Service Manual for Chery Fulwin 2 Hatchback (Engine Management System (EMS) from Unite !utomotive Electronic Systems Co"# $t" (U!ES))
!fter%Service &e'artment of Chery !utomobile Sales Co"# $t"
able of Contents Table Table of Contents..................................... Contents............................................................ ............................................. ............................................. .............................................. .................................................2 ..........................2 Chapter I
Engine Electronic Injection Part........................................ Part............................................................... .............................................. .............................................. ........................1 .1
Section Section 1
Introducti Introduction on to UEAS UEAS (!"#$ (!"#$ Engine Engine Electr Electronic onic Inject Injection ion S%ste& S%ste& for for 'ulin 'ulin 2 )atchba )atchbac* c* odel.. odel.. .1
I.
S%ste& Introduction................................ Introduction....................................................... .............................................. ............................................. ............................................. ..................................1 ...........1
II.
Sche&atic +iagra& of Engine anage&ent S%ste& (ES$..................................... (ES$............................................................ ..................................2 ...........2 1.
,asic ,asic Para&eter Para&eter of Engine.... Engine......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .............. .................. ............2 ...2
2.
ECU..................................... ECU............................................................ ............................................. ............................................. .................................................................................................................-
-.
+efinition +efinition of ECU Pins..... Pins.......... .......... ......... ......... .......... .......... ......... ......... .......... .......... ......... ......... .......... .......... .......... .......... .......... .......... .......... ............. .................. ..................-
/.
Technic Technical al Characte Characteristi risticc Para&eter Para&eters..... s.......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... ............. .................. ................./ ......./
0.
Precautions.......................... Precautions................................................. .............................................. .............................................. .............................................. ............................................. ....................../ /
.
'ault 'ault Pheno&en Pheno&enon on and udg&ent udg&ent ethod... ethod........ .......... .......... .......... .......... .......... .......... .......... ......... ......... .......... .......... .......... .......... .......... .......... ............. ........0 0
III.
Ignition Ignition S%ste&... S%ste&........ .......... .......... .......... ......... ......... .......... .......... ......... ......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... ........... ......0 0 1.
Ignition Coil............................................. Coil.................................................................... .............................................. ............................................. ............................................... .........................0 0
2.
Spar* Plug....................................... Plug.............................................................. ............................................. ............................................. .............................................. .................................. ...........
I3. I3.
3.
Speed Speed Sensor Sensor (Cran*shaf (Cran*shaftt Position Position Sensor$...... Sensor$........... .......... .......... .......... .......... ......... ......... .......... .......... ......... ......... .......... .......... .......... .......... ............ ..............! .......! 1.
+iagra& and pins......................................... pins................................................................ ............................................. ............................................. ............................................! .....................!
2.
Installat Installation ion location.. location....... .......... .......... .......... .......... .......... .......... ......... ......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... ............... .................... ..........! !
-.
4or*ing 4or*ing principle................................... principle.......................................................... .............................................. .............................................. ................................................" ........................."
/.
Technic Technical al Characte Characteristi risticc Para&eter Para&eters..... s.......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... ............. .................. ................." ......."
0.
Precautions.......................... Precautions................................................. .............................................. .............................................. .............................................. ............................................. ......................5 5
.
'ault 'ault pheno&eno pheno&enon n and judg&ent judg&ent ðod... ðod........ .......... .......... .......... .......... .......... .......... .......... .......... ......... ......... .......... .......... ......... ......... .............. ................5 .......5
Phase Sensor (Ca&shaft Position Sensor$................................. Sensor$........................................................ .............................................. ............................................5 .....................5 -.
4or*ing 4or*ing Principle............................... Principle...................................................... .............................................. .............................................. ..................................................1# ...........................1#
/.
Characte Characteristi risticc para&ete para&eters... rs........ .......... .......... .......... .......... ......... ......... .......... .......... ......... ......... .......... .......... ......... ......... .......... .......... .......... ........... ............... ................... ..........1# 1#
0.
'ault 'ault pheno&eno pheno&enon n and judg&ent judg&ent ðod... ðod........ .......... .......... .......... .......... .......... .......... .......... .......... ......... ......... .......... .......... ......... ......... ............... ..............1# ....1#
3I.
6noc* 6noc* Sensor... Sensor........ .......... .......... .......... .......... .......... .......... .......... .......... .......... ......... ......... .......... .......... ......... ......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... ........... ......1# 1# -.
4or*ing 4or*ing Principle............................... Principle...................................................... .............................................. .............................................. ..................................................11 ...........................11
/.
Characteristic Para&eters........................... Para&eters.................................................. .............................................. ............................................. ...................................... ................ ....11
0.
Precautions.......................... Precautions................................................. .............................................. .............................................. .............................................. ...........................................1 ....................11 1
.
'ault 'ault pheno&eno pheno&enon n and judg&ent judg&ent ðod... ðod........ .......... .......... .......... .......... .......... .......... .......... .......... ......... ......... .......... .......... ......... ......... ............... ..............12 ....12
3II.
'uel Injector................................... Injector.......................................................... .............................................. .............................................. .............................................. ....................................12 .............12 -.
4or*ing 4or*ing principle................................... principle.......................................................... .............................................. .............................................. ..............................................12 .......................12
/.
Technical Technical characteristic para&eters............................. para&eters................................................... ............................................. .............................................. ..........................1...1-
0.
Precautions.......................... Precautions................................................. .............................................. .............................................. .............................................. ........................................... ....................11-
.
'ault 'ault pheno&eno pheno&enon n and judg&ent judg&ent ðod... ðod........ .......... .......... .......... .......... .......... .......... .......... .......... ......... ......... .......... .......... ......... ......... ............... ..............1/ ....1/
3III.
Canister Control 3al7e..................... al7e............................................ .............................................. .............................................. .............................................. .................................. ...........1/ 1/ -.
4or*ing 4or*ing Principle............................... Principle...................................................... .............................................. .............................................. ..................................................10 ...........................10
/.
Technic Technical al Characte Characteristi risticc Para&eter Para&eters..... s.......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... ........... ............... ................... .............1 ...1
0.
Precautions.......................... Precautions................................................. .............................................. .............................................. .............................................. ........................................... ....................1 1
.
'ault 'ault pheno&eno pheno&enon n and judg&ent judg&ent ðod... ðod........ .......... .......... .......... .......... .......... .......... .......... .......... ......... ......... .......... .......... ......... ......... ............... ..............1 ....1
I8. Coolant Te&perature Te&perature Sensor..................................... Sensor............................................................ .............................................. ............................................................1! .....................................1! -.
4or*ing 4or*ing Principle............................... Principle...................................................... .............................................. .............................................. ..................................................1! ...........................1!
/.
Technic Technical al Characte Characteristi risticc Para&eter Para&eters..... s.......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... ........... ............... ................... .............1! ...1!
0.
Precautions.......................... Precautions................................................. .............................................. .............................................. .............................................. ........................................... ....................1" 1"
.
'ault 'ault pheno&eno pheno&enon n and judg&ent judg&ent ðod... ðod........ .......... .......... .......... .......... .......... .......... .......... .......... ......... ......... .......... .......... ......... ......... ............... ..............1" ....1"
8. Idling Stepping otor............................................................ otor.................................................................................. .......................................................................1" .................................................1" 2
able of Contents Table Table of Contents..................................... Contents............................................................ ............................................. ............................................. .............................................. .................................................2 ..........................2 Chapter I
Engine Electronic Injection Part........................................ Part............................................................... .............................................. .............................................. ........................1 .1
Section Section 1
Introducti Introduction on to UEAS UEAS (!"#$ (!"#$ Engine Engine Electr Electronic onic Inject Injection ion S%ste& S%ste& for for 'ulin 'ulin 2 )atchba )atchbac* c* odel.. odel.. .1
I.
S%ste& Introduction................................ Introduction....................................................... .............................................. ............................................. ............................................. ..................................1 ...........1
II.
Sche&atic +iagra& of Engine anage&ent S%ste& (ES$..................................... (ES$............................................................ ..................................2 ...........2 1.
,asic ,asic Para&eter Para&eter of Engine.... Engine......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .............. .................. ............2 ...2
2.
ECU..................................... ECU............................................................ ............................................. ............................................. .................................................................................................................-
-.
+efinition +efinition of ECU Pins..... Pins.......... .......... ......... ......... .......... .......... ......... ......... .......... .......... ......... ......... .......... .......... .......... .......... .......... .......... .......... ............. .................. ..................-
/.
Technic Technical al Characte Characteristi risticc Para&eter Para&eters..... s.......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... ............. .................. ................./ ......./
0.
Precautions.......................... Precautions................................................. .............................................. .............................................. .............................................. ............................................. ....................../ /
.
'ault 'ault Pheno&en Pheno&enon on and udg&ent udg&ent ethod... ethod........ .......... .......... .......... .......... .......... .......... .......... ......... ......... .......... .......... .......... .......... .......... .......... ............. ........0 0
III.
Ignition Ignition S%ste&... S%ste&........ .......... .......... .......... ......... ......... .......... .......... ......... ......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... ........... ......0 0 1.
Ignition Coil............................................. Coil.................................................................... .............................................. ............................................. ............................................... .........................0 0
2.
Spar* Plug....................................... Plug.............................................................. ............................................. ............................................. .............................................. .................................. ...........
I3. I3.
3.
Speed Speed Sensor Sensor (Cran*shaf (Cran*shaftt Position Position Sensor$...... Sensor$........... .......... .......... .......... .......... ......... ......... .......... .......... ......... ......... .......... .......... .......... .......... ............ ..............! .......! 1.
+iagra& and pins......................................... pins................................................................ ............................................. ............................................. ............................................! .....................!
2.
Installat Installation ion location.. location....... .......... .......... .......... .......... .......... .......... ......... ......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... ............... .................... ..........! !
-.
4or*ing 4or*ing principle................................... principle.......................................................... .............................................. .............................................. ................................................" ........................."
/.
Technic Technical al Characte Characteristi risticc Para&eter Para&eters..... s.......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... ............. .................. ................." ......."
0.
Precautions.......................... Precautions................................................. .............................................. .............................................. .............................................. ............................................. ......................5 5
.
'ault 'ault pheno&eno pheno&enon n and judg&ent judg&ent ðod... ðod........ .......... .......... .......... .......... .......... .......... .......... .......... ......... ......... .......... .......... ......... ......... .............. ................5 .......5
Phase Sensor (Ca&shaft Position Sensor$................................. Sensor$........................................................ .............................................. ............................................5 .....................5 -.
4or*ing 4or*ing Principle............................... Principle...................................................... .............................................. .............................................. ..................................................1# ...........................1#
/.
Characte Characteristi risticc para&ete para&eters... rs........ .......... .......... .......... .......... ......... ......... .......... .......... ......... ......... .......... .......... ......... ......... .......... .......... .......... ........... ............... ................... ..........1# 1#
0.
'ault 'ault pheno&eno pheno&enon n and judg&ent judg&ent ðod... ðod........ .......... .......... .......... .......... .......... .......... .......... .......... ......... ......... .......... .......... ......... ......... ............... ..............1# ....1#
3I.
6noc* 6noc* Sensor... Sensor........ .......... .......... .......... .......... .......... .......... .......... .......... .......... ......... ......... .......... .......... ......... ......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... ........... ......1# 1# -.
4or*ing 4or*ing Principle............................... Principle...................................................... .............................................. .............................................. ..................................................11 ...........................11
/.
Characteristic Para&eters........................... Para&eters.................................................. .............................................. ............................................. ...................................... ................ ....11
0.
Precautions.......................... Precautions................................................. .............................................. .............................................. .............................................. ...........................................1 ....................11 1
.
'ault 'ault pheno&eno pheno&enon n and judg&ent judg&ent ðod... ðod........ .......... .......... .......... .......... .......... .......... .......... .......... ......... ......... .......... .......... ......... ......... ............... ..............12 ....12
3II.
'uel Injector................................... Injector.......................................................... .............................................. .............................................. .............................................. ....................................12 .............12 -.
4or*ing 4or*ing principle................................... principle.......................................................... .............................................. .............................................. ..............................................12 .......................12
/.
Technical Technical characteristic para&eters............................. para&eters................................................... ............................................. .............................................. ..........................1...1-
0.
Precautions.......................... Precautions................................................. .............................................. .............................................. .............................................. ........................................... ....................11-
.
'ault 'ault pheno&eno pheno&enon n and judg&ent judg&ent ðod... ðod........ .......... .......... .......... .......... .......... .......... .......... .......... ......... ......... .......... .......... ......... ......... ............... ..............1/ ....1/
3III.
Canister Control 3al7e..................... al7e............................................ .............................................. .............................................. .............................................. .................................. ...........1/ 1/ -.
4or*ing 4or*ing Principle............................... Principle...................................................... .............................................. .............................................. ..................................................10 ...........................10
/.
Technic Technical al Characte Characteristi risticc Para&eter Para&eters..... s.......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... ........... ............... ................... .............1 ...1
0.
Precautions.......................... Precautions................................................. .............................................. .............................................. .............................................. ........................................... ....................1 1
.
'ault 'ault pheno&eno pheno&enon n and judg&ent judg&ent ðod... ðod........ .......... .......... .......... .......... .......... .......... .......... .......... ......... ......... .......... .......... ......... ......... ............... ..............1 ....1
I8. Coolant Te&perature Te&perature Sensor..................................... Sensor............................................................ .............................................. ............................................................1! .....................................1! -.
4or*ing 4or*ing Principle............................... Principle...................................................... .............................................. .............................................. ..................................................1! ...........................1!
/.
Technic Technical al Characte Characteristi risticc Para&eter Para&eters..... s.......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... ........... ............... ................... .............1! ...1!
0.
Precautions.......................... Precautions................................................. .............................................. .............................................. .............................................. ........................................... ....................1" 1"
.
'ault 'ault pheno&eno pheno&enon n and judg&ent judg&ent ðod... ðod........ .......... .......... .......... .......... .......... .......... .......... .......... ......... ......... .......... .......... ......... ......... ............... ..............1" ....1"
8. Idling Stepping otor............................................................ otor.................................................................................. .......................................................................1" .................................................1" 2
-. 4or*ing 4or*ing Principle................................... Principle.......................................................... .............................................. .............................................. ................................................1" .........................1" /.
Technic Technical al Characte Characteristi risticc Para&eter Para&eters..... s.......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... ........... ............... ................... .............15 ...15
0.
Precautions.......................... Precautions................................................. .............................................. .............................................. .............................................. ........................................... ....................2# 2#
.
'ault 'ault pheno&eno pheno&enon n and judg&ent judg&ent ðod... ðod........ .......... .......... .......... .......... .......... .......... .......... .......... ......... ......... .......... .......... ......... ......... ............... ..............2# ....2#
8I.
Air Inta*e Pressure and Te&perature Te&perature Sensor....................................... Sensor.............................................................. ..................................................2# ...........................2# -.
4or*ing 4or*ing Principle............................... Principle...................................................... .............................................. .............................................. ..................................................21 ...........................21
/.
Technical Technical characteristic para&eters............................. para&eters................................................... ............................................. .............................................. ..........................21 ...21
0.
Precautions.......................... Precautions................................................. .............................................. .............................................. .............................................. ........................................... ....................22 22
.
'ault 'ault pheno&eno pheno&enon n and judg&ent judg&ent ðod... ðod........ .......... .......... .......... .......... .......... .......... .......... .......... ......... ......... .......... .......... ......... ......... ............... ..............22 ....22
8II.
Throttle Throttle Position Position Sensor... Sensor........ .......... .......... .......... .......... .......... .......... .......... .......... ......... ......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .............. .................. ..........2.2-.
4or*ing 4or*ing principle................................... principle.......................................................... .............................................. .............................................. ..............................................2.......................2-
/.
Technical Technical characteristic para&eters............................. para&eters................................................... ............................................. .............................................. ..........................2/ ...2/
0.
Precautions.......................... Precautions................................................. .............................................. .............................................. .............................................. ........................................... ....................2/ 2/
.
'ault 'ault pheno&eno pheno&enon n and judg&ent judg&ent ðod... ðod........ .......... .......... .......... .......... .......... .......... .......... .......... ......... ......... .......... .......... ......... ......... ............... ..............2/ ....2/
8III.
9:%gen Sensor................................. Sensor........................................................ .............................................. .............................................. .............................................. ..................................20 ...........20 -.
4or*ing 4or*ing principle................................... principle.......................................................... .............................................. .............................................. ..............................................20 .......................20
/. Technical Technical characteristic para&eters............................ para&eters................................................... .............................................. .............................................. ..............................2 .......2 0.
Precautions.......................... Precautions................................................. .............................................. .............................................. .............................................. ........................................... ....................2! 2!
.
'ault 'ault pheno&eno pheno&enon n and judg&ent judg&ent ðod... ðod........ .......... .......... .......... .......... .......... .......... .......... .......... ......... ......... .......... .......... ......... ......... ............... ..............2" ....2"
Section Section II. II.
Co&&on Co&&on 'aults 'aults and and +iagno +iagnosis sis 'lo 'lo for for !"# !"# UAES UAES S%ste&... S%ste&........ .......... .......... .......... .......... .......... ............... .................... .............2" ...2"
1.
'ault +iagnosis Procedure......................... Procedure................................................ .............................................. .............................................. .............................................. ............................2" .....2"
2.
Co&&on Co&&on 'ault Pheno&ena Pheno&ena and +iagnosis +iagnosis 'lo...... 'lo........... .......... .......... .......... .......... .......... ......... ......... .......... .......... .......... .......... .......... .......... .............. ............25 ...25 2.1
;o rotation rotation or slo slo rotation rotation of engine engine during during start..... start.......... ......... ......... .......... .......... .......... .......... .......... .......... .......... .......... .......... ........... ........25 ..25
2.2
The engine engine can rotate rotate ith dragg dragging< ing< but but can=t can=t start start succe successful ssfull% l% during during start.... start......... .......... .......... .......... .......... ......-# .-#
2.-
+ifficult +ifficult hot start..... start.......... .......... ......... ......... .......... .......... ......... ......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... ............ ................ ................... ..........-# -#
2./
+ifficult +ifficult cold start..... start.......... .......... .......... .......... ......... ......... .......... .......... ......... ......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .....-1 -1
2.0
The engine engine speed speed is nor&al< nor&al< but the start start is diffic difficult ult at all ti&es... ti&es........ .......... .......... ......... ............. ................... ............................-2 2
2.
The start is nor&al< but the idling is unstable at all ti&es........................................... ti&es.............................................................. ...................---
2.!
The start start is nor&al< nor&al< but but the the idling idling is unstab unstable le during during engine engine ar&>u ar&>up..... p.......... .......... .......... .............. ................... ............-..--
2."
The start start is nor&al< nor&al< but but the the idling idling is unstab unstable le after after engine engine ar&> ar&>up.... up......... .......... .......... ............... ................... ...............-/ ......-/
2.5
The star startt is nor&al< nor&al< but but the idli idling ng is unstab unstable le or engin enginee is stoppe stopped d under under partia partiall load load (such (such as the
A?C is turned on$......................................... on$................................................................ .............................................. .............................................. ............................................ ..................... .....-0
-.
2.1#
The start is nor&al< nor&al< but the idling is too high.......... high............... .......... .......... ......... ......... .......... .......... ......... ......... ........... ............... ................... ............-0 ..-0
2.11
The engine engine speed speed can@t can@t increase increase or the the engine engine is stopped stopped during during accelera acceleration... tion....... ......... .......... .............. .............- ....-
2.12
Slo response response during during accelera acceleration.. tion....... .......... .......... .......... .......... .......... ......... ......... .......... .......... ......... ......... .......... .......... ......... ......... .......... ........... ............. .......- -
2.1-
4ea* accelerat acceleration ion and poor perfor&an perfor&ance.. ce....... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... ........... ................ .............-! ...-!
ist of Co&&on Co&&on 'ault 'ault Codes (PC9+E$...... (PC9+E$........... ......... ......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .............. ................... ......................-" "
-
Cha' ha'ter ter Sect Se ctio ion n,
Engin nginee Elec Electr tro onic nic n*e n*ect ctio ion n +art +art
ntr ntro ouc uctio tion n to UE!S UE!S (M-. (M-./) /) En Engi gine ne Elec Electr tron onic ic n*ec n*ecti tion on Syst System em for Fulwin 2 Hatchback Moel
"
System ntrouction
This s%ste& adopts the !"# electronic fuel injection s%ste& fro& United Auto&oti7e Electronic Electronic S%ste&s Co.< td. The ,osch otronic s%ste& is one set of ad7anced engine &anage&ent s%ste&. 4ith one engine electronic unit (hereinafter referred to as ECU$ as the control center and b% &eans of the sensors installed on 7arious portions of the engine< it &easures 7arious or*ing para&eters of the engine and< in accordance ith the preset control progra&s in the ECU< precisel% controls the fuel injection injection a&ount and ignition ad7ance angle so that the engine can function function at best state under 7arious or*ing conditions< na&el% the output at best state< &ost econo&ic fuel consu&ption< and best e:haust e&ission. The otronic s%ste& adopts the &ulti>point seBuential fuel injection control< of hich the control strateg% includes the start control< the &odel>based torBue indication control< idling closed>loop control< gas &i:ture closed>loop control and adapti7e control< canister control< transient or*ing condition control< ignition angle control< sla7e c%linder *noc* control< A?C control< fan control< 7ehicle speed and engine speed li&itation< heating and protection control of three>a% catal%tic con7erter< and s%ste& self>diagnosis (9,+ standard co&pliant$. The CA; bus interface and the co&&unication interface ith A,S< auto&atic trans&ission< airbag< and anti>theft s%ste& are reser7ed in the s%ste&. 4hat is ! s%ste& >
anifo nifold ld inj injeectio ction n s%st s%stee&
>
4ith air air (idli (idling$ ng$<< fuel< fuel< and and igniti ignition on angle angle as as the cont control rol objec objects ts
>
,ased ,ased on the the ph%sical ph%sical &odel and orient oriented ed on the the torBue torBue for for control control of of para&et para&eters ers and and interfac interfaces es
>
Introduc Introduced ed the the coordi coordination nation &echanis& &echanis& of ad7an ad7anced ced torBue torBue and and gas gas &i:tur &i:turee
>
SUE SUE3 3 and and E3I3 E3I3 e&i e&iss ssio ion n stan standa dard rd co& co&pl plia iant nt
>
Adopte Adopted d the the 9,+I 9,+III and and E9,+ E9,+ fault fault diagno diagnosis sis standa standard rd
>
odul odular ari ieed ope open n s% s%ste ste&
Si: ad7antages of introduction of ! s%ste& >
Eas% realiati realiation on for for &odific &odification ation of s%ste& s%ste& config configurati uration on and and adding adding of of ne ne subs%ste subs%ste&s &s
>
Possib Possibili ilit% t% of neto netor*i r*ing ng for for contro controll s%ste& s%ste& of of co&ple co&plete te 7ehic 7ehicle le
>
Dreatl% Dreatl% si&plif si&plified ied data data calibr calibration ation<< than*s than*s to to the decoupling decoupling of 7arious 7arious subs%ste&s. subs%ste&s.
>
ore ore pre preci cise se rea reali lia ati tion on of of torB torBue ue de& de&an ands ds
>
S%ste S%ste& & integra integrated ted gas gas &i:ture &i:ture coord coordina inatio tion n &echan &echanis& is& (b% (b% a&bda a&bda$$
>
Poerf Poerful ul s%ste s%ste& & e:pan e:pandab dabili ilit% t% than* than*ss to open open struct structure ure
Co&parison against pre7ious s%ste& >
;e engine engine functio functional nal structure structure as as a function function of torBue torBue 7ariable 7ariable enabl enables es eas% co&pat co&patibilit% ibilit% ith ith other other s%ste&s s%ste&s
>
;e ;e &odu &odular larie ied d soft softare are and harda hardare re struct structure uress
>
The &odel>ba &odel>based sed engine engine basic chara character cteristic istic diagra&s diagra&s are are independe independent nt ith each each other< other< si&plif%ing si&plif%ing the the calibration calibration process
>
S%st S%ste& e& inte integr grat ated ed anti anti>t >the heft ft func functi tion on
>
I&pro7e&e I&pro7e&ent nt of dri7ing dri7ing perfor& perfor&ance ance b% b% &eans &eans of the centrali centralied ed coordinat coordination ion of 7ariou 7ariouss torBue torBue de&ands de&ands
>
1>bit 1>bit centra centrall processi processing ng unit< unit< ith ith 2/) 2/) cloc* cloc* freBue freBuenc% nc% and 0126 cache cache
>
S%ste& S%ste& e:pandabi e:pandabilit% lit% against against future future de&and de&ands< s< such as future future e&issi e&ission on regulatio regulations< ns< 9,+II< 9,+II< and electr electronic onic throttle. throttle.
1
"
Schematic &iagram of Engine Management System (EMS)
-.2 Sche&atic +iagra& of ES Canister 7al7e
control Phase sensor
Canister
Air inta*e 'uel injector pressure?te&perat re sensor
Ignition coil
9:%gen sensor Three>a% catal%tic con7erter
6noc* sensor Throttle position sensor
Idling regulator 'uel filter
Speed sensor
r o s n e s e r u t a r e p & e t r e t a 4
Pressure regulator
'uel tan* Electric fuel pu&p and rac*et asse&bl%
,"
0asic +arameter of Engine
odel
F/!!'
T%pe
/>c%linder< inline< />stro*e< ater cooling
C%linder bore
!!./&&
Stro*e
"0.0&&
+isplace&ent
1/5!&
Co&pression ratio
1#.0
Ignition 9rder
1>->/>2
a:. poer output
"#6?###rp&
a:. torBue output
1/#;&?/0##rp&
Idling
"##G-#rp&
Dasoline
5-H and abo7e
E&ission
EUI3 co&pliant
Cold start
>-#C
The co&ponents of the engine &anage&ent s%ste& e:ert the i&portant function to the perfor&ance of the co&plete 7ehicle and the da&age of one co&ponent &a% se7erel% i&pair the engine perfor&ance or e7en ignition failure. Therefore< the &aintenance and repair of the engine &anage&ent s%ste& co&ponents are of great i&portance.
2
2"
ECU
,)
nstallation $ocation1
'ront passenger cabin 2)
Function 1
>
ulti>point seBuential injection
>
Control of ignition
>
Idling control
>
6noc* control< independent c%linder *noc* control (*noc* sensor 6S>
(ECU profile$
/$ >
Poer suppl% to sensors 03?1##&A
>
Adoption of c%linder judg&ent signal (phase sensor PD1$
>
J closed>loop control< ith adapti7e function
>
Control of canister control 7al7e
>
A?C sitch
>
Engine &alfunction indicator la&p
>
'uel Buantitati7e correction
>
9utput of engine speed signal (T; signal$
>
Input of 7ehicle speed signal
>
'ault self>diagnosis< ith flashing code function
>
Fecei7ing engine load signal< and so on.
"
&efinition of ECU +ins1
Pin
Connecting point
1
?
2
Upstrea&
o:%gen
sensor
T%pe heating
Pin
Connecting Point
/2
Ca& position sensor 2H
9utput
/-
1H of earth P1< ECU connector /"H
T%pe Input Dround
plug>in unit -H -
Ignition coil 1H
9utput
//
A?C pressure sitch 2H
Input
/
+onstrea& o:%gen sensor heating
9utput
/0
Upstrea& o:%gen sensor 2H
Input
Dround
/
Engine speed sensor 2H
Input
/!
Engine speed sensor 1H
9utput
9utput
/"
1H of earth P1< ECU connector /-H
Dround
Input
/5
'uel injector (-rd c%linder$ connector
-H 0
Ignition ground
?
!
Ignition coil 2H
"
01H of ECU control plug>in unit< 2H of electric bo: C
5
2H
?
0#
'uel injector (1st c%linder$ connector
9utput
2H 1#
A?C pressure sitch /H
Input
01
ECU connector "H< 2H of electric bo:
Input
C 11
?
02
Instru&ent harness connector 15H
9utput
12
Instru&ent harness connector 2#H
0-
?
Dround
1-
?
0/
?
1/
?
00
?
10
Instru&ent harness connector H
0
?
1
1!H of electric bo: C
Input
0!
?
1!
11H of electric bo: C
Dround
0"
?
1"
Air
Input
05
Air
inta*e
te&perature?pressure
Input
-
inta*e
te&perature?pressure
Input
sensor -H 15
sensor /H
Ca&shaft position sensor -H< throttle
Input
#
!H of electric bo: C
9utput
1
1"H of electric bo: C
9utput 9utput
position 1H 2#
?
21
Stepping &otor 2H
9utput
2
Instru&ent harness connector 1"H
22
Stepping &otor 1H
9utput
-
'uel injector (2nd c%linder$ 2H
Input
2-
?
/
'uel injector (/th c%linder$ 2H
9utput
2/
?
0
?
20
Air
Input
?
Input
!
?
inta*e
te&perature?pressure
sensor 2H 2
Throttle position sensor -H
2!
?
"
?
2"
?
5
?
25
+onstrea& o:%gen sensor 2H
Input
!#
?
-#
6noc* sensor 1H
Input
!1
?
-1
6noc* sensor 2H
Input
!2
?
-2
/H of electric bo: C
!-
?
--
CA;>)D) bus interface
!/
?
-/
CA;>94 bus interface
!0
?
-0
Stepping &otor -H
9utput
!
?
-
Stepping &otor /H
9utput
!!
?
-!
Canister solenoid 7al7e 2H
Input
!"
?
-"
?
!5
?
-5
Ca&shaft sensor 1H< throttle sensor
Dround
"#
?
Dround
"1
?
2H< front o:%gen 1H< rear o:%gen 1H /#
4ater te&perature sensor 2H< air inta*e pressure?te&perature sensor 1H
/1
3"
4ater te&perature sensor 1H
Input
?
echnical Characteristic +arameters i&it +ata
3alue in.
,atter% 7oltage
T%pical
Unit a:.
3
;or&al running
5.#
1.#
3
i&ited function
.#K5.#
1.#K1".#
S
#
S
#
C C
i&it and ti&e
2.#3
for batter% o7er> 7oltage resistance
So&e functions are &aintained and fault diagnosis is e:ecutable.
1-.#3
The start function is guaranteed and fault diagnosis is e:ecutable.
4" 1$
4or*ing te&perature
>/#
L!#
Storage te&perature
>/#
L5#
+recautions The aterproof shall be cautioned. ;e7er conta&inate the ECU ith ater nor i&&erge the ECU in the ater< or it
&a% burn out the ECU. 2$
The static protection shall be cautioned during the installation.
/
-$
;otice the protection of connector pins.
/$
,efore re&o7ing the ECU< disconnect the batter% ter&inals and &aintain for &ore than 1&in.
0$
it=s prohibited to install additional circuits onto the connecting ires of the ECU.
$
;o *noc*ing is alloed for ECU. )andle ith care during the replace&ent of ECU and do not drop carelessl%.
!$
it=s prohibited to replace the ECU hen the ignition sitch is turned on.
"$
The electronic control &odule is one high Bualit% unit< ith seldo& faults. The special eBuip&ent shall be used for
chec*ing and generall% the re&o7al and repair at libert% is disalloed. 5$
4hile replacing the ECU< upon the confir&ation of the professionals fro& the ser7ice station< choose the ECU ith
sa&e s%ste& and sa&e 7ersion< or it &a% lead to da&age of electronic control units< i&paired engine perfor&ance< ignition failure and so on.
5"
Fault +henomenon an 6ugment Metho1
Fault 'henomenon Unstable idling< poor acceleration< stature failure< o7er>high idling speed< e:cessi7e e:haust
e&ission< difficult start< failure of A?C< control failure of fuel injector< engine fla&eout< and so on. 7eneral fault causes1
1$ The electric o7erload of peripheral de7ices leads to burnout of ECU internal co&ponents and then leads to faultM 2$ The ater ingress into the ECU leads to rusting of circuit board. Sim'le Measurement Metho1
1$
(connect the connector$ Fead the engine fault record b% &eans of the engine data cable 6M
2$
(Fe&o7e the connector$ Chec* the ECU connecting ires for intactness< &ainl% chec* the ECU poer suppl% and grounding circuit for nor&al functioningM
-$
Chec* hether the e:ternal sensors function nor&all%< hether the signal output is credible< and hether the circuits are intactM
/$
Chec* hether the actuators function nor&all% and hether the circuits are intactM
0$
'inall%< replace the ECU for testing purpose.
" gnition System ,"
gnition Coil
,)
&iagram an 'ins
2)
&efinition of 'ins1
$ow voltage en1
+ouble>spar* ignition coil NS>62O2
1H coil pri&ar% inding is connected to -H pin of ECUM 2H coil pri&ar% inding is connected to !H pin of ECUM
-H pin is connected to 5H pin of electric bo: C and both pins are connected to positi7e pole of poer suppl%. High voltage en1
The 1H< 2H< -H< and /H pins are connected to engine spar* plugs respecti7el% 7ia the c%linder distribution ire. -$
Installation location
9n the engine. 3)
8orking 'rinci'le
The ignition coil NS>62O2 is co&posed of to pri&ar% indings< to secondar% indings< iron core< and housing. 9ne pri&ar% inding is charged once the grounding lead of such pri&ar% inding is connected. The charging is interrupted once the ECU cut off the pri&ar% inding circuit and at the sa&e ti&e the high 7oltage is generated in the secondar% inding to dri7e the discharge of the spar* plug. +iffering fro& the ignition coil ith distributor< one spar* plug is connected on both sides of the secondar% inding of ignition coil N6>62O2< in hich case these to spar* plugs fire at the sa&e ti&e. To pri&ar% indings are poered on and off alternatel% and accordingl% to secondar% indings discharge alternatel%. 0
0$
Technical Characteristic Para&eters
i&it +ata easure&ent
3alue in.
Alloable te&perature at specified
Unit
T%pical
a:.
>/#
a:. te&perature ithin 1hr
L12#
C
L1/#
C
Characteristic +ata easure&ent
3alue in.
3oltage rating
5)
T%pical
Unit a:.
1/
3
Fesistance
Pri&ar% inding
#./2
#.0
#.0"
(2#K20C$
Secondar% inding
11.2
1-.#
1/."
*
Inductance
Pri&ar% inding
-./
/.1
/."
&)
(2#K20C$
Secondar% inding
2.0
-2.#
-!.0
)
3oltage generated
Under load 0#p'
-#
*3
Under load 0#p'??1
2-
*3
Fault 'henomenon an *ugment metho
Fault 'henomenon1 Start failure and so on.
'ault cause ,urnout due to e:cessi7e current< da&age due to e:ternal force< and so on. +recautions1 +uring the repair< the Qshort>circuit ignition trialR for testing of ignition function is prohibited< in order to
pre7ent da&aging the electric controllers. Sim'le measurement metho1
(Fe&o7e the connector$ Turn the digital &ulti&eter to 9h& &easure&ent scale and connect to probes to to pins of the pri&ar% inding respecti7el%. Under 2#C< the resistance shall be #./2K#.0". The resistance &easure&ent shall be 11.2K1/."* for secondar% inding.
2"
S'ark +lug
&ue to the e9tremely harsh working conitions# the s'ark 'lug is sub*ect to the high voltage an high tem'erature im'act an to the harsh corrosion by combustion 'roucts an therefore the s'ark 'lug is classifie as one wearing 'art" ,)
hermal characteristic
To guarantee the good or*ing of spar* plugs< ensure to &aintain the spar* plug at proper te&perature. The practices pro7e that< hen the insulator s*irt of the spar* plug is &aintained at 0##K!##C te&perature< the oil drops falling onto the insulator can be burnt aa% i&&ediatel% against for&ing the carbon deposit. This te&perature is referred to as the self>cleaning te&perature of the spar* plug. 4hen belo this te&perature scope< the carbon deposit ill be for&ed on the spar* plug to cause electric lea*age and ignition failure. 4hen abo7e this te&perature scope< the gas &i:ture ill contact ith the hot insulator to cause possible earl% co&bustion and *noc* or e7en cause co&bustion during air inta*e process< leading to bac*fire. 2)
+ossible faults arising from eteriorate ignition 'erformance of s'ark 'lug
+ifficult start< unstable 7ehicle speed< engine tre&ble< blac* s&o*e fro& e:haust pipe< high fuel consu&ption< and insufficient poer output. )
6uge from s'ark 'lug color the matching between vehicle conition an s'ark 'lug moel ello or tan ;or&al It indicates that the co&bustion status of gas &i:ture is nor&al ,lac*< ith carbon Carbon deposit Chec* if the spar* plug &odel is &atched and replace deposit ith spar* plug ith loer ther&al 7alue (slo heat radiation$ ,lac*< ith dirt ,lac*ened If the fuel injector is dirt%< clean it. If the gas &i:ture ratio is too dense< thin the gas &i:ture If the high 7oltage is insufficient<
3)
,lac*< ith oil dirt
chec* ignition coil and so on ,urnout of engine oil
Dra%
97erheating
Chec* sealing condition of seal ring and chec* c%linder all for presence of scratches. Chec* if the spar* plug &odel is &atched and replace ith spar* plug ith higher ther&al 7alue (fast heat radiation$
+erioical re'lacement an overtime service
The spar* plug is one lo>7alue earing part< ith relati7el% lo price co&pared ith other parts. )oe7er< the ignition perfor&ance of the spar* plug directl% influences the engine perfor&ance and therefore the spar* plug shall be replaced periodicall%. 'or the spar* plugs used in our engine< it=s reco&&ended to replace the single electrode spar* plug for e7er% 1#<###K10<###*& and to replace the &ulti>electrode spar* plug for e7er 10<###K20<###*&. The deteriorated ignition perfor&ance of the spar* plug ill lead to increased fuel consu&ption and loered poer output. The dail% econo&ic loss arising fro& the e:cessi7e fuel consu&ption un*noingl% ill be enough to bu% hundreds of ne spar* plugs. The o7erti&e ser7ice of the spar* plug ill cause the engine to or* under poor condition for a long period and ill cause certain da&age to the engine. 4)
ns'ection an maintenance of s'ark 'lug
The chec*ing of spar* plug &ainl% includes the carbon deposit< electrode ablation< electrode gap< spar* plug sealing perfor&ance< and arcing perfor&ance. The electroe ga' of the spar* plug shall be /"-:/";mm. The insufficient electrode gap ill loer the puncture 7oltage and ea*en the spar* intensit%. The e:cessi7e electrode gap ill increase the reBuired 7oltage of the spar* plug and lead to &isfire< especiall% in e7ent of aged ignition coil and poor &aintenance of ignition s%ste&< in hich the &isfire ill &ore li*el% occur. The co&&on faults of spar* plug include loered sealing perfor&ance< presence of air lea*age< and blac*ened trace at air lea*age portion. Abo7e faults &a% be chec*ed and judged b% &eans of sealing test and arcing test. The sealing test and the arcing test can be conducted on the spar* plug cleaning tester. So&e dri7ers and repair personnel re&o7e the spar* plugs fro& the engine< place the& on the c%linder hood< and inspect ith onboard high 7oltage poer. It shall be pointed out that this ðod is unscientific. This is because that< in this test< the spar* plug electrode is tested under the at&ospheric pressure. )oe7er< the spar* plug is actuall% or*ing under air pressure ith abo7e "##*Pa. Therefore< the arcing of spar* plug under at&ospheric pressure doesn@t eBual to the reliable arcing under high pressure ithin the c%linder. +uring the ser7ice of the spar* plug< it=s reBuired to clean the carbon deposit and properl% adjust the spar* plug gap for e7er% 1#<###K10<###*&. 4hen the c%linder te&perature is increased< the electrode gap shall be increased properl%< na&el% the electrode gap shall be increased in su&&er and shall be reduced in inter. 4hen the gas &i:ture is dense< the electrode gap shall be properl% increased and on the contrar% the electrode gap shall be reduced. The electrode gap shall be reduced in plains and shall be increased in highlands.
<" S'ee Sensor (Crankshaft +osition Sensor) ,"
2"
&iagram an 'ins
nstallation location
agnetic inducti7e speed sensor
1H is connected to shieldM 2H and -H are connected to signal ire
!
"
8orking 'rinci'le
The inducti7e speed sensor is fitted ith the pulse heel to pro7ide the engine speed infor&ation and cran*shaft top dead point infor&ation in the ignition s%ste& ithout distributor. The inducti7e speed sensor is co&posed of on per&anent &agnet and the coil surrounding the &agnet. The pulse heel is one #>tooth fluted disc< in hich to teeth are &issing. The pulse heel is installed on the cran*shaft and rotates along ith the cran*shaft. 4hen the tooth tip passes closel% through the end of inducti7e speed sensor< the pulse heel &ade of ferro&agnetic &aterial cuts the &agnetic lines of the per&anent &agnet ithin the inducti7e speed sensor so that the inducti7e 7oltage is generated in the coil as the speed signal output. 3"
echnical Characteristic +arameters
i&it +ata 3ariable
3alue in.
T%pical
Unit a:.
Tolerable
Coil one
>/#
L10#
C
te&perature of
Transitional one
i:ed
i:ed
C
PUF ire
4ire one
>/#
L12#
C
inducti7e speed
Storage te&perature
>2#
L0#
C
sensor (see
En7iron&ent te&perature during non>or*ing
>/#
L12#
C
figure belo$
ong>ter& en7iron&ent te&perature during or*ing
>/#
L12#
C
Short>ter& en7iron&ent
10#hr
L10#
C
te&perature during or*ing
-"#hr
L1/#
C
4ithin entire ser7ice life of
10#hr
L10#
C
ire one
-"#hr
L1/#
C
11-#hr
L1-#
C
Tolerable
Coil one
>/#
L10#
C
te&perature of
Transitional one
i:ed
i:ed
C
)S ire
4ire one
>/#
L1-#
C
inducti7e speed
Storage te&perature
>2#
L0#
C
sensor (see
En7iron&ent te&perature during non>or*ing
>/#
L1-#
C
figure belo$
ong>ter& en7iron&ent te&perature during or*ing
>/#
L1-#
C
L10#
C
Short>ter& en7iron&ent te&perature during or*ing 4ithin entire ser7ice life of
0##hr
L10#
C
ire one
2##hr
L1#
C
1"hr 7ibration resistance
2#K!1)
Acceleration /#
&?s2
ithin each plane
!1K22#)
A&plitude #.2
&&
Alloable &agnetic field intensit% of e:ternal &agnetic field in
V2
*A?&
opposite direction Insulation resistance (1#s<
;e state
1
ith testing 7oltage at 1##3$
At end of ser7ice
1##
*
3oltage resistance (1K-s< under 1<2##3 AC$
;o puncture
"
Characteristic Para&eters 3ariable
3alue
Unit
in.
T%pical
a:.
Fesistance under 2# en7iron&ent te&perature
!!/
"#
5/
Inductance
-1#
-!#
/-#
&)
3oltage output at /1rp& of cran*shaft
W10#
&3
4"
+recautions
It=s onl% alloed to ta*e the inducti7e speed sensor out of the pac*aging &aterial right before the installation on the 7ehicle or on the tester.
The inducti7e speed sensor shall be installed b% &eans of press>in< instead of the ha&&ering.
It=s reco&&ended to adopt partiall% &icro>sealed bolts O12 to fi: the inducti7e speed sensor.
Tightening torBue "G2;&.
Air gap beteen inducti7e speed sensor and tooth tip of pulse heel #."K1.2&&
5"
Fault 'henomenon an *ugment metho
'ault pheno&enon Start failure and so on. Precautions +uring the repair< use the press>in instead of ha&&ering for installation. Si&ple &easure&ent ðod 1$
(Fe&o7e the connector$ Turn the digital &ulti&eter to 9h& &easure&ent scale and connect to probes to 2H and -H pins of the sensor respecti7el%. The rated resistance under 2#C shall be "#G1#X.
2$
(Connect the connector$ Turn the digital &ulti&eter to AC 3oltage &easure&ent scale and connect to probes to 2H and -H pins of the sensor respecti7el%. 4hen the engine is started< there shall be 7oltage output.
<"
+hase Sensor (Camshaft +osition Sensor)
," &iagram an 'ins Pins ar*ing Q1R stands for groundM ar*ing Q2Y stands for signal outputM ar*ing Y-R stands for connection to positi7e pole of poer suppl%.
2" nstallation location1
Ca&shaft position sensor
End cap of ca&shaft.
5
"
8orking +rinci'le
Sensor function Pro7ide the cran*shaft phase infor&ation to the ECU< na&el% differentiating the co&pression top dead point and the e:haust top dead point of the cran*shaft. Structure Co&posed of one )all sensor and one rotor &ade of steel plate. The )all sensor is fi:ed and the rotor is installed on the ca&shaft. The rotor is one se&i>c%lindrical shaped steel blade. 4hen the )all sensor is co7ered b% this blade< there is no signal output. 9therise< there is signal output. As to se&i>c%cles of the ca&shaft ill be eBui7alent to to co&plete turns of the cran*shaft< the co&pression top dead point and the e:haust top dead point can be differentiated.
3"
Characteristic 'arameters
i&it +ata 3ariable
3alue in.
En7iron&ent te&perature
T%pical
>/#
Unit a:. L1-#
C
Space 7ibration
En7iron&ent te&perature 1-#>0C< 0#hr
0##
&?s2
acceleration
En7iron&ent te&perature 1-#>0C< 20hr
##
&?s2
;otice There are to holes on the sensor housing for fi:ing purpose.
4"
Fault 'henomenon an *ugment metho
'ault pheno&enon 9ut>of>li&it of e&ission< increased fuel consu&ption< and so on. Si&ple &easure&ent ðod (Connect the connector$ Turn on the ignition sitch< but do not start the engine. Turn the digital &ulti&eter to +C 3oltage &easure&ent scale and connector to probes to 1H and -H pins of the sensor respecti7el%. Ensure there is the presence of 123 reference 7oltage. 4hen the engine is started< chec* ith auto&oti7e oscilloscope hether the signal at 2H pin is nor&al.
<"
=nock Sensor
," &iagram an 'ins
6noc* sensor ithout cable
6noc* sensor ith cable
Pins 1H and 2H are connected to ECU and -H is connected to shield.
2" nstallation location1 'or ->c%linder engine< it=s installed in the &iddle of 2H c%linder. 'or />c%linder engine< it=s installed beteen 2H and -H c%linders.
1#
"
8orking +rinci'le
The *noc* sensor is one *ind of 7ibration acceleration sensor and is installed on the engine c%linder bloc*. 9ne or &ore sensor(s$ can be installed. The sensing unit of the sensor is one pieoelectric unit. The 7ibration of the engine c%linder bloc* is trans&itted to the pieoelectric cr%stal 7ia the &ass bloc* ithin the sensor. Under the pressure generated fro& the 7ibration of &ass bloc*< the pieoelectric cr%stal generates 7oltage beteen to electrode faces and con7erts the 7ibration signal to alternating 7oltage signal output. Its freBuenc% response characteristic cur7e is shon in the figure belo. As the freBuenc% of the 7ibration signal arising fro& the engine *noc* is greatl% higher than that of nor&al engine 7ibration signal< the ECU can differentiate the *noc* signal and non>*noc* signal after processing the signal of the *noc* sensor. The *noc* sensor can be classified b% structure as to t%pes (ith cable and ithout cable$ at custo&ers= choice.
3"
Characteristic +arameters
i&it +ata 3ariable
3alue in.
4or*ing te&perature
T%pical
>/#
Unit a:. L1-#
C
Characteristic +ata 3ariable
3alue
Unit
Sensiti7it% of ne sensor toards 0*) signal
2G"
&3?g
inearit% beteen -*) and 10*)
G10X of 0*)
inearit% at resonance
10K-5
3ariation during entire ser7ice life
>1!X a:.
ain resonance freBuenc%
W2#
*)
Fesistance
W1
Capacit%
12##G/##
p'
Cable capacit% thereof
2"#G#
p'?&
/."G10X
I&pedance
ea* resistance
&3?g
(resistance beteen to output pins of sensor$ Sensiti7it% 7ariation arising fro& te&perature
4"
V>#.#
&3?g6
+recautions
There is one hole in the &iddle of the *noc* sensor and one " bolt is used to fi: the sensor onto the c%linder bloc*. 'or alu&inu& allo% c%linder bloc*< the bolt ith -#&& length is adopted. 'or cast iron c%linder bloc*< the bolt ith 20&& length is adopted. The tightening torBue shall be 2#G0;&. The installation location shall ensure that the sensor can easil% recei7e the 7ibration signal fro& all c%linders. The best installation location of the *noc* sensor shall be deter&ined b% &eans of the &odel anal%sis of the engine bloc*. Denerall%< the *noc* sensor is installed beteen 2H and -H c%linders for />c%linder engines and in the &iddle of 2H c%linder for ->c%linder engines. ;otice to *eep 7arious fluids (such as engine oil< coolant< bra*e fluid< and ater$ aa% fro& long>ter& contact ith the sensor. +uring the installation< the use of all *inds of gas*ets is disalloed. The sensor shall cling ith its &etallic surface to the c%linder bloc*. The ire arrange&ent for the signal cable of the sensor shall be cautioned to *eep the signal cable fro& resonance< in order to pre7ent brea*age. a*e sure to pre7ent appl%ing high 7oltage beteen 1H and 2H pins of the sensor< or it &a% da&age the pieoelectric unit.
11
5"
Fault 'henomenon an *ugment metho
Fault 'henomenon1 Poor acceleration and so on. 7eneral fault causes1 The sensor is corroded due to long>ter& contact ith 7arious fluids (such as engine oil< coolant<
bra*e fluid< and ater$. Sim'le measurement metho1
(Fe&o7e the connector$ Turn the digital &ulti&eter to 9h& &easure&ent scale and connect to probes to 1H and 2H pins and 1H and -H pins of the sensor respecti7el%. The resistance under at&osphere te&perature shall be abo7e 1. Turn the digital &ulti&er to &3 &easure&ent scale and *noc* lightl% the 7icinit% of the *noc* sensor ith s&all ha&&er. In such case< there shall be the presence of 7oltage signal output.
<" Fuel n*ector ," &iagram an 'ins Pins Each fuel injector has to pins< of hich the pin &ar*ed ith QLR on the housing side is connected to &ain rela% output end and another pin is connected to the ECU end.
'uel injector 1.
9>ring
2.
Strainer
-.
'uel
injector
bod%
ith
ith
coil
electric plug /.
Coil
0.
Spring
.
3al7e
needle
ar&ature !.
3al7e seat ith orifice plate
'uel injector on fuel distributor pipe
Sectional 7ie of fuel injector
2" nstallation location1 9n the air inta*e &anifold< closing to the air inta*e 7al7e.
"
8orking 'rinci'le
The ECU issues the electric pulse to the coil of fuel injector to for& the &agnetic field force. 4hen the &agnetic field force is increased to o7erco&e the resultant force fro& return spring pressure< needle 7al7e gra7it% force< and friction force< the needle 7al7e starts to lift and the fuel injection process begins. 4hen the fuel injection pulse is ended< the pressure of the return spring ill re>close the needle 7al7e.
12
3"
echnical characteristic 'arameters
i&it +ata 3ariable
3alue in.
Storage te&perature (as supplied pac*age$
T%pical
>/#
Alloable te&perature of fuel injector ithin 7ehicle
Unit a:. L!#
C
L1/#
C
L11#
C
L1-#
C
(non>or*ing$ 4or*ing te&perature of fuel
Continuousl%
>/#
injector
Short>ter& after hot start (appro:i&ate -&in$
Alloable te&perature of fuel
Continuousl%
L!#
C
at inlet of fuel injector
Short>ter& (appro:i&ate -&in$
L1-#
C
L/0
C
Te&perature on hich the 7ariation of fuel flo reaches 0X
>/#
against fuel flo at 2#C Alloable lea*age of 9>ring ithin >-0K>/#C
4ithin the 9>ring area< the fuel &oisture is alloed< but the fuel drops are prohibited.
a:. alloable 7ibration acceleration (pea*$ Poer suppl% 7oltage
Insulation resistance
1
/##
&?s 2
1
3
Tolerable internal fuel pressure
11##
*Pa
Tolerable bending stress
;&
Tolerable a:ial stress
##
;
Characteristic +ata 3ariable
3alue in.
4or*ing pressure (pressure difference$
T%pical
Unit a:.
/##
Fesistance of fuel injector at 2#C
11
*Pa 1
!llowable Fuel 7raes
The fuel injector shall onl% use the fuels specified in the national standard D, 1!5-#>1555 QAuto&oti7e Unleaded DasolineY and the national en7iron&ent protection standard D46,1>1555 QStandard on Control of )aardous Substances in Auto&oti7e DasolineR of the People=s Fepublic of China< ith added detergent additi7es. It shall be speciall% pointed out that the gasoline ill deteriorate after e:cessi7el% long storage period. Especiall% for the dual>fuel ta:is (PD L gasoline$< hich ta*e the PD as long>ter& fuel and ta*e the gasoline for start onl%< though the dail% gasoline consu&ption is reall% lo< the fuel pu &p runs continuousl% and the te&perature of fuel tan* is 7er% high. 4ithin the fuel tan* of such 7ehicles< the gasoline ill easil% get o:idied and deteriorated and &a% lead to bloc*age or da&age of fuel injector.
4"
+recautions
1$
Confir& the ,9SC) trade&ar* and product nu&ber.
2$
'or certain fuel injector< &a*e sure to use corresponding plug and ne7er &i: ith other plugs.
-$
To facilitate the installation< it=s reco&&ended to appl% silicon>free clean engine oil on the surface of upper 9>ring
connecting to the fuel distributor pipe. ;otice not to conta&inate the inside and injection hole of the fuel injector ith engine oil. /$
Install the fuel injector into the fuel injector seat along the direction perpendicular to the fuel injector seat and then
fi: the fuel injector onto the fuel injector seat ith clip.
1-
;otices (1$ The fuel injector clips can be classified b% position ðod into a:ial positioning clip and the a:ial?radial positioning clip. Pre7ent the use error. (2$ 'or the installation of a:ial positioning fuel injector< &a*e sure that the soc*et in the &iddle of the clip full% engages ith the groo7e of the fuel injector and the groo7e on both sides of clip full% engages ith the flange of the fuel injector seat. (-$ 'or the installation of fuel injector ith both a:ial and radial positioning reBuire&ents< use the a:ial?radial positioning clip and ensure that the positioning bloc* of the fuel injector and the positioning pin of the fuel injector seat engage ith corresponding groo7es on the positioning clip. (/$ If there are to groo7es on the fuel injector< notice to pre7ent the rong engage&ent< ith reference to the installation position of the original part. The installation of the fuel injector shall be fulfilled b% hand and it=s prohibited to *noc* the fuel injector
ith tools such as ha&&er. +uring the re&o7al and reinstallation of fuel injector< &a*e sure to replace the 9>ring. In such case< do
not da&age the sealing face of the fuel injector. +o not pull out the supporting ring of 9>ring fro& the fuel injector. +uring the installation< a7oid
da&aging the inlet end< 9>ring< supporting ring< orifice plate< and electric plug of fuel injector. An% da&aged part is prohibited for use. After the installation of fuel injector< test the sealing perfor&ance of the fuel distributor pipe asse&bl% and
onl% the one ithout lea*age is Bualified. The failed parts shall be re&o7ed &anuall%. Fe&o7e the clip fro& the fuel injector and pull out the fuel
injector fro& the fuel injector seat. After the re&o7al< ensure the cleanliness of the fuel injector seat and a7oid the conta&ination.
5"
Fault 'henomenon an *ugment metho
Fault 'henomenon Poor idling< poor acceleration< start failure (difficult start$ and so on. 7eneral fault causes The lac* of &aintenance leads to accu&ulation of colloid ithin the fuel injector and thus leads to
failure. Sim'le measurement metho1
(Fe&o7e the connector$ Turn the digital &ulti&eter to 9h& &easure&ent scale and connect to probes to to pins of fuel injector respecti7el%. The rated resistance under 2#C shall be 11K1. >ecommenation1 Use the fuel in*ector s'ecial cleaning analy?er to conuct 'erioical cleaning analysis for the fuel in*ector"
<" Canister Control
+efinition of canister control 7al7e pins Pins The canister control 7al7e contains to pins< of hich one is connected to &ain rela% and another is connected to ECU pin.
2" nstallation location 9n 7acuu& pipeline beteen canister and air inta*e &anifold.
1/
Carbon canister control 7al7e TE3>2
"
8orking +rinci'le
1.
'ro& oil tan*
2.
canister
-.
At&osphere air
/.
Canister control 7al7e
0.
To air inta*e &anifold
.
Throttle
ZP is difference beteen en7iron&ent pressure Pu and air inta*e &anifold pressure Ps Sectional 7ie of
Installation diagra& of canister
canister control 7al7e
control 7al7e
The canister control 7al7e is co&posed of the solenoid coil< ar&ature< and 7al7e. The strainer is set at the inlet. The air flo floing through the canister control 7al7e is on one h and related to the pulse dut% ratio of the canister control 7al7e and on another hand is related to the pressure difference beteen inlet and outlet of the canister control 7al7e. The canister control 7al7e is closed hen there is no pulse. +ifferent t%pes of canister control 7al7e ha7e different flo under 1##X dut% ratio< na&el% the 7al7es are thoroughl% opened. The figure belo gi7es to t%pical flo cur7es. It can be read fro& this figure that< under the 2##&bar pressure difference< the flo at thoroughl% open state is -.#& -?h for t%pe A canister control 7al7e and is 2.#& -?h for t%pe , canister control 7al7e.
$ h ? & ( o l '
-
T%pe A T%pe ,
Pressure difference (&bar$ (This 7ehicle &odel is t%pe A$
Canister control 7al7e flo diagra&
10
3"
echnical Characteristic +arameters
i&it +ata 3ariable
3alue in.
4or*ing 7oltage
T%pical
5
1&in o7er>7oltage
Unit a:. 1
22
3 3
in. start 7oltage
!
3
in. 7oltage drop
1.#
3
Alloable or*ing te&perature
>-#
L12#
C
L1-#
C
L1-#
C
"##
&bar
Alloable 7ibration acceleration on product
-##
&?s2
ea*age at /##&bar pressure difference
#.##2
& -?h
Short>ter& alloable or*ing te&perature Alloable storage te&perature
>/#
Tolerable pressure difference beteen inlet and outlet 1#"
Alloable sitching c%cle
Characteristic +ata 3ariable
3alue in.
T%pical
Unit a:.
Fated 7oltage
1-.0
3
Fesistance under L2#C
2
Current under rated 7oltage
#.0
A
'reBuenc% of control pulse T%pical control pulse idth
-#
)
T%pe A
!
&s
T%pe ,
&s
'lo under 2##&bar pressure
T%pe A
2.!
-.#
-.-
&-?h
difference and 1##X dut% ratio
T%pe ,
1.!
2.#
2.-
&-?h
4"
+recautions To a7oid the trans&ission of solid>borne noise< it=s reco&&ended to install the canister control 7al7e on the hose in such &anner that the control 7al7e hangs in the air.
+uring the installation< ensure that the air flo direction co&plies ith the reBuire&ent.
a*e sure to adopt proper &easures (such as filtration< purification$ to pre7ent the ingress of foreign &atters (such as particles$ into the canister control 7al7e 7ia canister or hose. It=s reco&&ended to install one corresponding protecti7e filter on the outlet of the canister.
5"
Fault 'henomenon an *ugment metho
Fault 'henomenon1 'unction failure and so on. 7eneral fault causes1 The ingress of foreign &atters into the 7al7e leads to rusting or poor sealing perfor&ance. +recautions1
1.
+uring the installation< ensure that the air flo direction co&plies ith the reBuire&ent.
1
2.
Upon the detection that the blac* particles ithin the 7al7e lead to the failure of control 7al7e and it=s necessar% to replace the control 7al7e< chec* the condition of the canister.
-.
+uring the repair< pre7ent the ingress of fluids (such as ater and oil$ into the 7al7e as far as possible.
/.
To a7oid the trans&ission of solid>borne noise< it=s reco&&ended to install the canister control 7al7e on the hose in such &anner that the control 7al7e hangs in the air.
Sim'le measurement metho1
Turn the digital &ulti&eter to 9h& &easure&ent scale and connect to probes to to pins of canister control 7al7e. The rated resistance under 2#C shall be 2G/.
@" Coolant em'erature Sensor ," &iagram an 'ins Pins This sensor contains to pins< hich are interchangeable.
2" nstallation location1
Coolant te&perature sensor
Installed on the outlet of engine.
"
8orking +rinci'le
This sensor is one negati7e te&perature coefficient (;TC$ ther&al>sensiti7e resistor< of hich the resistance reduces folloing the increasing of coolant te&perature< but not in linear relationship. The ;TC ther&al>sensiti7e resistor is installed on one copper surface< as shon in the figure belo. Structural diagra& 1.
Electric plug
2.
)ousing
-.
;TC resistor
Sectional 7ie of coolant te&perature sensor
3"
echnical Characteristic +arameters 3ariable
3alue
Fated 7oltage
'unctional onl% b% ECU
Fated resistance under 2#C
2.0G0X
*
4or*ing te&perature range
>-#KL1-#
C
a:. &easure&ent current through sensor
1
&A
Alloable 7ibration acceleration
##
&?s2
1!
Unit
Characteristic +ata ;o.
Fesistance (*$ Te&perature tolerance G1C
4"
Te&perature
Te&perature tolerance G#C
(C$
in.
a:.
in.
a:.
1
".1
1#.!/
".2
1#.2"
>1#
2
2.2!
2.!-
2.-!
2.-
L2#
-
#.25#
#.-0/
#.255
#.-/0
L"#
+recautions
The coolant te&perature sensor is installed on the c%linder bloc* and the copper heat conduction slee7e shall be inserted into the coolant. The slee7e contains thread. ,% &eans of the he:agon head on the slee7e< the coolant te&perature sensor can be easil% screed into the threaded hole of the c%linder bloc*. a:. alloable tightening torBue shall be 10;&.
5"
Fault 'henomenon an *ugment metho
Fault 'henomenon1 +ifficult start and so on. Sim'le measurement metho1
(Fe&o7e the connector$ Turn the digital &ulti&eter to 9h& &easure&ent scale and connect to probes to 1H and 2H pins of sensor respecti7el%. The rated resistance under 2#C shall be 2.0*G0X. The si&ulation ðod can be used for &easure&ent< na&el% i&&erse the or*ing area of the sensor into the boiling ater (notice that the i&&ersion ti&e shall be sufficient$ and obser7e the 7ariation of sensor resistance. In such case< the resistance shall drop to -##K/## (+epending on the te&perature of the boiling ater$.
@" ling Ste''ing Motor ," &iagram an 'ins The pin A is connected to 22H pin of ECU The pin , is connected to 21H pin of ECU The pin C is connected to -0H pin of ECU The pin + is connected to -H pin of ECU
2" nstallation $ocation1
Coolant te&perature sensor
9n the throttle bod%.
" 8orking +rinci'le The stepping &otor is one &iniature &otor co&posed of &ultiple steel stators that for& one circle and one rotor< as shon in the figure belo. Each steel stator is ound ith one coil. The rotor is one per&anent &agnet< of hich the center is one nut. All stator coils are constantl% electrified. The rotor turns for one certain angle once the current direction of an% coil is changed. 4hen the current direction of 7arious stator coils is changed as per the appropriate order< one rotating &agnetic field is for&ed so that the rotor &ade of per&anent &agnet rotates in certain direction. If the order for change of current direction is re7ersed< the rotation direction of the rotor is also re7ersed. The nut connected to the rotor center dri7es one scre. The scre is designed in such &anner that it can=t be rotated< therefore it can &o7e a:iall%< hich is referred to as linear shaft. The end of the scre is one plug so that the plug can retract or e:tend accordingl% to increase or reduce the sectional area of b%>inta*e passage of idling actuator< till the b%>inta*e passage is thoroughl% bloc*ed. 9nce the current direction of certain coil is changed< the rotor turns for one fi:ed angle< hich is referred to as one step and eBual to -# di7ided b% the nu&ber of the stators or coils. The step of this stepping &otor rotor is 10 Accordingl%< the distance for each &o7e&ent of the scre is also fi:ed. ,% controlling the change ti&es of the coil current direction< the ECU controls the nu&ber of the &o7e&ent steps of the stepping &otor to adjust the sectional area 1"
of the b%pass passage and the air flo passing through. Denerall%< the air flo is in linear relationship ith the step. There is one spring behind the plug of the scre end< as shon in figure belo. The force a7ailable in the e:tension direction of the plug is eBual to the force of the stepping &otor plus the spring force and the force a7ailable in the retraction direction of the plug is eBual to the force of the stepping &otor subtracted b% the spring force. )ousing
Spring asher
Cup shell Electrode plate
Stator asse&bl%
4inding reel Electro&agnet ire
9>ring Co&pression spring
Fotor slee7e
'ront bearing
Connector
+ust co7er
Pin
Fear bearing ,all bearing Slee7e bearing 9>ring
Shaft pin Fotor asse&bl%
inear shaft Fotor iron core
3"
echnical Characteristic +arameters
i&it +ata 3ariable
3alue in.
4or*ing 7oltage
T%pical
>/#
a:. alloable c%cles for contact seat of stepping &otor plug
Unit a:. L120
C
2.#O1#
C%cle
Characteristic +ata 3ariable
3alue
Unit
in.
T%pical
a:.
Fesistance of each coil under 20C
/!.!
0-
0".-
Fesistance of each coil ithin or*ing te&perature range
-0
50
(>/#C$
(L120C$
Inductance of each coil against 1###) under 20C
2."
;or&al or*ing 7oltage Possible or*ing 7oltage
--.0
/#.2
&)
!.0
12.#
3
-.0
1/.#
3
Step of stepping &otor rotor
10
+egree
Pressure drop beteen to ends hen b%pass passage is opened
#
*Pa
a:. a:ial force arising fro& air pressure difference
.2"
;
4"
+recautions
The stepping &otor idling actuator is installed on the throttle bod% casting< for&ing b%pass passage beteen to ends of throttle. 15
1$
The tightening torBue for bolts shall be /.#G#./;&. Use "O1/ bolts.
2$
+uring installation< use the spring ashers and appl% sealant.
-$
The shaft ith stepping &otor idling actuator shall not be installed at horiontal status or belo the horiontal status< in order to pre7ent the ingress of condensate ater.
/$
+o no appl% an% *ind of a:ial force to press in or pull out the shaft.
0$
,efore installing the idling actuator ith stepping &otor into the throttle bod%< its shaft &ust be thoroughl% retracted.
5"
Fault 'henomenon an *ugment metho
Fault 'henomenon1 97er>high idling speed< engine fla&eout during idling< and so on. 7eneral fault causes1 The accu&ulation of dust or oil gas causes the partial bloc*age of b%pass air passage< leading ot
abnor&al idling adjust&ent of stepping &otor. +recautions1
1$
+o no appl% an% *ind of a:ial force to press in or pull out the shaft.
2$
,efore installing the idling actuator ith stepping &otor into the throttle bod%< its shaft &ust be thoroughl% retracted.
-$
Pa% attention to the cleaning and &aintenance of b%pass air passage.
/$
After re&o7ing the batter% or ECU< notice to conduct the self>learning of stepping &otor ti&el%.
Self>learning ðod of !"# s%ste& Turn on the ignition sitch< but do not start the engine i&&ediatel%. After aiting for 0s< start the engine. In such case< upon the detection of poor idling of the engine< repeat abo7e step. Sim'le measurement metho1
(Fe&o7e the connector$ Turn the digital &ulti&eter to 9h& &easure&ent scale and connector to probes to A+ and ,C pins of the regulator. The rated resistance under 20C shall be 0-G0.-.
@" !ir ntake +ressure an em'erature Sensor ," &iagram an 'ins
+efinition of pins for air inta*e pressure and te&perature sensor
Air inta*e pressure and te&perature sensor
2#
Pins
1H is groundedM 2H outputs the te&perature signalM -H is poered b% 03M /H outputs the pressure signal.
2" nstallation location1 This sensor is co&posed of to sensor< na&el% air inta*e &anifold absolute pressure sensor and air inta*e te&perature sensor and is installed on the air inta*e &anifold.
"
8orking +rinci'le
The air inta*e &anifold absolute pressure sensing unit is co&posed of one silicone chip. 9ne pressure diaphrag& is etched on this silicone chip. There are four pieoelectric resistors on the pressure diaphrag&. ,eing the strain units< four pieoelectric resistors for& one 4heatstone bridge. In addition to this pressure diaphrag&< the silicone chip integrates the signal processing circuit. The silicone chip or*s ith one &etallic housing to for& one enclosed reference roo&< in hich the absolute air pressure closes to ero. In such case< one &icro>electronic &echanical s%ste& is for&ed. The acti7e surface of the silicone chip is subject to a near>ero pressure and its bac* surface is subject to the air inta*e &anifold absolute pressure introduced b% one connecting pipe for &easure&ent. The thic*ness of the silicone chip is onl% se7eral &icro&eters ([&$ so that the 7ariation of air inta*e &anifold absolute pressure ill result in the &echanical defor&ation of the silicone chip and four pieoelectric resistors ill defor& accordingl%< in hich their resistances are altered. After being processed b% the signal processing circuit of the silicone chip< it for&s the 7oltage signal in linear relationship ith the pressure. The air inta*e te&perature sensing unit is one negati7e te&perature coefficient (;TC$ resistor< of hich the resistance 7aries folloing the air inta*e te&perature. This sensor pro7ides the controller ith one 7oltage indicating the 7ariation of air inta*e te&perature.
Sectional 7ie of air inta*e &anifold absolute pressure and air in ta*e te&perature sensor 1. Seal ring
2. Stainless steel bush
. Pressure brac*et
3"
-. PC, board /. Sensing unit
!. 4elded connection
0. )ousing
". Adhesion connection
echnical characteristic 'arameters
i&it +ata 3ariable
3alue in.
T%pical
Unit a:.
Poer 7oltage resistance
1
3
Pressure resistance
0##
*Pa
L1-#
C
Storage te&perature resistance
>/#
21
Characteristic +ata 3ariable
3alue in.
T%pical
Unit a:.
Pressure &easure&ent range
2#
110
*Pa
4or*ing te&perature
>/#
120
C
4or*ing poer 7oltage
/.0
0.#
0.0
3
Current under Us\0.#3
.#
5.#
12.0
&A
oad current of output circuit
>#.1
#.1
&A
oad resistance against ground or batter%
0#
*
Fesponse ti&e
#.2
&s
ass
2!
g
(1$ Transfer function of pressure sensor UA \ (c1 pabs L C# $ Us 9f hich<
UA\ Signal output 7oltage (3$ Us\ Poer 7oltage (3$ C#\ Absolute pressure (*Pa$ pabs\ >5./?50 c1\#."0?50 (1?*Pa$
It can be seen fro& abo7e eBuation that the signal output 7oltage of the pressure sensor eBuals to the poer 7oltage under at&osphere pressure. If the poer 7oltage is 07< the signal output 7oltage of the pressure sensor is appro:i&ate /.03 hen the throttle is thoroughl% open. (2$ i&it data of te&perature sensor Storage te&perature >/#?L1-#C ,earing capacit% under 20C 1##&4 (-$ Characteristic data of te&perature sensor 4or*ing te&perature >/#?L120C 3oltage rating 4or* under 03 ith 1* pre>resistor or or* ith V1&A testing current. Fated resistance under 2#C 2.0* G 0X Te&perature>ti&e coefficient in air ] -< 7\&?s V/0ss
4"
+recautions
This sensor is designed to be installed on the plane of the auto&oti7e engine air inta*e &anifold. ,oth the pressure connecting pipe and the te&perature sensor protrude in the air inta*e &anifold and adopt one 9>ring to realie the air> tightness against the air. If appropriate &ode is adopted to install this sensor onto the 7ehicle (such as ta*e the pressure fro& air inta*e &anifold or incline donard the pressure connecting pipe$< it can be guaranteed that the condensate ater ill not for& on the pressure sensiti7e unit. The drilling and fi:ing on the air inta*e &anifold &ust be conducted as per the suppl% diagra&< in order to guarantee the long>ter& sealing and resistance against the corrosion of &edia. The reliabilit% of the electric connections is &ainl% subject to the influence of the connectors of the parts and also is related to the &aterial Bualit% and the sie precision of the fitting connectors on the harness.
5"
Fault 'henomenon an *ugment metho
Fault 'henomenon1 Engine fla&eout< poor idling< and so on. 7eneral fault causes1 22
1.
Abnor&al high 7oltage or high re7erse current during or*ing.
2.
+a&age of 7acuu& units during repair.
+recautions +uring the repair< it=s prohibited to blo the 7acuu& units ith high pressure air. 4hen it=s necessar% to
replace the fault sensor< chec* hether the alternator output 7oltage and current are nor&al. Sim'le measurement metho1 em'erature sensor 'art (Fe&o7e the connector$ Turn the digital &ulti&eter to 9h& &easure&ent scale and connect
to probes to 1H and 2H pins of the sensor. The rated resistance under 2#C shall be 2.0*G0X. Also< the si&ulation ðod &a% be used for &easure&ent. Use the blo dri7er to blo the sensor (Pa% attention not to close too &uch$ and obser7e the resistance 7ariation of the sensor. In such case< the resistance shall drop. +ressure sensor 'art (Connect the connector$ Turn the digital &ulti&eter to +C 3oltage &easure&ent scale and
connect the blac* probe to ground and connect the red probe to -H and /H pins respecti7el%. Under the idling< there shall be 03 reference 7oltage at -H pin and appro:i&ate 1.-3 7oltage at /H pin (depending on the specific 7ehicle &odel$. 4hen slol% opening the throttle under unloaded status< the 7oltage 7ariation is not &uch at /H pin. 4hen rapidl% opening the throttle< the 7oltage at /H pin can instantaneousl% reach appro:i&ate /3 (depending on the specific 7ehicle &odel$ and then loer to appro:i&ate 1.03 (depending on the specific 7ehicle &odel$.
@" hrottle +osition Sensor ," &iagram an 'ins
Circuit diagra& of throttle position sensor Pins 'or those rotating the throttle counter>cloc*ise (hen obser7ed fro& sensor side to throttle along the throttle a:is$ to increase open e:tent 1H pin is grounded and 2H pin is connected to 03 poer suppl%M 'or those rotating the throttle cloc*ise (hen obser7ed fro& sensor side to throttle along the throttle a:is$ to increase open e:tent 1H pin is connected to 03 poer suppl%< 2H pin is grounded< and -H pin outputs the signal.
2" nstallation location Installed on the throttle bod%.
"
8orking 'rinci'le
This sensor is one angle sensor ith linear output and is co&posed of to arc slide resistors and to sliders. The rotating shafts of the sliders are connected to one sa&e a:is along ith the throttle shaft. To ends of the slide resistors are charged ith 03 poer 7oltage U S. 4hen the throttle rotates< the slider rotates accordingl% and at the sa&e ti&e &o7es on the slide resistor and i&ports the potential at the contact U P as the 7oltage output. Therefore< it=s actuall% one angle potentio&eter< hich outputs the 7oltage signal in proportion to the throttle position.
3"
echnical characteristic 'arameters
i&it +ata 3ariable
3alue 2-
Unit
echanical angle beteen to li&it positions
50
+egree
A7ailable electric angle beteen to li&it positions
V"
+egree
Alloable slider current
V1"
[A
Storage te&perature
>/#?L1-#
C
Alloable 7ibration acceleration
V!##
&?s2
Characteristic +ata 3ariable
3alue
Unit
in.
T%pical
a:.
Total resistance (beteen 1H and 2H pins$
1.
2.#
2./
*
Slider protection resistance
!1#
1-"#
>/#
1-#
C
(beteen 2H and -H pins< ith slider at ero position$ 4or*ing te&perature Poer 7oltage
0
3oltage ratio at right li&it position
#.#/
#.#5-
3oltage ratio at left li&it position
#."!-
#.5#
Incre&ent folloing throttle rotation angle U P?US
#.##52!
ass
4"
3
22
20
1?dgree 2"
g
+recautions
In consideration of the lea*age at shaft sealed portion of throttle after long>ter& ser7ice< it=s reco&&ended to deflect the throttle shaft b% at least -# ith respect to the 7ertical direction for installation. The alloable tightening torBue for fi:ing scres shall be 1.0;&K2.0;&.
5"
Fault 'henomenon an *ugment metho
Fault 'henomenon Poor acceleration and so on. +recautions ;otice the installation position. Sim'le measurement metho1
1.
(Fe&o7e the connector$ Turn the digital &ulti&eter to 9h& &easure&ent scale and connect to probes to 1H and 2H pins of the sensor respecti7el%. The resistance under a&bient te&perature is 2*G2#X. Connect to probes to 1H and -H pins respecti7el% and rotate the throttle. Its resistance shall 7ar% linearl% folloing the opening of the throttle. The &easure&ent beteen 2H and -H pins shall be on the contrar%.
2.
(Connect the connector$ Turn on the ignition sitch< but do not start the engine. Turn the digital &ulti&eter to +C 3oltage &easure&ent scale and connect the blac* probe to ground and connect the red probe to 2H pin. In such case< there shall be the presence of 03 reference 7oltage. 4hen connecting the red probe to -H pin< the 7oltage &easure&ent shall be appro:i&ate #.-3 hen the throttle is thoroughl% closed (depending on the specific 7ehicle &odel$ and shall be appro:i&ate -3 hen the throttle is thoroughl% opened (depending on the specific 7ehicle &odel$.
;ote 4hen obser7ing the resistance 7ariation< pa% attention to obser7e hether there is an% resistance ju&p.
2/
@" A9ygen Sensor ," &iagram an 'ins
9:%gen sensor
1. Cable
2. +isc asher
. )eating rod
-. Insulation bush /. Protecti7e slee7e
!. Contact gas*et
0. )eating unit gripping connector
". Sensor seat 5. Cera&ic probe
1#. Protection tube
Sectional 7ie of o:%gen sensor The o:%gen sensor is eBuipped ith one cable< of hich one end is one electric connector. The electric connector of the o:%gen sensor &anufactured b% our co&pan% includes four pins 1H \ Sensor ground
2H \ Sensor signal
-H \ Sensor L
/H \ ain rela%
2" nstallation location1 The front of the e:haust pipe.
"
8orking 'rinci'le
The sensing unit of the o:%gen sensor is one cera&ic tube ith porosit%< of hich the outside is surrounded b% the engine e&ission and the inside is connected to the at&osphere air. The sensing cera&ic tube all is one *ind of solid electrol%te and the cera&ic tube contains the built>in electric heating tube< as shon in figure ->1!. The o:%gen sensor is functioned to con7ert the o:%gen ion concentration difference beteen inside and outside of the sensing cera&ic tube to 7oltage signal output. 4hen the te&perature of the sensing cera&ic tube reaches /##C< e&bod%ing the characteristic of the solid electrol%te< the special &aterial enables the o:%gen ion to pass through the cera&ic tube freel%. ,% utiliing this characteristic< the concentration difference is con7erted to potential difference to for& the electric signal output. If the gas &i:ture is too dense< the o:%gen ion concentration difference beteen inside and outside of cera&ic tube ill be high and the potential difference ill be high so that a large a&ount of o:%gen ion transfers fro& inside to outside of the cera&ic tube and thus the 7oltage output is high (closing to "##&3K1###&3$. If the gas &i:ture is too thin< the o:%gen ion concentration difference beteen inside and outside of cera&ic tube ill be loer and the potential difference ill be loer so that onl% a s&all a&ount of o:%gen ion transfers fro& inside to outside of the cera&ic tube and thus the 7oltage output is lo (closing to 1##&3$. The signal 7oltage changes abruptl% in the 7icinit% of the theoretical eBui7alent air>fuel ratio (J\1$< as shon in the figure abo7e.
3" echnical characteristic 'arameters i&it +ata 3ariable
3alue 20
Unit
in. Storage te&perature
T%pical
a:.
>/#
L1##
C
2##
"0#
C
)ousing he:agon head
V0!#
C
Cable &etallic retainer ring and
V20#
C
Connector
V12#
C
a:. alloable
E&ission at cera&ic tube end
5-#
C
te&perature hen
)ousing he:agon head
-#
C
heating unit is
Cable &etallic retainer ring and
2"#
C
electrified (a:. 1#&in
connecting cable
Alloable te&perature 7ariation ratio at cera&ic tube end
V1##
6?s
Alloable te&perature of cera&ic unit hen there is condensate
V/##
C
4or*ing te&perature
Cera&ic tube end
connecting cable
for each c%cle< a:. /#hr in total$
ater at e:haust side Alloable 7ibration of
Fando& 7ibration (pea*$
V"##
&?s2
housing
Si&ple har&onic 7ibration
V#.-
&&
V-##
&?s2
Absolute
[A
(7ibration displace&ent$ Si&ple har&onic 7ibration (7ibration acceleration$ Continuous +C current under /##C
7alueV1# a:. continuous AC current under /##C e:haust te&perature
G2#
[A
and f1) Alloable fuel additi7e
Unleaded gasoline< or alloable lead content up to #.10g?
Consu&ption and co&bustion of engine oil
The alloable 7alue and data &ust be deter&ined b% custo&ers as per proper scale of tests. Duidance 7alue V#.!?1###*&
Characteristic +ata 3ariable E:haust te&perature established b% characteristic
;e
After 20#hr stand test
/##C
"0#C
/##C
"0#C
"/#G!#
!1#G!#
"/#G!#
!1#G!#
Sensing unit 7oltage under J\1.1# (&3$
2#G0#
0#G-#
2#G0#
/#G/#
Internal resistance of sensing unit (*$
V1.#
V#.1
V1.0
V#.-
Fesponse ti&e (&s$
^2##
^2##
^/##
^/##
^2##
^2##
^/##
^/##
data Sensing unit 7oltage under J\#.5! (C9\1X$ (&3$
(##&3K-##&3$ Fesponse ti&e (&s$ (-##&3K##&3$
2
Electric +ata of Sensor 3ariable
3alue
Unit
Insulation resistance
A&bient te&perature< ith heating unit poered off
-#
beteen ne sensor heating
E:haust te&perature at /##C
1#
unit and sensor connector
E:haust te&perature at "0#C
1##
*
Poer 7oltage on connector
Fated 7oltage
12
3
Continuous or*ing 7oltage
12K1/
3
4or*ing 7oltage &aintaining up to 1X o7erall life
10
3
2/
3
1-
3
12
4
0
A
"
A
(e:haust te&perature V"0#C$ 4or*ing 7oltage &aintaining up to !0s (e:haust te&perature V/##C$ Testing 7oltage )eating poer hen the ther&al eBuilibriu& is reached< ith or*ing 7oltage at 1-3 (e:haust te&perature at /##C and e:haust flo at appro:i&ate #.!&?s$ )eating current hen the ther&al eBuilibriu& is reached< ith or*ing 7oltage at 1-3 (e:haust te&perature at /##C and e:haust flo at appro:i&ate #.!&?s$ 'use of heating circuit Ser7ice ife The ser7ice life of the o:%gen sensor is related to the lead content in the gasoline< as shon in the table belo.
4"
ead content in gasoline (g?$
ife (*&$
V#.
-#<###
V#./
0#<###
V#.10
"#<###
V#.##0 (unleaded gasoline$
1#<###
+recautions
The o:%gen sensor is installed on the e:haust pipe in such &anner that the installation location can stand for the e&ission contents and &eet the specified te&perature li&it. The installation location shall close to the engine as far as possible. The e:haust pipe contains the thread for engage&ent ith the o: %gen sensor< as shon in the figure belo.
Installation location of o:%gen sensor nstallation gesture of o9ygen sensor
The o:%gen sensor shall be installed to for& 1# angle ith the horiontal surface< ith the sensor tip facing donard< in order to pre7ent the accu&ulation of condensate ater beteen the sensor housing and the sensing cera&ic tube during the cold start< as shon in the figure belo. 2!
Installation gesture of o:%gen sensor
FeBuire&ent of e:haust pipe To enable the rapid radiation of e:haust pipe part in front of the o:%gen sensor. If possible< the e:haust pipe shall be designed to incline donard< in order to pre7ent the accu&ulation of condensate ater in front of the sensor.
+o not e:pose the cable &etallic retainer ring on o:%gen sensor side to i&propriate heating< especiall% hen the engine is stopped.
+o not use the detergent< oil% fluid or 7olatile solid on the connector of o:%gen sensor.
The thread of o:%gen sensor is 1"O1.0.
The he:agon head rench for o:%gen sensor is 22>#.--.
The tightening torBue for o:%gen sensor shall be /#K#;&.
5"
Fault 'henomenon an *ugment metho
Fault 'henomenon1 Poor idling< poor acceleration< out>of>li&it of e:haust e&ission< e:cessi7e fuel consu&ption< and so
on. 7eneral fault causes1
1.
The &oisture 7apor enters into the sensor< resulting in sudden change of te&perature and brea*age of probe.
2.
QInto:icationR of o:%gen sensor. (Pb< S< ,r< Si$
Precautions +uring the repair< it=s prohibited to use the detergent< oil% fluid or 7olatile solid on the o:%gen sensor. Sim'le measurement metho1
1.
(Fe&o7e the connector$ Turn the digital &ulti&eter to 9h& &easure&ent scale and connect to probes to 1H (hite$ and 2H (hite$ pins of the sensor respecti7el%. The resistance under a&bient te&perature shall be 1K.
2.
(Connect the connector$ Under the idling< after aiting for the o:%gen sensor to reach the or*ing te&perature /##C< turn the digital &ulti&eter to +C 3oltage &easure&ent scale and connect to probes to -H (gra%$ and /H (blac*$ pins of the sensor respecti7el%. In such case< the 7oltage &easure&ent shall fluctuate rapidl% beteen #.13 and #.53.
Section " Common Faults an &iagnosis Flow for M-./ U!ES System
,"
Fault &iagnosis +roceure
(,) 0efore conucting the fault iagnosis 'roceure as 'er the engine fault 'henomenon# firstly conuct the initial checking1 1$
Confir& hether the engine &alfunction indicator la&p functions nor&all%.
2$
Chec* ith fault diagnosis unit and confir& there is no fault infor&ation recorded.
-$
Confor& the presence of fault pheno&enon the oner clai&ed and confir& the conditions hen such fault
occurred.
(2) hen conuct the a''earance checking1 1$
Chec* the fuel pipeline for presence of lea*ageM 2"
2$
Chec* the 7acuu& pipeline for rupture and tist and chec* hether the connections are correctM
-$
Chec* the air inta*e pipeline for bloc*age< air lea*age< being flattened< and da&age.
/$
Chec* the high 7oltage ire of ignition s%ste& for brea*age and aging and chec* hether the ignition order is
correct. 0$
Chec* hether the grounding point of the harness is clean and secureM (1$ Chec* the connectors of 7arious sensors and actuators for looseness or poor contact.
In e7ent of an% of abo7e pheno&ena< firstl% conduct the repair in response to such fault pheno&enon< or it ill influence the afterards fault diagnosis and repair. +iagnosis assistance 1.
Confir& that the engine is free of an% fault record.
2.
Confir& that the fault pheno&enon clai&ed does e:ist.
-.
The chec*ing as per abo7e procedure is co&pleted and no abnor&al condition is detected.
/.
+uring the repair< do not neglect the s%ste& influences b% 7ehicle &aintenance< c%linder pressure< &echanical ignition ti&ing< and fuel condition.
0.
Feplace the ECU for testing.
In such case< if the fault pheno&enon disappears< it indicates that the fault lies in ECU. If the fault pheno&enon still e:ists< replace ith original ECU and repeat abo7e procedure for re>chec*ing.
2"
Common Fault +henomena an &iagnosis Flow
1.
;o rotation or slo rotation of engine during start
2.
The engine can rotate ith dragging< but can=t start successfull% during start.
-.
+ifficult hot start
/.
+ifficult cold start
0.
The engine speed is nor&al< but the start is difficult at all ti&es.
.
The start is nor&al< but the idling is unstable at all ti&es.
!.
The start is nor&al< but the idling is unstable during engine ar&>up.
".
The start is nor&al< but the idling is unstable after engine ar&>up.
5.
The start is nor&al< but the idling is unstable or engine is stopped under partial load (such as the A?C is turned on$.
1#. The start is nor&al< but the idling is too high. 11. The engine speed can@t increase or the engine is stopped during acceleration. 12. Slo response during acceleration. 1-. 4ea* acceleration and poor perfor&ance.
2",
Bo rotation or slow rotation of engine uring start
Fault 'ortions1
1. ,atter%M
2. Starter &otorM
-. )arness or ignition sitchM
/. Engine &echanical part
&iagnosis flow1
;o.
9peration Procedure
Chec*ing
SubseBuent Step
result 1 2
Use the &ulti&eter to chec* hether the 7oltage beteen to iring
es
;e:t
posts of the batter% is appro:i&ate "K123 during the engine start.
;o
Feplace batter%
aintain the ignition sitch at Start position and use &ulti&eter to chec*
es
;e:t
hether there is abo7e "3 7oltage at the positi7e post of starter &otor.
;o
Fepair
or
replace
or
replace
harness -
+isasse&ble the starter &otor and chec* or*ing condition of starter &otor. ainl% chec* hether there is open>circuit or bloc*age due to poor 25
es
Fepair
starter &otor
/
0
lubrication.
;o
;e:t
If the fault onl% occurs in inter< chec* hether this fault is caused b%
es
Feplace
ith
e:cessi7e resistance of starter &otor due to i&proper choice of engine
lubricating
lubricating oil and gearbo: oil.
appropriate trade&ar*.
Chec* hether the internal &echanical resistance of the engine is too
;o
;e:t
es
Chec*
high< leading to non>rotation or slo rotation of starter &otor.
oil
and
ith
repair
internal resistance of engine. ;o
2"2
Fepeat abo7e step
he engine can rotate with ragging# but cant start successfully uring start"
Fault 'ortions1
1. ;o fuel in fuel tan*M 2. 'uel pu&pM
-. Speed sensorM
/. Ignition coilM
0. Engine &ecahnical part.
&iagnosis flow1
;o.
9peration Procedure
Chec*ing
SubseBuent Step
result 1
Connect the fuel pressure gauge (The connection point shall be the front
es
;e:t
end of inlet pipe of fuel distributor pipe asse&bl%$< start the engine< and
;o
Chec* and repair fuel
chec* hether the fuel pressure of engine under all condition is
suppl% s%ste&
appro:i&ate /##*Pa. 2
Connect the electronic injection s%ste& diagnosis unit< obser7e the
es
;e:t
Qengine speedR data ite&< start the engine< and obser7e hether there is
;o
Chec* and repair speed
speed signal output. -
sensor circuit
Unplug one c%linder distribution ire< connect the spar* plug< position the
es
;e:t
spar* plug electrode to 0&& aa% fro& engine bloc*< start the engine<
;o
Chec*
and obser7e hether there is blue>hite high 7oltage fire. /
repair
ignition s%ste&
Chec* the pressure condition for each c%linder of engine and obser7e
es
hether there is insufficient pressure in the engine c%linders. 0
and
Fesol7e
engine
&echanical fault ;o
;e:t
Connect electronic injection s%ste& adapter< turn on the ignition sitch<
es
+iagnosis help
and chec* hether the poer suppl% at 12H< 1-H< //H< /0H< and -H pins
;o
Chec*
is nor&al and hether the earthing at -H< 01H< 0-H< 1H< and "#H pins is
and
repair
corresponding circuit
nor&al.
2"
&ifficult hot start
Fault 'ortions1
1. 4ater content in fuelM 2. 'uel pu&pM -. Coolant te&perature sensorM 0. Ignition coil &iagnosis flow1
-#
/. 'uel pressure regulator 7acuu& pipeM
;o.
9peration Procedure
Chec*ing
SubseBuent Step
result 1
Connect the fuel pressure gauge (The connection point shall be the front
es
;e:t
end of inlet pipe of fuel distributor pipe asse&bl%$< start the engine< and
;o
Chec* and repair fuel
chec* hether the fuel pressure of engine under all condition is
suppl% s%ste&
appro:i&ate /##*Pa. 2
Unplug one c%linder distribution ire< connect the spar* plug< position the
es
;e:t
spar* plug electrode to 0&& aa% fro& engine bloc*< start the engine<
;o
Chec*
and obser7e hether there is blue>hite high 7oltage fire. -
and
repair
ignition s%ste&
Unplug the coolant te&perature sensor connector and tr% to start the
Chec*
and
engine. 9bser7e hether the engine can start successfull%. (9r series
circuit
or
connect one -## resistor at the coolant te&perature sensor to replace the
sensor
coolant te&perature sensor and obser7e hether the engine can start
es
repair replace
;o
;e:t
es
Chec* and repair or
successfull%.$ /
Chec* hether there is looseness or air lea*age at the fuel pressure regulator 7acuu& pipe.
0
replace ;o
;e:t
Chec* the fuel condition and obser7e hether the fault pheno&enon
es
Feplace fuel
occurs right after the refueling.
;o
;e:t
Connect electronic injection s%ste& adapter< turn on the ignition sitch<
es
+iagnosis help
and chec* hether the poer suppl% at 12H< 1-H< //H< /0H< and -H pins
;o
Chec*
is nor&al and hether the earthing at -H< 01H< 0-H< 1H< and "#H pins is
and
repair
corresponding circuit
nor&al.
2"3
&ifficult col start
Fault 'ortions1
1. 4ater content in fuelM 2. 'uel pu&pM -. Coolant te&perature sensorM . Throttle bod% and idling b%pass air passage
/. 'uel injectorM
0. Ignition coilM
!. Engine &echanical part
&iagnosis flow1
;o.
9peration Procedure
Chec*ing
SubseBuent Step
result 1
Connect the fuel pressure gauge (The connection point shall be the front
es
;e:t
end of inlet pipe of fuel distributor pipe asse&bl%$< start the engine< and
;o
Chec* and repair fuel
chec* hether the fuel pressure of engine under all condition is
suppl% s%ste&
appro:i&ate /##*Pa. 2
Unplug one c%linder distribution ire< connect the spar* plug< position the
es
;e:t
spar* plug electrode to 0&& aa% fro& engine bloc*< start the engine<
;o
Chec*
and obser7e hether there is blue>hite high 7oltage fire. -
Unplug the coolant te&perature sensor connector and tr% to start the
and
ignition s%ste& Chec*
and
engine. 9bser7e hether the engine can start successfull%. (9r series
circuit
or
connect one 20## resistor at the coolant te&perature sensor to replace
sensor
the coolant te&perature sensor and obser7e hether the engine can start
repair
es
;o
;e:t
es
Clean
repair replace
successfull%.$ /
Step don the accelerator pedal lightl% and obser7e hether the engine can start easier.
0
throttle
idling air passage
Fe&o7e fuel injector and use the fuel injector special cleaning anal%er to -1
;o
;e:t
es
Feplace fault part
and
!
chec* hether there is lea*age or bloc*age in fuel injector.
;o
;e:t
Chec* the fuel condition and obser7e hether the fault pheno&enon
es
Feplace fuel
occurs right after the refueling.
;o
;e:t
Chec* the pressure of 7arious c%linders of the engine and obser7e hether
es
Fesol7e
there is insufficient pressure in engine c%linder. "
engine
&echanical fault ;o
;e:t
Connect electronic injection s%ste& adapter< turn on the ignition sitch<
es
+iagnosis help
and chec* hether the poer suppl% at 12H< 1-H< //H< /0H< and -H pins
;o
Chec*
is nor&al and hether the earthing at -H< 01H< 0-H< 1H< and "#H pins is
and
repair
corresponding circuit
nor&al.
2"4
he engine s'ee is normal# but the start is ifficult at all times"
Fault 'ortions1
1. 4ater content in fuelM 2. 'uel pu&pM -. Coolant te&perature sensorM
/. 'uel injectorM
. Throttle bod% and idling b%pass air passageM
". Ignition ti&ingM
!. Air inta*e passageM
0. Ignition coilM 5. Spar* plugM
1#. Engine &echanical part. &iagnosis flow1
;o.
9peration Procedure
Chec*ing
SubseBuent Step
result 1
Chec* hether the air cleaner is bloc*ed and hether there is air lea*age
es
in air inta*e passage. 2
Chec* and repair air inta*e s%ste&
;o
;e:t
Connect the fuel pressure gauge (The connection point shall be the front
es
;e:t
end of inlet pipe of fuel distributor pipe asse&bl%$< start the engine< and
;o
Chec* and repair fuel
chec* hether the fuel pressure of engine under all condition is
suppl% s%ste&
appro:i&ate /##*Pa. -
Unplug one c%linder distribution ire< connect the spar* plug< position the
es
;e:t
spar* plug electrode to 0&& aa% fro& engine bloc*< start the engine<
;o
Chec*
and obser7e hether there is blue>hite high 7oltage fire. / 0
and
repair
ignition s%ste&
Chec* the spar* plug for 7arious c%linders and obser7e hether the &odel
es
;e:t
and gap co&pl% ith the specification.
;o
Adjust or replace
Unplug the coolant te&perature sensor connector and tr% to start the
es
Chec*
and
circuit
or
engine. 9bser7e hether the engine can start successfull%.
repair replace
sensor
Step don the accelerator pedal lightl% and obser7e hether the engine
;o
;e:t
es
Clean
can start easier. ! " 5
and
idling air passage ;o
;e:t
Fe&o7e fuel injector and use the fuel injector special cleaning anal%er to
es
Feplace fault part
chec* hether there is lea*age or bloc*age in fuel injector.
;o
;e:t
Chec* the fuel condition and obser7e hether the fault pheno&enon
es
Feplace fuel
occurs right after the refueling.
;o
;e:t
Chec* the pressure of 7arious c%linders of the engine and obser7e hether
es
Fesol7e
there is insufficient pressure in engine c%linder. 1#
throttle
engine
&echanical fault ;o
;e:t
Chec* hether the ignition order and ignition ti&ing of the engine
es
;e:t
co&pl% ith the specification.
;o
Chec*
-2
and
repair
ignition ti&ing 11
Connect electronic injection s%ste& adapter< turn on the ignition sitch<
es
+iagnosis help
and chec* hether the poer suppl% at 12H< 1-H< //H< /0H< and -H pins
;o
Chec*
is nor&al and hether the earthing at -H< 01H< 0-H< 1H< and "#H pins is
and
repair
corresponding circuit
nor&al.
2"5
he start is normal# but the iling is unstable at all times"
Fault 'ortions1
1. 4ater content in fuelM 2. 'uel injectorM
-. Spar* plugM
inta*e passageM
!. Ignition ti&ingM
. Idling regulatorM
/. Throttle bod% and idling b%pass air passageM 0. Air ". Spar* plugM 1#. Engine &echanical part.
&iagnosis flow1
;o.
9peration Procedure
Chec*ing
SubseBuent Step
result 1
Chec* hether the air cleaner is bloc*ed and hether there is air lea*age
es
in air inta*e passage. 2 / 0 !
inta*e s%ste& ;o
;e:t
es
Clean or replace
;o
;e:t
Chec* the spar* plug for 7arious c%linders and obser7e hether the &odel
es
;e:t
and gap co&pl% ith the specification.
;o
Adjust or replace
Chec* the throttle bod% and idling b%pass air passage for presence of
es
Clean
carbon deposit
;o
;e:t
Fe&o7e fuel injector and use the fuel injector special cleaning anal%er to
es
Feplace fault part
chec* hether there is lea*age or bloc*age in fuel injector.
;o
;e:t
Chec* the fuel condition and obser7e hether the fault pheno&enon
es
Feplace fuel
occurs right after the refueling.
;o
;e:t
Chec* the pressure of 7arious c%linders of the engine and obser7e hether
es
Fesol7e
Chec* the idling regulator for cla&ping stagnation
there is high difference a&ong engine c%linders. "
Chec* and repair air
engine
&echanical fault ;o
;e:t
Chec* hether the ignition order and ignition ti&ing of the engine
es
;e:t
co&pl% ith the specification.
;o
Chec*
and
repair
ignition ti&ing 5
Connect electronic injection s%ste& adapter< turn on the ignition sitch<
es
+iagnosis help
and chec* hether the poer suppl% at 12H< 1-H< //H< /0H< and -H pins
;o
Chec*
is nor&al and hether the earthing at -H< 01H< 0-H< 1H< and "#H pins is
and
repair
corresponding circuit
nor&al.
2"-
he start is normal# but the iling is unstable uring engine warm%u'"
Fault 'ortions1
1. 4ater content in fuelM 2. Coolant te&perature sensorM
-. Spar* plugM /. Throttle bod% and idling b%pass air
passageM 0 Air inta*e passageM
!. Engine &echanical part.
. Idling regulatorM
&iagnosis flow1
;o.
9peration Procedure
Chec*ing
SubseBuent Step
result 1
Chec* hether the air cleaner is bloc*ed and hether there is air lea*age
es
in air inta*e passage.
Chec* and repair air inta*e s%ste&
;o --
;e:t
2 /
Chec* the spar* plug for 7arious c%linders and obser7e hether the &odel
es
;e:t
and gap co&pl% ith the specification.
;o
Adjust or replace
Fe&o7e the idling regulator and chec* the throttle bod%< idling regulator<
es
Clean rele7ant parts
and idling b%pass air passage for the presence of carbon deposit.
;o
;e:t
Unplug the coolant te&perature sensor connector< start the engine< and
es
Chec*
and
circuits
or
obser7e hether there is unstable idling during the engine ar&>up.
repair replace
sensor 0 !
;o
;e:t
Fe&o7e fuel injector and use the fuel injector special cleaning anal%er to
es
Feplace fault part
chec* hether there is lea*age or bloc*age in fuel injector.
;o
;e:t
Chec* the fuel condition and obser7e hether the fault pheno&enon
es
Feplace fuel
occurs right after the refueling.
;o
;e:t
Chec* the pressure of 7arious c%linders of the engine and obser7e hether
es
Fesol7e
there is high difference a&ong engine c%linders. "
engine
&echanical fault ;o
;e:t
Connect electronic injection s%ste& adapter< turn on the ignition sitch<
es
+iagnosis help
and chec* hether the poer suppl% at 12H< 1-H< //H< /0H< and -H pins
;o
Chec*
is nor&al and hether the earthing at -H< 01H< 0-H< 1H< and "#H pins is
and
repair
corresponding circuit
nor&al.
2".
he start is normal# but the iling is unstable after engine warm%u'"
Fault 'ortions1
1. 4ater content in fuelM 2. Coolant te&perature sensorM
-. Spar* plugM /. Throttle bod% and idling b%pass air
passageM 0 Air inta*e passageM
!. Engine &echanical part.
. Idling regulatorM
&iagnosis flow1
;o.
9peration Procedure
Chec*ing
SubseBuent Step
result 1
Chec* hether the air cleaner is bloc*ed and hether there is air lea*age
es
in air inta*e passage. 2 /
Chec* and repair air inta*e s%ste&
;o
;e:t
Chec* the spar* plug for 7arious c%linders and obser7e hether the &odel
es
;e:t
and gap co&pl% ith the specification.
;o
Adjust or replace
Fe&o7e the idling regulator and chec* the throttle bod%< idling regulator<
es
Clean rele7ant parts
and idling b%pass air passage for the presence of carbon deposit.
;o
;e:t
Unplug the coolant te&perature sensor connector< start the engine< and
es
Chec*
and
circuits
or
obser7e hether there is unstable idling during the engine ar&>up.
repair replace
sensor 0 !
;o
;e:t
Fe&o7e fuel injector and use the fuel injector special cleaning anal%er to
es
Feplace fault part
chec* hether there is lea*age or bloc*age in fuel injector.
;o
;e:t
Chec* the fuel condition and obser7e hether the fault pheno&enon
es
Feplace fuel
occurs right after the refueling.
;o
;e:t
Chec* the pressure of 7arious c%linders of the engine and obser7e hether
es
Fesol7e
there is high difference a&ong engine c%linders. "
engine
&echanical fault ;o
;e:t
Connect electronic injection s%ste& adapter< turn on the ignition sitch<
es
+iagnosis help
and chec* hether the poer suppl% at 12H< 1-H< //H< /0H< and -H pins
;o
Chec*
-/
and
repair
is nor&al and hether the earthing at -H< 01H< 0-H< 1H< and "#H pins is
corresponding circuit
nor&al.
2";
he start is normal# but the iling is unstable or engine is sto''e uner 'artial loa (such as the !DC is turne on)"
Fault 'ortions1
1. Air conditioning s%ste&M
2. Idling regulatorM -. 'uel injector.
&iagnosis flow1
;o.
9peration Procedure
Chec*ing
SubseBuent Step
result 1 2
Fe&o7e the idling regulator and chec* the throttle bod%< idling regulator<
es
Clean rele7ant parts
and idling b%pass air passage for the presence of carbon deposit.
;o
;e:t
9bser7e hether the engine poer output is increased hen the A?C is
es
Turn to step /
turned on< na&el% use the electronic injection s%ste& diagnosis unit to
;o
;e:t
Connect the electronic injection s%ste& adapter and disconnect the
es
;e:t
connecting ire of ECU !0H pin. Chec* hether there is high le7el signal
;o
Chec* and repair air
obser7e the 7ariation of ignition ad7ance angle< fuel injection pulse idth< and air inta*e a&ount. -
at harness end hen the A?C is turned on. /
conditioning s%ste&
Chec* hether the pressure of air conditioning s%ste&< electro&agnetic
es
;e:t
clutch of co&pressor< and the A?C co&pressor pu&p are nor&al.
;o
Chec* and repair air conditioning s%ste&
0
Fe&o7e fuel injector and use the fuel injector special cleaning anal%er to
es
Feplace fault part
chec* hether there is lea*age< bloc*age or e:cessi7e flo in fuel
;o
;e:t
Connect electronic injection s%ste& adapter< turn on the ignition sitch<
es
+iagnosis help
and chec* hether the poer suppl% at 12H< 1-H< //H< /0H< and -H pins
;o
Chec*
injector.
is nor&al and hether the earthing at -H< 01H< 0-H< 1H< and "#H pins is
and
repair
corresponding circuit
nor&al.
2",/ he start is normal# but the iling is too high" Fault 'ortions1
1. Throttle bod% and idling b%pass air passageM sensorM
2. 3acuu& pipeM
-. Idling regulatorM
/. Coolant
te&perature
0. Ignition ti&ing.
&iagnosis flow1
;o.
9peration Procedure
Chec*ing
SubseBuent Step
result 1 2
Chec* hether the accelerator cable is bloc*ed or is too tight. Chec* hether there is air lea*age in the air inta*e s%ste& and its
es
Adjust
;o
;e:t
es
Chec* and repair air
connecting 7acuu& pipes. /
inta*e s%ste& ;o
;e:t
Fe&o7e the idling regulator and chec* the throttle bod%< idling regulator<
es
Clean rele7ant parts
and idling b%pass air passage for the presence of carbon deposit.
;o
;e:t
Unplug the coolant te&perature sensor connector and start the engine.
es
Chec*
and
circuit
or
9bser7e hether the engine idling speed is too high.
sensor -0
repair replace
0
;o
;e:t
Chec* hether the ignition ti&ing of the engine co&plies ith the
es
;e:t
specification.
;o
Chec*
and
repair
ignition ti&ing
Connect electronic injection s%ste& adapter< turn on the ignition sitch<
es
+iagnosis help
and chec* hether the poer suppl% at 12H< 1-H< //H< /0H< and -H pins
;o
Chec*
is nor&al and hether the earthing at -H< 01H< 0-H< 1H< and "#H pins is nor&al.
-
and
repair
corresponding circuit
2",, he engine s'ee cant increase or the engine is sto''e uring acceleration Fault 'ortions1
1. 4ater content in fuelM 2. Air inta*e pressure sensor and throttle position sensorM /. Throttle bod% and idling b%pass air passageM ". Ignition ti&ingM
0. Air inta*e passageM
-. Spar* plugM
. Idling regulatorM
!. 'uel injectorM
1#. E:haust pipe.
&iagnosis flow1
;o.
9peration Procedure
Chec*ing
SubseBuent Step
result 1
Chec* hether the air cleaner is bloc*ed.
es
Chec* and repair air inta*e s%ste&
2
;o
;e:t
Connect the fuel pressure gauge (The connection point shall be the front
es
;e:t
end of inlet pipe of fuel distributor pipe asse&bl%$< start the engine< and
;o
Chec* and repair fuel
chec* hether the fuel pressure of engine under all condition is
suppl% s%ste&
appro:i&ate /##*Pa. / 0
Chec* the spar* plug for 7arious c%linders and obser7e hether the &odel
es
;e:t
and gap co&pl% ith the specification.
;o
Adjust or replace
Fe&o7e the idling regulator and chec* the throttle bod%< idling regulator<
es
Clean rele7ant parts
and idling b%pass air passage for the presence of carbon deposit.
;o
;e:t
Chec* hether the air inta*e pressure sensor< throttle position sensor and
es
;e:t
its circuit are nor&al.
;o
Chec*
and
circuit
or
repair replace
sensor ! "
Fe&o7e fuel injector and use the fuel injector special cleaning anal%er to
es
Feplace fault part
chec* hether there is lea*age or bloc*age in fuel injector.
;o
;e:t
Chec* the fuel condition and obser7e hether the fault pheno&enon
es
Feplace fuel
occurs right after the refueling.
;o
;e:t
Chec* hether the ignition order and the ignition ti&ing of the engine
es
;e:t
co&pl% ith the specification.
;o
Chec*
and
repair
ignition ti&ing 5
Chec* hether the e:haust is unhindered fro& the e:haust pipe.
es
;e:t
;o
Fepair
or
replace
e:haust pipe 1#
Connect electronic injection s%ste& adapter< turn on the ignition sitch<
es
+iagnosis help
and chec* hether the poer suppl% at 12H< 1-H< //H< /0H< and -H pins
;o
Chec*
is nor&al and hether the earthing at -H< 01H< 0-H< 1H< and "#H pins is
and
repair
corresponding circuit
nor&al.
2",2 Slow res'onse uring acceleration" Fault 'ortions1
1. 4ater content in fuelM 2. Air inta*e pressure sensor and throttle position sensorM /. Throttle bod% and idling b%pass air passageM
0. Air inta*e passageM
". Ignition ti&ingM 5. E:haust pipe. &iagnosis flow1
-!
-. Spar* plugM
. Idling regulatorM
!. 'uel injectorM
;o.
9peration Procedure
Chec*ing
SubseBuent Step
result 1
Chec* hether the air cleaner is bloc*ed.
es
Chec* and repair air inta*e s%ste&
2
;o
;e:t
Connect the fuel pressure gauge (The connection point shall be the front
es
;e:t
end of inlet pipe of fuel distributor pipe asse&bl%$< start the engine< and
;o
Chec* and repair fuel
chec* hether the fuel pressure of engine under all condition is
suppl% s%ste&
appro:i&ate /##*Pa. / 0
Chec* the spar* plug for 7arious c%linders and obser7e hether the &odel
es
;e:t
and gap co&pl% ith the specification.
;o
Adjust or replace
Fe&o7e the idling regulator and chec* the throttle bod%< idling regulator<
es
Clean rele7ant parts
and idling b%pass air passage for the presence of carbon deposit.
;o
;e:t
Chec* hether the air inta*e pressure sensor< throttle position sensor and
es
;e:t
its circuit are nor&al.
;o
Chec*
and
circuit
or
repair replace
sensor ! "
Fe&o7e fuel injector and use the fuel injector special cleaning anal%er to
es
Feplace fault part
chec* hether there is lea*age or bloc*age in fuel injector.
;o
;e:t
Chec* the fuel condition and obser7e hether the fault pheno&enon
es
Feplace fuel
occurs right after the refueling.
;o
;e:t
Chec* hether the ignition order and the ignition ti&ing of the engine
es
;e:t
co&pl% ith the specification.
;o
Chec*
and
repair
ignition ti&ing 5
Chec* hether the e:haust is unhindered fro& the e:haust pipe.
es
;e:t
;o
Fepair
or
replace
e:haust pipe 1#
Connect electronic injection s%ste& adapter< turn on the ignition sitch<
es
+iagnosis help
and chec* hether the poer suppl% at 12H< 1-H< //H< /0H< and -H pins
;o
Chec*
is nor&al and hether the earthing at -H< 01H< 0-H< 1H< and "#H pins is
and
repair
corresponding circuit
nor&al.
2", 8eak acceleration an 'oor 'erformance Fault 'ortions1
1. 4ater content in fuelM 2. Air inta*e pressure sensor and throttle position sensorM /. Ignition coilM
0. Throttle bod% and idling b%pass air passageM
". 'uel injectorM
5. Ignition ti&ingM
-. Spar* plugM
. Air inta*e passageM
!. Idling regulatorM
1#. E:haust pipe.
&iagnosis flow1
;o.
9peration Procedure
Chec*ing
SubseBuent Step
result 1 2
Chec* hether there is the presence of clutch s*id< lo tire pressure<
es
Fepair
bra*ing stagnation< incorrect tire sie< and incorrect heel align&ent.
;o
;e:t
Chec* hether the air cleaner is bloc*ed.
es
Chec* and repair air inta*e s%ste&
-
Connect the fuel pressure gauge (The connection point shall be the front -"
;o
;e:t
es
;e:t
end of inlet pipe of fuel distributor pipe asse&bl%$< start the engine< and
;o
chec* hether the fuel pressure of engine under all condition is
Chec* and repair fuel suppl% s%ste&
appro:i&ate /##*Pa. /
Unplug one c%linder distribution ire< connect the spar* plug< position the
es
;e:t
spar* plug electrode to 0&& aa% fro& engine bloc*< start the engine<
;o
Chec*
and obser7e hether the high 7oltage fire strength is nor&al. 0 !
and
repair
ignition s%ste&
Chec* the spar* plug for 7arious c%linders and obser7e hether the &odel
es
;e:t
and gap co&pl% ith the specification.
;o
Adjust or replace
Fe&o7e the idling regulator and chec* the throttle bod%< idling regulator<
es
Clean rele7ant parts
and idling b%pass air passage for the presence of carbon deposit.
;o
;e:t
Chec* hether the air inta*e pressure sensor< throttle position sensor and
es
;e:t
its circuit are nor&al.
;o
Chec*
and
circuit
or
repair replace
sensor " 5 1#
Fe&o7e fuel injector and use the fuel injector special cleaning anal%er to
es
Feplace fault part
chec* hether there is lea*age or bloc*age in fuel injector.
;o
;e:t
Chec* the fuel condition and obser7e hether the fault pheno&enon
es
Feplace fuel
occurs right after the refueling.
;o
;e:t
Chec* hether the ignition order and the ignition ti&ing of the engine
es
;e:t
co&pl% ith the specification.
;o
Chec*
and
repair
ignition ti&ing 11
Chec* hether the e:haust is unhindered fro& the e:haust pipe.
es
;e:t
;o
Fepair
or
replace
e:haust pipe 12
Connect electronic injection s%ste& adapter< turn on the ignition sitch<
es
+iagnosis help
and chec* hether the poer suppl% at 12H< 1-H< //H< /0H< and -H pins
;o
Chec*
is nor&al and hether the earthing at -H< 01H< 0-H< 1H< and "#H pins is
and
repair
corresponding circuit
nor&al.
" 1
2
-
/
0
!
$ist of Common Fault Coes (+CA&E) P##1
P##-#
P##-1
P##-2
P##-
P##-!
P##-"
Cran*shaft Position>Ca&shaft Position
Inappropriate relati7e installation location beteen
Correlation ,an* 1 Sensor A
ca&shaft and cran*shaft
92 Sensor )eater Contr. Circ.(,an*1(1$Sensor
9pen>circuit of upstrea& o:%gen sensor heating
1$
control circuit
92 Sensor )eater Contr. Circ.(,an*1(1$Sensor
Short>circuit of upstrea& o:%gen sensor heating
1$ o
control circuit to ground
92 Sensor )eater Contr. Circ.(,an*1(1$Sensor
Short>circuit of upstrea& o:%gen sensor heating
1$ )igh
control circuit to poer suppl%
92 Sensor )eater Contr. Circ.(,an*1(1$Sensor
9pen>circuit of donstrea& o:%gen sensor heating
2$
control circuit
92 Sensor )eater Contr. Circ.(,an*1(1$Sensor
Short>circuit of donstrea& o:%gen sensor heating
2$ o
control circuit to ground
92 Sensor )eater Contr. Circ.(,an*1(1$Sensor
Short>circuit of donstrea& o:%gen sensor heating
2$ )igh
control circuit to poer suppl% -5
"
5
1#
11
P##0-
P##0/
P#1#0
P#1#
92 Sensor )eater Fesistance(,an*1(1$Sensor
Inappropriate heating internal resistance of upstrea&
1$
o:%gen sensor
92 Sensor )eater Fesistance(,an*1(1$Sensor
Inappropriate heating internal resistance of
2$
donstrea& o:%gen sensor
anifold Absolute Pressure?,aro&etric
;o signal 7ariation of air inta*e pressure sensor
Pressure Circuit
('roen$
anifold Abs. Pressure or ,ar. Pressure
Inappropriate air inta*e pressure sensor
Fange?Perfor&ance 12
P#1#!
anifold Abs. Pressure or ,ar. Pressure o
Short>circuit of air inta*e pressure sensor to ground
Input 1-
P#1#"
anifold Abs. Pressure or ,ar. Pressure )igh
Short>circuit of air inta*e pressure sensor to poer
Input
suppl%
1/
P#112
Inta*e Air Te&p. Circ. o Input
o signal 7oltage of air inta*e pressure sensor
10
P#11-
Inta*e Air Te&p. Circ. )igh Input
)igh signal 7oltage of air inta*e pressure sensor
1
P#11
Engine Coolant Te&p. Circ. Fange?Perfor&ance
Inappropriate engine coolant te&perature sensor
1!
P#11!
Engine Coolant Te&p. Circ. o Input
o 7oltage of engine coolant te&perature sensor circuit
1"
P#11"
Engine Coolant Te&p. Circ. )igh Input
)igh 7oltage of engine coolant te&perature sensor circuit
15
P#122
Throttle?Pedal Pos.Sensor A Circ. o Input
9ut>of>loer>li&it of throttle position sensor circuit 7oltage
2#
P#12-
Throttle?Pedal Pos.Sensor A Circ. )igh Input
9ut>of>upper>li&it of throttle position sensor circuit 7oltage
21
P#1-#
92 Sensor Circ.<,an*1>Sensor1 alfunction
Inappropriate upstrea& o:%gen sensor signal
22
P#1-1
92 Sensor Circ.<,an*1>Sensor1 o 3oltage
o upstrea& o:%gen sensor signal 7oltage
2-
P#1-2
92 Sensor Circ.<,an*1>Sensor1 )igh 3oltage
)igh upstrea& o:%gen sensor signal circuit 7oltage
2/
P#1--
92 Sensor Circ.<,an*1>Sensor1 Slo Fesponse
Aging of upstrea& o:%gen sensor
20
P#1-/
92 Sensor Circ.<,an*1>Sensor1 ;o Acti7it%
'ault of upstrea& o:%gen sensor circuit signal
+etected 2
P#1-
92 Sensor Circ.<,an*1>Sensor2 alfunction
Inappropriate donstrea& o:%gen sensor signal
2!
P#1-!
92 Sensor Circ.<,an*1>Sensor2 o 3oltage
o donstrea& o:%gen sensor signal 7oltage
2"
P#1-"
92 Sensor Circ.<,an*1>Sensor2 )igh 3oltage
)igh donstrea& o:%gen sensor signal circuit 7oltage
25
P#1/#
92 Sensor Circ.<,an*1>Sensor2 ;o Acti7it%
'ault of donstrea& o:%gen sensor circuit signal
+etected -#
P#1!#
'uel Tri&<,an*1 alfunction
Inappropriate closed>loop control self>learning of off>line testing air>fuel ratio
-1
P#1!1
'uel Tri&<,an*1 S%ste& too ean
Thin closed>loop control self>learning of off>line testing air>fuel ratio
-2
P#1!2
'uel Tri&<,an*1 S%ste& too Fich
+ense closed>loop control self>learning of off>line /#
testing air>fuel ratio --
P#2#1
C%linder 1> Injector Circuit
9pen>circuit of 1H fuel injector control circuit
-/
P#2#2
C%linder 2> Injector Circuit
9pen>circuit of 2H fuel injector control circuit
-0
P#2#-
C%linder -> Injector Circuit
9pen>circuit of -H fuel injector control circuit
-
P#2#/
C%linder /> Injector Circuit
9pen>circuit of /H fuel injector control circuit
-!
P#21
C%linder 1> Injector Circuit o
Short>circuit of 1H c%linder fuel injector control circuit to ground
-"
P#22
C%linder 1> Injector Circuit )igh
Short>circuit of 1H c%linder fuel injector control circuit to poer suppl%
-5
P#2/
C%linder 2> Injector Circuit o
Short>circuit of 2H c%linder fuel injector control circuit to ground
/#
P#20
C%linder 2> Injector Circuit )igh
Short>circuit of 2H c%linder fuel injector control circuit to poer suppl%
/1
P#2!
C%linder -> Injector Circuit o
Short>circuit of -H c%linder fuel injector control circuit to ground
/2
P#2"
C%linder -> Injector Circuit )igh
Short>circuit of -H c%linder fuel injector control circuit to poer suppl%
/-
P#2!#
C%linder /> Injector Circuit o
Short>circuit of /H c%linder fuel injector control circuit to ground
//
P#2!1
C%linder /> Injector Circuit )igh
Short>circuit of /H c%linder fuel injector control circuit to poer suppl%
/0
P#-##
Fando&?ultiple C%linder isfire +etected
+etection of &isfire in 7arious c%linders
/
P#-#1
C%l.1 isfire +etected
+etection of &isfire in 1H c%linder
/!
P#-#2
C%l.2 isfire +etected
+etection of &isfire in 2H c%linder
/"
P#-#-
C%l.- isfire +etected
+etection of &isfire in -H c%linder
/5
P#-#/
C%l./ isfire +etected
+etection of &isfire in /H c%linder
0#
P#-1!
Fough Foad Sensor YAY ;ot present
A,S loss of rough road detection signal
01
P#-21
Ign.?+istributor Eng. Speed Inp. Circ.
'ault of cran*shaft upper dead point signal
Fange?Perfor&ance 02
P#-22
Ign.?+istributor Eng. Speed Inp. Circ. ;o Signal
'ault of engine speed sensor signal
0-
P#-2!
6noc* Sensor 1 Circ. o Input
o 7oltage of *noc* sensor signal circuit
0/
P#-2"
6noc* Sensor 1 Circ. )igh Input
)igh 7oltage of *noc* sensor signal circuit
00
P#-/#
Ca&shaft Position Sensor Circuit
Inappropriate installation location of phase sensor
0
P#-/1
Ca&shaft Pos. Sensor Circ. Fange?Perfor&ance
Poor contact of phase sensor
0!
P#-/2
Ca&shaft Pos. Sensor Circ. o Input
Short>circuit of phase sensor to ground
0"
P#-/-
Ca&shaft Pos. Sensor Circ. )igh Input
Short>circuit of phase sensor to poer suppl%
05
P#/2#
Catal%st S%ste&<,an*1 Efficienc% ,elo
Aged o:%gen storage capacit% of three>a% catal%tic
Threshold
con7erter (out>of>li&it of e&ission$
E7aporati7e E&iss. S%ste& Purge Control 3al7e
9pen>circuit of canister control 7al7e control circuit
#
P#///
Circ. 9pen 1
P#/0"
E7aporati7e E&ission S%ste& Purge Control 3al7e Circuit o /1
o 7oltage of canister control 7al7e control circuit
2
P#/05
E7aporati7e E&ission S%ste& Purge Control
)igh 7oltage of canister control 7 al7e control circuit
3al7e Circuit )igh -
P#/"#
Cooling 'an 1 Control Circuit
'ault of cooling fan rela% control circuit (lo speed$
/
P#/"1
Cooling 'an 2 Control Circuit
'ault of cooling fan rela% control circuit (high speed$
0
P#0#1
3ehicle Speed Sensor Fange?Perfor&ance
Inappropriate 7ehicle speed sensor signal
P#0#
Idle Control S%ste& FP oer than E:pected
Idling control speed loer than target idling speed
!
P#0#!
Idle Control S%ste& FP )igher than E:pected
Idling control speed higher than target idling speed
"
P#0#"
Idle Air Control S%ste& Circuit o
Short>circuit of stepping &otor dri7e pin to ground
5
P#0#5
Idle Air Control S%ste& Circuit )igh
Short>circuit of stepping &otor dri7e pin to poer suppl%
!#
P#011
Idle Air Control Circuit
ore than one fault at stepping &otor dri7e pin
!1
P#0#
S%ste& 3oltage alfunction
Inappropriate s%ste& batter% 7oltage signal
!2
P#02
S%ste& 3oltage o 3oltage
o s%ste& batter% 7oltage
!-
P#0-
S%ste& 3oltage )igh 3oltage
)igh s%ste& batter% 7oltage
!/
P##2
Control odule Progra&&ing Error
Progra&&ing error of electronic control unit
!0
P#2!
'uel Pu&p QAR Control Circuit ?9pen
9pen>circuit of fuel pu&p rela% control circuit
!
P#2"
'uel Pu&p QAR Control Circuit o
Short>circuit of fuel pu&p rela% control circuit to ground
!!
P#25
'uel Pu&p QAR Control Circuit )igh
Short>circuit of fuel pu&p rela% control circuit to poer suppl%
!"
P#/0
AC clutch rela% circuit
9pen>circuit of A?C co&pressor rela% control circuit
!5
P#/
A?C Clutch Fela% Control Circuit o
Short>circuit of A?C co&pressor rela% control circuit to ground
"#
P#/!
A?C Clutch Fela% Control Circuit )igh
Short>circuit of A?C co&pressor rela% control circuit to poer suppl%
"1
P#51
Cooling 'an 1 Control Circuit o
Short>circuit of cooling fan rela% control circuit to ground (lo speed$
"2
P#52
Cooling 'an 1 Control Circuit )igh
Short>circuit of cooling fan rela% control circuit to poer suppl% (lo speed$
"-
P#5-
Cooling 'an 2 Control Circuit o
Short>circuit of cooling fan rela% control circuit to ground (high speed$
"/
P#5/
Cooling 'an 2 Control Circuit )igh
Short>circuit of cooling fan rela% control circuit to poer suppl% (high speed$
"0
P11#
ECU defecti7e
;on>progra&&ing error of Secret 6e% and Securit% Code
"
P111
I Call>up Circ.?Trans&. Contr. odule Short
Feceipt error of Securit% Code
to Dround "!
P112
Electronic Control odule Incorrect Coding
'ailure of Challenge reBuest
""
P11-
I Call>up Circ. 9pen?Short to ,L
'ailure of I9 Code reBuest
"5
P11/
I Call>up Circ.?Trans&. Contr. odule
Transponder 7erification error
/2
