit to high voltage of front oxygen sensor

E

P0133

Slow response of front oxygen sensor

E

P0134

Open circuit of front oxygen sensor

A

P0135

Failure of front oxygen sensor heating

A

P0137

Rear oxygen sensor short circuit to the low voltage

E

P0138

Rear oxygen sensor short circuit to high voltage

E

P0140

Open circuit of rear oxygen sensor open circuit

E

P0141

Overheating of rear oxygen sensor overheating

A

P0171

Fuel system, thin

E

P0172

Fuel system, thick

E

P0222

Low voltage of ETC throttle position sensor # 2 circuit

E

P0223

High voltage or open of ETC throttle position sensor 2 # circuit

E

P0230

Oil pump relay failure

C

P0261

1 # nozzle line low voltage

A

P0262

1 # nozzle line high voltage

A

P0264


A

P0265


A

P0267

3# nozzle line low voltage

A

P0268


A

P0270


A

P0271


A

P0300

Misfire of one or more cylinders

B

P0324

Knock control system failure

C

P0325

Knock sensor failure

E

P0336

Interference of crankshaft position sensor circuit signal

C

P0337

Crankshaft position sensor circuit no signal

P0340

VCP intake camshaft position sensor state diagnosis

A

P0341

VCP intake target wheel diagnose failure

A

P0341

Camshaft position sensor rationality fault

E

P0342

Camshaft position sensor no signal

A

P0351

# 1 ignition coil failure

A

P0352


A

P0353


A

167



DTC


Default type

P0354


A

P0420

Deterioration diagnosis of catalytic converter

A

P0458

Short circuit of canister solenoid valve to the low-voltage

E

P0459

Short circuit of canister solenoid valve to high voltage

E

P0480

Low-speed fan failure

A

P0481

High-speed fan failure

C

P0502

Speed sensor no signal

C

P0504

Brake switch related faults

E

P0506

Low idling speed

E

P0507

High idling speed

E

P0537

Low voltage of AC front evaporator temperature sensor circuit

C

P0538

High voltage or open circuit of AC front evaporator temperature sensor circuit

C

P0551

Power steering signal failure

C

P0562

System voltage low

C

P0563

System voltage high

C

P0571

Brake indicator switch failure

E

P0601

ROM checksum failure

A

P0602

ECM programming error

A

P0604

Main CPU RAM failure

A

P0606

ECM processor failure

A

P0641

ETC reference voltage A# amplitude fault

A

P0646

AC clutch relay short circuit to low voltage

C

P0647

AC clutch relay short circuit to high voltage

C

P0650

Malfunction indicator light failure

C

P0651

ETC reference voltage B # amplitude fault

A

P0685

Main relay fault

A

P0700

Transmission control system malfunction light request

C

P0863

CAN communication malfunction of control system

A

P1167

Front oxygen too thick fuel cutoff deceleration

E

P1171

Front oxygen too thin at power deliveration

E

P1336

58-teeth gear error, not learning

A

P1396

Wheel speed sensor signal variation

C

P1397

Wheel speed sensor no signal

C

P1516

ETC steady throttle control fault

A

P1690

Anti-theft alarm signal failure

C

P2101

ETC throttle control fault

A

P2104

Engine forced idle mode

A

P2105

Engine forced shutdown mode

A

P2106

Restriction mode of engine performance

A

P2110

Engine Power Management mode

A

P2119

ETC throttle back failure

C

168



DTC


P2122

Low voltage or open of electronic accelerator pedal position sensor 1 # circuit

A

P2123

High voltage of electronic accelerator pedal position sensor 1 # circuit

A

P2127

Low voltage or open of electronic accelerator pedal position sensor #2 circuit

A

P2128

High voltage of electronic accelerator pedal position sensor #2 circuit

A

P2135

ETC throttle position sensor 1 #, 2 #-related failures

A

P2138

Electronic accelerator pedal position sensor 1 #, 2 #-related failures

A

P2610

LPC failure

C

P2610

LPC reset fault

C

P161B

Torque control rationality failure

A

169

Default type



IV. Engine Trouble Diagnosis 1.

Trouble diagnosis general for engine control system

In case of failure with Engine Electronic control system components (such as sensor, ECM, injector), fuel may be cut off or insufficient fuel will be supplied resulting in following conditions: a. Starting hardship or failure of engine b. Unstable idle c.

Poor drivability

If any of these situations occurs, first of all, carry out the regular inspection including the basic inspection of engine (ignition system trouble and correct adjustment of engine etc.). Then inspect the sub-assemblies of the electronic control system with trouble diagnose apparatus. Attention: ■

■

■

■

■

Before dismantling or installing any component, read the DTC at first and then disconnect battery negative poles. Before disconnecting battery cables, firstly turn off the ignition switch. If battery cable is disconnected with engine rungin or ignition at ON position, ECM may be damaged. The harness between the ECM and sensor should be shielded by the grounding wire connected to the vehicle body in order to prevent the interference from the ignition system and radio. If fails, the harness s hould be replaced. When checking the charging state of engine, don’t disconnect the negative pole of battery to prevent damage of ECM. When using the outside charger to charge the battery, it is necessary to disconnect battery cable to prevent damage of ECM.

170



Trouble Diagnosis Flow Chart The check starts 1. Acquire the symptom information Ask the user for more information associated with symptom

1. Check the DTC User described the

Check DTC and print DTC and freeze frame

User described the

symptom and

data, inspect related maintenance record

symptom and the

apparatus did not

apparatus displays DTC

show DTC

User did not describe the symptom, but

4. Recognize the symptom

Attempt to diagnose the

apparatus

Attempt to diagnose the symptom

symptom described by the user.

displays the

described by the user.

2. Recognize the symptom

DTC.

5. Implement the confirmation steps of DTC.

6. Implement the basic check.

Do not use the trouble diagnosis apparatus

9. Use the trouble

Inspect with trouble diagnosis apparatus

Within the scope of technical 7. Run the trouble diagnosis & parameters

symptom table to check troubled system No troubled component found

check mode

Beyond the scope of the technical parameters

8. Check the troubled 10. Check the troubled component through the diagnosis steps A b n o r m a l ( D T C d e t e c t e d )

component Troubled component found

11. Repair or replace the troubled components

12. Final check

Abnormal (symptom

Confirm no symptom found

still exists)

Implement the “DTC confirmation steps” again, and be sure to repaire the trouble properly. Normal The check ends

171



Trouble Symptom Check Table List of Trouble Symptom Inspection Symptoms

Check Order No.

Unable to communicate with

Unable to communicate with all the systems

1

diagnosis apparatus

Unable to communicate with ECM only

2

Engine alarm lamp and corresponding components

Engine alarm lamp failed to light up immediately after the ignition switch is turned to ON. Engine alarm lamp keeps bright

4

No initial ignition (unable to start)

5

There is initial ignition but it burns incompletely (unable to

Start

start)

Idle Stability (abnormal idle speed)

7

Unstable idle (fluctuant idle speed and hunting)

8

High idle speed (abnormal idle speed)

9

Low idle speed (abnormal idle speed)

10

deceleration)

Driving

6

Too long starting duration (unable to start normally)

The engine stops at the idle when it is cold. (stop with

Idle Stability (engine stops)

3

The engine stops at the idle when it is hot. (stop with deceleration)

11

12

The engine stops at the start. (stop with acceleration)

13

The engine stops with deceleration

14

Vehicle surge, drop or instability of vehicle speed

15

Shock or vibration during acceleration

16

Shock or vibration during deceleration

17

Poor acceleration

18

Surge

19

Knock

20

Fail to stop engine

21

High concentration of CO and HC at the idle operation

22

Low voltage of alternator

23

Abnormal idling speed when starting the air conditioner

24

Abnormal operation of fan

25

172



Symptom List Symptom List Items Failure of starting

Start

Extinguishment after combustion Hard to start

Stability of idle speed

5.

Starter drags the engine, but there is no combustion in cylinder and the engine does not start. There is combustion in cylinder, but the engine extinguishes immediately. Engine starts after the crankshaft rotates a while.

Hunting

Engine does not maintain a constant speed and the speed changes within range of idle speed.

Fluctuation of idle

Usually, it can be determined with the swing of tachometer pointer and the vibration transferred to the steering wheel, selector rod and body etc.

Incorrect idle

Engine is running idly at the incorrect rotation speed.

Extinguishment of engine (with deceleration)

When releasing the accelerator pedal, no matter whether the vehicle is moving, the engine stops.

Extinguishment of engine (with acceleration)

When the accelerator pedal is depressed or being depressed, the engine stops.

Vehicle surge, drop of speed

The phenomenon of “vehicle surge” refers to that the vehicle speed (rotation speed of engine) responds slow when there is a need to accelerate and depress down the accelerator pedal at the current vehicle speed or the temporary decline of vehicle speed (rotation speed of engine) during acceleration.

Poor acceleration

Poor acceleration refers to that the vehicle is unable to acquire acceleration with the opening of air throttle even with stable acceleration; or refers to the disability to reach the maximum vehicle speed.

Instability

When firstly depressing down the accelerator pedal to speed up, engine speed increases slowly.

Driving

Parking

Symptoms

Shock

There is huge shock or vibration of engine with accelerating or decelerating.

Surge

There is repeatedly forward surge when traveling with constant or variable speed.

Knock

There is a strong voice like the hammer against the cylinder wall during the driving which is harmful to driving.

Keep running(fail to stop)

General Trouble Inspection

Engine trouble inspection should begin with the basic system. In case of starting failure, unstable idle or insufficient fuel supply, begin the following basic systems: a. power supply: battery, fusible link and fuse wire b. Grounding c.

Fuel supply: fuel pipe, fuel filter, fuel pump

d. Ignition system: spark plug, high tension line, ignition coil. e. Emission control system: Leakage of vacuum system. f.

Others: ignition timing and idle.

The trouble of electronic control system of engine is generally caused by poor contact of the harness connector. All the harness connectors should be checked to verify whether they are connected correctly.

173


Inspection of Idling Speed

1)

Conditions


Attention: ■

Check the regular items including spark plug, fuel injector and compression pressure of the cylinder at beginning of inspection.

①

The engine coolant temperature is 80-95℃.

②

Lamps, electronic fan and all the accessories are turned off.

③

Shiftlever is at neutral position.

④

The steering wheel is at center (equipped with power steering system).

2)

Connect the diagnosis apparatus.

3)

Start engine and run it at the lowest idle speed.

4)

Run engine for over 5s with speed of 2000-3000 rpm and then make the engine operate for 2min at the idle speed.

5)

Read idling speed (750±50r/min).

7.

Fuel Pressure Test

Attention: ■

Before disconnecting the fuel pipeline, it is necessary to release the fuel pressure inside the fuel pipeline to eliminate the danger.

■

The O-ring should always be used to keep the seal of the connecting joint of fuel hose.

■

Don’t operate the electrical system during inspection.

Note: Prepare a container under fuel pipe to avoid the fuel spillage when pipes disconnected. 1)

Dismount the nut at fuel pressure inspection port on the guide rail of fuel injector.

2)

Connect fuel pressure gauge.

3)

With ignition switch at “ON” position, check for fuel leakage.

4)

With engine running with idling speed, check for the fuel leakage.

5)

Take down reading of fuel pressure gauge.

■

Fuel pressure: 350KPa

Attention: ■

Don’t check fuel pressure with system operating.

174



During inspection of fuel pressure, always to make sure whether there is fuel leakage in fuel

■

pipeline. 7)

If the measured fuel pressure is more than the standard value, analyze the possible reasons referring the following table and repair as required. Fuel System Trouble Diagnosis Table 1 Phenomenon

Possible Cause Blockage of fuel filter

Too low fuel pressure

Damaged fuel pump or poor sealing of fuel pressure regulator resulting in fuel leakage at returning side Cementation of fuel pressure

Too high fuel pressure

Blockage or bend of fuel return pipe

Troubleshooting Replace the fuel filter Replace fuel pump Replace fuel pump Repair or replace fuel pipe

8) Turn off engine and check the changes of fuel pressure gauge reading for 5min. If the reading drops, observe the reduction rate. Referring to following table to analyze and eliminate the trouble. Fuel System Trouble Diagnosis Table 2 Phenomenon Fuel pressure drops slowly after engine stopped

Possible Cause

Troubleshooting

Leakage of fuel injector

Replace injector

Trouble of fuel pump

Replace pump

Fuel pressure drops completely after engine stopped. 9)

Reduce the pressure in fuel pipeline.

10) Disconnect the fuel pressure gauge and install the inspection port nut. 11) Check for fuel leakage with following steps.

①

Turn the ignition switch to the "ON" position (with engine stopped), and then check for leakage at the joint of the fuel pipeline.

②

Start the engine and increase speed, inspect whether there is leakage at joint of fuel system.

175

Maintenance Manual of Tojoy Sedan Section III


Structural Principle and Inspection of Engine Electronic Components

I.

Intake Manifold Absolute Pressure (MAP) Sensor

1.

Description

1)

MT60 EFI system uses speed density air metering method to detect the amount of air entering the engine, thus control the fuel injection pulse width, realized precisely control of engine power output. Sensors include the absolute pressure sensor and intake air temperature sensor. In addition, the system can use air pressure cylinder judgment technology; with which an air pressure sensor is installed near the cylinder 1 intake manifold; when the air valve opens in an instant, there will be an instantaneous voltage drop about 1kPa on sensor. Which can be detected by ECU. When ECU receives this signal, the compression TDC signal will be defined through processing with software analysis.

2)

Intake absolute pressure sensor (MAP) is a pressure sensitive variable resistor. Diaphragm inside of sensor is connected with a magnet core placed through the coil. When intake pipe pressure changes, the diaphragm will drive the core to movement and thus change output voltage of sensor .With sensor output voltage, ECU can determine engine intake volume, with which and reference to other signals, injection volume control is achieved. .MAP sensor is also used to measure atmospheric pressure during starting; under certain conditions, it allows the ECM to be adjusted automatically at different altitudes. ECM provides 5V voltage to MAP sensor and receives voltage signal by the signal line. The sensor is grounded with a wire from its variable resistor. MAP sensor input signal affects ECM fuel output and ignition timing control.

3)

Intake temperature sensor element is a thermistor with negative temperature coefficient (NTC). Its resistance increases with the intake air temperature decreases. Engine ECU detects intake air temperature changes via a contrast circuit.

2.

Installation Position

Fig. 3.3.001

Installed at rear of the electronic throttle.

176


3.


Circuit Diagram

Pin 13: 5V voltage signal Pin 11: Manifold pressure sensor signal Pin 14: Power ground Pin 07: Intake air temperature sensor signal Operating voltage: 5 ± 0.1V Fig. 3.3.002 Intake air temperature/ pressure sensor

4.

Diagnosis



Sensor short circuit (to ground, to power supply);



Sensor circuit open;



Sensor detects the intake pressure exceeds the upper limit;



Sensor detects the Intake pressure exceeds the lower limit;

5.

Trouble Solution



Mainly check the 4 connections of the sensor and connection with ECU for short circuit, open circuit;



Check sensor detection holes for blockage.



Whether a short circuit, open circuit, grounding problem exists in sensor wiring harness



Whether sensor is highly impacted resulting in sensor failure.



Operating pressure range: 12.5kPa - 115kPa



Operating temperature range: -40 - 125 ℃

177



1)

Dismantlement

①

Disconnect the wire harness connectors of intake


Fig. 3.3.002

manifold pressure & temperature sensors. Attention: ■

Make sure that the ignition switch is at “Off” position.

②

Disassemble the fixing screws of the intake pressure/temperature

sensor

with

crosshead

screw driver, remove the sensor.

2)

Fig. 3.3.003

Installation

Be aware of following precautions and install with steps contrary to dismantlement. ■

Apply a small amount of engine oil on seal ring of sensor in order to facilitate the installation.

■

Make sure that adhesive of sensor and intake manifold is well, tighten the self-tapping screw

■

Verify reliable installation of wire harness connector.

178


Coolant Temperature (ECT) Sensor

1.

Instruction of Parts


Coolant temperature sensor is used to detect coolant temperature of engine and sent signal to ECM, whereby used to control ignition timing and fuel injection pulse width during starting, idling and normal driving, meanwhile provides signal for meters to indicates coolant temperature. A thermistor with negative temperature coefficient (NTC) is used. Resistance of thermistor decreases with increasing of temperature. ECM determines coolant with voltage output of sensor and provides optimal air/fuel mixing to engine base on this voltage signal.

2.

Installation Position of Element Fig. 3.3.004

See figure right for installation positions.

3.

Wiring Diagram

Remarks: This model is equipped with a three-wire water temperature sensor, saving costs and ensuring the unity of the system. Pin 12: 5V Grounding Pin 39: Cooling water temperature signal output B port: To coolant temperature meter

Water temperature sensor To coolant temperature meter

179


Diagnosis



Water temperature signal higher than the limit;



Water temperature signal lower than the limit;



Water temperature sensor short circuit, open circuit.


Room temperature resistance data: 2.5 ± 5%k k Ω Characteristic parameters (standard)

5.

Trouble Solution



Mainly check connections of the three wires on sensor with ECU, instrument for short circuit, open circuit.



Short circuit, open circuit, grounding problems between sensor harness.



Grounding: poor grounding easily lead to excessively high engine water temperature indication;



Operating voltage: 5V;



Operating temperature range: -40 - 135 ℃

6.


1)

Dismantlement

①

Discharge coolant from radiator. Please refer to "Change Engine Coolant".

②

Disconnect the wire harness connector of the engine coolant temperature sensor.

③

Dismantle the engine coolant temperature sensor.

180

Fig. 3.3.005



Installation

Be aware of following precaution to install with steps contrary to dismantlement. ■

Apply surface sealant on threaded part of sensor and tighten with specified torque. Tightening torque :16-24N. M

■

Verify reliable installation of wire harness connector.

■

With engine idling，visually inspect coolant leakage.

III. Electronic throttle 1.


Electronically controlled throttle valve assembly is the main component of intake control and management in modern engine management system. It directly controls the engine air intake volume, and thus controls speed and power output. On electronically controlled throttle valve, the mechanical control mechanism throttle body control has been instead by driving motor, drive gear mechanism, necessary mechanical transmission components and more powerful and reliable special throttle position sensor. 2.


Fig. 3.3.006

Installed in intake manifold.

3. Wiring diagram of throttle position sensor Pin 65: output signal of throttle position sensor 1 Pin 21: 5V reference power supply Pin 66: output signal of throttle position sensor 2 Pin 19: 5V ground Pin 24: Controlled power Pin 49: Throttle motor, high level

181



G6 electronic controlled throttle valve body

4.

Diagnosis



Throttle valve driving motor failure:





Drive motor assembly open circuit;



Drive motor assembly coil short circuit;



Drive motor assembly circuit burn out;



Drive motor assembly circuit excessively worn or damaged.

Throttle valve body unload failure: 

Throttle valve gear excessively worn and damaged;



Throttle valve gear bearing clogged or damaged;



Throttle position sensor connection is poor; signal output is instability;



Valve blocked by impurities or sludge; clean regularly.

5.

Solutions



Mainly inspect sensor and ECU wiring harness for short circuit, open circuit, grounding problems;



Detect jumping between sensor signal circuit and grounding with an universal meter during opening and closing of throttle;



Operating temperature: -40 - 125 ℃;



Responding time: ≤ 100ms (fully open to fully closed), ≤ 150ms (fully closed to fully open)

Measurement range of throttle position sensor:

182


Idling condition Fully open condition Idling condition Fully open condition

6.

Dismantlement and installation of throttle Fig. 3.3.07

position sensor 1)

Dismantlement

①

Disconnect the wire harness connector of air

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

②

Dismantle the air throttle body assembly. Fig. 3.3.08

③

Unscrew electronic throttle position sensor screws, remove the sensor.

Fig. 3.3.09

183




Installation

Be aware of following to install with steps contrary to dismantlement. ■

Verify that the of the wire harness connector is inserted securely.

■

Tighten self-tapping screw.

IV. Hall sensor 1.

Component Description Camshaft position sensor, crankshaft position sensors are Hall sensors and work together with the signal wheel of camshaft and crankshaft which correspond to specific positions of engine. ECU determines engine working conditions with digital voltage signals of the sensor to implements one by one control. Performance: Operating temperature: -40～150 ℃ System input voltage: 5.0V (powered by controller) Working gap: 0.5-1.5 mm

2.

Installation position Close to the camshaft, crankshaft respectively.

Fig. 3.3.010

3.

Fig. 3.3.011

Wiring Diagram

Pin 18: 5V reference voltage Pin 30: signal of crankshaft position sensor Pin 19: 5V grounding Pin 46: 5V reference voltage Pin 05: signal camshaft position sensor Pin 45: 5V grounding 184





4.

Diagnosis

ECU real-time monitoring of the sensor and circuit 

Sensor open circuit;



Internal short-circuit of sensor;



Hall element of sensor grounded;



Hall element of sensor short to reference voltage signal circuit.

5.

Trouble Solution



Check sensor circuit for normal function and incorrect connection of grounding



Connect the sensor and wiring harness connector with a T connector to inspect power, grounding, and signal circuit for normal working.

6.

Removal and installation

1）Removal

①

Disconnect the crankshaft position sensor, camshaft position sensor wiring harness connectors.

Fig. 3.3.012

②

Fig. 3.3.013

Unscrew fixing bolts, remove the sensor.

185


Fig. 3.3.014


Fig. 3.3.015

2） Installation Be aware of following precaution to install with steps contrarily. ■

Be aware of installation gap. Standard: 0.5 - 1.5mm

■

Tightening torque: 7.8 - 9 N • m

IV. Oxygen sensor 1.

Component Description

Oxygen sensor is used to provide information for judging whether the oxygen in air inhaled to the fuel in engine cylinder is excessive or not after combustion. ECU uses this quantitative information for defined cycle control of the fuel cycle so that the three major toxic components can be mostly converted and purified in the three-way catalytic converter. The sensing component is a kind of porous ceramic tube; the wall is surrounded by the engine exhaust while the inside is put through to the atmosphere. The oxygen sensor, based on concentration difference inside and outside, calculates indirectly the fuel injection pulse width to be transmitted to ECU for controlling of fuel injection. Simu ltaneously, it detects rear oxygen sensor output data and compares with front sensors data within the ECU to monitor the working conditions of the three-way catalyst converter. Oxygen sensor operating voltage fluctuates between 0.1-0.9V; in 10 seconds it may change for 5-8 times; if it is lower, indicates that the sensor is aged and need to be replaced. The sensor can not be repaired. 2.

Installation position

Front (upstream) oxygen sensor is installed on the exhaust

manifold

before

the

three-way

catalyst

converter and the rear (downstream) oxygen sensor is installed behind the three-way catalytic converter.

186

Fig. 3.3.016



Wiring diagram

Pin 40: Oxygen sensor A signal, high level Pin 42: Oxygen sensor A signal, low level Pin 88: Sensor heating cable control D:

To main relay power

Pin 10: Oxygen sensor B signal high level Pin 20: Oxygen sensor B signal, low level Pin 90: Sensor heating control D:

To main relay power

Heated oxygen sensor (front)

Heated oxygen sensor (rear)

4.

Diagnosis

ECU detects the oxygen sensor circuit and ECU internal power amplifier circuit and testing circuit. If one of the following conditions occurs, the oxygen sensor fault indicator will be set: 

Battery voltage not reliable



Intake manifold absolute pressure signal not reliable



Engine coolant temperature signal not reliable



Injector drive-level fault

Oxygen sensor fault indication is set, with the fuel cycle quantitative control cut off; use the basic fuel injection time stored in the ECU for the quantitative fuel control. 5.

Diagnosis



Mainly check sensor wiring connection for short circuit, open circuit;



Sensor damages are generally caused by lead or phosphorus poisoning; so pay attention to the fuel quality; meanwhile, excessive fuel consumption may also lead to sensor failure;

187





Changes of the oxygen sensors should be not less than a certain times in certain period of time.

6.


1)

Dismantlement

①

Disconnect oxygen sensor harness connector. Fig. 3.3.017

②

Remove oxygen sensor with special remover. Fig. 3.3.018

Attention: ■

Plug mounting hole of the oxygen sensor with hairless cotton yarn to keep the debris or oil & water away from the exhaust manifold.

■

Visually inspect appearance of oxygen sensor.

Reddish brown: lead poisoning Off-white: normal Black: carbon deposition 2)

Installation

Be aware of following items to install with steps contrary to dismantlement. ■

Be aware of routing of oxygen sensor wire harness.

■


■

After replacement of oxygen sensor, oxygen sensor should be coated with a layer of anti-rust oil to prevent rust which impede removal. 188



VII. Fuel Injector (INJ) 1.


Fuel coming from the fuel pump is stored and distributed via the fuel rail components and provides the fuel system with a more stable pressure environment in which the fuel supply pressure and quantity of each cylinder will be balanced while the engine is running smoothly. Injector injects fuel as per the signal from the ECM signal and defines fuel injection volume depending on opening time of injector solenoid valve. 2.

Installation Position Fig. 3.3.019

It is installed on the fuel guide rail.

3.

Wiring Diagram Fuel Injector

4.

Inspection

Attention: ■

Please clean the fuel injector and analyze with special cleaning and analysis instrument for fuel inject at certain interval..

1)

Check the resistance.

Note: check with wire harness connector disconnected. ■

Standard resistance: 11.4-12.6Ω

2)

Inspect operating time of the fuel injector with trouble diagnosis apparatus. 189



■

Standard operation time: 2.0-3.0ms at the idle speed and more during the acceleration.

3)

Check the operating sound of fuel injector.

Note: Use a stethoscope to check the click sound of the fuel injector at the idling speed or use the fingers to check the vibration situation of fuel injector. If vibration can not be felt, check the wire harness connector, fuel injector or the control signal of fuel injector by ECM. 5.


Please refer to “Fuel System”.

VII. Knock sensor 1.

Description

Knock sensor is installed in the cylinder block side usually between the 2, 3-cylinder, it is helpful for engine knock balance; the ECU uses the knock sensor output vibration frequency signal to judge whether there is knock with ECU internal filtering. When the knock signal is d etected, ECU will gradually reduce it until the knock disappeared; and then gradually restore to the knock threshold; the cycle is done repeatedly. 2.


Fig. 3.3.020

Installed aside of cylinder.

3.

Inspection

1)

Wiring diagram Pin 71: Knock sensor signal, low Pin 72: Knock sensor signal, high

Knock sensor Twisted pair (9 pitches/feet) 2)

Check the resistance. Resistance: greater than 1MΩ 190



Diagnosis:

ECU monitors the knock sensor, power amplifier circuit and testing circuit. If one of the following circumstances is detected, knock sensor fault indication will be set: 

Knock sensor failure;



Knock control data processing circuit fault;



Cylinder judging signal not reliable;



Sensor circuit failure.

After knock sensor fault flagging out the failure position, knock set control loop is Disconnect and the advance angle of ignition stored in the ECU will be fixed to a safe angle by the software program. When the error frequency drops below the set value, the fault indication will reset. 5.

Removal and installation Fig. 3.3.021

1） Removal

①

Disconnect knock sensor harness connector.

②

Unscrew knock sensor locking nut, remove

the knock sensor.

Fig. 3.3.022

Attention: ■

Do not drop or damage the sensor.

2)

Installation Install with reversed steps of disassembly.

■

Tightening torque: 16 - 24N • m

191


Maintenance Manual of Tojoy Sedan VIII. 1.

Air-conditioning switch and relay Description

When air conditioner is turned on, the air conditioning switch will send the battery voltage signal to the ECM. After air conditioner turned-on signal input, ECM drives electronic throttle to increase idling speed of engine, and correct ignition advance angle. At the same time, ECM controls air conditioning relay to make the compressor magnetic clutch working. 2.

Inspection

With engine idling, use fault diagnostic apparatus to check air-conditioning switch for normal working. Air conditioning switch Checklist Items

Air conditioning switch

Air conditioning switch

Air compressor

Normal direction

Off

Off

On

On

Off

Off (compressor clutch does not work)

On

IX. 1.

On

(compressor clutch works)

Continuously variable cam phase regulator and control valve Description

Continuously variable cam phase regulator is used to change timing of admission gear. It controls the air distribution phase through the continuous adjustment of the camshaft and crankshaft phase relationship. VVT voltage control valve is a four-way pulse controlled solenoid valve which can move in double way; it is used to control oil flow with axial movement of plunger. Engine ECU regulates the oil flow to rotor blade sides with duty cycle signal regulated by pulse width. And based on this, the timing and phase of camshaft relative to the crankshaft are controlled. Target wheel

Control valve

Fig. 3.3.023

Fig. 3.3.024

Phaser

e g a s s a p l i O



In figure: Electrical signal Hydraulic circuit

Oil pump

The system's main functions: 

Improve air intake efficiency;



In partial load, improve dilution control for better fuel economy;



Instead of the exhaust gas recirculation (EGR) system to reduce equivalent NOx emissions while 192



potentially reducing HC emissions and thermal radiation; 

WIth default variable cam phase system, it is helpful for cold starting performance and reducing HC emissions.

2.


Fig. 3.3.025

3.

Fig. 3.3.026

Wiring diagram Pin 99: variable valve timing control signal

A:

Relay control

Air intake VVT valve

4.

Diagnosis

One of the most complex areas of cam phase regulating control system is the diagnostic system. For the cam sensor, target wheel and oil control valve, it must have the components level diagnostic features and constantly determine cam signal integrity to ensure proper cam phase measurement. The oil control valve drive signals should also be ch ecked as fuel nozzle and ignition coil driver. For oil control valve and phaser, there is often more responsible diagnosis. ECU checks the phaser and the oil control valve regulator circuit to detect whether there are any of the following cases: 

Intake VCP phase response slow;



Large error of air intake VCP camshaft phase;



Intake VCP cam tooth learning bias out of range;



Intake VCP hydraulic control valve blocked;

5.

Trouble Solution



Check sensor signal for short circuit, open circuit;



Check wiring harness channeling;



Check sensor for short circuit with power line; 193

Maintenance Manual of Tojoy Sedan 

Check VCP and oil control valve for blockage and normal ventilation;



Check working conditions of VCP as follows:


Item

Value

Input voltage

11.5-18.0VDC; nominal 13.5 ± 1.0VDC

*Average operating current at position *

1.0 amps

Maximum current

100% duty cycle, at -40 º C, 15.5V, 2.5 amps

Ambient temperature

-40 to 150ºC

Chamber temperature

-40 to 150ºC

Temperature of solenoid valve

-10 to 150ºC



Check working conditions of the oil control valve as follows:

Type

Oil control solenoid valve

Coil impedance

Nominal: 7.0 Ω@20 ºC 5.6Ω@-30 ºC 10.6 Ω@150 ºC

Coil inductance

18mH@1KHz

Minimum current required for full stroke of plunger valve

1.07 amps

Voltage input (through the coil)

Nominal: 13 ± 0.5 V Minimum: 11.0 V Max: 18.0 V (CARB required)

Starting response with normal voltage input

<50 ms in the T coil <65 º C

Close response

<50 ms in the T coil <65 º C

6.

Removal and installation ”See the "timing sprocket system"

X.

Canister solenoid valve

1.

Description

Control air intake from the canister to the general intake piping. The adsorption amount of canister has certain limits, if evaporation of gasoline attached to the canister is not consumed, it may emit into ambient air resulting in pollution and increased insecurity. Internal of canister valve is a solenoid valve structure and its opening is controlled with the digital pulse square wave sent from the ECU.

According to different engine operating conditions, canister solenoid

valve opening is also different; at big loading of the engine and idle time, canister solenoid valve is not working in order to ensure the engine's output power.

194



3.

Wiring diagram

A:

Main relay output end

Fig. 3.3.027

Pin 95: Canister solenoid valve control signal Canister solenoid valve

4.

Diagnosis



Short circuit of sensor with ground



Short circuit of sensor with power line



Open circuit of sensor

5.

Trouble Solution



Check sensor signal for short circuit, open circuit;



Check wiring harness for channeling;



Check sensor circuit for short circuit with power line;



Check canister magnet valve for blockage and normal ventilation;



Operating Temperature: -40 - 120 ℃;



Coil resistance: 19 - 22Ω;



Working voltage: 8 - 16V;

195



6.

Removal and installation


Fig. 3.3.028

1） Removal

①

Disconnect hose at canister solenoid valve side.

②

Disconnect the canister solenoid valve wiring harness connector.

③

Remove canister solenoid valve from the bracket.

Fig. 3.3.029

Fig. 3.3.030

2） Installation Be aware of following precautions to install with steps contrary to removal. ■

When installing, air flow direction must meet requirement, meanwhile checking the canister solenoid valve for wearing and cracks.

■

During the disassembly process, avoid water, oil and other liquid entering into the valve.

196



XI. Ignition coil 1.

Fig. 3.3.031

Description

Ignition coil converts the low voltage of the primary winding into the high voltage of secondary winding and discharged at spark plug to ignite the fuel air mixture in cylinder.

MT60 uses separate ignition technology. Based on the principle that using electromagnetic coil mutual inductance to produce high-energy, the primary coil powering time, power off time are controlled; by using high voltage generated in the secondary coil, spark plug gap is broken, producing a strong spark tp ignite the mixture. As in the engine exhaust stroke, air ionization is great while the resistance is very low, only low-voltage will be able to break the spark plug gap. So the system uses a grouping ignition technology which will not waste energy, achieving significant cost saving. 

Ignition coil operating voltage range: 6 - 16V



Secondary ignition coil resistance: 8.7 ± 0.87 KΩ



Primary charge time: 2.15ms



Minimum ignition duration: 1.0ms



Minimum ignition energy: 35mJ.

2.


Fig. 3.3.032

Installed at top of the cylinder head cover.

197


3.


Wiring diagram

Duel-core screener

Duel-core screener

4.

Diagnosis

ECU does not function to diagnose ignition coil failures. Therefore, if there is any failure of ignition coil, no DTC is set. Only by checking the ignition coil resistance can the proper working of the ignition coil be determined; under normal circumstances, the ignition coil heats up more during working, but overheated temperature of the ignition coil causes increaseing in ignition coil resistance, resulting in instability of engine work, automatic flameout and other failures. But the ECU can detect the control cable of the ignition coil. When failure of an ignition coil is detected, injector of corresponding cylinder will be turned off. 

Control cable short circuit with ground;



Control cable short circuit with power line;



Control circuit open.

5.

Diagnosis



Internal short circuit, open circuit of coil;



Coil leakage, cracks in the housing;



Aging coil leading to energy shortage in ignition.

6.

Removal and installation For removal and installation, please see "Ignition System."

198



XII. Electric Fuel Pump 1.

Description

It is used to deliver the fuel to the main fuel supply pipe from the fuel tank at a certain fuel pressure and flow, and maintain the stable fuel pressure (through the fuel pressure regulator). 2.


It is installed inside the fuel tank 3.

Wiring diagram

Pins description: the electric fuel pump has two pins, and the fuel pump casings next to the two pins are marked with "+" and "-" signs, which represent respectively the connections to the positive (fuel pump relay) and ground.

Fuel pump relay Fuel pump

4.

Inspection

1)

Check internal resistance of fuel pump. Internal resistance should not be zero or infinity.

2)

Check the fuel pressure Refer to “Fuel System”.

5.

Dismantlement and Installation Refer to “Fuel Pump Assembly”.

Attention: ■

In order to prevent accidental damage of fuel fuel pump, please do not run the fuel fuel pump without fuel.

■

In case that the fuel pump need to be replaced, please pay attention to the the cleaning of fuel tank and pipeline and replacement of fuel filter.

199



XIII. Electronic Control Module (ECM) of Engine 1.

System description

Delphi MT60 engine control system takes the MT60 Engine Control Module (ECU) as the core of the system and it is characterized by computerized closed-loop control, sequential multi-point fuel injection, direct ignition without distributor block and catalytic converter post treatment. MT60 Engine Control Module (ECU) is a kind of ECU Delphi EFI developed exclusively for China market. The engine control module uses the latest electronic hardware technology with higher cost/performance ratio; the hardware uses 16-bit microprocessor with adequate memory, has high-strength computing speed and flexible definition of input and output ports; the software is the second generation software of control programmed with Delphi Modular C Language, meeting all current technical specifications in Euro IV engines and OBD emission regulations. 1） Functions 

Vehicle main power relay control



Speed-density airflow



Closed-loop controlled controlled multi-point sequential fuel injection (package (package MAP CID cylinder cylinder pressure pressure judgment)



Closed-loop controlled multi-point sequential fuel injection



Oil supply supply in different ways including including oil returning, without returning, semi-free oil return, etc.



Fuel pump controlled



Direct ignition without distributor; ECU built-in ignition module for 4-cylinder sequential ignition ignition



Electronic throttle controls air flow volume, with rapid and accurate response; ECU is used to achieve torque control and improved reliability



VVT-i (electronically controlled variable variable intake cam phase adjustment device) controls the engine's intake volume, with improved torque and power



Knock control



Canister solenoid valve control



Air conditioning, cooling radiator fan control



Mileage memory



Over-voltage protection



Electronic anti-theft device



CAN-BUS communication interface for communication with automatic transmission control module and ABS system



Open, modular C Language programming, etc.

200



2） ECM pin definitions: ECM pin definition list Pin

Function

Pin

Function

1

Ignition coil C drive (4 cylinder)

51

Radiator fan 2 (high speed)

2

Ignition Coil B drive (3 cylinder)

52

Radiator fan 1 (low speed)

3

Ignition Coil D drive (2 cylinder)

53

Brake switch input (active LOW)

4

Power grounding

54

CAN high (for diagnostic)

5

Camshaft position sensor 1

55

CAN low (for diagnostic)

6

Standby terminal

56

Brake indicator switch signal input (active HIGH)

7

Intake air temperature sensor

57

KW2000 communication cable

8

Standby terminal

58

Wheel speed signal input

9

Standby terminal

59

Standby terminal

10

Oxygen Sensor B

60

Air conditioning request signal (active HIGH)

11

Intake manifold pressure sensor

61

Power steering pressure switch (active LOW)

12

5V ground

62

Standby Standby terminal

13

5V reference voltage # 1

63

Electrical load (active HIGH)

14

5V ground

64

Air conditioning pressure switch

15

5V ground

65

Throttle position sensor # 1

16


66

Throttle position sensor # 2

17

Battery power +

67

5V ground

18


68

Speed sensor

19

5V ground

69

5V ground

20

5V ground

70


21


71

Knock sensor low

22

Standby terminal

72

Knock sensor high

23

Standby terminal

73

Standby terminal

24

Throttle motor low

74

Chassis ground

25

Controlled power

75

Chassis ground

26

Ignition coil A drive (1 cylinder)

76


27

Power source

77

Air conditioning clutch relay

28

Power source

78

2-cylinder injector

29

Power source

79

3-cylinder injector

30

58X position sensor

80

1-cylinder injector

31

58X signal low (only for VR sensor)

81

4-cylinder injector

32

Pedal position sensor # 1

82

Vehicle Vehicle maintenance tip light

33

5V ground

83


34

Pedal position sensor # 2

84

Standby terminal

85

Standby terminal

86

Fuel pump relay (high drive)

35 36

Air-conditioning front evaporator temperature sensor Standby terminal 201



Pin

Function

Pin

Function

37

Oil level sensor

87

Standby terminal

38

Oil temperature sensor

88

Oxygen sensor A heating control

39


89

Standby terminal

40

Oxygen sensor A

90

Oxygen sensor B heating control

41

Electrical load (active LOW)

91

Standby terminal

42

5V ground

92

(Emission) MIL

43


93

Standby terminal

44

5V ground

94

Main relay control

45

5V ground

95

Canister cleaning solenoid valve

46


96

Fuel pump relay (low drive)

47

IGN signal (ignition IGN location)

97

Speed signal output

98

Standby terminal

48

Ancillary electrical power signal (ignition lock ACC position)

49

Throttle motor high

99

Variable valve timing control 1 (intake)

50

Controlled power

100

Standby terminal

* Specific pin number is subject to harness schematic diagram (standby terminal defined as empty pin).

202



3)

Electrical Principle Diagram Injector Crankshaft position sensor


Canister solenoid valve Heated oxygen sensor (front) Air intake VVT valve

Pen ignition coil Heated oxygen sensor (rear)

Duel-core shielded cable Intake air temperature/ pressure sensor

Water temperature sensor Duel-core shielded cable

To coolant temperature meter

Oil temperature sensor (only applied as required) Speed sensor Knock sensor Twisted pair (9 pitches/feet) G6 electronic controlled throttle body

Speedometer Fuel meter Tachometer Water temperature sensor

Coolant temperature meter Fault indicator Maintenance light

Accelerator pedal sensor 1

Accelerator pedal sensor 2 Brake switch

Brake indicator

AC switch

Temperature control switch for evaporator

High/low voltage switch Fuel pump relay Fuel pump Mid-voltage switch Battery AC relay AC clutch

Load of blower Load of headlight

Radiator fan relay Ignition switch

Radiator fan

Condensator fan 2# Condensator fan 1#

Condensator fan Main relay

Battery Grounding with vehicle body close to ECN Single point help on engine

203


2.



Fig. 3.3.033

Installation position is shown in the figure right.

5.

Inspection

1)

Read the engine trouble record with the data wire K.

2)

Check whether the connecting wire of ECM for normal conditions and put the focus on the ECM power supply and grounding line.

3)

Check for normal conditions of external sensor and reliability of output signal normal connection of its circuit.

4)

Check whether the actuator is normal and whether its line is intact.

5)

Finally, replace the ECM to carry out the test.

6.


1)

Dismantlement

①

Turn the ignition switch to “OFF” position to dismantle the negative terminal of battery.

②

Dismantle the lower part of the console referring to “console”.

③

Disconnect the wire harness connector of ECM port. Refer to “Precautions”.

④

Unscrew fixing bolts of ECM to remove the ECM.

2)

Installation

■

Install in the reverse order with dismantlement.

■

For precautions about the installation, please refer to “Precautions”.

204

Maintenance Manual of Tojoy Sedan Section IV


Trouble Diagnosis Procedures for Engine Control System

I.

Diagnosis with DTC

1.

Instruction

1)

The following Repair can be carried out only after the current stable trouble has been identified, otherwise the diagnosis will be wrong.

2)

The "multi-meter" hereinafter refers to the digital multi-meter and it is not permitted to use the analog multi-meter to check the electric control system circuits.

3)

When carrying out the Repair for the vehicle with the anti-theft system, if the requirement of replacing the ECM is included in the "Next Steps" column, it is necessary to program the ECM after replacement.

4)

If the DTC points to low voltage of a specific circuit, it indicates that the circuit is likely to have short circuit with ground or open circuit; if the DTC points to high voltage of a specific circuit, it indicates that the circuit is likely to have short circuit with power circuit; if the DTC points to a circuit trouble, it indicates that the circuit is likely to have broken circuit or a variety of line troubles.

2.

Diagnosis Help

1)

If the DTC can not be erased, it means the trouble is stable; in case of the sporadic trouble, it is necessary to check whether the connector of wire harness is loosened.

2)

The check has been accomplished with steps above and nothing unusual has been found.

3)

Effects of the maintenance of vehicle, cylinder pressure and mechanical ignition timing etc. on the system should not be neglected during the inspection and repairing.

4)

Replace the ECM to carry out the test.

■

If the DTC can be cleared at this time, it means the trouble site is at ECM; if the DTC still can not be erased at this point, then remount the original ECM and repeat the procedures again to carry out the Repair.

205



DTC Diagnosis

■

ECM pins referred to below should be subject to the actual wire harness diagrams.

DTC

P0011

Intake VCP phase response too slow

Set emergency control scheme:

Fault indicator lights up until the fault disappears

Terminals:

MT60

VCP control

Normal measurement signals

Variable timing control signals:

99

B

0-1000mV

Main relay:

\

A

12V

Judging conditions 1. 2. 3. 4. 5. 6.

Engine running fault duration > 2 seconds

DTC

Reference troubleshooting programs

Possible causes of the malfunction Connector not in place Variable timing control signal circuit open Variable timing control signal circuit grounded Main relay circuit fault Sensor damaged Timing control signal input of ECM failure

P0026


1. Reconnect 2. Repair harness 3. Repair harness 4. Repair harness 5. Change sensor 6. Change ECM

Intake VCP hydraulic control valve blocked Fault indicator lights up until the fault disappears Close intake VCP hydraulic control valve

Terminals:

MT60

VCP control


Main relay:

\

A

12V

Variable timing control signals:

99

B

0-12V square wave

Judging conditions

Duration > 2 seconds

Possible causes of the malfunction 1. Hydraulic control valve drive circuit short with system power supply positive side 2. Hydraulic control valve damaged 3. ECM failure

206

Reference troubleshooting programs 1. Repair harness 2. Replace control valve 3. Change ECM



DTC

P0107


Terminals:

Low voltage or open circuit of intake pressure sensor circuit Fault indicator lights up until the fault disappears Engine stopped: 100kPa Engine idling:≈32kPa Engine running: manifold pressure changes with the throttle opening Pressure sensor

MT60


5V reference voltage: 13

5V

Manifold pressure signal:

11

0.5-4.5V

Sensor signal/grounding:

14

0V

Judging conditions

Engine running No TPS failure MAP 14.017 kPa RPM

1050 rpm

TPS 18.75 % Fault duration> 2.5 seconds

DTC


Possible causes of the malfunction 1. Connector not in place 2. Harness pressure signal line open 3. Harness pressure signal line to ground short circuit 4. 5V reference voltage circuit open 5. Sensor signal ground circuit open 6. Harness 5V reference voltage and reference ground reversed (This failure may cause sensor damaged) 7. Sensor damaged 8. ECM MAP signal input fault

P0108


1. Reconnect 2. Repair harness 3. Repair harness 4. Repair harness 5. Repair harness 6. Repair harness 7. Change sensor 8. Change ECM

Intake pressure sensor circuit high voltage Fault indicator lights up until the fault disappears Engine stopped: 100kPa Engine idling:≈32kPa Engine running: manifold pressure changes with the throttle opening variations Pressure sensor


Terminals:

MT60

5V reference voltage:

13

5V

Manifold pressure signal:

11

0.5-4.5V


14

0V

Judging conditions Engine running No TPS failure MAP 98.117kPa TPS 19.141% Fault duration> 2.5 seconds

Possible causes of the malfunction 1. Constraint pressure signal circuit shorted with 5V reference voltage or positive power supply 2. Sensor damaged 3. ECM pressure signal input fault

207

Reference troubleshooting programs 1.Repair harness 2.Change sensor 3.Change ECM


DTC

P0112



Intake air temperature sensor circuit low voltage Fault indicator lights up until the fault disappears Intake temperature is equal to the coolant temperature, but not more than 44.25 degrees Temperature sensor


Terminals:

MT60

Intake air temperature signal:

07

0.5-4.5V


14

0V

Judging conditions

Engine operating time> 120 seconds MAT> -38.25 degrees Fault duration> 2.5 seconds

DTC

Possible causes of the malfunction


1. Connector not in place 2. Temperature signal circuit open 3. Sensor signal grounding open 4. Temperature signal circuit to positive power supply short circuit 5. Sensor damaged 6. ECM signal input failure

P0113



Intake air temperature sensor circuit high voltage Fault indicator lights up until the fault disappears Intake temperature is equal to the coolant temperature, but not more than 44.25 degrees Intake air temperature sensor


Terminals:

MT60

Intake air temperature signal:

07

0.5-4.5V


14

0V

Judging conditions Engine operating time 60 seconds MAT 148.5 degrees Fault duration 2 seconds

DTC



1. Temperature signal to ground short circuit 2. Sensor damaged 3. ECM signal input failure

P0117


1. Repair harness 2. Change sensor 3. Change ECM

Coolant temperature sensor circuit low voltage Fault indicator lights up until the fault disappears Starts with the intake air temperature, increasing to 79.5 degrees with time before fixing it

Terminals:

MT60



Coolant temperature signal:

39

A

0.5-4.5V


12

C

0V

Judging conditions

Engine operating time 10 seconds CTS -38.25 degrees Fault duration 2 seconds

Possible causes of the malfunction 1. Connector not in place 2. Temperature signal circuit open 3. Sensor signal grounding open 4. Temperature signal to positive power supply short circuit 5. Sensor damaged 6. ECM signal input failure 208

Reference troubleshooting programs 1. Reconnect 2. Repair harness 3. Repair harness 4. Repair harness 5. Change sensor 6. Change ECM


DTC

P0118



Coolant temperature sensor circuit high voltage or open Fault indicator lights up until the fault disappears Starts with the intake air temperature, increasing to 79.5 degrees with time before fixing it

Terminals:

MT60



Coolant temperature signal:

39

A

0.5-4.5V


12

C

0V

Judging conditions Engine operating time 2s CTS

135 degrees

Fault duration 2 seconds

DTC



1. Temperature signal circuited with ground short circuit 2. Sensor damaged 3. ECM signal input failure

P0122



ETC throttle position sensor # 1 circuit low voltage Fault indicator lights up until the fault disappears With idling, set the throttle position sensor opening 0%; at other rotating speed, the throttle position sensor opening changes with the rotating speed Automatic zero calibration function of throttle position sensor suspended Cleaning function suspended for the time being

Terminals:

MT60

Throttle position sensor



21

A

5V

Throttle position 1 signal:

65

D

0.5-4.5V


19

F

0V

Judging conditions Engine running, but the speed <3000rpm no MAP failure, and MAP <70kpa Fault duration 2 seconds

DTC



1. Sensor signal line to positive power supply or reference voltage circuit short circuit 2. Sensor damaged 3. ECM signal input failure

P0123


ETC throttle position sensor


#1 circuit high voltage or open

Fault indicator lights up until the fault disappears At idling, set the throttle position sensor opening 0%; at other rotating speed, the throttle position sensor opening changes with the rotating speed Automatic zero calibration function of throttle position sensor suspended Cleaning function suspended for the time being

Terminals:

MT60




21

A

5V


65

D

0.5-4.5V


19

F

0V

Judging conditions


Possible causes of the malfunction 1. Connector not in place 2. Sensor signal circuit open 3. Sensor signal line to ground short circuit 4. Sensor damaged 5. ECM signal input failure

209

Reference troubleshooting programs 1. Reconnect 2. Repair harness 3. Repair harness 4. Change sensor 5. Change ECM

Maintenance Manual of Tojoy Sedan DTC

P0131



Front oxygen sensor short circuit to low voltage Fault indicator lights up until the fault disappears and closes off ignition switch System closed loop delayed

Terminals:

MT60

Heated oxygen sensor


System main power supply:

\

D

12V

Heated drive:

88

C

0V

Oxygen sensor and high signal:

40

B

0-1000mV fluctuation

Oxygen sensor and low signal:

42

A

0V

Judging conditions

Duration 1 seconds

DTC

Possible causes of the malfunction 1. Heating drive circuit to positive po wer supply short circuit 2. Sensor damaged 3. ECM signal output interface failure

P0132


Reference troubleshooting programs 1. Repair harness 2. Change sensor 3. Change ECM

Front oxygen sensor open short to high voltage Fault indicator lights up until the fault disappears and closes off ignition switch System closed loop delayed

Terminals:

MT60




\

D

12V

Heated drive:

88

C

0V


40

B



42

A

0V

Judging conditions

No main relay fault Duration> 1 sec

DTC

Possible causes of the malfunction 1. Connector not in place 2. Harness Heating drive circuit open 3. Harness Heating drive to ground short circuit 4. Sensor damaged 5. ECM signal output interface failure

P0133



Front oxygen sensor response too slow Fault indicator lights up until the fault disappears and closes off ignition switch System closed loop delayed

Terminals:

MT60




\

D

12V

Heated drive:

88

C

0V


40

B



42

A

0V

Judging conditions


Possible causes of the malfunction 1. Connector not in place 2. Harness Heating drive circuit open 3. Harness Heating drive short with ground 4. Sensor damaged 5. ECM signal output interface failure

210



DTC

P0137



Rear oxygen sensor short circuit to the low voltage Fault indicator lights up until the fault disappears and closes off ignition switch System closed loop delayed

Terminals:

MT60




\

D

12V

Heated drive:

90

C

0V


10

B



20

A

0V

Judging conditions

Duration 1 seconds

DTC



1. Heating drive circuit short with positive power supply 2. Sensor damaged 3. ECM signal output interface failure

P0138



Front oxygen sensor short circuit to high voltage Fault indicator lights up until the fault disappears and closes off ignition switch System closed loop delayed

Terminals:

MT60




\

D

12V

Heated drive:

90

C

0V


10

B



20

A

0V

Judging conditions


DTC



1. Connector not in place 2. Harness Heating drive circuit open 3. Harness Heating drive grounded 4. Sensor damaged 5. ECM signal output interface failure

P0222


1. Reconnect 2. Repair harness 3. Repair harness 4. Change sensor 5. Change ECM

ETC throttle position sensor # 2 circuit low voltage Fault indicator lights up until the fault disappears At idling, set the throttle position sensor opening 0%; at other rotating speed, the throttle position sensor opening changes with the rotating speed Automatic zero calibration function of throttle position sensor suspended Cleaning function suspended for the time being

Terminals:

MT60




21

A

5V


66

E

0.5-4.5V


19

F

0V

Judging conditions Engine running, but the speed <3000rpm no MAP failure, and MAP <70kpa Fault duration 2 seconds

Possible causes of the malfunction 1. Sensor signal line to positive power supply or reference voltage circuit short 2. Sensor damaged 3. ECM signal input failure

211

Reference troubleshooting programs 1. Repair harness 2. Change sensor 3. Change ECM


P0223



ETC throttle position sensor # 2 circuit high voltage or open circuit Fault indicator lights up until the fault disappears At idling, set the throttle position sensor opening 0%; at other rotating speed, the throttle position sensor opening changes with the rotating speed Automatic zero calibration function of throttle position sensor suspended Cleaning function suspended for the time being

Terminals:

MT60




21

A

5V


66

E

0.5-4.5V


19

F

0V

Judging conditions


DTC

Possible causes of the malfunction 1. Connector not in place 2. Sensor signal circuit open 3. Sensor signal line grounded 4. Sensor damaged 5. ECM signal input failure

P0230



Fuel pump relay failure Fault indicator lights up until the fault disappears None

Terminals:

MT60

Fuel pump relay

System main power supply

\

See Electrical System Description


96

Judging conditions

Duration 1.5625 seconds

DTC


Possible causes of the malfunction 1. Connector not in place 2. Connection to system main power supply circuit open 3. Relay drive circuit to negative system power supply terminal circuit short 4. Relay drive circuit open 5. Relay damaged 6. ECM signal output interface failure

P0325


Normal measurement signals 12V 0V (work), 12V (stop)

Reference troubleshooting programs 1. Reconnect 2. Repair harness 3. Repair harness 4. Repair harness 5. Replace relay 6. Change ECM

Knock sensor failure Fault indicator lights up until closing off ignition switch Adopts safety spark advance angle table data MT60

Knock signal high:

72

0-1V

Knock signal low:

71

0V

Judging conditions

Engine running 2000rpm MAP>50kPa Duration 5 seconds

Knock sensor


Terminals:

Possible causes of the malfunction 1. Connector not in place 2. Knock signal circuit open 3. Sensor signal circuit short 4. Knock signal circuit to other circuits short 5. Sensor damaged 6. ECM signal output interface failure

212



DTC

P0336



Crankshaft position sensor circuit signal interference Fault indicator lights up until the fault disappears None Normal measurement signals

Terminals:

MT60


Sensor signal:

30

2

Voltage signal:

18

3

> 400mV sine wave (with sensor A)

System grounding:

19

1

0V

Judging conditions Engine running 5 consecutive cycles and the number of teeth fed into the ECM is not equal to 58

DTC



1. Poor signal line shielding 2. 58x gear ring has metal impurities

P0337


Terminals:

> 400mV sine wave (with sensor B)

1. Use shielded cable 2. Clean 58x gear ring

Crankshaft position sensor circuit no signal Fault indicator lights up until the fault disappears None Engine can not start MT60


Normal measurement signals > 400mV sine wave (with sensor B)

Sensor signal:

30

2

Voltage signal:

18

3

〉> 400mV sine wave (with sensor A)

System grounding:

19

1

0V

Judging conditions



Start engine No engine speed signal MAP decreases .9509 kPa 0.8VSystem voltage drops 0.8V

1. Connector not in place 2. Signal high and low reversed 3. Signal circuit open 4. Signal lines to other circuit short 5. Sensor damaged 6. ECM signal input interface failure


Duration 2 seconds

DTC

P0341


Camshaft position sensor rationality fault Fault indicator lights up until the fault disappears Injection sequence having 50% dislocation for 360 degrees

Terminals:

MT60

Camshaft position sensor 1



46

3

5V

Camshaft signal:

05

2

0-5V square wave


45

1

0V

Judging conditions

Engine running

Possible causes of the malfunction 1. Connector not in place 2. Reference voltage circuit open 3. Signal grounding circuit open 4. Camshaft signal circuit open 5. Sensor damaged 6 ECM interface failure 213



DTC

P0342



Camshaft position sensor no signal Fault indicator lights up until the fault disappears Injection sequence having 50% dislocation for 360 degrees

Terminals:

MT60




46

3

5V

Camshaft signal:

05

2

0-5V square wave


45

1

0V

Judging conditions

Possible causes of the malfunction 1. Connector not in place 2. Reference voltage circuit open 3. Sensor grounding circuit open 4. Sensor signal grounding circuit open 5. Sensor damaged 6. ECM interface failure

Engine running

DTC

P0351



# 1 ignition coil failure Fault indicator lights up until the fault disappears 1-cylinder fuel injection stops Target idle speed increased to 1200rpm Normal signals

Ignition coil

measurement

Terminals:

MT60


\

12V

1-cylinder drive:

26

0-12V approximate square wave signal induced peak> 300V

Judging conditions



Duration of 1.25 seconds

1. 1-cylinder drive circuit short with the positive power line 2. Ignition coil damaged 3. ECM failure

1. Repair harness 2.Ignition coil damaged 3. Change ECM

DTC

P0352


# 2 ignition coil failure Fault indicator lights up until the fault disappears 1-cylinder fuel injection stops Target idle speed increased to 1200rpm Normal measurement signals

Terminals:

M60


\

12V

2-cylinder drive:

03


Judging conditions


Ignition coil

Possible causes of the malfunction 1. 21-cylinder drive circuit short with the positive power line 2. Ignition coil damaged 3. ECM failure

214

Reference troubleshooting programs 1. Repair harness 2. Replace ignition coil 3. Change ECM



DTC

P0353



Terminals:

MT60


\

12V

02


3-cylinder drive: Judging conditions


DTC

Ignition coil



1. -Cylinder drive circuit short with the positive power line 2. Ignition coil damaged 3. ECM failure

P0354


1. Repair harness 2. Replace ignition coil 3. Change ECM


Terminals:

MT60


\

12V

4-cylinder drive:

01


Judging conditions


DTC

Ignition coil



1. 41-cylinder drive circuit short with the positive power line 2. Ignition coil damaged 3. ECM failure

P0458


1. Repair harness 2. Replace ignition coil 3. Change ECM

Canister magnet valve to the low-voltage short circuit Fault indicator lights up until the fault disappears Close off canister magnet valve

Terminals:

MT60

Canister magnet valve



\

A

12V

Magnet valve drive:

99

B

0-12V square wave

Judging conditions

Duration>2 seconds


Possible causes of the malfunction 1. Magnet valve drive circuit short with system power line 2. Solenoid valve damaged 3. ECM failure

215

positive

1. Repair harness 2. Replace solenoid valve 3. Change ECM



P0459


Canister solenoid valve short with high voltage circuit Fault indicator lights up until the fault disappears Close off canister magnet valve

Terminals:

MT60

Canister magnet valve



\

A

12V

Magnet valve drive:

99

B

0-12V square wave

Judging conditions

Duration>5 seconds

DTC

Possible causes of the malfunction 1. Connector not in place 2. Magnet valve drive circuit short with system negative power line 3. Magnet valve drive circuit open 4. Connection with system main power open 5. Magnet valve damaged 6. ECM failure

P0480


Reference troubleshooting programs 1. Reconnect 2. Repair harness 3. Repair harness 4. Repair harness 5. Replace magnet valve 6. Change ECM

Low-speed fan failure Fault indicator lights up until the fault disappears None Fan not working (open), water temperature rises to 98 degrees, high speed fan turned on, fan al ways working(to ground short circuit)

Terminals:

MT60

Low-speed fan relay


Battery:

\

Vehicle OEM to provide instructions

12V

Relay drive:

51


Judging conditions

Duration>3 seconds

DTC

Possible causes of the malfunction 1. Connector not in place 2. Relay drive circuit short with system negative power line 3. Relay drive circuit open 4. Connection with battery circuit open 5. Relay damaged 6. ECM failure

P0481



High-speed fan failure Fault indicator lights up until the fault disappears None Fan not working (open), water temperature rises to 98 degrees, high speed fan turned on, fan always working(to ground short circuit)

Terminals:

MT60

Low-speed fan relay

Battery:

\


Relay drive:

52


Judging conditions

Duration>3 seconds

0V (work), 12V (stop)

Possible causes of the malfunction 1. Connector not in place 2. Relay drive circuit short with system negative power line 3. Relay drive circuit open 4. Battery cable opened 5. Relay damaged 216

Normal measurement signals 12V 0V (work), 12V (stop)




6. ECM failure DTC

P0502

Speed sensor no signal Fault indicator lights up until the fault disappears None Driving restrictions may be taken


Terminals:

MT60

Speed sensor



68

/

0-12V square wave

Judging conditions Engine running Speed <2kph MAP<25.82Kpa 1200 rpm5 seconds

DTC



1. Connector not in place 2. Transmission to the instrument signal circuit open 3. Instrument to ECM wiring open 4. Speed sensor damaged 5. Instrument failure 6. ECM failure

1. Reconnect 2. Replace flexible shaft or signal line 3. Repair harness 4. Replace speed sensor 5. Repair or replace instrument 6. Change ECM

P0562

System voltage low


Fault indicator lights up until the fault disappears System fuel injection stopped

Terminals:

MT60

Ignition switch


Ignition switch

17


12V

Judging conditions Connect ignition switch System voltage 7.6V Duration>5 seconds

DTC



1. Generator regulator damaged

1. Replace damaged voltage

2. Wrong use of a low voltage battery

2. Use the correct battery

P0563


regulator

System voltage high Fault indicator lights up until the fault disappears System fuel injection stopped

Terminals:

MT60

Ignition switch


Ignition switch

17


12V

Judging conditions Connect ignition switch System voltage <17.2V Duration>5 seconds



1. Generator regulator damaged

1. Replace damaged voltage regulator

2.Wrong use of a high voltage battery

2. Use the correct battery

217


DTC

P0571



Brake light switch failure Does not light up (open)） Always on (to ground short circuit)

Terminals:

MT60

System failure indicator


Ignition switch:

\


12V

LED drive:

56


OFF=12V, ON=0V

Judging conditions

Duration>2 seconds

DTC

Possible causes of the malfunction 1. Failure bulb not properly installed. 2. Connection to ignition switch broken. 3. Drive circuit lines short with negative power line 4. Fault bulb damage

P0601

Set emergency control scheme: Terminals:

1. Reinstall light bulb 2. Repair harness 3. Repair harness 4.Replace bulb

ROM verification failure Fault indicator lights up until the fault disappears MT60

ECM:


ECM


Judging conditions

Possible causes of the malfunction ECM failure

Fault exists

DTC


P0646


\

Reference troubleshooting programs Change ECM

Air conditioning clutch

to low voltage short circuit

Fault indicator lights up until the fault disappears Disconnect the clutch relay circuit

Terminals:

MT60



\

12V

Air conditioning clutch signal:

77

0-12V square wave

Judging conditions

Duration >2 seconds

Possible causes of the malfunction 1. Clutch drive circuit short with system positive power line 2. Air conditioning clutch damaged 3. ECM failure

218

Reference troubleshooting programs 1. Repair harness 2. Replace of air conditioning clutch 3. Change ECM


DTC

P0647



Air conditioning clutch short with high voltage circuit Fault indicator lights up until the fault disappears Disconnect the clutch relay circuit

Terminals:

MT60



\

12V

Air conditioning clutch signal:

77

0-12V square wave

Judging conditions

Duration>5 seconds

DTC



1. Connector not in place 2. Clutch driving circuit short with system negative power line 3. Clutch drive circuit open 4. Connection with system main power open 5. Air conditioning clutch damaged 6. ECM failure

P0650


1. Reconnect 2. Repair harness 3. Repair harness 4. Repair harness 5. Replace of air conditioning clutch 6. Change ECM

Fault indicator malfunction Does not light (open) Always on (to ground short circuit)

Terminals:

MT60

System failure indicator


Ignition switch:

\


12V

LED drive:

92


灭=12V，亮=0V

Judging conditions

Duration>2 seconds

DTC



1.Failure bulb not properly installed 2. Connection to ignition switch circuit failure 3. Drive circuit lines short with negative power line 4. Fault bulb damage

P1397


1. Reinstall light bulb 2. Repair harness 3. Repair harness 4. Replace bulb

Wheel speed sensor no signal Fault indicator lights up until the fault disappears None Driving restrictions may be taken

Terminals:

MT60

Speed sensor



97

/

0-12V square wave

Judging conditions Engine running Speed<2kph MAP<25.82Kpa 1200 rpm5 seconds



1. Connector not in place 2. Transmission to the instrument signal circuit open 3. Instrument to ECM wiring open 4. Speed Sensor damaged 5. Instrument failure 6. ECM failure

1. Reconnect 2. Replace flexible shaft or signal line 3. Repair harness 4. Replace speed sensor 5. Repair or replace instrument 6. Change ECM

219



DTC

P2122


Electronic accelerator pedal position sensor 1 # line low voltage or open circuit Fault indicator lights up until the fault disappears

Terminals:

MT60

Electronic accelerator pedal position sensor 1


16

2

5V

Accelerator pedal signal 1：

32

4

0.5-4.5V


15

3

0V

Judging conditions


Engine running Fault duration> 2.5 seconds

1. Accelerator pedal position sensor signal short with the 5V reference voltage or positive power line 2. Sensor damaged 3. ECM pressure signal input fault

DTC

P2123




Electronic accelerator pedal position sensor 1 # high voltage Fault indicator lights up until the fault disappears

Terminals:

MT60



16

2

5V

Accelerator pedal signal 1:

32

4

0.5-4.5V


15

3

0V

Judging conditions

DTC




P2127



1. Connector not in place 2. Sensor signal circuit open 3. Sensor signal line grounded 4. Sensor damaged 5. ECM signal input failure

1. Reconnect 2. Repair harness 3. Repair harness 4. Change sensor 5. Change ECM

Electronic accelerator pedal position sensor #2 circuit low voltage or open circuit Fault indicator lights up until the fault disappears

Terminals:

MT60



43

1

5V

Accelerator pedal signal 2

34

6

0.5-4.5V


44

5

0V

Judging conditions


Engine running Fault duration 2.5 seconds

1. Accelerator pedal position sensor signal short with the 5V reference voltage or positive power line 2. Sensor damaged 3. ECM pressure signal input fault

220





P2128


Electronic accelerator pedal position sensor #2 circuit high voltage Fault indicator lights up until the fault disappears

Terminals:

MT60



43

1

5V

Accelerator pedal signal 2

34

6

0.5-4.5V


44

5

0V

Judging conditions


Possible causes of the malfunction 1. Connector not in place 2. Sensor signal circuit open 3. Sensor signal line grounded 4. Sensor damaged 5. ECM signal input failure

221




Diagnosis by Trouble Phenomena

1.

Instruction


Before carrying out the trouble diagnosis steps with the engine trouble phenomenon, it is necessary to firstly conduct the preliminary check: 1)

Confirm that the malfunction indicator lamp of engine operates normally.

2)

Check with trouble diagnoses apparatus to confirm that there is no trouble information record.

3)

Confirm existence of the trouble complain from owner and the conditions about the occurrence of the trouble.

And then check the appearance: 1)

Check fuel pipes for leakage.

2)

Check vacuum pipes for breakage or kink and proper connection.

3)

Check intake pipes for blockage, leakage, flatness or damage.

4)

Check high-voltage wire of ignition system for broken, aging, verify correct ignition sequence.

5)

Check grounding position of wire harness for clean and firm.

6)

Check the connector of each sensor and actuator for the looseness or poor contact.

Attention: If any of above-mentioned phenomena exists, firstly conduct maintenance operation against it; otherwise the following trouble diagnosis and maintenance will be affected. 2.

Diagnosis Help

1)

Confirm that there is no trouble record related to engine.

2)

Confirm the existence of the trouble complained by the owner.

3)

The check has been done with steps above, and there is nothing unusual found.

4)

It is not permitted to neglect the effects of the maintenance of vehicle, cylinder pressure, mechanical ignition timing and fuel etc. on the system during the Repair process.

5)

Replace the ECM to test.

If the trouble phenomenon can be cleared at this time, it means the trouble site is at ECM; if the trouble phenomenon still exists at this point, reinstall the original ECM and repeat the procedures again to carry out the Repair.

222



Trouble phenomenon 1: during the start-up, the engine does not run or runs slowly General trouble position: 1.

Battery; 2. Starter; 3.Wire harness or ignition switch; 4.Mechanical part of engine

General diagnosis procedure: No.

Operating Steps

Detection Results

Check the voltage between the two terminals of battery with 1

3

Yes

Next step

No

Replace battery

Yes

Next step

multi-meter to see whether it is about 8-12V during starting of engine.

2

Subsequent Steps

With ignition switch at the starting position, check voltage of starter negative terminal to verify that it is above 8V.

Dismantle the starter to check its operating state. Mainly

No

Yes

Repair or replace wire harness Repair or replace the starter

check for sticking due to open circuit or poor lubrication. No

Next step Change with

If the trouble only present in winter, then check whether too 4

Yes

large resistance of starter is caused by improper selection of

lubricating oil of proper grade

the lubricating oil for engine or the gearbox oil. No

Next step Remove large

Check engine for too large internal mechanical resistance; if it 5

Yes

is a case, the failure of rotation or the slow rotation of starter

internal resistance of engine

may occur. No

223

Repeat above steps



Trouble phenomenon 2: Engine start to run but can not be started successfully during the start-up General trouble position: 1.

No fuel in the fuel tank; 2. Fuel injection pump; 3.Crankshaft position sensor; 4.Ignition coil; 5.Mechanical part of engine

General diagnosis procedure:

No.

Detection

Operating Steps

Results

Connect the fuel pressure gauge (the access point is at the front

Yes

Subsequent Steps Next step

end of the induction manifold of the fuel distribution pipe 1

assembly) to the engine, and start the engine to determine whether the readings of fuel pressure gauge when idling is at

No

about 260kPa; disconnect vacuum hose of pressure regulator

Repair the fuel supply system

and observe whether fuel pressure is about 300kPa. Connect the electric control system diagnosis apparatus to the 2

engine to observe the data of "rotating speed of engine" and start the engine to observe whether there is speed signal output. Pull out the high-voltage wire of one of the cylinders and connect

3

Yes

No

Next step Repair crankshaft position sensor circuit

Yes

Next step

No

Repaire ignition system

the spark plug to make the spark plug electrodes around 5mm away from the engine body, and start the engine to check whether there is blue and white high-voltage spark.

4

Check the pressure of all the cylinders and observe whether the

Eliminate mechanical trouble of engine

pressure of engine cylinders is insufficient.

Connect the adapter of electric control system and turn on the 5

Yes No

Next step

Yes

Diagnosis help

No

Repair related circuit

ignition switch to check power supplies of pins #16, #17, #8 and #51; check groundings of pins #5, #43 and #48.

224



Trouble phenomenon 3: Difficulty in warm start General trouble position: 1.

Poor quality of fuel; 2.Fuel injection pump; 3.Coolant temperature sensor; 4.Ignition coil


Detection

Operating Steps

Results

Connect the fuel pressure gauge (the access point is at the front end

Yes

Subsequent Steps Next step

of the induction manifold of the fuel distribution pipe assembly) to the 1

engine and start the engine to check whether the reading of fuel pressure gauge at idle condition is at about 260kPa. Disconnect

No

vacuum hose on pressure regulator and observe whether fuel

Repair fuel supply system

pressure is about 300kPa. Pull out the high-voltage wire of one of the cylinders and connect the 2

Yes

Next step

No

Repair ignition system

spark plug to make the spark plug electrodes about 5mm away from the engine body, and start the engine to check whether there is the blue and white high-voltage spark. Pull out connector of coolant temperature sensor and start the engine to observe whether the engine is successfully started at this

3

Yes

Repair circuit or replace the sensor

time. (Alternatively, connect a 300 ohm resistance in series at the connector of coolant temperature sensor to observe whether the

No

Next step

Check the vacuum pipe of fuel pressure regulator for the shedding or

Yes

Repair or replace

air leakage.

No

Next step

Check fuel conditions and observe whether the trouble phenomenon

Yes

Change fuel

occurs just after adding fuel.

No

Next step

Connect the adapter of electric control system and turn on the

Yes

Diagnosis help

No


engine is successfully started at this time.)

4

5

6

ignition switch to check power circuits of the pins #16, #17, #8 and #51; check groundings of pins #5, #43 and #48.

225



Trouble phenomenon 4: Difficulty in cold start General trouble position: 1.

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


Operating Steps

Detection Results Yes

Next step

1

Connect the fuel pressure gauge (the access point is at the front end of the induction manifold of the fuel distribution pipe assembly) to the engine and start the engine to check whether the reading of fuel pressure gauge at idle condition is at about 260kPa. Disconnect vacuum hose on pressure regulator and observe whether fuel pressure is about 300kPa.

No


Yes

Next step

2

Pull out the high-voltage wire of one of the cylinders and connect the spark plug to make the spark plug electrodes about 5mm away from the engine body, and start the engine to check whether there is the blue and white high-voltage spark.

No

Repair the ignition system

Yes

Repair circuit or replace the sensor

3

Pull out the connector of coolant temperature sensor and start the engine to observe whether the engine is successfully started at this time. (Alternatively, connect a 2500 ohm resistance in series at the connector of coolant temperature sensor to observe whether the engine is successfully started at this time.)

No

Next step

Gently step down the accelerator pedal to observe whether it is easy to start.

Yes

Wash the air throttle and idle air passage

No

Next step

Dismantle the fuel injector and check whether there is leakage or blockage in the fuel injector with the cleaning analyzer special for fuel injector.

Yes

Failure of Replacement

No

Next step

6

Check the fuel conditions and observe whether the trouble phenomenon occurs just after adding the fuel.

Yes

Change fuel

No

Next step

7

Check the pressure states of all the cylinders of engine and observe whether the pressure of engine cylinder is insufficient.

Yes

Eliminate the mechanical trouble of engine

No

Next step

Connect the adapter of electric control system and turn on the ignition switch to check power line of pins #16, #17, #8 and #51; check groundings of pins #5, #43 and #48.

Yes

Diagnosis help

No


4

5

8

226

Subsequent Steps



Trouble phenomenon 5: Engine speed is normal, but it is difficult to start all the time General trouble position: 1.

Poor quality of fuel; 2. Fuel injection pump; 3.Coolant temperature sensor; 4.Fuel injector; 5.Ignition coil; 6.Throttle body and idle bypass air passage; 7.Intake passage; 8.Ignition timing; 9.Spark plug; 10.Mechanical part of engine


1

2

3

4

5

6

7

8

9

10

11

Operating Steps

Detection Results

Subsequent Steps

Yes

Repair air intake system

No

Next step

Connect the fuel pressure gauge (the access point is at the front end of the induction manifold of the fuel distribution pipe assembly) to the engine and start the engine to check whether the reading of fuel pressure gauge at idle condition is at about 260kPa. Disconnect vacuum hose on pressure regulator and observe whether fuel pressure is about 300kPa.

Yes

Next step

No


Pull out the high-voltage wire of one of the cylinders and connect the spark plug to keep the spark plug electrodes about 5mm away from the engine body, then start the engine to check whether there is the blue and white high-voltage spark.

Yes

Next step

No

Repair the ignition system

Check the spark plug of each cylinder to observe whether model and gap are in compliance with the specification.

Yes

Next step

No

Adjust or replace

Pull out the connector of coolant temperature sensor and start the engine to observe whether the engine is successfully started at this time.

Yes

Repair the lien or replace the sensor

No

Next step

Yes

Wash throttle and idling air passage

No

Next step

Dismantle the fuel injector and check whether there is leakage or blockage in the fuel injector with cleaning analyzer special for fuel injector.

Yes


No

Next step

Check fuel condition and observe whether the trouble phenomenon occurs just after adding the fuel.

Yes

Change fuel

No

Next step

Yes

Eliminate the mechanical trouble of engine

No

Next step

Yes

Next step

No

Repair the ignition timing

Yes

Diagnosis help

No


Check air filter for blockage and intake passage for leakage.

Gently step down the throttle to observe whether it is easy to start.

Check pressure of all the cylinders and observe whether the pressure of engine cylinder is insufficient.

Check whether the ignition sequence of engine and ignition timing is in line with the specification. Connect the adapter of electric control system and turn on the ignition switch to check power lines of pins #16, #17, #8 and #51; check groundings of pins #5, #43 and #48. 227



Trouble phenomenon 6: Normal start-up but unstable idling at any time General trouble position: 1.

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


Detection

Operating Steps

Results Yes

1

2

3

4

Check air filter for blockage and intake passage for leakage.

6

Repair the intake system

No

Next step

Yes

Wash or replace

No

Next step

Check the spark plug of each cylinder to observe whether its model

Yes

Next step

and gap are in compliance with the specification.

No

Adjust or replace

Check air throttle body and idle bypass air passage for carbon

Yes

Wash

deposit.

No

Next step

Check idle adjustor for sticking.

Dismantle the fuel injector and use the cleaning analyzer special for 5

Subsequent Steps

Yes

fuel injector to check whether there is leakage, blockage or too poor


flow in the fuel injector.

No

Next step

Check fuel condition and observe whether the trouble phenomenon

Yes

Change fuel

occurs just after adding the fuel.

No

Next step Eliminate the

7

8

9

Check pressure of all the cylinders and observe whether the

Yes

mechanical trouble of engine

pressure difference of each engine cylinders is large. No

Next step

Check whether the ignition sequence of engine and ignition timing is

Yes

Next step

in compliance with specification.

No

Repair ignition timing


Yes

Diagnosis help

No


ignition switch to check power lines of the pins #16, #17, #8 and #51; check groundings of pins #5, #43 and #48.

228



Trouble phenomenon 7: Normal start-up but unstable idling during the warming-up General trouble position: 1.

Poor quality of fuel; 2. Coolant temperature sensor; 3.Spark plug; 4.Throttle body and idle bypass air passage; 5.Intake passage; 6.Idle adjustor; 7.Mechanical part of engine.


Detection

Operating Steps

Results Yes

1

2

3

Check air filter for blockage and air intake passage for leakage.

Check the spark plug of each cylinder to observe whether its model

Yes

Next step

and gap are in compliance with the specification.

No

Adjust or replace

Dismantle the idle adjustor to check whether there is carbon deposit

Yes

Wash related components

in the air throttle body, idle adjustor or idle bypass air passage.

Yes

engine to observe whether the idle speed of engine is unstable during warming-up.

No

Dismantle the fuel injector and check whether there is leakage,

6

system Next step

Pull out the connector of coolant temperature sensor and start the

5

Repair air intake

No

No

4

Subsequent Steps

Yes

blockage or too poor flow in the fuel injector with cleaning analyzer

Next step Repair circuit or replace sensor Next step Failure of Replacement

special for fuel injector.

No

Next step

Check fuel condition and observe whether the trouble phenomenon

Yes

Change fuel

occurs just after adding the fuel.

No

Next step Eliminate the

Check pressure of all the cylinders and observe whether the 7


Yes

pressure difference of each engine cylinders is large.

mechanical trouble of engine

No

Next step

Yes

Diagnosis help

No


ignition switch to check power lines of pins #16, #17, #8 and #51; check groundings of pins #5, #43 and #48.

229



Trouble phenomenon 8: Normal start-up but unstable idle speed after warmed-up General trouble position: 1.

Poor quality of fuel; 2. Coolant temperature sensor; 3.Spark plug; 4.Air throttle body and idle bypass air passage; 5.Intake passage; 6.Idle adjustor; 7.Mechanical part of engine.


1

2

3

Detection

Operating Steps

Results

Check air filter for blockage and air intake passage for

Yes

Repair the intake system

leakage.

No

Next step

Check spark plug of each cylinder to observe whether its

Yes

Next step

model and gap are in compliance with the specification.

No

Adjust or replace

Dismantle the idle adjustor to check whether there is

Yes


No

Next step

carbon deposit in the air throttle body, idle adjustor and idle bypass air passage. Pull out the connector of coolant temperature sensor and

4

5

7

Repair circuit or replace sensor(s)

engine is unstable during warm-up process.

No

Next step

Dismantle the fuel injector and check whether there is

Yes

Failure of replacement

No

Next step

Check fuel condition and observe whether the trouble

Yes

Change fuel

phenomenon occurs just after adding the fuel.

No

Next step

Check pressure of all the cylinders and observe whether

Yes

leakage, blockage or too poor flow in the fuel injector

Eliminate mechanical trouble of engine

the pressure difference of each engine cylinders is large.

Connect the adapter of electric control system and turn 8

Yes

start the engine to observe whether the idle speed of

with cleaning analyzer special for fuel injector.

6

Subsequent Steps

No

Next step

Yes

Diagnosis help

No


on the ignition switch to check power lines of the pins #16, #17, #8 and #51; check groundings of pins #5, #43 and #48.

230



Trouble phenomenon 9: Normal start-up but unstable idling speed or flameout with partially load (for example, when the air conditioner is on) General trouble position: 1.

Air conditioning system; 2. Idle adjustor; 3.Fuel injector

General diagnosis procedure:

No.

1

Detection

Operating Steps

Results



in the air throttle body, idle adjustor and idle bypass air passage.

Observe whether power output of engine is increased air conditioner 2

Yes

Subsequent Steps

No

Next step

Yes

To step 4

No

Next step

Yes

Next step

operation, namely, use the electric control system diagnosis apparatus to observe the changes of ignition advance angle, fuel injector pulse width and intake volume. Connect the adapter of electric control system and disconnect the

3

connecting wire of the pin #75 of electronic control module to check whether there is high level signal at the wire harness end with AC

No

turned on.

4

6

system

Yes

Next step

No

Repair AC system

Yes


special for fuel injector.

No

Next step


Yes

Diagnosis help

No


Inspect pressure of air conditioning system, electromagnetic clutch of compressor and the compressor pump of air conditioner. Dismantle the fuel injector and check whether there is leakage,

5

Repair air conditioning

blockage or too poor flow in the fuel injector with cleaning analyzer


231



Trouble phenomenon 10: Normal start-up but too high idling speed General trouble position: 1.

Throttle body and idle bypass air passage; 2.Vacuum pipe; 3.Idle adjustor; 4.Coolant temperature sensor; 5.Ignition timing


1

2

Detection

Operating Steps

Results Yes

Adjust

No

Next step

Yes

Repair intake system

No

Next step

Check throttle cable for catching or overtension..

Check air intake system and vacuum pipeline or leakage.

Yes 3


Pull out the connector of coolant temperature sensor and start the

Yes

Next step

Repair circuit or replace sensor

No

Next step

Yes

Next step

No


Yes

Diagnosis help

No


Check whether the ignition timing of engine is in compliance with the specification.


components

engine to observe whether the idle speed of engine is too high at this time.

5

Wash related

in the air throttle body, idle adjustor and idle bypass air passage. No

4

Subsequent Steps


232



Trouble phenomenon 11: Engine speed fails to increase or flameout occurs during acce leration General trouble position: 1.

Poor quality of fuel; 2. Intake pressure sensor and air throttle position sensor; 3.Spark plug; 4. Throttle body and idle bypass air passage; 5.Intake passage; 6.Idle adjustor; 7.Fuel injector; 8.Ignition timing; 9.Exhaust pipe.


Operating Steps

Detection Results

Subsequent Steps

Yes

Repair intake system

No

Next step

Yes

Next step

2

Connect the fuel pressure gauge (the access point is at the front end of the induction manifold of the fuel distribution pipe assembly) to the engine and start the engine to check whether the reading of fuel pressure gauge when idling is at about 260kPa; disconnect vacuum hose from pressure regulator to see whether fuel pressure is about 200kPa.

No


3

Check spark plug of each cylinder to observe whether its model and gap are in compliance with the specification.

Yes

Next step

No

Adjust or replace

4

Dismantle the idle adjustor to check whether there is carbon deposit in the air throttle body, idle adjustor and idle bypass air passage.

Yes


No

Next step

Yes

Next step

No

Repair circuit or replace sensor(s)

1

Check air filter for blockage.

5

Check whether the intake pressure sensor, air throttle position sensor and their circuits are normal. Dismantle the fuel injector and check whether there is leakage or blockage in the fuel injector with cleaning analyzer special for fuel injector.

Yes


6

No

Next step

7

Check fuel condition and observe whether the trouble phenomenon occurs just after adding the fuel.

Yes

Change fuel

No

Next step

8

Check whether the ignition sequence of engine and ignition timing is in compliance with specification.

Yes

Next step

No


Yes

Next step

No

Repair or replace the exhaust pipe

Yes

Diagnosis help

No


9

Check whether the operation of the exhaust pipe is smooth.

10

Connect the adapter of electric control system and turn on the ignition switch to check power lines of the pins #16, #17, #8 and #51; check groundings of pins #5, #43 and #48.

233



Trouble phenomenon 12: Slow response of acceleration General trouble position: 1.

Poor quality of fuel; 2. Intake pressure sensor and air throttle position sensor; 3.Spark plug; 4 .Throttle body and idle bypass air passage; 5.Intake passage; 6.Idle adjustor; 7.Fuel injector; 8.Ignition timing; 9. Exhaust pipe


Operating Steps

Detection Results Yes

1

Check air filter for blockage.

Connect the fuel pressure gauge (the access point is at the

Subsequent Steps Repair air intake system

No

Next step

Yes

Next step

front end of the induction manifold of the fuel distribution pipe 2

assembly) to the engine and start the engine to check whether the reading of fuel pressure gauge when idling is at about

No

260kPa. disconnect vacuum hose from pressure regulator to


see whether fuel pressure is about 300kPa.

3

4

Check the spark plug of each cylinder to observe whether its

Yes

Next step

model and gap are in compliance with the specification.

No

Adjust or replace

Dismantle the idle adjustor to check whether there is carbon

Yes

deposit in the air throttle body, idle adjustor and idle bypass air passage.

5

7

8

9

sensor and its circuit are normal.

No

Next step

Yes

Next step

No

Repair circuit or replace sensor

Yes


for fuel injector.

No

Next step

Check fuel condition and observe whether the trouble

Yes

Change fuel

phenomenon occurs just after adding the fuel.

No

Next step

Check whether the ignition sequence of engine and ignition

Yes

Next step

timing is in line with the specification.

No


Check whether the operation of the exhaust pipe is smooth.

No

or blockage in the fuel injector with cleaning analyzer special


components

Check whether the intake pressure sensor, air throttle position

Dismantle the fuel injector and check whether there is leakage 6

Wash related

Repair or replace the exhaust pipe

Yes

Diagnosis help

No



234

Motor j3 Vvt a137.PDF

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