Common Malfunction Diagnosis Flow of Geely Automobile
GEELY INTERNATIONAL CORPORATION
JUN.
2008
Common Malfunction Diagnosis Flow of Geely Automobile
Common Malfunction Diagnosis Flow Content of Geely Automobile Engine ....................................................................................................................................... 1 No.001
Engine shuts off abnormally when driving..................................................................... 1
No.002 Engine surging .............................................................................................................. 3 No.003
Over idle speed when warm-up .................................................................................... 5
No.004
Idle speed fluctuation .................................................................................................... 7
No.005
Idle speed unstable or engine shut-off when opening AC or steering ........................... 9
No.006
Engine shuts off intermittently ..................................................................................... 11
No.007
Poor accelerating performance in cold condition ........................................................ 13
No.008
Spark plug non-sparking ............................................................................................. 15
No.009
Low idle speed during engine heating in cold condition .............................................. 17
No.010 Canister oil leaking...................................................................................................... 19 No.011 Fuel smells in vehicle .................................................................................................. 20 No.012
Engine vibration when operating................................................................................. 22
No.013
Engine noise over normal level ................................................................................... 24
No.014
Water temperature over normal value after AC activated............................................ 26
No.015 Oil pan leak ................................................................................................................. 27 No.016
Distributor oil leaking................................................................................................... 29
No.017
JL376/378 engine shut-off when sliding at neutral gear.............................................. 30
No.018 High idle speed when sliding at neutral gear, MK ....................................................... 32 No.019 Engine vibration .......................................................................................................... 33 No.020
Exhaust pipe pours black smoke ................................................................................ 34
No.021
Engine idle speed decreases when activating head beam or fan ............................... 36
No.022
Exhaust pipe blows water ........................................................................................... 38
No.023
Engine shuts off when accelerating ............................................................................ 39
No.024 Oil indicator is always on ............................................................................................ 41 No.025
Water temperature is over normal value when engine running with large load ........... 42
No.026
Canister electromagnetic valve sounds abnormal....................................................... 44
No.027
Engine fails to start ..................................................................................................... 45
No.028
Hard to start in cold condition...................................................................................... 47
No.029
Hard to stard engine when heating ............................................................................. 49
No.030
Idle speed unstable..................................................................................................... 51
Common Malfunction Diagnosis Flow of Geely Automobile
No.031 Non-idle speed............................................................................................................ 54 No.032
Idle speed over normal value ...................................................................................... 56
No.033
Engine accelerates abnormal...................................................................................... 58
No.034
Water temperature over normal value......................................................................... 60
No.035
Oil existing in the water tank ....................................................................................... 62
No.036 There is water in the oil............................................................................................... 64 No.037
Abnormal sound of crankshaft bearing ....................................................................... 65
No.038
Abnormal sound of connecting rod bush..................................................................... 67
No.039
Camshaft with abnormal sound................................................................................... 69
No.040
Camshaft driving gear with abnormal sound ............................................................... 70
No.041
Cylinder knocking sound............................................................................................. 71
No.042 Oil pump with abnormal sound.................................................................................... 73 No.043
Crankshaft thrust piece with abnormal sound ............................................................. 74
No.044 Valve with abnormal sound ......................................................................................... 75 No.045
Engine with insufficient power.....................................................................................76
No.046 Oil consumption too large ........................................................................................... 78 No.047
Intake tempering ......................................................................................................... 83
No.048
Exhaust pipe bombs ................................................................................................... 85
No.049 Engine knocking.......................................................................................................... 86 No.050 Engine burning oil ....................................................................................................... 88 No.051
Cooling water unusually consumed ............................................................................ 89
No.052 Low engine oil pressure .............................................................................................. 90 No.053 Quick diagnosis for ECU............................................................................................. 91 No.054
Quick diagnosis for idling-speed governor EWD......................................................... 93
No.055
Quick diagnosis for knocking sensor........................................................................... 94
No.056
Quick diagnosis for stepper motor .............................................................................. 96
No.057
Quick diagnosis for ignition coil................................................................................. 100
No.058
Quick diagnosis for throttle valve position sensor ..................................................... 102
No.059
Quick diagnosis for inlet pressure temperature sensor ............................................. 104
No.060
Quick diagnosis for water temperature sensor.......................................................... 107
No.061
Quick diagnosis for canister solenoid valve .............................................................. 109
No.062
Fuel injector EV......................................................................................................... 111
No.063
Quick diagnosis for Hall sensor................................................................................. 113
Common Malfunction Diagnosis Flow of Geely Automobile
No.064
Electric fuel pump EKP ............................................................................................. 115
No.065
Fuel pressure regulator DR....................................................................................... 117
No.066
Oxygen sensor LSH.................................................................................................. 119
No.067 JL376/378QE engine’s electric control system check ............................................... 121 No.068
Diagnosis and solution of common malfunctions of JL376/378QE engine’s electric control system.......................................................................................................... 129
No.069
Flashing code list of M1.5.4 series............................................................................ 130
No.070
Malfunction code: P0107 "voltage of intake pressure sensor circuit too low"............ 132
No.071
Malfunction code: P0108
No.072
Malfunction code: P0112 "temperature indicated by intake temperature sensor too low" .......................................................................................................................... 133
No.073
Malfunction code: P0113 "temperature indicated by intake temperature sensor too high"......................................................................................................................... 134
No.074
Malfunction code: P0117 "temperature indicated by cooling liquid temperature sensor too low" .................................................................................................................... 134
No.075
Malfunction code: P0118 "temperature indicated by cooling liquid temperature sensor too high"...................................................................................................................135
No.076
Malfunction code: P0122 "voltage of throttle valve position sensor circuit too low"... 135
No.077
Malfunction code: P0123 "voltage of throttle valve position sensor circuit too high" . 136
No.078
Malfunction code: P0130 "signal circuit of upstream oxygen sensor malfunction" .... 137
No.079
Malfunction code: P0132 "voltage of upstream oxygen sensor circuit too high" ....... 137
No.080
Malfunction code: P0134 "upstream oxygen sensor signal malfunction" .................. 137
No.081
Malfunction code: P0135 "heating circuit of upstream oxygen sensor malfunction".. 138
No.082
Malfunction code: P0171 “self-adapting of closed-loop control of air fuel ratio shall exceed upper part”................................................................................................... 138
No.083
Malfunction code: P0172 “self-adapting of closed-loop control of air fuel ratio shall exceed lower part” ................................................................................................... 139
No.084
Malfunction code: P0201 "one-cylinder oil injector circuit malfunction"..................... 140
No.085
Malfunction code: P0202 "two-cylinder oil injector circuit malfunction" ..................... 140
No.086
Malfunction code: P0203 "three-cylinder oil injector circuit malfunction"................... 141
No.087
Malfunction code: P0204 "four-cylinder oil injector circuit malfunction"..................... 141
No.088
Malfunction code: P0230 "oil pump control circuit malfunction" ................................ 142
No.089
Malfunction code: P0325 "knock sensor circuit malfunction" .................................... 142
No.090
Malfunction code: P0335 “crankshaft position sensor signal malfunction” ................ 143
"voltage of intake pressure sensor circuit too high"........ 133
Common Malfunction Diagnosis Flow of Geely Automobile
No.091
Malfunction code: P0336 “crankshaft position sensor signal with unreasonable malfunction” ............................................................................................................. 143
No.092
Malfunction code: P0340 “Phase sensor signal malfunction”.................................... 144
No.093
Malfunction code: P0342 “circuit voltage of phase sensor too low”........................... 144
No.094
Malfunction code: P0343 “circuit voltage of phase sensor too high” ......................... 145
No.095
Malfunction code: P0443 "Malfunction of control circuit of driver stage of canister control valve" ...........................................................................................................146
No.096
Malfunction code: P0444 "voltage of control circuit of driver stage of canister control valve too low" ........................................................................................................... 146
No.097
Malfunction code: P0445 "voltage of control circuit of driver stage of canister control valve too high" .........................................................................................................147
No.098
Malfunction code: P0480 "malfunction control circuit of cooling fan relay of AC condenser"............................................................................................................... 148
No.099
Malfunction code: P0500 "unreasonable malfunction of speed signal" ..................... 148
No.100
Malfunction code: P0506 "idling speed lower than target speed value" .................... 149
No.101
Malfunction code: P0507 "idling speed higher than target speed value"................... 149
No.102 Malfunction code: P0508 "voltage of control circuit of idling speed governor too low" ................................................................................................................................. 149 No.103
Malfunction code: P0509 "voltage of control circuit of idling speed governor too high" ................................................................................................................................. 150
No.104
Malfunction code: P0511 "malfunction control circuit of idling speed governor"........ 150
No.105
Malfunction code: P0560 "unreasonable system voltage signal" .............................. 150
No.106
Malfunction code: P0562 "system voltage too low" ................................................... 151
No.107
Malfunction code: P0563 "system voltage too high" ................................................. 151
No.108
Malfunction code: P0601 "error of check code of electronic control unit".................. 152
No.109 Malfunction code: P0602 "error of identification code of diagnosis data of electronic control unit" .............................................................................................................. 152 No.110
Malfunction code: P0645 "malfunction of relay control circuit of AC compressor"..... 152
No.111 Malfunction code: P0646 "voltage of relay control circuit of AC compressor too low" 153 No.112 Malfunction code: P0647 "voltage of relay control circuit of AC compressor too high" ................................................................................................................................. 154 No.113
Malfunction code: P1508 "voltage of control circuit of idling speed governor too high" ................................................................................................................................. 155
No.114
Malfunction code: P1651 "malfunction of control circuit of engine malfunction lamp (SVS)" ...................................................................................................................... 155
Common Malfunction Diagnosis Flow of Geely Automobile
No.115
Engine not running or slowly running while startup ................................................... 157
No.116
While startup, engine running, but unable to start ..................................................... 158
No.117
Difficult to start for hot startup.................................................................................... 159
No.118
Difficult to start for cold startup .................................................................................. 160
No.119
Difficulty startup at any time though with normal speed ............................................ 161
No.120 Normal startup with instable idling speed at any time ............................................... 162 No.121 Normal startup, with instable idling speed during warming up .................................. 163 No.122 Normal startup, with instable idling speed after warming up ..................................... 164 No.123 Normal startup, idling speed is instable or the vehicle will flame out when partially loaded (such as: when air conditioner is on) ............................................................ 165 No.124
Normal startup, the idling speed is too high .............................................................. 166
No.125
Unable to rotating speed or flameout while accelerating........................................... 167
No.126
Slow reaction while accelerating ............................................................................... 168
No.127
Weak with poor performance while accelerating....................................................... 169
No.128 Malfunction code with EOBD system ........................................................................ 170 No.129 Malfunction code without EOBD system ................................................................... 174
Transmission ..................................................................................................... 176 No.130
Transmission hard to put into gear............................................................................ 176
No.131 Park position fails...................................................................................................... 177 No.132 Gear indicator lamp off sometimes ........................................................................... 178 No.133
Auto transmission with abnormal sound ................................................................... 179
No.134
Transmission shaking during driving ......................................................................... 181
No.135
Auto transmission case oil temperature rises, reverse gear fails .............................. 183
No.136
Auto transmission upshifts too late............................................................................ 184
No.137
Auto transmission unable to upshift .......................................................................... 186
No.138
Auto transmission unable to force downshift............................................................. 187
No.139 Engine shuts down after putting into gear ................................................................. 188 No.140
No forward gear ........................................................................................................ 189
No.141 Transmission oil easily deteriorate ............................................................................ 190 No.142
Auto transmission oil easily deteriorate..................................................................... 191
No.143
No reversing gear ..................................................................................................... 192
No.144
Trip stop of fourth gear of transmission case ............................................................ 193
Common Malfunction Diagnosis Flow of Geely Automobile
No.145
Transmission with abnormal sound........................................................................... 195
No.146
Gear shifting lever swinging, hard to shift ................................................................. 197
No.147
Sounding when releasing throttle of third, fourth gears and decelerating ................. 198
No.148
Fifth gear not easily shifted up .................................................................................. 199
No.149 Fifth gear, first gear blocks, relieved only when the vehicle stops............................. 200 No.150
Hiss sound when put into gear during driving ........................................................... 201
No.151
Transmission gear runout ......................................................................................... 203
No.152 Hiss sound when second, third, fourth gear upshift .................................................. 204 No.153 Chug sound in transmission case at idling speed ..................................................... 205 No.154
Da-da sound in transmission at idling speed ............................................................ 206
No.155 Buzz sound during driving at high speed .................................................................. 208 No.156
Transmission with abnormal sound while shifting ..................................................... 210
No.157
Transmission gear disorder....................................................................................... 211
No.158 Shaking startup ......................................................................................................... 213
Chassis ................................................................................................................................. 215 No.159 Shaking startup ......................................................................................................... 215 No.160
Clutch slipping........................................................................................................... 217
No.161 Heavy clutch ............................................................................................................. 218 No.162
Not fully separated ....................................................................................................219
No.163 Clutch with abnormal sound...................................................................................... 221 No.164
Shock absorber with abnormal sound....................................................................... 223
No.165 Front wheel with abnormal sound when turning........................................................ 225 No.166 Heavy steering .......................................................................................................... 227 No.167
Steering wheel not well back to original position ....................................................... 229
No.170
Steering power insufficient (hydraulic) ...................................................................... 232
No.171
Power-assisted pump with abnormal sound ............................................................. 233
No.172
Direction running out................................................................................................. 235
No.173
Steering wander during normal driving...................................................................... 237
No.174
Front wheel tire abnormally worn .............................................................................. 239
No.175
Normally when driving straightly, but with abnormal sound while turning.................. 241
No.176 Braking wandering .................................................................................................... 242 No.177
Braking dragging.......................................................................................................244
No.178 Braking with abnormal sound.................................................................................... 246
Common Malfunction Diagnosis Flow of Geely Automobile
No.179
Braking sideslipping, swerving .................................................................................. 248
No.180
Braking intermittently stiffening ............................................................................... 249
No.181 Braking ineffective..................................................................................................... 251 No.182
Brake fails ................................................................................................................. 253
No.183
Steering wheel with too large free stroke .................................................................. 255
No.184
Buzzing noise at rear wheel while driving at high speed........................................... 257
No.185
Braking force of brake master cylinder insufficient.................................................... 258
No.186
Stepping on pedal too heavily ................................................................................... 259
No.187
Common malfunction diagnosis and Solution for Geely automobile tire ................... 260
No.188
Causes analysis for common manufacturing defects of Geely automobile tire ......... 262
Electrics ...............................................................................................................................263 No.189
CD-player disk boot malfunction (without MP3) ........................................................ 263
No.190
CD-player fails to work when activating .................................................................... 265
No.191
CD-player keeps soundless under all modes............................................................ 265
No.192
CD-player/radio gains no power................................................................................ 267
No.193
A loudspeaker of CD-player/radio is soundless......................................................... 268
No.194 Onboard hand-free phone has no sound output (MK)............................................... 269 No.195 CD-player/radio button out of control ........................................................................ 271 No.196
CD-player/radio button indicator malfunction ............................................................ 271
No.197
CD-player/radio memory function malfunction .......................................................... 273
No.198
CD-player/radio no signal ......................................................................................... 273
No.199 CD-player/radio sound distortion at large volume ..................................................... 274 No.200
CD-player/radio tuner can’t stop ............................................................................... 275
No.201 CD-player/radio has noise when receiving signal ..................................................... 276 No.202
CD-player fails to insert disk ..................................................................................... 277
No.203
CD-player fails to popup disk .................................................................................... 279
No.204
CD-player with poor vibration resistance performance ............................................. 280
No.205 USB interface of CD –player malfunction (U-disk) (MK) ........................................... 281 No.206
CD-player burns out when connecting power source................................................ 283
No.207
CD-player consists back drop ................................................................................... 284
No.208
Cassette stuck or failed to popup.............................................................................. 286
No.209
Cassette speed abnormal, turned over automatically and chewed ........................... 287
No.210
Poor timbre, low volume or noise jump when playing CD ......................................... 289
Common Malfunction Diagnosis Flow of Geely Automobile
No.211 Low loudspeaker volume........................................................................................... 291 No.212 Large loudspeaker noise........................................................................................... 293 No.213
Loudspeaker susurrates when pressing horn ........................................................... 295
No.214
Speedometer non-display ......................................................................................... 297
No.215 Freedom ship speedometer malfunction, indicates automatically when pressing horn ................................................................................................................................................. 299 No.216
Incorrect indication of speedometer .......................................................................... 301
No.217 Kilometrage on LCD of odometer will accumulate automatically after the engine starts ................................................................................................................................................. 303 No.218
Automatic movement of odometer pointer after start-up of engine ........................... 305
No.219
Incorrect indication or no indication of engine tachometer ........................................ 307
No.220
Incorrect indication (or no indication) of fuel gauge................................................... 309
No.221
No indication of water temperature gauge ................................................................ 311
No.222
Electric mirror can’t work........................................................................................... 313
No.223
Always-On or failure of water temperature alarm indicator ....................................... 314
No.224
Safety & alarm indicator is always on or not on ........................................................ 315
No.225
Brake fluid level alarm indicator is always on or can’t alarm..................................... 316
No.226 Oil alarm indicator is always on................................................................................. 317 No.227
Headlight is always on or not on ............................................................................... 318
No.228
Weak running of starter............................................................................................. 319
No.229
Starter can’t work ...................................................................................................... 320
No.230 Idling of starter .......................................................................................................... 322 No.231 Abnormal sound during start-up of starter................................................................. 323 No.232
Over-high or over-low recharging voltage from generator......................................... 324
No.233
Generator can’t work................................................................................................. 326
No.234
Charging indicator of generator is always on or not on ............................................. 328
No.235 Flashing of charging indicator of generator ............................................................... 329 No.236 Abnormal sound of generator.................................................................................... 331 No.237
Failure of battery storage .......................................................................................... 332
No.238
Weak running of blower ............................................................................................ 333
No.239
Blower can’t work......................................................................................................334
No.240 Abnormal sound of blower ........................................................................................ 335 No.241
Continuous running of cooling fan............................................................................. 336
No.242
Cooling fan can’t work............................................................................................... 337
No.243
Weak running of cooling fan...................................................................................... 338
Common Malfunction Diagnosis Flow of Geely Automobile
No.244
Wiper can’t work .......................................................................................................339
No.245
Wipe doesn’t work at intermitting position ................................................................. 340
No.246
Electric fuel pump can’t work .................................................................................... 341
No.247
Insufficient pressure of electric fuel pump ................................................................. 342
No.248
Positive pressure of fuel tank too high ...................................................................... 343
No.249
Failure of remote controller ....................................................................................... 344
No.250
Door lock is not self-locked after driving 30 feet........................................................ 346
No.251
Failure of central control locking while driving........................................................... 347
No.252 Flashing CGQ alarm indicator for speedometer........................................................ 348 No.253
Window lifter can’t work ............................................................................................ 349
No.254 Blocking Door lock .................................................................................................... 350 No.255
Failure of door lock ................................................................................................... 351
No.256
If four doors of vehicle are not closed, the anti-theft alarm will be activated automatically and central control will be locked automatically ................................. 352
No.257
Reversing radar can’t work while reversing .............................................................. 353
No.258
Wrong information from the reversing radar.............................................................. 354
No.259 Sunroof can’t move, including malfunction of automatic closing and anti-nip ........... 355 No.260 Abnormal sound and vibration of sunroof while operating ........................................ 356 No.261
Leaking of sunroof (water on internal decoration of roof).......................................... 357
No.262
Air-conditioner can’t work.......................................................................................... 358
No.263 Normal suction pressure and too high exhaust pressure for AC compressor ........... 361 No.264 Too high suction pressure and exhaust pressure for AC compressor ....................... 362 No.265 Too high suction pressure and normal exhaust pressure for AC compressor ........... 363 No.266
Too low suction pressure and exhaust pressure for AC compressor......................... 364
No.267
Air conditioning has abnormal sound ........................................................................ 365
No.268
The air conditioning has no heating supply or the heating air is not warm................ 366
No.269
A/C compressor fails to start ..................................................................................... 368
No.270 The A/C control mechanism is hard to operate ......................................................... 370 No.271 The A/C evaporator is frosting................................................................................... 370 No.272
Constant malfunction and solution of A/C components ............................................. 372
No.273
Vehicle temperature sensor is in poor condition (code display 01)......................... 376
No.274
The vehicle exterior temperature sensor is in poor condition; (code display 02)....... 376
No.275
The evaporator temperature sensor is in poor condition.
No.276
The temperature adjustment performer is in poor condition; (code display 04) ........ 377
(code display 03) ........... 377
Common Malfunction Diagnosis Flow of Geely Automobile
No.277 The sun sensor is in poor condition.(code display 05) .............................................. 378 No.278
The fan governing module is in poor condition;
(code display 06).......................... 378
No.279
The high speed relay is in poor condition; (code display 07) .................................... 379
No.280
The rear defrosting function is invalid ....................................................................... 379
No.281
The display screen has no display ............................................................................ 380
No.282
The internal and external circulation regulation is invalid.......................................... 380
No.283 The wind direction adjustment is abnormal ............................................................... 381 No.284
The blower is in poor operation................................................................................. 381
No.285
Vehicle interior air conditioning is in poor condition................................................... 382
No.286
Vehicle interior central heating is in poor condition ................................................... 383
No.287
Night light regulation function of the a/c controller is invalid...................................... 383
No.288
The compressor is out of service .............................................................................. 384
No.289
Effect of the air conditioning is in poor condition (check it per the content in the following table) .........................................................................................................384
No.290 Installation and Commissioning of the Air Conditioning ............................................ 386 No.291 Line inspection of "EPS" indicating lamp (the "EPS" indicator does not light up when the ignition switch is opened) ................................................................................... 397 No.292
Inspection to "EPS" indicator line ("EPS" indicator does not light up or keep on lighting up when the cross-line connection is made between the diagnoses switch terminal and the ground terminal)................................................................................................. 398
No.293 Main line of DTC11 torque sensor (the main line is broken or short circuit) .............. 398 No.294 DTC13 torque sensor (there is big difference between the auxiliary line outputs of the main line and the torque sensor).............................................................................. 398 No.295
DTC14 torque sensor (power supply voltage of the torque sensor is too high or too low) ................................................................................................................................. 399
No.296 Auxiliary line of DTC15 torque sensor (the auxiliary line is disconnected or short circuit) ................................................................................................................................................. 399 No.297 DTC22 engine speed signal (no engine signal input)................................................ 399 No.298
Vss line(Vss line is disconnected or short circuit) ........................................................................401
No.299
DTC41 motor (the motor voltage is too high or too low)............................................ 401
No.300
DTC51 clutch line (the clutch line is disconnected or short)...................................... 401
No.301
Power circuit of DTC54 control module (low voltage of the battery) ....................... 402
No.302 DTC52 and DTC55 control modules (failure of control module)................................ 402 No.303 Voltage inspection.....................................................................................................402
Common Malfunction Diagnosis Flow of Geely Automobile
No.304
Introduction of mechanical assembly ........................................................................ 403
No.305
Diagnoses to the ABS system failure ........................................................................ 405
No.306
Quick index list of malfunction clearance .................................................................. 406
No.307
Index of malfunction code free malfunction check list ............................................... 406
No.308
Malfunction check list of malfunction code................................................................ 407
No.309 The malfunction codes are 00283, 00285, 00290 and 00287 (mechanical malfunction) ................................................................................................................................................. 408 No.310
Malfunction codes: 00283, 00285, 00290 and 00287 ............................................... 409
No.311 Malfunction codes are 00283, 00285, 00290 and 00287
(electric failure) .............. 410
No.312
Malfunction code: 01044........................................................................................... 411
No.313
Malfunction code: 00668........................................................................................... 411
No.314 Malfunction code: 01130 ........................................................................................... 412 No.315
Malfunction check list of malfunction free code......................................................... 413
No.316
The ABS alarm lamp is normally open after the engine starts................................... 414
No.317 ABS is in abnormal operation.................................................................................... 414 No.318 The brake pedal stroke is too long ............................................................................ 416 No.319
Large force is required to stamp the pedal................................................................ 417
No.320 There is no diagnostic code output ........................................................................... 417 No.321 ABS system inspection ............................................................................................. 419 No.322
ECU code ................................................................................................................. 422
No.323 Fluid filling and air exhaust ....................................................................................... 423
Common Malfunction Diagnosis Flow of Geely Automobile
Engine No. 001 Engine shuts off abnormally when driving Malfunction
Cause
Low fuel pressure or injector blockage
Improper ignition timing, engine shuts off sometimes
Valve clearance too small or throttle body too dirty
Check the injection volume and the atomization of the injector, whether they are normal, clean or replace the injector when necessary. Check fuel pressure. When idling the value shall correspond to 265~304 kPa, when accelerating the value shall increase approximately 50 kPa. If fuel pressure is too low, check fuel pressure controller, electric fuel pump and fuel filter etc. Check engine ignition timing. When idling, the ignition advance angle shall be 10~12°. Otherwise, shall adjust engine initial advance angle. When accelerating, the ignition advance angle shall over 20~30°, automatically adjusted. Otherwise, shall replace ECU or maintain ignition controlling system. Check valve clearance, whether it is too small. When heating, the clearance of air intake and exhaust valve shall be 0.20±0.05mm, otherwise, adjust it to prescribed value according to maintenance manual. Check throttle body, whether it is too dirty. Clean throttle body and idle speed controller when necessary.
Fuel quality problem
When applying poor quality fuel, the fuel pipe must be cleaned then replace standard gasoline, 93# or above.
Spark plug malfunction
Check spark plug resistance, whether the value is 5~8KΩ, as well as the clearance, whether the value is 0.8~1.0mm. Otherwise, shall adjust or replace them.
Ignition coil malfunction
Check ignition coil, the initial winding shall be 0.4~0.6Ω, and the 2nd winding shall be 11~15Ω. Otherwise, shall replace ignition coil.
Spark plug wire Engine shuts off in normal driving, such as geared driving or cornering
Solution
If there is short or open circuit in spark plug wire, then shall replace it.
Idle speed control valve or stepper motor malfunction
When stuck, shall clean or replace it.
Fuel pump relay burnt
Check the relay by multimeter, whether it is connected, as well as the coil resistance, whether the value is 75~90Ω. Replace when necessary.
Valve gumming
Determine whether it is valve gumming, according to local and gasoline using condition. Generally, the malfunction appears in cold condition, and will disappear after vehicle heated. It is recommended that driver shall clean engine without components removing, meanwhile, replace qualified gasoline.
ECU harness pin poor contact
Check ECU, whether it is poor contact, which results signal deviation when idling, as well as abnormal shut-off. Fasten wire connector again, when necessary.
Three way catalytic converter damaged or blocked
Check three way catalytic converter, whether it is free-flowing, as well as the housing, whether there is collision mark. Replace the converter assembly when necessary.
Pressure temperature sensor malfunction
Temperature sensor part (pin disconnected) pin 1# and 2#: the rated resistance at 20℃ is 2.5KΩ±5%, and the value shall decrease when temperature raising. Pressure sensor part (pin connected): black pen connects to earth; red pen connects with pin 3# and 4# respectively. In idle condition, the reference voltage on pin 3# shall be 5V, and the voltage on pin 4# shall be approximately 1.3V (determined by vehicle). If the value abnormal, then the pressure temperature sensor is damaged and shall be replaced.
Poor ECU signal
Check main ECU wire harness connectors, whether they are fixed, as well as poor connecting caused by rust and oxidation. Clean and fix it when necessary. Load data stream by K61 detector, and check the display value of ECU, whether it coordinates to the standard. Replace ECU when necessary.
Insufficient engine cylinder pressure
Check engine compression ratio and pressure, whether they are corresponding with the standard value: 479Q 9.3: 1/1250kpa/250r/min; 479QA 9.8: 1/1440kpa/250r/min; 481Q9.4: 1/1360kpa/250r/min; JI376QE9.5: 1/1225kpa/350r/min; JL378QE 9.5: 1 / 1225kpa/350r/min; audit and maintain engine when necessary.
1
Common Malfunction Diagnosis Flow of Geely Automobile
Engine shuts off abnormally when driving
Abnormal Spark plug, ignition coil, spark plug wire malfunction
Normal
Replace
Improper Adjust
Improper ignition timing
Normal Abnormal Valve clearance too small or throttle body too dirty
Adjust and clean
Normal Abnormal Fuel quality problem
Normal
Replace
Abnormal
Three way catalytic converter damaged or blocked Normal
Replace
Burnt
Fuel pump relay burnt
Normal
Replace
Abnormal
Pressure temperature sensor failure
Normal
Replace
Abnormal Replace
Poor ECU signal Normal Abnormal
Mainatain
Valve gumming Normal
Abnormal
Idle speed control valve or stepper motor malfunction
Normal
Clean or replace
Too low or bocked
Low fuel pressure or injector blockage Normal
Check or replace Abnormal Check engine
Inssuficient engine cylinder pressure
2
Common Malfunction Diagnosis Flow of Geely Automobile
No. 002 Engine surging Malfunction
Cause Fuel fliter blockage
Tachometer large vibrates when engine surging
Solution Check fuel filter, whether it is blocked, and replace it when necessary.
Charcoal canister
Check charcoal canister, whether it contains gasoline, replace it if gasoline contains.
Fuel injector blockage or poor atomized
Check the injection volume and atomization of injector, if they are abnormal, then shall clean and replace injector assembly.
Low fuel pressure
Check fuel pressure, when idling, the pressure shall be in accordance with regular value, 265~304kPa, and shall increase about 50kPa when accelerating. If fuel pressure is too low, shall check fuel pressure controller, electric fuel pump and etc.
Air intake system leakage
Test the actual pressure of manifold, whether it is in accordance with standard. Check intake manifold gasket whether it is damaged, as well as the gasket between intake manifold and throttle. Check the cylinder gasket, whether it is bent and damaged. Check all hoses whether they are ageing and broken.
Poor ignition
Check spark plug applying condition, whether it operates well. Check cylinder wire, whether there is short or open circuit. Check the operating condition of ignition coil and distributor. Check the connecting condition between ignition control and ECU.
Idle motor malfunction
Check idle motor, whether it is too dirty or stuck, clean or replace it when necessary. Load data stream to confirm idle operation parameter status.
Small valve clearance
Check valve clearance: on 4-cylinder engine, the clearance of intake valve shall be 0.20±0.05 mm, exhaust valve 0.30±0.05mm. On 3-cylinder engine, the clearance of intake / exhaust valve shall be 0.20±0.05mm when heating, 0.12±0.04mm in cold condition. Otherwise, shall adjust it.
Improper ignition time
Check ignition advance angle, whether it is normal. In idle condition: on 4-cylinder engine, the advance angle shall be 10°~12° before top dead center. on 3-cylinder engine, the advance angle shall be 12°±3.75° before top dead center. Otherwise, shall adjust it.
Engine mechanical parts
Check exhaust system, whether it is blocked or damaged. Check timing, whether it is misaligned. Check valve spring, whether it is damaged. Check camshaft, cylinder head and piston, whether they are malfunction. Check cylinder pressure, whether it is in normal condition.
3
Common Malfunction Diagnosis Flow of Geely Automobile
Engine surging
Fuel fliter blockage
Blocked Clean or replace
Normal Poor Check the injector whether it is blocked or poor atomized
Clean or replace
Normal Low Low fuel pressure
Maintain
Normal Intake system leaking
Leak Maintain
Normal Poor Poor ignition
Maintain or replace
Normal Abnormal Charcoal canister
Replace
Normal Abnormal Adjust
Engine valve clearance
Normal Engine ignition timing
Abnormal Adjust
Normal Abnormal Clean or replace
Idle motor
Normal Abnormal Engine mechanical parts
Check
4
Common Malfunction Diagnosis Flow of Geely Automobile
No. 003 Over idle speed when warm-up Malfunction
Idle speed raised when warm-up
Cause
Solution
Improper ignition time
Adjust ignition time
Incorrect fuel pressure
Check fuel pressure, whether the value is 265~304kPa. If it is abnormal, shall check fuel pump and pressure controller, as well as the balance fuel injection volume of each injector.
Throttle cable or inner damper fails to return origin position
If throttle cable or inner damper fails to return origin position, sc. opening degree remains, shall check throttle cable and throttle.
Idle speed control valve or stepping motor stuck
Check idle controller, whether there is over carbonization. Implement clean and self-adaption value adjust when necessary.
Intake system leak
Check intake system, whether it is leaking. Maintain or replace when necessary.
The sensitive resistance temperature coefficient of water temperature sensor indicates inaccurately
Check water temperature sensor, at each temperature, whether the operation resistance is in regulated range. For example, at 20℃± 1 ℃ (temperature tolerance), the resistance shall be 2.27~2.73kΩ. Replace when necessary.
Exhaust gas oxygen sensor malfunction
Check heater resistance of heated oxygen sensor (UAES 1~6Ω, Delphi 12Ω, Polarsun 13.2±10%) , heater voltage (12V) and signal voltage (0.1~0.9V), whether they are normal. Check oxygen sensor, whether it is polluted or poisoned. When oxygen senor outputs low voltage or signal error, then ECU will send thick injection order, otherwise, replace the sensor.
A/C control signal error
Check A/C controlling system, whether it is normal. Check pressure switch current, whether it is normal. Check AC system pressure, whether it is normal.
ECU inner data unmatching
Check ECU, whether it is damaged. Replace ECU assembly when necessary.
5
Common Malfunction Diagnosis Flow of Geely Automobile
Over idle speed when warm-up
Abnormal Water temperature sensor malfunction
Replace
Normal Oxygen sensor malfunction
Abnormal
Replace
Normal Abnormal Intake system leaking
Check
Normal Stuck Idle speed control valve or stepping motor stuck Clean or replace
Normal Abnormal Incorrect fuel pressure
Check
Normal A/C control signal error
Abnormal Check
Normal
Improper ignition time (too early)
Abnormal Adjust
Normal Abnormal Maintain
Throttle cable or damper malfunction
Normal Abnormal Replace
ECU inner malfunction
6
Common Malfunction Diagnosis Flow of Geely Automobile
No. 004 Idle speed fluctuation Malfunction
Cause Throttle is stuck and dirty
Ignition maladjustment
Voltage unstable
Sensor and executive unit malfunction
Solution Clean and check throttle sealing condition. Check spark plug, whether it is dirty, cracked or tracking; Check wire of each cylinder, whether they are ageing, tracking, short or open circuit; Check ignition timing, whether it is maladjustment. (ignition timing shall position at 10~12° before top dead center when idling. Adjust ignition timing advance angle if necessary, when accelerating, the angle shall increase 20~30°) Check battery voltage, whether the value is 12~14.5V; Check generator, whether it operates normally; Check body earth lead, whether it is fastened. Check cooling temperature sensor, whether the resistance is according with the standard in different temperatures. Check intake temperature sensor, and replace it when necessary. Check idle speed control valve or stepping motor, whether it is stuck or damaged, clean or replace it when necessary. Check throttle position sensor, whether the bolts are over raised, and adjust them when necessary. Check oxygen sensor, whether it waves between 0.1V and 0.9V. If injector sealing leaking, then replace injector assembly. If spark plug operates poorly, then replace the plug.
Exhaust system malfunction
Check canister, whether it is polluted and blocked. Check exhaust pipe, whether it is deformed and damaged. Check 3-way catalytic converter, whether it is damaged or blocked.
Poor tachometer sensitivity
Check instrument connector, whether it is poor contact. Fix it again when necessary. If it conducts normally, then replace the instrument panel.
ECU malfunction
Test the voltage between each 2 terminals of ECU, whether the value is in normal range. Check the connecting condition between ECU and wire. Load data stream according to origin data.
Engine mechanical malfunction
Check the pressure difference between each cylinder, whether they are over normal range. Check the sealing condition of each cylinder.
7
Common Malfunction Diagnosis Flow of Geely Automobile Idle speed fluctuation
Stuck, dirty Clean
Throttle is stuck and dirty Normal
Abnormal Adjust
Ignition maladjustment Normal
Abnormal
Exhaust system malfunction
Check or replace
Normal Abnormal Voltage unstable Normal
Check or replace Abnormal
Sensor and executive unit malfunction Replace Normal
Abnormal
ECU malfunction
Replace
Normal Abnormal Engine mechanical malfunction
Check
8
Common Malfunction Diagnosis Flow of Geely Automobile
No. 005 Idle speed unstable or engine shut-off when opening AC or steering Malfunction
Idle speed unstable or engine shut-off when openinig AC or steering
Cause
Solution
Compressor or booster pump malfunction
AC compressor over load (for example, coolant over filling, tube blocked, condenser is dirty, and etc.), belt over tensioned, compressor inner stuck, as well as booster pump inner rotor stuck and results over load.
Intake system abnormal
When intake manifold leaking, repair or replace relevant component. When valve clearance disalignment, adjust it. When air filter blocking, replace it.
Oil line pressure abnormal
Replace oil pump, when it operates abnormally. Fuel filter blocked, replace it. Fuel pressure controller operates abnormally, replace it. Oil pump relay poor contact, maintain or replace it.
AC switch or booster pump oil pressure sensor malfunction
When opening AC or steering, ECU doesn't receive loading signal, which results low idle speed and engine shut-off. Maintain or replace it.
Idle speed controller or stepping mortor malfunction
Check stepping motor, whether it is stuck or dirty. Clean or replace it when necessary.
Injector malfunction
When injector blocked or poor atomized, shall clean the injector, and replace it if necessary.
Improper ignition timing or weak jump-spark power
Check ignition timing, coil, wire and spark plug etc. and each connecting part, whether they are damaged. Maintain or replace them.
ECU malfunction
Check ECU and each connecting part, whether there are damage.
Low engine pressure
cylinder
Disassemble and maintain the engine.
9
Common Malfunction Diagnosis Flow of Geely Automobile Idle speed unstable or engine shut-off when openinig AC or steering
Abnormal Compressor or booster pump failure Normal
Check or replace Abnormal
Intake system abnormal
Check
Normal Abnormal Check or replace
Oil line pressure abnormal Normal Abnormal AC switch or booster pump oil pressure sensor malfunction Normal
Replace
Abnormal Clean or replace
Idle speed controller or stepping mortor malfunction Normal
Abnormal
Injector malfunction Normal
Clean or replace
Abnormal
Improper ignition timing or weak jump-spark power
Normal
Adjust or replace
Abnormal
ECU malfunction Normal
Replace Abnormal
Insufficient engine cylinder pressure
Check
10
Common Malfunction Diagnosis Flow of Geely Automobile
No. 006 Engine shuts off intermittently Malfunction
Cause
Solution
Spark plug clearance abnormal or tracking
Engine shuts off intermittently when running at idle speed
is
Adjust spark plug clearance: on 4-cylinder engine, 0.8~1.0mm. On 3-cylinder engine, 1.0~1.1mm. Replace the plug when there is current leaking.
Ignition wire tracking, short or open circuit
Replace ignition wire.
Fuel pump relay conducting point burnt
Check relay conducting point, whether it is burnt. Replace it when necessary.
Improper fuel pressure
Check oil pressure and the atomization of each injector, whether they are normal. Check oil pump, oil pressure controller and fuel filter when necessary. As well as clean and replace the injector.
Fuel pollution
Check oil, whether it is polluted or mixed with water.
Ignition coil malfunction
Check ignition coil, whether it is over heat or short circuit. Measure primary winding, the resistance shall be 0.4~0.6Ω, and secondary winding, the resistance shall be 11~15kΩ. Otherwise, shall replace ignition coil.
Canister oil leaking
Check canister, whether it contains gasoline or it is blocked. Replace it when necessary.
Distributor malfunction
Replace distributor assembly.
Exhaust system blocked
Check 3-way catalytic converter or exhaust pipe, whether it is bent or blocked. Replace it when necessary.
Improper valve adjustment
Check the valve clearance of each cylinder, whether the value is too small. Adjust it to standard value when necessary. For 4-cylinder engine, the intake valve clearance shall be 0.20±0.05mm, the exhaust valve clearance shall be 0.30±0.05mm. For 3-cylinder engine, the intake / exhaust valve clearance shall be 0.20±0.05mm when heating, and 0.12±0.04mm when in cold condition. Otherwise, shall adjust the clearance.
Crankcase malfunction
clearance
venting
device
Check PCV valve, whether it is blocked or stuck. Maintain or replace it when necessary.
Fuel tank inner vacuum
Check fuel tank, whether it contains inner vacuum. Replace tank cover or canister electromagnetic valve when necessary.
Oxygen sensor malfunction
Check oxygen sensor, whether it is polluted or poisoned. Replace it when necessary.
Idle speed control valve or stepping motor operates abnormal
Check idle speed control valve or stepping motor, whether it is stuck or operating abnormal. Clean or replace idle speed control valve or stepping motor when necessary.
ECU and connecting circuit malfunction
Check ECU body, whether the heat condition and operating condition are in according with manufacturer requirements. Replace ECU assembly when necessary. Check engine computer wire harness connector, whether it is loose, fix it again when necessary.
11
Common Malfunction Diagnosis Flow of Geely Automobile Engine shuts off intermittently
Abnormal Improper fuel pressure
Maintain or replace
Normal Burnt Fuel pump relay conducting point burnt
Normal
Replace
Abnormal
Idle speed control valve or stepping motor is dirty or stuck
Normal
Check or replace
Abnormal
Fuel pollution
Replace
Normal Abnormal Ignition coil malfunction
Replace
Normal Abnormal Canister oil leaking
Check or replace
Normal Blocked Exhaust system blocked
Check or replace
Normal Abnormal Oxygen sensor malfunction
Replace
Normal Abnormal Improper valve clearance
Adjust
Normal Abnormal Crankcase venting device malfunction
Check
Normal Abnormal Fuel tank inner vacuum Normal
Check Abnormal Replace
Spark plug and ignition wire malfunction Normal
Abnormal
ECU and connecting circuit malfunction
Check or replace
12
Common Malfunction Diagnosis Flow of Geely Automobile
No. 007 Poor accelerating performance in cold condition Malfunction
Poor accelerating performance in cold condition, particularly in low speed and middle speed.
Cause
Solution
Improper gasoline quality
Clean fuel pipe and replace clean gasoline, 93# or above.
Low gasoline pressure
Check filter, whether it is blocked. As well as fuel pressure controller, whether it operates normally, replace it when necessary. Check gasoline pump pressure whether the value is normal, maintain or replace it when necessary.
Air filter blocked
Check air filter, whether it is blocked, clean or replace it when necessary.
Low cylinder pressure
Check cylinder pressure, whether there is carbon deposit at intake valve, as well as valve leaking and cylinder wearing malfunction. Maintain or replace then according to the malfunction.
Idle speed controlling valve or stepping motor operates abnormal
Clean or replace idle speed control valve or stepping motor
Throttle malfunction
Check throttle body, whether it is stuck, clean or replace it when necessary.
Ignition system malfunction
Check ignition coil, wire and spark plug, whether they are malfunction, replace them when necessary.
Intake temperature pressure sensor
Pressure sensor malfunction. Check the resistance and voltage, whether the value is in normal range. Replace the sensor when necessary.
Oxygen sensor malfunction
Check oxygen sensor, whether the heating function is normal. As well as the voltage signal, whether it varies between 0.1V and 0.9V.
Intake manifold leaking
Check the vacuum, whether the value is in normal range. Check the connecting condition of each vacuum hose, as well as intake/exhaust manifold gasket, whether it is damaged.
Ignition timing maladjustment
Check tachometer sensor signal and ignition datum, whether they are normal.
ECU and malfunction
connecting
circuit
Check ECU, whether it is malfunction. Check connecting wire, whether it is of poor contact. Maintain or replace it when necessary.
13
Common Malfunction Diagnosis Flow of Geely Automobile Poor accelerating performance in cold condition
Lack Improper gasoline quality or low gasoline
Check or replace
pressure Normal Blocked Air filter blockage
Clean
Normal Low Low cylinder pressure
Check
Normal Stuck Idle speed valve or throttle malfunction
Check
Normal Abnormal Ignition system malfunction
Check or replace
Normal Abnormal Intake temperature pressure sensor
Replace
Normal Oxygen sensor malfunction
Abnormal Replace
Normal Abnormal Intake manifold leaking
Check
Normal Abnormal Ignition timing maladjustment
Check and adjust
Normal Abnormal ECU and connecting wire malfunction
Check or replace
14
Common Malfunction Diagnosis Flow of Geely Automobile
No. 008 Spark plug non-sparking Malfunction
Engine has no start symptom and spark plug non-sparking
Cause
Solution
Ignition coil malfunction
Measure the primary winding, the resistance shall be 0.4~0.6Ω, and the secondary winding, the resistance shall be 11~15kΩ. Otherwise shall replace ignition coil. Check the coil, whether there is short or open circuit. Replace it when necessary.
Spark plug malfunction
Check spark plug, whether it is leaking current, as well as the clearance of electrode.
Distributor cover or distributor arm malfunction
Check cover or distributor arm, whether there is current leaking, dielectric puncture or damage. Replace it when necessary.
Ignition wire malfunction
Check ignition wire, whether it is leaking current or open circuit. Replace it when necessary.
Tachometer sensor malfunction or the Hall sensor in distributor malfunction
Measure sensor resistance (UAES 4-cylinder engine tacho sensor resistance shall be 770~950Ω, Delphi 540Ω, Polarsun 530±50Ω), as well as the signal output and ECU wire, whether they are operating normally. Maintain it when necessary.
EFI fuse and relay malfunction
Check EFI fuse, whether it is burnt or poor contact. Check main relay, whether it is burnt. Check the circuit, whether it is poor contact. Maintain them when necessary.
ECU malfunction
Check terminal input and output signal, whether they are normal.
Ignition control system circuit malfunction
Check all connecting wires, whether they are poor contact or open circuit. Maintain it when necessary.
Engine anti-thief system malfunction
Check anti-thief controller and all connecting wires, whether they are normal connected, as well as the anti-thief status activated.
control
15
Common Malfunction Diagnosis Flow of Geely Automobile Spark plug non-sparking
Abnormal Ignition coil malfunction
Replace
Normal Abnormal Spark plug malfunction
Adjust or replace
Normal
Abnormal
Distributor cover or distributor arm malfunction
Replace
Normal
Abnormal
Ignition wire malfunction
Replace
Normal
Abnormal
Tachometer sensor failure or the Hall sensor in distributor malfunction
Replace
Normal Abnormal ECU malfunction
Replace
Normal Abnormal Ignition control system circuit malfunction
Check
Normal Abnormal Engine anti-thief control system malfunction
Replace
16
Common Malfunction Diagnosis Flow of Geely Automobile
No. 009 Low idle speed during engine heating in cold condition Malfunction
Cause
Solution
Weak ignition spark
Check ignition coil, wire and spark plug, whether they are normal. Adjust or replace them when necessary.
Crankcase device fails
Check PCV valve, whether it is normal. Replace crankcase venting device when necessary.
venting
Intake system leaking
Measure vacuum, check the connecting condition of manifold gasket, throttle gasket, and all vacuum pipes.
Thermostat malfunction
Check thermostat, whether it is leaking, which results warm-up period over normal value. Replace thermostat when necessary.
Idle speed (steeping maladjustment
Measure the resistance (UAES idle speed valve 17.6Ω, Delphi motor 53Ω, Polarsun motor 48±2.4Ω) and voltage of idle motor, whether they are normal. Check idle speed motor, whether it is dirty and stuck. Maintain and replace it when necessary.
valve motor)
Improper clearance
Low idle speed during engine heating in cold condition
valve
Adjust valve clearance: on 4-cylinder engine, the intake valve clearance shall be 0.20±0.05 mm, the exhaust valve clearance shall be 0.30±0.05mm. On 3-cylinder engine, the intake/exhaust valve clearance shall be 0.20±0.05mm when warming-up, and 0.12±0.04mm in cold condition.
Low cylinder pressure
Check engine compression ratio and pressure, whether they are in accordance with standard value. 479Q 9.3: 1/1250kpa/250r/min; 479QA 9.8: 1/1440kpa/250r/min; 481Q 9.4: 1/1360kpa/250r/min; JI376QE 9.5: 1/1225kpa/350r/min; JL378QE 9.5: 1 / 1225kpa/350r/min; Inspemction the cause, whether valve leaking or piston ring and cylinder wearing. Disassembly and maintain the engine when necessary.
Water temperature sensor damaged
Check the resistance of water temperature sensor in cold condition (UAES 2.5kΩ, at 20℃; Delphi 3.56~2.26kΩ, at 20~30℃; Polarsun 2.5kΩ, at 20℃), whether they are in accordance with standard. Or measure the temperature of cold vehicle by scanner, whether it is in accordance with actual engine temperature. Replace coolant fluid temperature sensor when necessary.
Injector malfunction
Check injector, whether it is blocked or stuck. Check atomization and implement leak test. Clean or replace injector.
Oxygen malfunction
Check heat-type oxygen sensor heater resistance (UAES 1~6Ω, Delphi 12Ω, Polarsun 13.2Ω±10%), as well as heater voltage, 12V, and signal voltage, 0.1~0.9V, whether they are in normal range. Check sensor surface, whether it is dirty and results voltage over normal value, as well as the fuel-air mixture is too thin.
Ignition maladjustment ECU malfunction
sensor
timing
Check ignition time and calibrate ignition timing, in idle condition: on 4-cylinder engine, the ignition advance angle shall be 10°~12° before top dead center. On 3-cylinder engine, the value shall be 12°±3.75° before top dead center. Check connecting conditions of ECU and all wires.
17
Common Malfunction Diagnosis Flow of Geely Automobile Low idle speed during engine heating in cold condition
Abnormal Check and replace
Weak ignition spark
Normal
Abnormal
Crankcase venting device failure
Normal
Check
Damaged Replace
Water temperature sensor damaged Normal
Abnormal Replace
Thermostat failure Normal
Abnormal
Improper valve clearance
Adjust
Normal Abnormal Check
Intake system leaking Normal Abnormal Ignition timing maladjustment
Normal
Check Low Check
Low cylinder pressure Normal
Abnormal
Idle speed valve (steeping motor)
Clean and replace
maladjustment Normal
Abnormal Clean and replace
Injector failure
Normal Abnormal Oxygen sensor malfunction Normal
Replace Abnormal Replace
ECU malfunction
18
Common Malfunction Diagnosis Flow of Geely Automobile
No. 010 Canister oil leaking Malfunction
Cause
There is fuel under vehichle when parking, and the engine speed is unstable when idling.
Solution
Check valve damage, on fuel tank
Check the single check valve on fuel tank, whether it is damaged. Replace fuel tank assembly when necessary.
Fuel tank cover damage
Check the single check valve of fuel tank cover, whether it can open. Replace fuel tank cover when necessary.
Canister venting (air) pipe blocked
Check the white venting pipe, to air, at the bottom of canister, whether it is blocked by silt and result oil leaking. Unplug or replace it when necessary.
Controlling canister malfunction
Check controlling canister inner charcoal and pipe export, whether they are blocked. Replace them when necessary. Check canister, whether the mounting position is too low. Adjust the mounting height when necessary.
Vacuum pipe blocked, on top of canister
Raise engine speed to 2000r/min, if vacuum pipe suction is low, then shall check vacuum pipe system.
Canister control valve malfunction
Check canister controlling valve resistance, which shall be 22~30Ω at 20℃. Check controlling wire and valve element, whether they are in normal condition. Maintain and replace them when stuck.
ECU malfunction
Check ECU and canister electromagnetic valve controlling circuit, whether they are in normal condition.
Canister oil leaking
Damaged Check valve damage, on fuel tank
Replace
Normal Damaged Fuel tank cover damage
Replace
Normal Damaged Controlling canister malfunction
Replace
Normal Pipe blocked, on top of canister
Blocked Check
Normal Damaged Canister control valve malfunction
Replace
Normal Abnormal ECU malfunction
Replace
19
Common Malfunction Diagnosis Flow of Geely Automobile
No. 011 Fuel smells in vehicle Malfunction
Cause
Solution
Gas station man-made malfunction
Fuel smells in vehicle, when opening window, it smells even worse
When filling, fuel dropped around tank filling port and cover, then flows into vehicle. Clean vehicle.
Fuel tank filling port and port cover leaking
Check or replace fuel tank filling port and cover.
Fuel pipe leak
Check or replace leaking fuel pipe.
Fuel tank cracked and leaking
Check fuel tank, whether it is leaking. Replace it when necessary.
Canister leak
Check canister controlling system and venting system.
Fuel tank inner pressure abnormal
Replace fuel tank, check valve and fuel filling port cover etc.
Controlling canister pipe malfunction
Check canister pipe, whether it is dropped.
Canister malfunction
Check canister controlling valve, whether it is blocked, as well as the suction capacity, whether it is poor or fails to open.
controlling
valve
Fuel pump and fuel sensor mounting Check or replace fuel pump and fuel sensor mounting sealing. gasket leaking Ignition timing maladjustment
Maintain ignition timing, whether it is delayed.
Injector leak
Check sealing of injector and pipe.
Engine operates abnormal
Check engine operation, whether there is unavailable cylinder.
Oxygen sensor
Measure the voltage of sensor, whether it is too low, as well as the fuel-air ratio, whether it is over normal value.
20
Common Malfunction Diagnosis Flow of Geely Automobile Fuel smelling strong in vehicle
Leak Fuel pipe leakage Normal
Check Leak
Fuel tank leakage Normal
Replace Leak, blocked Replace or check
Canister leak or block Normal
Abnormal
Fuel tank inner pressure abnormal Normal
Check Leak
Injector leak
Check Normal
Abnormal
Engine oprates abnormal Normal
Check
Abnormal Check
Ignition timing maladjustment Normal
Abnormal
Canister controlling valve malfunction Normal
Replace Abnormal
Canister pipe malfunction Normal
Replace Abnormal Replace
Oxygen sensor
21
Common Malfunction Diagnosis Flow of Geely Automobile
No. 012 Engine vibration when operating Malfunction
Engine operates unstably and vibrations, when running in idle and low speed, there is tu-tu-tu sound in exhaust pipe.
Cause
Solution
Engine operates with unavailable cylinder
Check cylinder pressure, spark plug, ignition wire and valve etc., whether they are abnormal. Replace the malfunction part when necessary.
Incorrect ignition timing
Adjust ignition time
Fuel pressure abnormal
Check electric fuel pump, fuel pressure controller and pipes
Engine fuel grade doesn't in accordance with standard Injector malfunction
Replace qualified fuel Check injector fuel atomization and pulse width
Engine shock pad malfunction or mounting bracket deformed Cylinder gasket damage
Adjust or replace relevant components Replace cylinder gasket
Clutch operates abnormal
Maintain or replace relevant components
Gearbox or vehicle transmission accessories damage
Adjust or replace relevant components According to components
Crank link mechanism malfunction
22
sound
position,
maintain
relevant
Common Malfunction Diagnosis Flow of Geely Automobile Engine vibration when operating
Unavailable cylinder Engine operates with unavailable cylinder
Normal
Check Abnormal
Incorrect ignition timing
Normal
Check
Abnormal Check
Fuel pressure abnormal Normal
Abnormal
Injector failure Normal
Check Abnormal Check
Cylinder gasket damage Normal
Abnormal
Engine fuel grade doesn't in accordance with standard Normal
Replace
Abnormal
Engine mounting bracket deformed Normal
Check Abnormal Check
Crank link mechanism malfunction Normal
Abnormal
Clutch operates abnormal
Check
Normal Abnormal Gearbox or vehicle transmission accessories
Check
damaged
23
Common Malfunction Diagnosis Flow of Geely Automobile
No. 013 Engine noise over normal level Malfunction Engine noise over normal level, and vibration when idling
Cause
Solution
Exhaust system leaking or block
Maintain leaking components, as well as replace blocking parts.
Poor fuel quality, which results engine operating abnormal
Replace qualified fuel that match Geely vehicle requirement.
Engine operates abnormal
When engine operating with unavailable cylinder, the malfunction shall be excluded. When camshaft assembly and gear sound abnormally, shall adjust or replace them. As well as the crankshaft and piston link mechanism.
Generator water pump, booster pump etc. sound abnormally
Replace generator, water pump and booster pump assembly.
Water tank fan and AC fan sound abnormally
Replace relevant components.
Water temperature over normal value
Maintain fan and cooling system, whether they operate normally.
Ignition timing maladjustment
Maintain or adjust ignition timing.
Compressing ratio over normal value
Maintain cylinder capacity, combustion chamber volume, as well as the end surface of cylinder block and cylinder head, whether they are normal.
Detonation sensor malfunction
Maintain mounting condition of sensor and correct the voltage.
Poor lubrication
Check oil pressure and quality.
Engine interferences accessories
with
Intake system leak or block
relevant
Maintain and exclude the malfunction. Replace relevant components when leaking. Unplug or replace them when blocked.
24
Common Malfunction Diagnosis Flow of Geely Automobile Engine noise over normal level
Leaking or block Exhaust system leaking or block
Normal
Check and replace
Abnormal
Engine operates abnormal Normal
Check
Abnormal sound
Generator water pump, booster pump etc. sound abnormally Normal
Check and replace
Abnormal sound
Water tank fan and AC fan sound abnormally Normal
Check and replace
Abnormal
Water temperature over normal value Normal
Interferen
Engine interferences with relevant accessories
Normal
Check Over normal value Check
Compressing ratio over normal value Normal
Check
Leak or block
Intake system leak or block
Check
25
Common Malfunction Diagnosis Flow of Geely Automobile
No. 014 Water temperature over normal value after AC activated Malfunction
Cause
Radiator over heated after AC activated when driving
Solution
Insufficient coolant fluid
Fill coolant according to requirements.
Radiator fan operates abnormal
Radiator fan blade deformed and stuck. Replace radiator fan assembly when the fan speed is low.
Too much refrigerant
Check refrigerant, whether it is too much, which increases engine load and high water temperature. The refrigerant shall be filled to standard level.
Condenser fan malfunction
Maintain fan wire and motor.
AC system pressure over normal value
Adjust system pressure to normal value.
The cooling and cycling performance of cooling system lower than normal level
Too much furring contains in engine water pipe, which results poor water cycling and cooling, and shall be cleaned. Clean or replace the radiator, when it is dirty and blocked.
Generator belt loose
Adjust belt tightness according to requirement.
Water pump operates abnormal and results poor cooling water recycles.
Maintain or replace pump assembly
Thermostat fails to open
Replace thermostat assembly
ECU malfunction
Maintain ECU and all wire terminals
Engine operates abnormally
Disassemble and maintain engine
Water temperature over normal value after AC activated Lack Insufficient coolant fluid Normal
Add
Poor
Radiator fan operates abnormal Normal
Check and replace
Over normal value
Too much refrigerant
Drain
Normal
Failure
Condenser fan malfunction Normal
Check and replace Over normal value
AC system pressure over normal value
Check
Normal The cooling and cycling performance of cooling system lower than normal level Normal
Not smooth Check
Poor
Poor cooling water recycles Normal
Check Abnormal
ECU failure
Replace Normal
Abnormal
Engine operates abnormally
Check
26
Common Malfunction Diagnosis Flow of Geely Automobile
No. 015 Oil pan leak Malfunction
Oil leak at rear end of oil pan after vehicle parked.
Cause
Solution
Too much oil
Fill oil according to standard. For 4-cylinder engine, dry, 3.5L; wet, 3.0L. For 4G18 engine, with oil filter, 4.0L; without oil filter, 3.8L. For 3-cylinder engine, 3.0L.
Oil pan gasket damage
Replace oil pan gasket; tighten the bolts after sealant coated.
Rear end cover gasket leak
Replace rear end cover gasket and coat with sealant.
Rear oil pipe capping leak
Replace or maintain rear main oil pipe capping.
There is blow hole on rear end
Maintain the blow hole on rear end.
Oil pan bolt loose
Tighten oil pan retaining bolt or replace damaged bolt.
Oil pan damaged or deformed
Maintain or replace oil pan.
Irregular assembly procedure
Inner engine pressure over normal value Crankshaft rear oil seal ageing or damage
Oil pan retaining bolt adjust to 4.9NM, evenly. Coat sealant with proper quantity, otherwise, the gasket may slid and move. Unplug or replace gas exhaust system (PCV valve) Engine cylinder, piston ring and piston worn out. Maintain or replace relevant component when necessary. Replace crankshaft rear oil seal.
27
Common Malfunction Diagnosis Flow of Geely Automobile Oil pan leaking Too much Fill oil according to standard
Too much oil Normal
Damage
Oil pan gasket damage
Replace
Normal Irregular assembly procedure
Irregular Remount
Normal Oil pan damaged
Damage Replace
Normal Rear end panel deformed or seal gasket failure
Normal
Abnormal Check and replace
Blocked
Rear oil pipe capping leaking
Check and replace
Normal Oil pan bolt loose
Loose Tighten
Normal Over normal value Inner engine pressure over normal value
Normal
Check
Abnormal Replace
Cranksahfe rear oil seal ageing or damage
28
Common Malfunction Diagnosis Flow of Geely Automobile
No. 016 Distributor oil leaking Malfunction
Cause
Engine stands stil after activated. There is visible oil leaking at distributor
Solution
Too much oil
Drain spare oil
Poor crankcase venting
Check crankcase intake pipe, whether it is blocked. Clean and unplug intake pipe to exclude the malfunction.
Distributor seal ring ageing and damage
Check distributor seal ring, whether it is ageing or damaged. Replace O-ring when necessary.
High inner engine pressure
Check exhaust pipe and single check valve, whether they are blocked. Unplug or replace them when necessary.
Distributor rotating shaft loose
Check distributor rotating shaft, whether the loose volume is in accordance with standard. Replace distributor assembly when necessary.
Distributor rotor gear wearing
Check distributor gear, whether it is worn out. Replace distributor assembly when necessary.
Blow hole or crack on distributor
Check oil leak of distributor sear and further determine the processing accuracy of distributor. If there is blow hole or crack, then shall replace distributor seat.
Distributor oil leaking Y Drain spare oil
Too much oil N
Damage
Poor crankcase venting
Normal
Check
Loose Check
High inner engine pressure
Normal
Loose
Distributor seal ring ageing and damage
Replace
Normal Wearing Distributor rotating shaft loose
Replace
Normal Over normal value Distributor rotor gear wearing
Normal
Replace
Poor
Blow hole or crack on distributor
Replace
29
Common Malfunction Diagnosis Flow of Geely Automobile
No. 017 JL376/378 engine shut-off when sliding at neutral gear Malfunction
Engine operates well when accelerating normally, while shut-off when sliding at neutral gear or steering.
Cause
Solution
Improper spark plag electrode clearance or spark plug current leak and non-resistance
Adjust or replace spark plug (spark plug clearance is 1.0~1.1mm)
Improper adjustment
Adjust valve clearance, 0.20±0.05mm in hot condition, 0.12±0.05mm in cold condition
valve
clearance
Distributor malfunction
Maintain and replace distributor assembly
Intake system leaking
Maintain or replace relevant component；
Idle speed controller motor) malfunction Crankcase pressure
generates
(stepping negative
Check stepping motor controlling wire, resistance and blocked. Clean and replace then when necessary. Check exhaust single check valve
Fuel circuit stuck (when steering)
Maintain fuel tank, whether there is impurity in it.
Fuel pressure abnormal
When fuel pipe is leaking, replace it When air filter is blocked, replace it. When fuel pump or fuel pressure controller, which value shall between 264kPa and 305kPa, is damaged, replace it.
Fuel contains in canister
Maintain and replace canister
Fuel contains in vacuum pipe
Maintain oil pressure controller
Throttle shaft run-out
Replace throttle body assembly
Wire malfunction
Check wire circuit, whether it is poor contact.
Low cylinder pressure
Check cylinder pressure, whether the valve is leaking, as well as the wearing condition of piston ring and cylinder.
30
Common Malfunction Diagnosis Flow of Geely Automobile JL376/378 engine shut-off when sliding at neutral gear Improper Improper spark plug and valve clearance adjustment Normal
Adjust
Stuck
Fuel circuit stuck (when steering) Normal
Check
Abnormal
Idle speed controller (stepping motor) Normal
Clean and replace Abnormal
Fuel pressure abnormal
Check
Normal Distributor failure
Abnormal Replace
Normal Intake system leaking
Leak Maintain
Normal Fuel contains Fuel contains in vaccum pipe Normal
Maintain
Low
Low cylinder pressure
Check
31
Common Malfunction Diagnosis Flow of Geely Automobile
No. 018 High idle speed when sliding at neutral gear, MK Malfunction
Cause
Solution
Improper ignition timing
Adjust ignition timing
Throttle body or cable fails to return
Clean throttle, adjust or replace throttle cable
Intake system leaking
Maintain or replace relevant component
Improper valve clearance High idle speed when sliding at neutral gear, MK
Adjust valve clearance
Improper fuel pressure
Normal pressure: between 250kPa and 300kPa. When fuel pump, fuel filter and fuel pressure controller operating abnormally, shall replace relevant component.
Electric injection unit operates poorly
Stepping motor stuck, clean it. Throttle position sensor sensitive poorly, adjust or replace it. Fuel injector leaking, replace it. Intake temperature pressure sensor malfunction, replace it. (see the table above for details of check method)
ECU software malfunction or inner damage
Software malfunction, update it or check ECU, whether it is damaged. Replace ECU when necessary.
High idle speed when sliding at neutral gear, MK
Fails to return Throttle body or cable fails to return
Check and replace
Normal Improper ignition timing
Abnormal Check and adjust
Normal Intake system leaking
Leak Check
Normal
Improper valve clearance
Normal
Abnormal Adjust
Operates poorly
Electric injection unit operates poorly
Normal ECU software failure or inner damage
Check and replace
Abnormal Replace
32
Common Malfunction Diagnosis Flow of Geely Automobile
No. 019 Engine vibration Malfunction
Cause
Engine operating unstably, starting slowly, with surge and vibration
Solution
Engine bracket or vehicle body deformed
Replace engine bracket or correct vehicle body.
Low fuel pressure
Check supply pressure of fuel system, whether it is too low, while the normal value is between 250kPa and 300kPa. Replace fuel pressure controller, fuel filter or electric fuel pump and other relevant damaged components.
Clutch system malfunction
Generally, the malfunction is caused by unbalance fly wheel or press plate etc. Replace relevant components.
Engine operating with unavailable cylinder
Spark plug, cylinder cable, valve, valve clearance, injector and cylinder sleeve worn out, and results unavailable cylinder. Exclude the malfunction. Check idle speed stepping motor, whether it is too much carbon deposit. Clean or replace it when necessary.
Electric injection unit malfunction
Check throttle opening degree, clean or replace throttle sensor when necessary. Check ECU integrated circuit, whether it is damaged. Replace it when necessary.
ECU damaged
Engine vibration
Check Engine oprating with unavailable cylinder
Normal
Check
Low
Low fuel pressure
Check
Normal Deform Engine bracket or vehicle body deformed
Normal
Check and replace
Abnormal
Clutch system malfunction
Normal
Check and replace
Damage
ECU damaged
Replace
33
Common Malfunction Diagnosis Flow of Geely Automobile
No. 020 Exhaust pipe pours black smoke Malfunction Light smoke when idling, heavier when accelerating
Cause
Solution
Air filter blocked
Check and clean/replace air filter
Low fuel quality
Apply unleaded clean fuel, 93# or above, which is in accordance with manufacturer requirements.
Fuel contains in vacuum pipe
Check fuel pressure controller, whether it is damaged and leaking
High oil pressure
Check fuel pump, pumping pressure and controller function.
Improper ignition timing
Check and adjust ignition timing
Unavailable cylinder
Implement cylinder cross firing test respectively, check the performance of wire and spark plug.
Valve leaking
Clean combustion chamber carbon deposit. Replace or grind valve.
Injector leak or atomization abnormal
Clean or replace malfunction injector
Throttle position sensor malfunction
Measure the resistance and voltage of throttle, replace it when necessary.
Oxygen sensor voltage abnormal
Measure sensor voltage and resistance, replace it when necessary.
Cylinder gasket damage
Maintain or replace cylinder gasket.
ECU malfunction
Check ECU and circuit whether they are normal.
Low cylinder pressure
Disassemble and maintain engine.
34
Common Malfunction Diagnosis Flow of Geely Automobile Exhaust pipe pours black smoke
Blocked Clean or replace
Air filter blocked Normal
Abnormal
Low fuel quality
Replace
Normal
Low
High oil pressure
Check and replace
Normal
Abnormal
Unavailable cylinder Normal
Check and replace
Abnormal
Improper ignition timing Normal
Adjust Abnormal
Oxygen sensor voltage abnormal Normal
Check
Leaking
Valve leaking
Check and replace Normal
Abnormal
Cylinder gasket damage Normal
Replace
Abnormal
ECU failure
Replace Normal
Abnormal
Injector leak or atomization abnormal
Clean or replace Abnormal
Normal Low cylinder pressure
Check
35
Common Malfunction Diagnosis Flow of Geely Automobile
No. 021 Engine idle speed decreases when activating head beam or fan Malfunction
Engine speed decreases, with vibration, when activating head beam or fan
Cause
Solution
Fuel quality is not in accordance with requirement
Apply unleaded clean fuel, 93# or above.
Generator belt loose
Adjust belt tension to 50NM, when pressuring downwards, and the deflection shall be 10MM.
Earth lead loose
Check gearbox, body earth lead and instrument earth lead, whether they are loose. Tighten them when necessary.
Generator operates abnormal
Check the electrical energy of generator, whether it is beneath 9V. Replace generator voltage controller when necessary.
Battery open circuit
Check the gravity of battery electrolyte, maintain or replace battery assembly when necessary.
Idle speed controlling valve or stepping motor malfunction
Clean idle speed control valve or stepping motor. Replace it when damaged.
Grouped switch short circuit
Maintain grouped switch and relevant harness.
The power of head beam or the load of fan is over normal value.
Check head beam, whether it applies the bulb requires the power over standard value. Replace standard power bulb when necessary. Replace fan motor or maintain the circuit.
Low generator charging current (75A)
Replace generator assembly, which supplies 90A charging current.
Poor ECU signal
Measure the voltage among terminals and wire connecting condition. Maintain or replace them when necessary.
Engine operates abnormal
Maintain engine
36
Common Malfunction Diagnosis Flow of Geely Automobile Engine idle speed decreases when activating head beam or fan
Loose Generator belt loose
Adjust
Normal Low Earth lead loose
Check
Normal Open circuit Generator operates abnormal
Check or replace
Normal Battery open circuit
Check
Normal Idle speed controlling valve or stepping motor failure Normal
Abnormal Clean and replace
Short circuit
Combined switch short circuit Normal
Check and replace Over load
The power of head beam or the load of fan is over normal value Normal
Replace Poor Replace
Poor ECU signal Normal
Abnormal Check
Engine operates abnormal
37
Common Malfunction Diagnosis Flow of Geely Automobile
No. 022 Exhaust pipe blows water Malfunction
Cause
Solution
Water log in silencer
Check silencer inner water log. The tail water exhaust port of silencer is blocked, and blows large quantity of water when accelerating. Punch a hole on silencer to drain water.
Throttle body water leak Engine vibration when idling, with abnormal noise, and cooling water is always polluted.
Maintain or replace throttle body.
Gasket damaged
Maintain cylinder and cylinder head surface, replace gasket.
Crack or blow hole in cylinder head
Check cylinder head, whether there is crack or blow hole in it, which results coolant flow into cylinder. Remove cylinder head and inspect the crack in it, by magnaflux. Replace cylinder head when necessary.
Crack or blow hole on clinder wall
Check cylinder wall, whether there is crack or blow hole in it, which results coolant flow into cylinder. Remove cylinder wall and inspect the crack in it, by magnaflux. Replace cylinder head when necessary.
Exhaust pipe blows water
Water log Check
Water log in silencer
Normal
Water leak Replace
Throttle body water leak
Normal Damage Gasket damage
Normal
Replace
Crack or blow hole
Crack or blow hole in cylinder head
Normal
Replace
Crack or blow hole Replace
Crack or blow hole on clinder wall
38
Common Malfunction Diagnosis Flow of Geely Automobile
No. 023 Engine shuts off when accelerating Malfunction
Cause Fuel tank lacks of fuel
Engine shut-off when vehicle picking up
Solution Fill fuel
Poor fuel quality
Replace with standard fuel
Air filter blocked
Clean or replace air filter
Low intake vacuum
Vacuum sense port of intake pressure sensor is blocked by carbon deposit. Clean it. Intake vacuum pipe cracked, and results vacuum decreased, mixture gas rarefied, as well as engine shut-off when vehicle picking up.
Exhaust system partly blocked
Check 3-way catalytic converter, whether it is dropped or blocked.
Ignition maladjustment
Check fly wheel signal rim, whether it operates correctly. Check tachospeed sensor, whether it is normal. Check valve timing, whether it is normal. Check ignition system, whether it contains ignition miss.
Positive electrode of oxygen sensor short or open circuit.
Check output voltage of oxygen sensor, in idle condition the value shall be about 4.5V. Otherwise, replace oxygen sensor.
Fuel pressure decrease when accelerating
Normal fuel pressure is between 250kPa and 300kPa. Check fuel pump, fuel filter and fuel pressure controller etc. Replace them when necessary.
Throttle position sensor short or open circuit
Check throttle position sensor, whether there is short or open circuit. Replace it when necessary.
Low cylinder pressure
Check operation of each cylinder, whether it operates normal. Disassemble and maintain engine when necessary.
39
Common Malfunction Diagnosis Flow of Geely Automobile Engine shuts off when accelerating
Lack Fuel tank lacks of fuel
Fill
Normal Poor fuel quality
Poor quality Replace
Normal Air filter blocked
Normal
Blocked Clean or replace
Low
Low intake vaccum Normal
Check Blocked
Exhaust system blocked
Check and replace
Normal Abnormal Ignition maladjustment Normal
Check
Decrease
Fuel pressure decrease when accelerating Normal Positive electrode of oxygen sensor short or open circuit Normal
Replace
Abnormal Replace Abnormal Check
Low cylinder pressure
40
Common Malfunction Diagnosis Flow of Geely Automobile
No. 024 Oil indicator is always on Malfunction Instrument warning lamp is always on after engine started
Cause
Solution
Low oil quantity results low oil pressure
Fill oil to standard level
Low oil viscosity or oil deteriorated
Replace required oil
Oil pressure switch damage
The inner conducting point of oil pressure switch burnt seriously and results short circuit. Replace oil sensing plug.
Oil indicator circuit leads to earth partly
The wire between oil sensing plug and grouped instrument partly leads to earth at front wall, and results oil indicator lightening constantly after circuit lead to earth.
Grouped instrument inner short circuit
Replace grouped instrument
Low oil pressure
Maintain oil pump and oil pipe, whether it is blocked. Unplug it when necessary. Check oil leaking condition and maintain it.
Large engine liner clearance, which results low oil pressure
Large clearance results oil leaking and low oil pressure. Normal value shall be 49kPa. Replace relevant component.
Oil pipe leaking
Maintain or replace relevant component.
Oil indicator is always on
Low Low oil quantity results low oil pressure
Normal
Fill
Deteriorate
Low oil viscocity or oil deteriorated
Replace
Normal Oil pressure switch damage
Normal
Damage Replace
Short circuit
Grouped instrumernt inner short circuit
Replace
Earth lead
Normal Oil indicator circuit leads to earth partly
Normal
Check
Low
Low oil pressure
Check
Normal Large clearance Large engine liner clearance, which results low oil pressure
Check
Normal
Leak Check
Oil pipe leaking
41
Common Malfunction Diagnosis Flow of Geely Automobile
No. 025 Water temperature is over normal value when engine running with large load Malfunction
Cause
Solution
Lack of coolant fluid
Water temperature is over normal value when diving in high speed, and is normal in low speed.
Fill non-standard anti-freeze fluid
Replace standard anti-freeze fluid
Fuel grade against requirement
Apply specified fuel
Low thermostat open travel
Thermostat shall be fully opened when water temperature reaches 82℃, otherwise, replace it.
Water pump belt loose
Adjust tension rate
Radiator is too dirty inside or outside, and results low cooling performance, as well as water temperature increased.
Clean radiator, the dirt and water mark, replace water tank when necessary.
Radiator fun operates abnormal (low speed or fails to work sometimes)
Maintain fan circuit and replace fan.
Improper ignition timing
Adjust timing
Engine water pipe rust
Clean rust
Engine mixed gas is too thick
Engine oxygen sensor damaged and results mixed gas viscosity misadjusted.
Improper piston fit clearance
Low cylinder pressure, maintain it. Low clearance often caused by applying non-standard piston, replace and reassemble with proper piston.
Cylinder bolt loose or cracked
42
Common Malfunction Diagnosis Flow of Geely Automobile Water temperature is over normal value when engine running with large load Poor Low cooling performance of rediator Normal
Check and replace Poor
Fan operates abnormal
Check and replace
Normal Improper piston fit clearance
Abnormal Check
Normal Too thick Engine mixed gas is too thick
Adjust
Normal Low thermostat open travel
Too small Replace
Normal Loose Water pump belt loose
Adjust
Normal Rust Engine water pipe rust Normal
Clean
Against
Fuel grade againsts requiremen
Replace
43
Common Malfunction Diagnosis Flow of Geely Automobile
No. 026 Canister electromagnetic valve sounds abnormal Malfunction
Cause
Electromagnetic valve sounds abnormal when idling
Solution
Canister electromagnetic valve is dirty inside
Clean it with carburetor detergent
Canister electromagnetic valve retaining rubber seat damage
Replace canister electromagnetic valve retaining rubber seat and adjust the position, as far as possible with vehicle body
Serious fuel tank inner vacuum
Replace fuel tank cap
Over adjustment of canister electromagnetic valve inner tube
Adjust canister electromagnetic valve according to standard flow rate
Serious canister electromagnetic valve wearing
Replace canister electromagnetic valve assembly
Canister electromagnetic valve sounds abnormal
Dirt Canister electromagnetic valve is dirty inside
Clean and replace
Normal Damage Canister electromagnetic valve retaining rubber seat
Replace
damage
Normal Vaccum Maintain
Serious fuel tank inner vaccum
Normal Over normal value Over adjustment of canister solenoid valve inner tube
Adjust
Normal Wearing Serious canister solenoid valve wearing
Replace
44
Common Malfunction Diagnosis Flow of Geely Automobile
No. 027 Engine fails to start Malfunction
Cause
Solution
No fuel
Check fuel gauge and fuel level
Low battery voltage
Check battery voltage, whether it is normal, which shall above 11.5V. Charge or replace battery when the value is too low. Check or replace circuit, if battery fails to be charged as normal (check whether there is short circuit in inner/outer circuit, which results current leaking). Check battery circuit and all connections, whether they are well conducted. Check starter, whether it operates normally. Maintain or replace it when necessary.
Starter malfunction
Ignition switch circuit and malfunction
Check starter, whether it operates normally. Check starter circuit, solenoid switch, carbon brush, coil and rotor, whether there is short or open circuit, as well as poor conduction. Check one-way clutch whether it is slipping, as well as one-way clutch and fly wheel tooth, whether they are damaged. Maintain or replace them when necessary.
open wire
Check circuit, fuse, ignition switch by multimeter, set to resistance range, whether they are open circuit. To inspection the malfunction.
Electric control system malfunction
Connect Geely special No. to check whether there is malfunction No.. And inspect again if it shows malfunction No.. Then check relevant component and circuit according to the indication of malfunction No..
Improper ignition timing or weak spark voltage Engine fails to start
Check high voltage spark, if it operates normally, then check engine speed sensor, ignition coil, ECU and relating circuit. Maintain or replace them when necessary. (Connect two pins of primary winding respectively to multimeter, and the resistance shall be 0.4~0.6Ω at 20℃. In same condition, the resistance of secondary winding shall be 11~15kΩ. Connect pin 2 and pin 3 of sensor to multimeter pen respectively, and at 20℃ the rated resistance shall be 860Ω±10%) Check ignition timing, if it is improper, then check flywheel signal plate, whether it is loose and malposition. Maintain or replace it when necessary. Check high voltage spark energy, if it is weak, then check ignition coil, high voltage resistance. Replace it when necessary.
Spark plug malfunction Incorrect valve timing
Check spark plug electrode clearance and carbon deposit condition. Adjust or replace it when abnormal. Check timing belt, whether there is damage. Replace it when necessary. Check timing belt, whether there is damage. Replace it when necessary.
Air filter blocked or intake system leaking
Check air filter, whether it is blocked. Clean or replace it when necessary. Check intake system, particularly intake manifold, injector, vacuum pipe and connector, whether they are leaking. Exclude the malfunction when necessary.
Fuel malfunction
Fuel pressure shall above 260kPa when idling. Otherwise, the fuel pressure is low, and shall check fuel pump, fuel pressure controller and fuel pipe, whether there is malfunction.
system
Engine signal loose or moved Exhaust blocked
plate
system
Check engine signal plate, whether is it loose or moved. When necessary, shall position it (20 teeth after point T for 4-cylinder, 16 teeth after point T for 3-cylinder) first, then weld or replace engine signal plate. Check or replace exhaust system blocking position
Low cylinder pressure
Measure cylinder pressure. Fill a few oil into cylinder to determine whether the cylinder or piston ring worn out, as well as valve sealing leaking. Adjust valve clearance or disassemble engine when cylinder pressure is too low.
Injector malfunction
Check both ends of connector of each injector by oscillograph or multimeter, whether there is pulse signal. If not, shall check parts of controlling circuit or ECU. Otherwise, remove injector and check fuel injection quantity and atomization, whether it is normal. Clean or replace it when necessary.
ECU malfunction
ECU controller fails to input or output signal normally, replace it.
45
Common Malfunction Diagnosis Flow of Geely Automobile Engine fails to start
N No fuel
Fill
Y
Lack
Low battery voltage
Charge
Normal Abnormal Starter failure Normal
Check and replace
Abnormal
Ignition switch open circuit and wire failure
Check and replace
Normal Abnormal Electric control system failure Normal
Check and replace Abnormal
Improper ignition timing or weak spark voltage
Check
Normal Abnormal Spark plug failure
Replace
Normal
Error
Incorrect valve timing
Check
Normal
Blocked
Air filter blocked
Clean
Normal Abnormal Fuel system failure
Maintain
Normal Low pressure Low cylinder pressure Normal
Maintain
Abnormal
Exhaust system blocked Normal
Unplug
Abnormal
Injector failure
Clean and replace
Normal Abnormal Engine signal plate loose or moved Normal
Check or replace Abnormal Replace
ECU inner short circuit
46
Common Malfunction Diagnosis Flow of Geely Automobile
No. 028 Hard to start in cold condition Malfunction
Cause
Solution Check battery voltage whether it is normal. Charge or replace it when necessary.
Low engine speed when driven by starter
Check starter, whether it operates normally. Maintain or replace it when necessary. Check oil condition, whether it is too thick. Replace standard grade oil when the oil is too thick, which results large inner engine friction and further causes low engine speed.
Hard to start in cold condition
Electric controlling system malfunction
Connect Geely special decoder to check whether there is malfunction code.. And inspect again if it shows malfunction code. Then check relevant component and circuit according to the indication of malfunction code.
Cooling fluid temperature sensor malfunction
Water temperature sensor fails to output signal or outputs incorrectly, which will affect fuel injecting adjustment of engine ECU and results improper mixture gas viscosity. And further causes engine fails to start, operates unstably, stop operating or running intermittently. Check cooling fluid temperature sensor. In different temperatures, its resistance shall vary according to specified standard. Replace it when necessary.
Spark plug abnormally
The spark plug clearance shall between 0.8mm and 1.2mm. If there is lots of fuel on spark plug surface, it indicates fuel fouling in cylinder. In this case, shall remove all spark plugs, disconnect injector circuit, full open the throttle, and start engine for several times to exclude the malfunction.
operates
Low fuel pressure
Check fuel pressure, if it is too low, shall check fuel pressure controller, electric fuel pump and fuel filter etc.
Incorrect oil grade, too thick
Since oil grade is improper, which results large oil viscosity and hardly start, the oil shall be replaced according to local temperature. Check valve timing, whether it is correct. Adjust it when necessary.
Improper ignition timing or weak spark energy
Check igniting operation, whether there is high voltage spark. If not, shall check engine speed sensor, ignition coil and related ECU circuit. Maintain or replace them when necessary. Check high voltage spark energy, if it is weak, then check ignition coil, high voltage resistance. Replace it when necessary.
Exhaust system blocked
Unplug blocked exhaust system
Over carbon deposit in intake manifold or valve
Over carbon deposit in intake manifold and valve, will cause low viscosity of mixture gas in cold condition, and results hard to start. Shall clean the carbon deposit.
Air filter blocked or intake system leaking
If the filter element is too dirty and blocked, the engine will be hard to start. Remove the filter element and start engine, if it operates normally, then replace the element. Check intake system, whether it is leaking. Particularly the intake mainfold gasket, vacuum pipe and connector etc. Exclude the malfunction.
Injector blocked or fuel atomized abnormally
Remove injector, check fuel injection quantity and fuel atomization, whether they are normal. Clean or replace it when necessary.
Low cylinder pressure
Measure engine cylinder compressing pressure, if it is low, but will increase after filled a few oil into the cylinder, then the cylinder or piston ring is worn out and need to replace or implement cylinder boring repair. If the pressure remains at low value, then it indicates improper valve clearance, valve burnt or leaking. Shall adjust valve clearance or replace valve.
ECU malfunction
ECU controller fails to input or output signal normally, replace it.
47
Common Malfunction Diagnosis Flow of Geely Automobile Hard to start in cold condition
Abnormal Low engine speed when driven by starter
Check
Normal Electric controlling system short or open circuit
Abnormal Check
Normal Abnormal Cooling fluid temperature sensor failure
Replace
Normal Poor Spark plug operates abnormally
Adjust and replace
Normal Low Low fuel pressure
Check
Normal
Abnormal
Improper ignition timing or weak spark energy
Maintain
Normal Abnormal Injector blocked or fuel atomized abnormally
Clean and replace
Normal Blocked Air filter blocked
Normal
Clean
Over carbon deposit
Over carbon deposit in intake mainfold or valve; exhaust pipe blocked
Normal
Check
Lack
Low cylinder pressure
Check
Normal Abnormal ECU malfunction
Replace
48
Common Malfunction Diagnosis Flow of Geely Automobile
No. 029 Hard to stard engine when heating Malfunction
Cause
Solution Check battery voltage, whether it is normal. If the value is too low, shall charge and check charge circuit, as well as related components.
Low starter speed or sliding
Check starter, and maintain or replace it when starter coil is heated and short circuit. If motor idles, then the starter flywheel gear and motor gear slide when match, which results engine hard to start.
Electric malfunction
controlling
system
Connect Geely special decoder to check whether there is malfunction code. And inspect again if it shows malfunction code. Then check relevant component and circuit according to the indication of malfunction code. Check spark plug electrode clearance and carbon deposit condition. Adjust or replace it when necessary.
Spark plug malfunction
Check heating operation, whether there is high voltage spark. If not, check engine speed sensor, ignition coil, ECU and relating circuit. Maintain or replace them when necessary.
Weak high voltage spark
Check high voltage spark energy. If it is weak, check ignition coil, spark wire resistance. Replace them when abnormal. Cooling fluid malfunction
temperature
sensor
Hard to start engine when heating
Check cooling fluid temperature sensor. In different temperatures, its resistance shall vary according to specified standard. Replace it when necessary.
Injector malfunction
When heating, the expansion difference of valve seat and element may affect injector pin valve and result valve seat and element stuck or leak, which relates with spark plug drown and primary fuel pressure lose and cause hardly to ignite. Check injector, replace it when necessary.
Fuel quality problem
Check fuel, whether it is polluted, or contains other problem. It is recommended that customers shall change the gas station, where they often attend.
Engine cylinder, connect rod, crankshaft and camshaft bearing fit pressure is over normal value
Engine cylinder, connect rod, crankshaft and camshaft bearing fit pressure is over normal value, the expansion when heating will result crankshaft stuck. Maintain relating part.
Speed sensor output signal abnormal
Engine speed sensor resistance or output signal and signal tooth clearance abnormal, which results improper ECU ignition timing, as well as engine hard to start. Shall adjust or replace engine speed sensor.
Air filter blocked
Clean or replace
Low fuel pressure
Check fuel pressure, if it is too low, shall inspect fuel pressure controller, electric fuel pump, fuel filter and pipes.
Intake pressure temperature sensor operates abnormally
Intake pressure temperature sensor is heated, which results signal misalignment.
ECU inner malfunction
The triode in ECU controller is heated, and fails to input or output signal normally. Shall replace ECU.
49
Common Malfunction Diagnosis Flow of Geely Automobile Hard to stard engine when heating
Low Low starter speed or sliding
Normal
Check and replace
Abnormal
Electric controlling system failure
Normal
Check and replace
Abnormal
Spark plug failure
Replace
Normal
Abnormal
Weak high voltage spark
Check
Normal Abnormal Cooling fluid temperature sensor failure
Replace
Normal Abnormal Injector failure
Clean and replace Normal Abnormal
Fuel quality problem
Replace
Normal Over fitted Engine fit pressure is over normal value
Check
Normal Abnormal Speed sensor output signal abnormal Normal
Replace
Blocked
Air filter blocked
Clean
Normal
Lack
Low fuel pressure
Check Normal
Abnormal
Intake pressure temperature sensor operates abnormally Normal
Replace Abnormal Replace
ECU inner malfunction
50
Common Malfunction Diagnosis Flow of Geely Automobile
No. 030 Idle speed unstable Malfunction
Engine idle unstable
Cause
Solution
Improper throttle position sensor adjustment
When idling, the action, such as open AC, operate steering wheel or open front lamp, will increase engine load. ECU will add injection quantity to remain engine running stably, as well as to prevent engine shut-off when engine load increased. Disconnect idle speed conducting point, while engine is not running in idle condition, determined by ECU, and it will remain injection quantity instead of increase it. Therefore, the engine speed remains as before, and ECU will adjust idle speed according to the order of oxygen sensor mixer. The malfunction is indicated by low engine speed when open AC or operate steering wheel in idle condition. When the throttle is closed totally, inspect idle switch of throttle position sensor by Geely special deNo.r, whether it is normal. Adjust or replace it when necessary.
Idle speed by-pass pipe blocked
Check throttle and idle speed by-pass pipe, whether they are blocked. Clean it when necessary to ensure free-flowing air intake.
Idle speed control valve or stepping motor malfunction
According to engine speed, temperature, throttle open degree and AC signal etc., ECU will calculate and adjust idle speed control valve or stepping motor, as well as by-pass pipe, to decrease engine speed. If idle speed control valve delayed or stuck, as well as in the case of throttle malposition etc., ECU will fail to implement idle speed adjusting correctly, which results idle speed unstable. Shall clean or replace relating parts, sc. replace idle speed control valve and implement self-adaption on idle speed control valve or stepping motor by deNo.r, series Geely, when necessary.
Electric controlling malfunction
Connect Geely special decoder to check whether there is malfunction code. And inspect again if it shows malfunction code. Then check relevant component and circuit according to the indication of malfunction code.
speed
system
Individual cylinder fails to work
Check operating condition of each cylinder, whether there is individual cylinder, which operating abnormal. Particularly the spark plug, spark wire, cylinder pressure etc. Maintain or replace then when malfunction cause was found.
51
Common Malfunction Diagnosis Flow of Geely Automobile
Intake pipe leak
Intake pipe leaking and results incorrect flow rate decision on ECU, which will cause unstable idle speed. Check leaking position, particularly intake manifold gasket, injector seal ring, vacuum pipe and connector etc.
It has not implement self-adaption, after engine ECU or battery was replaced.
In case of replacing engine ECU, battery or disconnect battery power for a long time, it shall implement self-adaption according to Geely engine self-adaption procedure.
Generator voltage abnormal
Check running engine, whether the output voltage of generator is in normal value. If it is abnormal and results unstable idle speed, then check generator and relating circuit and parts. Maintain or replace them when necessary.
Injector leak or block
If the injector is leaking or blocked, and fails to inject according to ECU order, which results improper mixure gas viscosity, as well as individual cylinder operating abnormal and unstable idle speed, then shall replace the injector.
Exhaust system blocked
Gum deposit, carbon deposit, broken or such problems in 3-way catalytic converter result partly or random blockage, which will increase the backpressure when exhausting, as well as low vacuum of intake pipe, which results abnormal engine exhaust and intake performance, that relating with cylinder operating performance directly. Replace 3-way catalytic converter.
Improper stepping motor gasket thickness
Often appears on vehicle MR7131A, stepping motor gasket is too thin caused by manufacture process, and results motor operating abnormal. Exclude the malfunction by replacing gasket.
Intake temperature malfunction
sensor
Low fuel pressure Improper spark plug and ignition advance angle, which results unstable idle speed
Check sensor data and voltage, replace it when necessary. Measure fuel pressure, check electric fuel pump, pipes and circuit when it is lower than normal value. Maintain or replace them when necessary. Check spark wire cross firing condition, as well as ignition timing. Adjust or replace it when necessary.
Engine bracket cracked
Check vehicle, whether there is any sign of accident. Engine bracket cracked will cause engine vibration, and unstable idle speed.
Oxygen sensor malfunction
Check oxygen sensor signal, replace it when necessary.
Canister valve malfunction
Check canister control valve, replace it when necessary.
52
Common Malfunction Diagnosis Flow of Geely Automobile Idle speed unstable Improper adjusted Improper throttle position sensor adjustment
Normal
Adjust and replace
Blocked
Idle speed by-pass pipe blocked
Clean
Normal Abnormal Idle speed control valve or stepping motor failure
Normal
Clean and replace
Abnormal
Replace
Electric controlling system failure Normal
Fails to work
Individual cylinder fails to work
Check
Normal Leak Intake pipe leak
Check
Normal Abnormal Voltage abnormal
Check
Normal Abnormal Injector failure
Normal
Clean and replace
Blocked
Exhaust system blocked
Normal
Check and replace
Abnormal Replace
Intake temperature sensor failure
Normal
Low
Low fuel pressure
Normal
Check
Cracked
Engine bracket cracked
Normal
Replace
Abnormal
Oxygen sensor failure
Normal
Replace
Fail
Canister valve failure
Replace
53
Common Malfunction Diagnosis Flow of Geely Automobile
No. 031 Non-idle speed Malfunction
Cause
Solution
Idle speed air pipe blocked
Check throttle and idle speed air pipe, whether they are blocked. Clean them if there is too much carbon deposit to ensure free-flowing intake.
Ilde speed stepping motor malfunction
Check idle speed stepping motor, whether it operates normally and flexibly. Clean it if there is too much carbon deposit. Replace motor when necessary.
Improper throttle cable or thorttle position sensor adjustment
Non-idle speed, engine shut-off when pressing throttle pedal
Loose throttle pedal and check throttle cable condition, adjust it if the clearance is improper. When throttle is closed totally, inspect throttle position sensor idle speed switch, by Geely special decoder, whether it operates normally. Adjust or replace it when necessary.
Electric controlling system malfunction
Connect Geely special decoder to check whether there is malfunction code. And inspect again if it shows malfunction code. Then check relevant component and circuit according to the indication of malfunction code.
Cooling fluid temperature sensor malfunction
Check cooling fluid temperature sensor. In different temperatures, the resistance of coolant temperature sensor shall vary according to regulated standard. Otherwise, replace it.
Indicidual cylinder fails to work
Check operating condition of each cylinder, whether individual cylinder operates abnormally, particularly inspect the spark plug, spark wire and cylinder pressure etc. Maintain or replace relating parts when malfunction cause was found.
Engine voltage abnormal
Check running engine, whether the output voltage of generator is in normal value. If it is abnormal and results unstable idle speed, then check generator and relating circuit and parts. Maintain or replace them when necessary.
Intake system leaking
According to idle speed operating principle, vacuum pipe leaking will result non-idle speed. Shall replace vacuum pipe.
Incorrect timing
engine
valve
Timing belt loose and cause gear malposition, as well as similar condition with non-idle speed. Shall adjust ignition timing.
Circuit malfunction
Part of idle speed controlling circuit is ageing or affected by water, may result non-idle speed. Shall maintain circuit.
Engine ECU malfunction
Pull out ECU engine connector, measure the resistance between each terminal by multimeter, whether the value is corresponding to technical requirements. Replace engine ECU when abnormal.
54
Common Malfunction Diagnosis Flow of Geely Automobile Non-idle speed
Blocked Idle speed air pipe blocked
Normal
Clean
Abnormal
Ilde speed stepping motor failure
Clean and replace
Normal Improper throttle cable or thorttle position sensor adjustment
Normal
Abnormal
Clean and replace
Abnormal
Electric controlling system failure
Check
Normal Abnormal Cooling fluid temperature sensor failure
Replace
Normal Fails to work Indicidual cylinder fails to work
Check
Normal Abnormal Engine voltage abnormal
Check
Normal Leak Intake system leaking
Normal
Check
Error Check and adjust
Incorrect engine valve timing
Normal Abnormal Circuit failure
Check
Normal Abnormal Engine ECU failure
Replace
55
Common Malfunction Diagnosis Flow of Geely Automobile
No. 032 Idle speed over normal value Malfunction
Idle speed normal value
Cause
Solution
Improper throttle cable or throttle position sensor adjustment
Loose throttle pedal and check throttle cable condition. Adjust it when the clearance is improper.
Throttle contains too much carbon deposit, sc. it is stuck, which results the throttle fails to close normally.
Check throttle, if there is too much carbon deposit, which results throttle fails to close as normal, then shall clean it.
Idle speed stepping motor malfunction
Check idle speed stepping motor, whether it operates flexibly. If it is stuck, caused by carbon deposit, and then shall clean it. Replace stepping motor when necessary.
Intake system leaking
Intake pipe leaking, result incorrect decision to air flow rate on ECU, and causes improper control, which leads to over idle speed. Check leaking position, particularly the intake manifold gasket, fuel injector seal ring, vacuum pipe and connector etc.
Electric controlling system malfunction
Connect Geely special decoder to check whether there is malfunction code. And inspect again if it shows malfunction code. Then check relevant component and circuit according to the indication of malfunction code.
Cooling fluid temperature sensor malfunction
Check water temperature sensor, whether it can send temperature signal to ECU correctly. In normal condition, the coolant temperature is applied to adjust fuel injecting quantity, sc. mixture gas viscosity. In low temperature, ECU controls injector to inject more fuel to increase mixture gas viscosity, as well as idle speed. Check water temperature sensor, if it fails to measure temperature as normal. In different temperatures, the resistance of cooling temperature sensor shall vary according to regulated standard. Otherwise, replace coolant temperature sensor.
Intake pressure sensor malfunction
Check intake manifold pressure temperature sensor, replace it when abnormal.
Oxygen sensor malfunction
Measure oxygen sensor, if the voltage is low, beneath 0.5V, then will cause incorrect ECU order, which results mixture gas viscosity increase, as well as idle speed. Replace oxygen sensor when necessary.
Engine ECU malfunction
Pull out engine ECU pin and measure the resistance between each terminal of ECU, whether the value is accordance with technical requirements. Replace engine ECU when abnormal.
over
56
Common Malfunction Diagnosis Flow of Geely Automobile Idle speed over normal value
Improper Improper throttle cable or thorttle position sensor adjustment
Normal
Adjust
Over normal value
Throttle contains too much carbon deposit
Clean
Normal Abnormal Idle speed stepping motor failure
Clean and replace
Normal Leak Intake system leaking
Check
Normal Abnormal Electric controlling system failure
Check
Normal Abnormal Temperature sensor failure
Normal
Replace
Abnormal
Intake pressure sensor failure
Replace
Normal Abnormal Oxygen sensor failure
Replace
Normal Abnormal Engine ECU failure
Replace
57
Common Malfunction Diagnosis Flow of Geely Automobile
No. 033 Engine accelerates abnormal Malfunction
Cause
Solution Check air filter, whether it is blocked. Clean or replace when necessary.
Air filter blocked
Check intake system, whether it is leaking. Measure intake manifold vacuum, the value shall above 30kPa when idling. Otherwise, the intake system is leaking. Shall check connectors and all hoses and vacuum pipes carefully.
Improper adjustment of throttle cable or throttle position sensor, which results throttle fail to fully open.
Press accelerate pedal fully, and check whether the throttle fully opens. Adjust throttle cable or pedal, if it fails to open fully.
Improper ignition timing or weak spark energy.
Check ignition timing. When idling, the ignition advance angle shall be 10º~12º. Otherwise, shall adjust the primary ignition advance angle. When accelerating, the angle shall increase to 20º~30º automatically. When abnormal, shall check ignition controlling system, including ignition coil, spark wire and spark plug etc., alternative replace ECU.
Low fuel pressure
Check fuel pressure. When idling, fuel pressure shall in accordance with regulation, 265~304kPa. When accelerating, fuel pressure shall increase about 50kPa. If fuel pressure is too low, then shall check fuel pressure controller, electric fuel pump, fuel filter and etc.
Injector blocked poor atomization
Engine accelerates abnormal
Check throttle position sensor. During throttle varies from full close to full open, the resistance between signal terminal and earth terminal shall increase constantly, without interruption. Adjust or replace the sensor according to regulation, when abnormal.
or
Remove injector and check injecting quantity and atomization quality, whether they are normal. When abnormal, clean or replace the injector.
Low battery voltage
Check battery voltage, whether it is normal. If the value is too low, when will cause fuel injecting quantity decrease, which results low engine power, as well as accelerating delay. In this case, shall check charging system or replace battery.
Coolant temperature sensor malfunction
Check coolant temperature sensor. In different temperatures, the resistance of the sensor shall vary in accordance with regulated standard. Otherwise, shall replace the sensor.
Intake pressure sensor malfunction
Check intake manifold pressure temperature sensor. Replace it when abnormal.
Clutch sliding
Replace driven plate of clutch.
Low engine cylinder pressure
Measure the compressing pressure of engine cylinder. If it is too low, then shall adjust valve clearance, or disassemble and inspect engine.
Poor flywheel signal
In case of low power and accelerating performance, caused by poor flywheel and signal wheel signal, shall replace flywheel assembly.
Crankshaft position sensor malfunction
In case of ECU order delay and low accelerating performance, caused by the sensor fails to indicate crankshaft position correctly, shall replace the sensor.
Incorrect engine valve timing
Check engine valve timing, whether it is correct. Adjust it when incorrect.
Individual fails to work
cylinder
Exhaust blocked
system
Oxygen malfunction
sensor
Check the operating condition of each cylinder, such as individual cylinder operating, whether it is abnormal. Particularly the spark plug, spark wire and cylinder pressure etc. Determine the malfunction cause and maintain or replace relating parts. Check 3 way catalytic converter, whether it is blocked. The reverse interfere caused by blockage will result poor engine accelerating performance. In this case, replace 3-way catalytic converter. It results indiscernible mixture gas rate, as well as low power.
58
Common Malfunction Diagnosis Flow of Geely Automobile Engine accelerates abnormal
Blocked Air filter blocked Normal
Clean Improper adjusted
Improper adjustment of throttle cable or throttle position sensor
Adjust
Normal
Abnormal
Improper ignition timing or weak spark energy
Check
Normal
Low
Low fuel pressure
Check
Normal Blocked Injector blocked
Clean and replace
Normal
Low
Low battery voltage Normal
Charge Abnormal
Cooling fluid temperature sensor failure Normal
Replace Abnormal
Intake pressure sensor failure
Normal
Normal
Sliding
Clutch sliding
Replace Normal
Low
Low engine cylinder pressure
Check
Normal Poor Poor flywheel signal
Check
Normal Abnormal Crankshaft position sensor failure Normal
Replace
Error
Incorrect engine valve timing Normal
Check and adjust
Fails to work
Individual cylinder fails to work
Check
Normal
Blocked
Exhaust system blocked
Check and replace
Normal Abnormal Oxygen sensor failure
Replace
59
Common Malfunction Diagnosis Flow of Geely Automobile
No. 034 Water temperature over normal value Malfunction
Cause
Solution
Lack of coolant
Check cooling system, whether there is enough coolant. Add coolant if it is lack of coolant, which will affect cooling performance.
Water temperature meter and sensor malfunction
Water temperature over normal value, virtually. Replace relating components.
Radiator leaking
Check radiator cap and radiator, maintain or replace leaking part.
Thermostat fails to open as normal
Check upper and lower pipe temperature of radiator, if there is high value difference, then shall remove thermostat and measure the activating temperature. Replace thermostat if it fails to open normally.
Water pipe leaking
Check water pipe, maintain leaking position and fasten loose clip Check water pump driving belt, whether it is loose or damaged. Adjust or replace when necessary. Open radiator cap and start engine, to inspect coolant flowing condition and determine whether the water pump is working. If the coolant keeps still, then remove and check water pump. Replace it when blade wheel is damaged.
Water pump malfunction Water temperature over normal value, when engine operating
Heater radiator leaking
Check heater radiator, maintain or replace it. Check radiator cooling fan motor and fan blade, whether they are damaged. Maintain or replace them when necessary.
Radiator cooling fan fails to operate normally
Check coolant temperature sensor. In different temperatures, the resistance of coolant temperature sensor shall vary in accordance with regulated standard. Otherwise, shall replace the sensor. Check engine ECU and radiator cooling fan motor controlling circuit. Maintain or replace them when necessary. Check radiator, whether there are bubbles nearby. Replace cylinder head gasket, may exclude the malfunction.
Cylinder head gasket damage
Poor radiator cooling performance
Check radiator, whether it is blocked by mud or other impurity. Clean or replace it, when cooling performance is affected by blockage. Check furring condition in radiator. Clean or replace it, when cooling performance is affected.
Part blockage in engine inner water cycling pipe
60
Unplug or replace cylinder block
Common Malfunction Diagnosis Flow of Geely Automobile Water overheat
Insufficient Insufficient coolant
Fill
Normal Failure Water temperature gauge and sensor fails
Replace
Normal Abnormal
Thermostat can not open normally
Replace
Normal Water leaking Check
Water leakage in water tank Normal Abnormal Water pump trouble
Replace
Normal Water leaking Water leakage in water pipe
Replace
Normal Water leaking Replace it
Water leakage in water tank of fan heater Normal Radiator cooling fan can not run normally
Overhaul and replace it
Normal Cylinder head gasket damaged
Replace it
Normal Poor heat radiating of the radiator
Check and replace
Normal Partial clogging in engine’s internal circulating water pipe
Check and replace
61
Common Malfunction Diagnosis Flow of Geely Automobile
No.035 Oil existing in the water tank Malfunction
Oil appears in the water tank during engine operation
Cause
Solution
Man-made malfunction
Oil enters cooling system during engine repair, and oil enters water tank along with coolant after the engine operates to normal water temperature. This malfunction can be eliminated through replacing coolant for several times;
Malfunction of cylinder head gasket
Cylinder head gasket is slightly damaged or not pressed tightly, after the engine starts, oil appears in the water tank due to oil pressure higher than the pressure of cooling system which causes oil entering into cooling system along the damage of cylinder head gasket. In case of this malfunction , disassemble the engine to check cylinder head and its gasket, cylinder block surface, repair or replace it and then tighten it in accordance with standard torque;
Cylinder head or cylinder block deforming
Check whether cylinder head or cylinder block is deformed, if any, repair or replace it;
There is crack on the cylinder head
There is crack inside oil way of cylinder head, and the crack is enlarged once heated, therefore oil enters into cooling system through it. In this case, check carefully that there is any crank on the cylinder head, use instrument if necessary, if any, replace it;
There is crack on the cylinder block
There is crack inside oil way of cylinder block, and the crack is enlarged once heated, therefore oil enters into cooling system through it. In this case, check carefully that there is any crank on the cylinder block, use instrument if necessary, if any, replace it;
In case of this malfunction , the pipeline must be Automatic transmission fluid and radiating treated timely, the malfunction exists in automatic pipe connect and oil enters transmission type Geely Vehicle;
62
Common Malfunction Diagnosis Flow of Geely Automobile Oil existing in the water tank
Man-made trouble
Replace
Malfunction of cylinder head
Replace
Cylinder head or cylinder block deforming
There is crack cylinder head
on
Replace
the
Replace
There is crack on the cylinder block
Replace
Automatic transmission fluid and radiating pipe connect and oil enters
Replace
63
Common Malfunction Diagnosis Flow of Geely Automobile
No. 036 There is water in the oil Malfunction
Cause
Man-made malfunction
Solution During engine repairing, there is water mixed into crankcase, oil mixes with water and color changes after the engine operates to normal water temperature. This malfunction can be eliminated by changing oil;
Cylinder head gasket is slightly damaged or not pressed tightly, after the engine starts, water enters into crankcase through cylinder head gasket. In case of this Malfunction of malfunction , disassemble the engine to check cylinder head and its gasket, cylinder cylinder head gasket block surface, repair or replace it and then tighten it in accordance with standard torque; There is water in the engine oil There is crack on cylinder head, and the crack is enlarged once heated, therefore There is crack on the water enters into crankcase through it. In this case, check carefully that there is any cylinder head crank on the cylinder head, use instrument if necessary, if any, replace it;
There is crack on cylinder block, and the crack is enlarged once heated, therefore There is crack on the water enters into crankcase through it. In this case, check carefully that there is any cylinder block crank on the cylinder block, use instrument if necessary, if any, replace it; There is water in the oil
Incorrect
Man-made trouble
Check
Normal Malfunction of cylinder head gasket
Damaged
Replace
Normal There is crack on the cylinder head
Crack
Replace
Crack
Replace
Normal There is crack cylinder block
on
the
64
Common Malfunction Diagnosis Flow of Geely Automobile
No. 037 Abnormal sound of crankshaft bearing Malfunction
Cause
Solution
Oil filter blocked
Replace the oil filter
Poor oil quality
Change oil
Engine water temperature high
Eliminate it in accordance with malfunction of high water temperature;
Abnormal pressure of oil pump
Check oil pressure, abnormality will also cause abnormal sound, if necessary, change oil pump;
Check the matching clearance between main bearing shell and main bearing There is abnormal sound in journal, the value is 0.020mm-0.059mm, if crankshaft bearing, sound is Matching clearance between main bearing shell and the clearance exceeds limit 0.1mm, it is heavy in crankcase with necessary to select main bearing shell main bearing journal too large toneless “plump”; the faster again according to measured diameter of the engine speed, the louder main bearing journal and technical the noise, and the noise is requirements (empirical value); obvious particularly when accelerating suddenly. When serious, engine block Measure thrust clearance of crankshaft at vibrates, lubricant pressure thrust washer, the value is reduces; the noise does not Thrust clearance between thrust washers too large 0.087mm-0.177mm, if the value exceeds change when engine limit 0.300mm, the thrust washer should be temperature changes. changed; (empirical value)
Crankshaft bending
Check crankshaft camber, if the camber exceeds limit 0.1mm, the crankshaft should be corrected or changed (empirical value);
Main bearing shell is ablated and worn seriously
Check that there is any peeling, ablation or other abnormality on the surface of bearing shell, if the bearing shell fails, it should be changed;
Bolt on the cover of main bearing shell is loose
If main bearing shell is just loose, tighten the bolt on the cover of main bearing shell by torque specified;
65
Common Malfunction Diagnosis Flow of Geely Automobile Abnormal sound of crankshaft bearing
Poor
Poor oil quality
Replace
Normal Blocked
Oil filter blocked
Replace
Normal Water temperature high
Engine water temperature high
Check
Normal Bend
Crankshaft bending
Replace
Normal Wearing Replace
Main bearing shell is ablated and worn seriously
Normal Abnormal
Abnormal pressure of oil pump
Check
Normal Thrust clearance washers too large
between
Too large
thrust
Check
Normal Too large
Matching clearance between main bearing shell and main bearing journal too large
Check
Normal Loose
Bolt on the cover of main bearing shell is loose
66
Check
Common Malfunction Diagnosis Flow of Geely Automobile
No. 038 Abnormal sound of connecting rod bush Malfunction
When engine accelerates suddenly, obvious clear and short knocking is produced and becomes louder as the loading increases; creaking can be heard by shaking throttle slightly; the noise does not change obviously when engine temperature changes.
Cause
Solution
Poor oil quality
Change oil
Oil filter clogged
Replace the oil filter
Oil too diluents
Change oil
Abnormal pressure of oil Check oil pressure, abnormality will also cause abnormal sound, if pump necessary, replace oil pump;
Shell clearance too large
Check the clearance between connecting rod bearing shells, the value is 0.020mm-0.063mm, if the clearance exceeds limit 0.1mm, it is necessary to select connecting rod bearing shell again according to measured connecting rod bearing diameter and technical requirements. (empirical value);
Check that there is any peeling, wearing, ablation or other Shell wearing excessively, abnormality on the surface of connecting rod bearing shell, if the loosing or breaking etc. bearing shell fails, it should be changed;
Connecting rod bolt is loose
If connecting rod bearing shell is just loose, tighten the bolt by torque specified;
67
Common Malfunction Diagnosis Flow of Geely Automobile Abnormal sound of connecting rod bush
Poor oil quality
Replace
Normal Oil too diluent
Replace
Normal Oil filter blocked
Replace
Normal Abnormal pressure of oil pump
Check
Normal Halfshell clearance too large
Adjust it
Normal Connecting rod bolt loose
Overhaul
Normal Halfshell wearing loosing or breaking
excessively,
Replace it
68
Common Malfunction Diagnosis Flow of Geely Automobile
No. 039 Camshaft with abnormal sound Malfunction
Causes
When the engine is normal, sound similar as resonance appears; when severe, irregular noise appears.
Solution
Engine with high water temperature
Eliminate malfunction based on high water temperature;
Engine oil with poor quality
Replace engine oil;
Oil filter blocked
Replace filter;
Camshaft cam is worn, causing Check camshaft; repair or replace; abnormal sound Fit clearance between camshaft and Check fit clearance; if necessary, repair engine or replace camshaft bearing too large concerned malfunction parts; Camshaft seat burnt and damaged
Check it is burnt and damaged; repair the engine;
Hardness of internal spring of the Replace the spring or assembly; gear not enough Pressure of oil pump abnormal
Check oil pressure, which will cause abnormal sound if abnormal; if necessary, replace oil pump;
Camshaft with abnormal sound
Worn
Engine with high water temperature
Repair
Normal Not good
Engine oil with poor quality
Replace
Normal blocked
Oil filter blocked
Normal
Burnt
Camshaft seat burnt and damaged
Replace
Normal
Abnormal
Pressure of oil pump abnormal
Normal
Repair
Stiffness
Hardness of internal spring of the gear not enough
Normal
Replace
Repair
Too large
Fit clearance between camshaft and wall
Replace
Normal Cam worn
Abnormal
69
Replace
Common Malfunction Diagnosis Flow of Geely Automobile
No. 040 Camshaft driving gear with abnormal sound Malfunction
Causes
Solution
Lubricating oil with poor quality
Replace lubricating oil
Fit clearance not matched
Strained clearance of driving gear not matched, causing abnormal sound;
Improper assembling
Check driving gear of admission camshaft and that of exhaust camshaft are correctly assembled; if not, reassemble;
Matching angle under stress not even
Adjust angle of driving gear; if necessary, replace it;
Camshaft driving Hardness of internal spring of the gear not Replace the spring or assembly; gear with enough abnormal sound Check inlet filter screen of oil pump is blocked; if so, clean or replace; Check clearance between drive gear and driven gear of oil pump. And check relief valve is blocked; if so, repair or replace;
Engine oil pressure too low
Check lubricating system is leaking, and mainly check clearance of connecting rod tile; if leaking, eliminate it; check driving gear is with obvious metal damaging traces, causing noises; if so, replace it;
Driving gear worn Camshfat driving gear with abnormal sound
Improper
Improper assembling
Reassemble
Normal Lubricating quality
oil
with
Poor
poor
Replace
Normal Unusual Matching angle under stress not even
Replace
Normal Not matching
Fit clearance of gears not matching Normal
Repair
Stiffness insufficient
Hardness of internal spring of the gear not enough
Replace
Normal Too low Repair
Engine oil pressure too low
Normal
Worn Replace
Driving gear worn
70
Common Malfunction Diagnosis Flow of Geely Automobile
No. 041 Cylinder knocking sound Malfunction
Causes
Solution Put screwdriver at filler port, and put your ear against the screwdriver lever, and carefully observe and listen; Flame out for cylinders gradually; if sound of this cylinder weakens or disappears, then it is confirmed that this cylinder has abnormal sound;
Piston and cylinder wall severely To differentiate from other abnormal sound, fill in some lubricating worn, with too large clearance oil at spark plug hole of this cylinder; if the sound weakens or disappears, then it is confirmed as piston knocking sound;
When knocking sound is very severe and filler port is smoking externally, it is because that clearance between piston and cylinder wall is too large; When the engine operates at idling speed, upper of cylinder body generates clear and rhythmical metal knocking sound “Dang”. When cooling, the sound becomes obvious. With rising engine temperature and speed, the sound becomes smaller or disappears.
Fuel grade too low, with poor Check fuel quality, and confirm its grade; if not reaching specified quality requirements, replace it;
Ignition time too early
Check ignition timing. When the engine is at idling speed, ignition advance angle is 10°--12°; if not correct, adjust advance angle of initial ignition of the engine. When accelerating, ignition advance angle could automatically be increased to 20°--30°. If unusual, check ignition control system or replace ECU;
Engine oil filter blocked
Replace engine oil filter;
Knock sensor malfunction
Check knock sensor; if piston knocking is caused due to damaged knock sensor, replace it;
Carbon deposit cylinder too many
within
the Check carbon deposit within the cylinder; if too many causing glowing ignition and piston knocking, clean it;
Clearance of connecting rod tile Check and repair the engine; too large Piston ring blocked
Check operations of piston ring; if blocked, repair or replace it;
Compression ratio too large
Check cylinder cover is grinding; if grinding too large causing combustion chamber smaller, and compression ratio too large causing piston knocking, replace cylinder cover;
Clearance of piston ring too Check piston ring; if necessary, replace it; large
71
Common Malfunction Diagnosis Flow of Geely Automobile Cylinder sound
knocking
Piston and cylinder wall severely worn its clearance
Worn
Repair
Normal Fuel grade too low, with poor quality
Poor quality
Replace
Normal Ignition time too early
Too early
Adjust
Normal Knock sensor malfunction
Abnormal
Replace
Normal Carbon deposit within the cylinder too many
Too many
Repair
Normal Clearance of connecting rod tile too large
Large clearance Repair
Normal Piston ring blocked
Blocked
Replace
Normal Filter element blocked
Blocked
Replace
Too large
Replace
Normal Clearance of piston too large
72
Common Malfunction Diagnosis Flow of Geely Automobile
No. 042 Oil pump with abnormal sound Malfunction
Engine with clattering
bottom regular
Causes
Solution
Engine oil not sufficient
Check oil level within crankcase; if too low, fill up to standard height;
Engine oil with poor quality
Replace engine oil;
Filter screen blocked
Check filter screen is blocked; if so, clean or replace;
Clearance of driving gear of oil pump too large
Check clearance; if necessary, replace it;
Oil pump sounding
When at idling speed, probably oil pan position appearing with clear clattering; if necessary, replace oil pump;
Valve blocked
Check and clean;
Driving gear of oil pump sounding
Fit clearance between driving gear of oil pump and driving gear of camshaft changes, thus damaging driving gear of oil pump;
JL376/378 driving chain sounding
Replace driving chain;
Oil pump with abnormal sound
Insufficient Engine oil not sufficient
Add
Normal Engine oil with poor quality
Poor
Replace
Normal Filter screen blocked
Blocked
Clean
Normal Clearance of driving gear of oil pump too large
Large clearance
Replace
Normal Sounding
Oil pump sounding
Replace
Normal blocked
Valve blocked
Clean Normal
Driving gear of oil pump sounding
Sounding Repair
Normal Driving sounding
chain
Sounding
73
Replace
Common Malfunction Diagnosis Flow of Geely Automobile
No. 043 Crankshaft thrust piece with abnormal sound Malfunction
Causes
Solution
Engine oil not sufficient
Check oil level within crankcase; if too low, fill up to standard height;
Engine oil with poor quality
Replace engine oil; ②Check filter screen is blocked; if so, clean or replace;
Engine oil with too low pressure
③Check clearance between drive gear and driven gear of oil pump. Crankshaft thrust And check relief valve is blocked; if so, repair or replace; piece with Crankshaft and thrust piece severely Crankshaft and thrust piece severely worn, causing too large axial abnormal sound worn play, and abnormal sound; disassemble the engine and repair; Thrust piece burnt and damaged
Check it is burnt and damaged; if necessary, replace thrust piece;
Thrust clearance too large
Measure thrust clearance at thrust piece, with standard value as 0.087mm-0.177mm; if exceeding limit value 0.300mm, replace thrust piece. (empirical value)
Crankshaft thrust unusual noise
piece
with
Insufficient
Engine oil not sufficient
Add
Normal Poor
Engine oil with poor quality
Replace
Normal Engine oil with too low pressure
Too large
Repair
Normal Crankshaft and thrust piece severely worn
Worn
Replace
Normal Thrust piece damaged
burnt
and
Burnt and damaged
Replace
Normal Thrust large
clearance
too
Large clearance
74
Repair
Common Malfunction Diagnosis Flow of Geely Automobile
No. 044 Valve with abnormal sound Malfunction
Causes
Continuous, regular and clear “da-da” sound is heard at one side of valve chamber. When the engine is at idling, medium speed, the sound becomes obvious; when high speed, the sound is in disorder. This sound is not affected by engine temperature and flameout.
Solution
Valve clearance too large
Remove valve chamber cover, and make the engine run at idling speed; listen to the sound and observe splashing of lubricating oil, and make preliminary judgment; insert feeler gage to suspected valve clearance; if the sound weakens or disappears, then it is this valve that is sounding; with the engine under cold state, adjust valve clearance; when clearance of intake valve is 0.12mm~0.15mm, corresponding exhaust valve clearance is 0.20mm~0.25mm. when adjusting, make the valve closed;
Engine oil not sufficient
Check oil level within crankcase; if too low, fill up to standard height;
Cylinder cover deformed
Replace cylinder cover; Check oil screen is blocked; if so, clean or replace;
Engine oil with too low Check clearance between drive gear and driven gear of oil pump. And pressure, poor lubrication check relief valve is blocked; if so, repair or replace; causing abnormal sound Check clearance between crankshaft and connecting rod tile is too large causing oil leaking too much and oil pressure too low; Camshaft worn
If abnormal sound still exists after adjustment of valve clearance, check and measure cam lobe is damaged or severely worn; if exceeding limit value 0.300mm, replace it. (empirical value)
Valve with abnormal sound
Valve clearance too large
Too large
Adjust
Normal Engine oil sufficient
not
Insufficient
Add
Normal Cylinder deformed
cover
Deformed
Replace
Normal Poor
Engine oil with too low pressure, poor lubrication causing unusual noise
Repair
Normal Camshaft worn
Worn
Replace
75
Common Malfunction Diagnosis Flow of Geely Automobile
No. 045 Engine with insufficient power Malfunction
Causes
Solution ① Check air filter is blocked; if so, clean or replace;
① Air filter blocked
② Check intake system is leaking. Measure degree of vacuum of intake manifold. When at idling speed, degree of vacuum shall be larger than 30KPA; if too small, it indicates that intake system is leaking; carefully check connection and each hose, vacuum pipe; ③ Step on accelerator pedal to the bottom, and check throttle valve is fully opened; if not, adjust its dragline or pedal;
② Throttle valve tie-line or throttle valve ③ Check throttle valve position sensor. When throttle valve is position sensor improperly adjusted, and changed from fully closed to fully opened, resistance of its could be fully opened signal terminal and earthing terminal shall be increased The engine is continuously, without interruption; if unusual, adjust or replace it basically running accordingly; normally without load; but ⑤Check ignition timing. When the engine is at idling speed, accelerating slowly ignition advance angle is 10°--12°; if not correct, adjust advance ③ Improper ignition timing or weak and hard to grade angle of initial ignition of the engine. When accelerating, ignition high-pressure spark up with load; when advance angle could automatically be increased to 20°--30°. If stepping on unusual, check ignition control system or replace ECU; accelerator pedal ⑥ Check fuel pressure. When at idling speed, fuel pressure to the bottom, still shall conform to specified value 265~304kpa. When feels that power is accelerating, fuel pressure shall increase about 50kpa. If too not enough, ④Fuel pressure too low low, check fuel pressure adjuster, electric fuel pump, gasoline rotating speed filter, etc; could not be increased, and ⑤ Oil injector blocked or with poor ⑦ Remove oil injector; check ejecting amounts and atomization unable to reach atomization are normal; if not, clean or replace oil injector; maximum speed. ⑧ Check battery voltage is normal; if too low, it will cause reduced ejecting amounts, causing insufficient dynamic force, ⑥ Battery voltage too low and slow acceleration; if too low, check charging system or replace battery; ⑨ Check cooling liquid temperature sensor. Resistance of this ⑦ Cooling liquid temperature sensor sensor could be changed according to specified standard under malfunction different temperatures; if not, replace this sensor; ⑧
Inlet pressure sensor malfunction
⑨Engine cylinder pressure too low
⑩ Check intake manifold pressure temperature sensor; if unusual, replace it; ⑾ Measure compression pressure of engine cylinder; if too low, adjust valve clearance or remove the engine;
76
Common Malfunction Diagnosis Flow of Geely Automobile Engine with insufficient power
Blocked
Air filter blocked
Clean or replace Normal Leaking
Intake system leaking
Repair leaks
Normal Throttle valve opening abnormal
Unusual
Adjust
Normal Throttle valve position sensor malfunction
Unusual
Adjust or replace
Normal Improper ignition timing
Abnormal
Adjust advance angle of initial ignition
Too low
Repair
Normal Fuel pressure too low Normal Remove, ejector
clean
Abnormal
oil
Replace oil injector
Normal Battery low
voltage
Abnormal
too
Check charging battery
system
or
Normal Cooling liquid temperature sensor malfunction
Abnormal
Replace cooling temperature sensor
liquid
Normal Intake manifold pressure sensor malfunction
temperature
Unusual
Replace intake manifold pressure
Normal Replace ECU contrast test
Changes
Replace ECU
No changes Compression pressure of cylinder too low
Unusual
Remove and repair engine
77
replace
Common Malfunction Diagnosis Flow of Geely Automobile
No. 046 Oil consumption too large Malfunction
Causes
Solution
Driving habit problem
Also the most common problem. The counselor shall explain to the customer patiently and nicely, using euphemism;
Oxygen sensor malfunction
Check oxygen sensor could correctly identify concentration of gas mixture; if not, it will cause high oil consumption;
Clearance of spark plug too Clearance of spark plug is too large, causing poor ignition, which is one of large reasons causing high oil consumption; Check ignition timing; when the engine is at idling speed, ignition advance angle shall be 10º~12º; if not correct, it may cause rising oil consumption; adjust ignition advance angle of the engine;
Improper ignition timing
Oil injector blocked or poor Remove oil injector; check ejecting amounts and sealing are normal; if not, sealing clean or replace oil injector; Check cylinder pressure, valve, etc. If individual cylinders are not working, repair it accordingly; replace or adjust parts causing unusual working;
Cylinder poorly operating
Check cooling liquid temperature sensor. Resistance of this sensor could be Cooling liquid temperature changed according to specified standard under different temperatures; if sensor malfunction not, replace this sensor; Air filter blocked
During using, oil consumption of the engine is a lot Poor fuel quality higher than Tire obviously worn or standard value pressure severely insufficient
Check air filter is blocked; if so, it may cause poor intake and large oil consumption; clean or repair it; Fuel with poor quality may cause this malfunction; recommend the customer to replace it at filling station that he often uses; Tire will cause increased friction force, balancing out partial engine power, causing increased oil consumption; With sudden acceleration, speed counter of the engine is quickly increased, but the vehicle speed is very slowly increased, which could be judged that the clutch is slipping, causing idle running and increased oil consumption; replace clutch pressure plate and driven disk;
Clutch slipping
For carburetor vehicle in old Geely model, the following malfunctions may Temperature control system occur: temperature control switch and thermostat are damaged, causing malfunction causing large oil increased oil consumption as these damages will cause reduced water consumption temperature, and carburetor cold not work normally, causing poor gasoline atomization and obviously increased oil consumption; replace it; Fuel pipe leaking
Check fuel pipe; replace leaking pipe;
Braking seizing
Adjust front and rear braking; if necessary, burnish brake disk;
Oil tank cover not well sealed
Poor sealing causes fuel evaporation;
Canister control valve damaged
Replace it;
non-return
Intake quantity not conforming to standard values, causing error control, Inlet pressure and and high oil consumption when the vehicle is driving; check it with computer temperature sensor damaged diagnosis instrument; if necessary, replace inlet pressure sensor; Throttle valve position sensor Unable to identify opening; replace sensor; with broken circuit Three-way catalyzer blocked
Cementing within three-way catalyze blocked, with poor exhaust, causing high oil consumption; replace it;
Inlet pipe leaking
Replace inlet pipe;
Individual working
cylinders
not
Check operations of each cylinder; if individual cylinders are poorly operating, mainly check spark plug, high tension line, cylinder pressure, etc. Confirm causes and repair or replace;
Incorrect valve timing of the Check valve timing is correct; if not, adjust it; engine Cylinder pressure too low
Measure compression pressure of engine cylinder; if too low, check valve clearance or remove and repair engine;
Idling speed too large or too Eliminate one by one according to idling speed-related malfunction 78
Common Malfunction Diagnosis Flow of Geely Automobile small
template, making idling speed reach normal state;
Water temperature abnormal
Eliminate one by one according to water temperature-related malfunction template, making water temperature reach normal state;
79
Common Malfunction Diagnosis Flow of Geely Automobile Oil consumption too high
Driving habit problem
Habit problem
Drive correctly
Normal Abnormal Oxygen malfunction
sensor
Normal
Replac e
Too large Adjust
Clearance of spark plug too large
Normal
Improper
Improper ignition timing
Check and adjust
Normal Poor sealing Oil ejector obstructed or poor sealing
Clean
Normal Cylinder poorly operating
Repair
Repair
80
Common Malfunction Diagnosis Flow of Geely Automobile
Normal Abnormal Cooling liquid malfunction
temperature
Replace
sensor
Normal blocked
Air filter blocked
Clean
Normal Poor
Poor fuel quality
Replace
Normal Unusual
Tire obviously worn or pressure severely insufficient
Repair or replace
Normal Slipping Clutch slipping
Replace
Normal Abnormal Repair
Temperature control system malfunction causing large oil consumption
Normal Leaking Fuel pipe leaking
Repair
Normal Seizing
Braking seizing
Replace
Normal Oil tank sealed
cover
not
Not well sealed
well
Replace
Normal Canister control damaged
non-return
valve
Damaged
Replace
Normal Abnormal
Inlet pressure and temperature sensor damaged
Replace
Normal Throttle valve position sensor with open circuit
Open circuit
81
Replace
Common Malfunction Diagnosis Flow of Geely Automobile
Three-way catalyzer blocked
Blocked Replace
Normal Not working Individual working
cylinders
Repair
not
Normal Incorrect valve timing of the engine
Normal
Incorrect
Repair
Too low
Cylinder pressure too low
Repair
Normal Idling speed too large or too small
Abnormal Repair
Normal Water temperature abnormal l
Abnormal
Repair
82
Common Malfunction Diagnosis Flow of Geely Automobile
No. 047 Intake tempering Malfunction
Causes
Solution
Improper ignition timing
Check ignition timing. When the engine is at idling speed, ignition advance angle is 10°--12°; if not correct, adjust advance angle of initial ignition of the engine. When accelerating, ignition advance angle could automatically be increased to 20°--30°. If unusual, check ignition control system or replace ECU;
Valve not well closed
Check valve clearance is normal; if not, adjust it; if the valve is burnt and deformed and not well closed, replace the valve and re-furbish;
Oil injector blocked or with Remove oil injector; check ejecting amounts and atomization are normal; if not, poor atomization clean or replace oil injector; Inlet pressure sensor Check intake manifold pressure temperature sensor; if unusual, replace it; malfunction Intake manifold with Check throttle valve position sensor. When throttle valve is changed from fully tempering Throttle valve position sensor closed to fully opened, resistance of its signal terminal and earthing terminal shall malfunction be increased continuously, without interruption; if unusual, adjust or replace it accordingly; Gas mixture too thin
Oil duct malfunction is caused by too low oil ejected, which is caused mainly as: oil pressure is too low; oil injector blocked. Malfunction of intake system is caused as intake amounts are too many, which is caused mainly as: sensor controlling intake amounts are invalid; intake manifold leaking;
Engine valve timing error
Check valve timing is correct; if not, adjust it;
Oil injection control program Replace engine’s Electronically Controlled Unit (ECU); malfunction within ECU
83
Common Malfunction Diagnosis Flow of Geely Automobile Intake tempering
Improper ignition timing
Improper Check and adjust
Normal Not well closed Valve not well closed
Repair
Normal Poor atomization Oil ejector blocked or with poor atomization
Clean
Normal Abnormal Inlet pressure sensor malfunction
Replace
Normal Unusual Throttle valve position sensor malfunction
Replace
Normal Gas mixture too thin
Too thin
Repair
Normal Error Engine valve timing error
Repair
Normal Malfunction of oil injection control program within ECU
Abnormal Replace
84
Common Malfunction Diagnosis Flow of Geely Automobile
No. 048 Exhaust pipe bombs Malfunction
Exhaust bombs
Causes
Solution
①Improper ignition timing
①Check ignition timing. When the engine is at idling speed, ignition advance angle is 10°--12°; if not correct, adjust advance angle of initial ignition of the engine. When accelerating, ignition advance angle could automatically be increased to 20°--30°. If unusual, check ignition control system or replace ECU;
pipe
②Oil injector leaking, causing gas mixture ②Check oil injector is leaking; if so, replace it; too thick ③Engine valve timing error
③Check valve timing is correct; if not, adjust it;
④Oil injection control program malfunction ④Replace engine’s Electronically Controlled Unit (ECU); within ECU
Exhaust pipe bombs
Improper Improper ignition timing
Repair
Normal Leaking Oil injector leaking
Clean
Normal Engine valve timing error
Error
Repair
Normal Oil ejection control program malfunction
Unusual Replace
85
Common Malfunction Diagnosis Flow of Geely Automobile
No. 049 Engine knocking Malfunction
Causes
Solution
Fuel with low grade and poor quality
Check fuel quality and confirm fuel grade; if not reaching specified requirements, replace it;
Ignition time too early
Check ignition timing. When the engine is at idling speed, ignition advance angle is 10°--12°; if not correct, adjust advance angle of initial ignition of the engine. When accelerating, ignition advance angle could automatically be increased to 20°--30°. If unusual, check ignition control system or replace ECU;
Cooling system malfunction
Engine overheating may cause this problem; check cooling system; Put screwdriver at filler port, and put your ear against the screwdriver lever, and carefully observe and listen; Flame out for cylinders gradually; if sound of this cylinder weakens or disappears, then it is confirmed that this cylinder has abnormal sound;
To differentiate from other abnormal sound, fill in some Piston and cylinder wall severely worn, lubricating oil at spark plug hole of this cylinder; if the sound weakens or disappears, then it is confirmed as piston knocking with too large clearance sound; When knocking sound is very severe and filler port is smoking externally, it is because that clearance between piston and cylinder wall is too large;
Metal knocking sound occurs when the engine increases the load or grades up
After confirming knocking sound, check cylinder diameter and piston dimension; repair according to technical requirements or replace it; Intake manifold leaking
Causing too many intake amounts, and thin gas mixture causes engine knocking; check pipes; if abnormal, repair or replace;
Oil pressure too low
Oil pressure too low, causing too few ejecting amounts, and thin gas mixture causes engine knocking; check fuel pump and pipe; if necessary, replace it;
Oil injector blocked
Oil injector blocked, causing too few ejecting amounts, and thin gas mixture causes engine knocking; check and clean the oil injector; if necessary, replace it;
Carbon deposit within the cylinder too Check carbon deposit within the cylinder; if too many causing many glowing ignition and knocking, clean it; Compression rate too large
Check cylinder cover is grinding; if grinding too large causing combustion chamber smaller, and compression ratio too large causing piston knocking, replace cylinder cover;
Individual cylinders not working
Eliminate it one by one
Causing too many intake amounts, and thin gas mixture Intake manifold pressure temperature causing engine knocking; check electrical signal of sensor; if sensor invalid abnormal, replace it; Program malfunction within ECU
Replace ECU assembly;
86
Common Malfunction Diagnosis Flow of Geely Automobile Engine knocking
Poor quality
Fuel with low grade and poor quality
Replace
Normal Worn
Piston and cylinder wall severely worn, with too large clearance
Repair
Normal Too early
Ignition time too early
Repair
Normal Too low
Repair
Oil pressure too low
Normal blocked
Oil ejector blocked
Clean
Normal Carbon deposit within the cylinder too many
Too much
Repair
Normal Compression rate too large
Too large
Repair
Normal Individual working
cylinders
not
Not working
Repair
Normal Abnormal
Replace
Intake manifold pressure temperature sensor invalid Normal Leaking
Repair
Intake manifold leaking
Normal Abnormal Cooling malfunction
Repair
system
Normal Program malfunction within ECU
Abnormal
87
Replace
Common Malfunction Diagnosis Flow of Geely Automobile
No. 050 Engine burning oil Malfunction
Causes
Solution
PCV valve invalid
Check one-way throughout of PCV valve at upper of valve chamber hood; if not, it will cause exhaust gas pressure too high within the engine, thus burning engine oil; otherwise replace it;
Engine oil too much
Reduce oil amounts;
Engine oil with poor quality
Replace engine oil;
Oil consumption too much, tail gas Valve oil seal malfunction in blue
Check valve oil seal is aged, without sealing, engine oil enters to combustion chamber through valve stem. Replace valve oil seal; Check clearance between valve stem and valve guide; if too large caused by abrasion, replace it;
Valve oil seal malfunction
Check piston ring is broken and elasticity and end clearance, side clearance, back clearance conform to requirements; if not, replace;
Piston and cylinder severely worn
Check clearance between piston and cylinder bushing conforms to requirements; if not, repair the engine;
Engine burning oil
Invalid
PCV valve invalid
Replace
Normal Abnormal
Valve oil seal malfunction
Repair
Normal Too much Engine oil too much
Discharge
Normal Engine oil poor quality
Poor
with
Replace
Normal Piston ring, piston cylinder malfunction
and
Abnormal Repair
88
Common Malfunction Diagnosis Flow of Geely Automobile
No. 051 Cooling water unusually consumed Malfunction
Causes
Solution
Cooling system leaking
Check water tank, water bottle, pipe, radiator, radiator cap, warm-wind radiator are water leaking; repair or replace. (pay attention to unusual consumption of cooling water caused by deformed assembling of rubber ring of radiator cap)
Cylinder ring malfunction
Cylinder ring is damaged or not pressed out. After startup of engine, water enters to crankcase or combustion chamber through cylinder ring; combustion chamber is through with water duct; if there is bubble out or water column spraying out of cooling water, it will cause unusual cooling water; observe engine oil is emulsified; if so, replace cylinder ring;
Cooling water of the engine consumed too Water without anti-freezing This malfunction is rare in higher temperature area, but still with possibility; in much during efficiency, causing icing after case of this situation, replace anti-freezing liquid conforming to requirements; parking in winter using Cylinder cover with cracks, which will be increased under heating, and water will enter to crankcase or combustion chamber through cracks. Under this Cylinder cover with cracks situation, check carefully cylinder cover is with cracks; if necessary, use special instruments; in case of cracks, replace it; Cylinder body with cracks
Consumption cooling water
Cylinder body with cracks, which will be increased under heating, and water will enter to crankcase or combustion chamber through cracks. Under this situation, check carefully cylinder body is with cracks; if necessary, use special instruments; in case of cracks, replace it;
of
Leaking Cooling system leaking
Repair replace
Normal Cylinder malfunction
Abnormal Replace
ring
Normal
Icing Replace
Water without antifreezing efficiency, causing icing after parking in winter
Normal
Cracks
Cylinder cover with cracks
Replace
Normal Cylinder body with cracks
Cracks
89
Replace
or
Common Malfunction Diagnosis Flow of Geely Automobile
No. 052 Low engine oil pressure Malfunction
Causes
Solution
Insufficient lubricating oil
Check engine oil; if necessary, replace or add lubricating oil;
Oil viscosity too small
Use engine oil with correct grade; at least above SG of summer SAE10W-40/winter 5W-30 Check oil screen is blocked; if so, clean or replace;
Oil pump malfunction Clearance of connecting rod tile Engine oil with too too large, causing oil leaking low pressure when Clearance of crankshaft tile too engine is working large, causing oil leaking Main oil duct blocked or leaking
Check clearance between drive gear and driven gear of oil pump. And check relief valve is blocked; if so, repair or replace; Check clearance of connecting rod tile is too large, causing oil leaking; if so, repair or replace; Check clearance of crankshaft tile is too large, causing oil leaking; if so, repair or replace; Analyze causes and repair accordingly;
Oil pressure sensor or indicator Check electrical signal of sensor and oil indicator lamp; if abnormal, lamp damaged replace it; Oil induction plug leaking
Replace induction plug
High water temperature
Eliminate malfunction one by one according to relevant template, making water temperature normal;
Low engine oil pressure
Insufficient Insufficient lubricating oil
Add
Normal Too small
Oil viscosity too small
Replace
Normal Damaged Oil pressure damaged
sensor
or
indicator
Repair
lamp
Normal Too large
Clearance of connecting rod tile too large, causing oil leaking
Normal
Too large
Clearance of crankshaft tile too large, causing oil leaking
Repair
Replace
Normal Main oil duct blocked or leaking
Blocked or leaking
90
Repair replace
or
Common Malfunction Diagnosis Flow of Geely Automobile
Quick diagnosis for M1.5.4 Electrical injection system components of MR479 engine No.053 Quick diagnosis for ECU Power source: Power supplied by the battery continuously via 18# pin; Power supplied while main relay is turned on via 37# pin; power supplied while ignition switch is turned on via 27# pin. Earthing: 2#, 10#, 14#, 19#, 24#, 30#, 48# pin. Malfunction diagnosis interface: 55# pin, engine data K line. Call out malfunction information records within ECU via K line, or manually input some instructions, such as clear malfunction information records, make idle speed actuator self-learning, etc; General causes: 1. Invalid caused by burnt and damaged parts and components within ECU due to electrical overload of externally connected device; 2. ECU entered with water causing circuit board rusty, etc; Maintenance precautions: 1. Before removing ECU, remove battery cell firstly; 2. For welding on the vehicles, cut off ECU power source; 3. Close ignition switch firstly while startup with externally connected power source or as externally connected power source; 4. Radio speaker could not approach the controller; Simple measuring method: 1 (connect the connector) Read engine malfunction records via engine data K line, and make comparison based on engine system data and normal vehicle data, find out differences and continue in-depth inquiry; 2 (Remove the connector) check ECU connections are complete, and mainly check ECU power supply, earthing lines are normal; 3. Check external sensor is working normally, output signal is reliable, and its lines are complete; 4. Recommend the ECU replaced to be assembled in the normal vehicle, and simulate malfunction malfunction, and further confirm the malfunction;
91
Common Malfunction Diagnosis Flow of Geely Automobile
Diagnosis flowchart for voltage of M1.5.4 electrical injection system
92
Common Malfunction Diagnosis Flow of Geely Automobile Y
1. Switch on diagnosis instrument, and display voltage value of battery cell; when the engine is running under normal operating temperature, check voltage is higher than 15V? N 2. When the engine is running under normal operating temperature, check voltage displayed on the instrument is lower than 15V?.
N
N
3. Check voltage value of battery anode and earthing is higher than 15V?.
N
Y
Y 4. Check when the engine is running at 20001Vm, and switch on head lamp, air conditioner, voltage value of battery cell is higher than 15V?.
N
Till malfunction elimination instructions
Y 5. Repair or replace the engine; confirm it is repairable.
No.054 Quick diagnosis for idling-speed governor EWD Function: provide idling-speed bypass air route, and control air quantity by changing cross-section of the route, realizing closed-loop control over rotating speed while the engine is under idling-speed condition; principle: one permanent magnet rotating freely on the shaft within idling-speed governor is rigidly connected with one rotating slide block, and could rotating driven by the coil, making slide block also rotating. Angular position of slide block determines opening of bypass duct, and thus adjusting bypass air quantity. Angular position of slide block is controlled by duty ratio of electrical pulse output by electronic controller;
Idle speed actuator
93
Common Malfunction Diagnosis Flow of Geely Automobile
Definition of EWD3 pin: #4# EWD3-1# pin; 2#26# EWD3-2# pin;
Simple measuring method:
1. (Remove the connector) place digital multimeter to ohm position, and two pens are respectively connected to 1#, 2# pins of governor; rated resistance is 17.6Ω±0.6Ω under 20℃; otherwise, replace it; 2. (Connect the connector) Start the engine, and make it rotate under idling speed; carefully put the hands against EWD3, and you feel slight vibration (recommend oscillograph); 3. When the engine is rotating under idling speed, take off harness connector of idling-speed governor, and rotating speed of the engine shall be changed, which indicates that idling-speed governor is working normally; 4. Take out harness connector of idling-speed governor, and measure its terminal voltage via multimeter or oscillograph. When the engine is rotating, terminal of harness connector of idling-speed governor shall be output with impulse voltage, which indicates that control system lines of ECU and idlings-peed governor are faul-free; if idling speed is still not stable at this point, with large deviations from specified value, check idling-speed governor. If output without impulse voltage, open the air conditioner and test again; if still not, it means that control system lines of ECU and idlings-peed governor are malfunction. If after installation of governor, too low idling speed, idling-speed-free appears, replace for the pad with 0.3-0.5mm thick, and screw down bolt twice, with the first torque as 2N·M, and 7N·M for the second, and maximum torque no larger than 7N·M. If the torque is too large, it will cause EWD casing deformed, and internal slide block and valve body blocked with above-mentioned malfunctions;
No.055 Quick diagnosis for knocking sensor Function: this sensor is for providing engine knocking information to electronic controller ECU for knocking control. Principle: knocking sensor is a vibration acceleration sensor, which is installed at engine cylinder body. Only one or several sensors installed is ok. Its sensitive element is a piezoelectric crystal, to which vibration of cylinder body is transferred via mass block within the sensor, and which will generate voltage at two pole faces due to pressure generated from vibration of mass block, and transforms vibration signal into voltage signal;
94
Common Malfunction Diagnosis Flow of Geely Automobile
95
Common Malfunction Diagnosis Flow of Geely Automobile
Definition of sensor pin: 1#11#
Knocking signal output;
2#30#
Earthing;
3#19#
Earthing (shielded)
Simple measuring method: 1. (Remove the connector) place digital multimeter to ohm position, and two pens are respectively connected to 1#, 2# and 1#, 3# pins of sensor; resistance under normal temperature shall be larger than 1MΩ; 2. Place digital multimeter to MV position, and knock at knocking sensor slightly with a small hammer; at this point, voltage signal shall be output; Note: please check 3# shielded line is well earthed. 3. Communicate diagnosis instrument specified by complete vehicle plant with electrical injection ECU, and read malfunction data within ECU, thus making judgment over throttle valve position sensor;
No.056 Quick diagnosis for stepper motor Function: provide idling-speed bypass air route, and control air quantity by changing cross-section of the route, realizing closed-loop control over rotating speed while the engine is under idling-speed condition; Principle: stepper motor is actuall a miniature motor, and its stator is polyphase coil winding and rotor is permanent magnet, through which one spiral axis is threaded, and these two are contacted with thread. When stator coil is switched with current, the rotor will rotate towards corresponding directions. As rotor and spiral axis are contacted with thread, angular displacement of rotor is transformed into linear displacement of spiral axis. Bypass cross-section could be changed by front and rear moving of spiral axis. If the rotor rotates fixed angle each time, spiral axis will move a certain displacement, i.e. one step. Electronic controller could control moving steps of stepper motor by changing coil energization phase to obtain corresponding bypass air flow.
96
Common Malfunction Diagnosis Flow of Geely Automobile
Idle speed actuator step motor
97
Common Malfunction Diagnosis Flow of Geely Automobile
Maintenance precautions: 1. Do not apply any forces axially to press down or take out the axle; Before idle speed governor with stepper motor is installed within throttle valve body, the axle must be at completely holdback position; 3. Pay attention to cleaning of bypass air route; 4. After removing battery cell, manually trigger self-learning function of stepper motor duly by using K line for malfunction diagnosis for earthing with three times, and earthing time equaling to and larger than 2.5s each time, or self-learning by using diagnosis instrument; Simple measuring method: 1. (Remove the connector) place digital multimeter to ohm position, and two pens are respectively connected into AD, BC pins of regovernor, and rated resistance under 25℃ is 53±5.3Ω; otherwise, replace it; 2. (Connect the connector) Start the engine, and make it rotate under idling speed; put hands slightly against stepper motor, and you feel slight vibration at this point; 3. Read amount of step of idle speed stepper motor out of engine parameter with diagnosis instrument, and start the air conditioner, and amount of step will increase. If rotating speed of the engine is kept at 3000rpm for a certain time, check amount of step will continue to rise, till to maximum opening value, which indicates that stepper motor is working normally; 4. If you cannot make judgment, recommend malfunction recurrence testing on malfunction-free vehicle;
98
Common Malfunction Diagnosis Flow of Geely Automobile
Diagnosis flowchart of idling speed stepper motor 1. Switch on diagnosis instrument, and start the engine, and observe its idling speed is stable? Observe stepper motor is within normal working range through idling speed status of diagnosis instrument?
Y
N N
2. Check bypass opening is clean and not obstructed?
Y 3. Check control lines of stepper motor are with the following conditions? Socket connector is tightly inserted or loosening; open circuited; shorted to ground or shorted to voltage source; joint of stepper motor falls out.
Y Repair
N N
4. Check resistance of stepper motor coil is within 35-95ohm? Note: this value is related to temperature.
Y N
5. Check resistance between terminal B and D, and A and C of idling speed stepper motor is infinitely large?
Y Y
6. Check joint terminal and earthing resistance is larger than 10000ohm?
7. Clean idling speed bypass opening with compressed air gun; drive stepper motor with idling-speed initialization function of diagnosis instrument, making valve stem slide to clean pollutants with compressed air; confirm repairs are completed.
8. Replace idling-speed control stepper motor; confirm repairs are completed?
9. Replace ECU, and confirm repairs are completed?
99
N
Y
Common Malfunction Diagnosis Flow of Geely Automobile
No.057 Quick diagnosis for ignition coil Function: transform low-voltage direct current of the battery into high-voltage, and generate spark through discharging of spark plug, causing gas mixture within the cylinder. Principle: when earthing channel of primary winding is switched on, this winding is charged. If circuits of primary winding are cut off by ECU, then charging is terminated, and meanwhile, high voltage is inducted from secondary winding, making spark plug discharge. What is different from ignition coil with distributor is that, secondary winding of ignition coil ZSK2 2 has spark plug each connected to its two terminals, and these two plugs will ignite at the same time. ignition coil
Ignition switch #90
Ignition coil ZSK-ROV has two pins at its low-voltage sides: Pin with “+” is connected with the battery, and pin with “-” with ECU1#; High voltage side: connected to center of distributor Double-spark ignition coil
Ignition switch #90
100
Common Malfunction Diagnosis Flow of Geely Automobile
Low-voltage side: 1# connected with ECU20# earthing channel of No. 1 coil primary winding; 2# connected with ECU1# earthing channel of No. 2 coil primary winding; 3# and 4# connected both to power source (+); High-voltage side: 1, 2, 3, 4 respectively connected with spark plug of engine cylinder of same numbering; Simple measuring method: 1. (Remove the connector) place digital multimeter to ohm position, and two pens are respectively connected to two pins of primary winding, resistance is 0.41-0.53Ω for Type ROV, and 0.42-0.58Ω for Type 2X2 under 20℃; and for secondary winding, resistance is 7-9kΩ for Type ROV, and 11.2-14.8kΩ for Type 2X2; 2. Take out spark plug within the engine, and connect with high voltage line, and make its casing earthed; start the starting motor and observe flashover of spark plug; Diagnosis flowchart for ignition coil 1. Check and confirm connection between ignition coil and ECU is loosening,
Y
and terminal damaged? N 2. Check ignition switch to terminal 1 is open circuited or shorted to ground? Check support of ignition coil is earthed?
Y
N 3. Ignition switch closed; remove joint of ECU and ignition coil; and check ECU
Y
and ignition coil is shorted circuited to voltage source?
N 4. Check ignition coil terminal 2 to ECU terminal 1 is shorted to earth?
5. Check ignition coil terminal 2 to ECU terminal 1 is open circuited?
N 6. Replace ignition coil; confirm malfunction still exists after replacement?
Y 7. Replace ECU
Y Completed
101
Y
Y
Repair
Common Malfunction Diagnosis Flow of Geely Automobile
No.058 Quick diagnosis for throttle valve position sensor Function: this sensor is for providing information about outer corner of throttle valve to ECU, based on which, ECU could obtain information related to engine load, condition (such as startup, idling speed, dragging, partial load, full load) and acceleration and deceleration. Principle: this sensor is actually corner potentiometer with linear output characteristics. Rocker arm of potentiometer is installed with throttle valve at the same axis; when throttle valve rotates, it will make rocker arm slide to certain position; potentiometer will output voltage signal proportional to throttle valve position.
Definition of sensor pin: 1#30# earthing; 2#12# connected to 5V reference voltage; 3#53# sensor signal output Simple measuring method: 1. (Remove the connector) place digital multimeter to ohm position, and two pens are respectively connected to 1#, 2# pins of sensor, with its resistance as 2kΩ±20% under normal temperature; 2. Two pens are respectively connected to 1#, 3# pins; rotate throttle valve, and its resistance will increase as opening of throttle valve, and for 2#, 3# pins, the opposite condition will occur; Note: while observing changes of resistance value, observe it jumps largely; if so, it indicates that the signal has break point; then replace it; 3. (Connect the connector) Open ignition switch and do not start the engine, then place digital multimeter to direct current voltage position, with black pen for earthing, and red pen for 2# pin; which shall have 5V reference voltage at this point; connect 3# pin and measure signal output; when throttle valve is fully closed, its voltage value is about 0.3V (specific value related to vehicle model); when throttle valve is fully opened, its voltage value is about 3V (specific value related to vehicle model).
102
Common Malfunction Diagnosis Flow of Geely Automobile
Diagnosis flowchart for throttle valve position sensor 1. Switch on ignition switch, the engine not started Change opening of throttle valve, and check it is indicated as C degree to
N
about 34 degree with diagnosis instrument? Y Y
2. Close ignition switch; take out sensor joint; ignition switch switched on.
Y
Opening of throttle valve is indicated as 10 degree? N N
3. Check signal circuit of the sensor (53-3) is shorted circuited or shorted to
Y
earth with B+? N 4. Check reference voltage circuit of the sensor (12-1) is open circuited,
Y
shorted to earth or shorted to B+? N 5. Check signal circuit of the sensor (53-3) is open circuited, shorted to earth
Y
or shorted to B+? N Y 6. Check earth circuit of the sensor (30-2) is open circuited, shorted to earth or shorted to B+? N 7. Ignition switch closed; signal terminal 3 of sensor is shorted circuit to N
reference voltage terminal 12 of ECU; ignition switch turned on, opening of throttle valve is fully opened 84 degree (about 5V)? Y
N
8. Ignition switch turned on; measure voltage between earth circuit (terminal 2) and reference voltage (terminal 1) is 5V with the voltmeter?
Repairs
Y Completed
9. Replace throttle position sensor
10. Replace ECU
103
Common Malfunction Diagnosis Flow of Geely Automobile
No.059 Quick diagnosis for inlet pressure temperature sensor Function: this sensor is for measuring absolute pressure and inlet temperature of intake manifold, and providing information related to engine load and inlet temperature. Principle: piezoelectric transducer is for measuring inlet pressure, and will provide "load signal" to the controller according to difference between atmospheric pressure and intake manifold pressure; provide 5V via controller and feed 0-5V to the controller according to difference of inlet pressure. Type NTC (negative temperature coefficient) sensor is for measuring inlet temperature, and resistance changes by inlet temperature, and this sensor will transfer one voltage indicating changes of inlet temperature to the controller.
air intake manifold absolute pressure and air intake temperature sensor
Definition of sensor pin: #30# earthing; 2#44# temperature signal output; 3#12# connecting 5V reference voltage; 4#7# pressure signal output; Simple measuring method: 1. Read malfunction code via engine diagnosis instrument and check malfunction information by referencing parameter of inlet temperature and inlet pressure. When the vehicle is not started, inlet pressure is close to the local atmosphere pressure, generally as one atmosphere pressure; after startup, pressure is reduced to 300～400kpa, and inlet temperature is ambient temperature at that time; 2. For temperature sensor, (remove the connector) place digital multimeter to ohm position, and two pens are respectively connected to 1#, 2# pins of sensor, and rated resistance is 2.5kΩ±5% under 20℃, and other corresponding resistance values could be measured from characteristic curve above. When measuring, use simulation method, specifically, supply air to the sensor via air blower (do not approach too closely), and observe changes of sensor resistance, which shall be reduced at this point; 3. For pressure sensor, (connect the connector) place digital multimeter to DC voltage position, with black pen for earthing and red pen respectively connecting with 3#, 4# pins. At idling speed, 3# pin shall have 5V reference voltage, and voltage of 4# pin is about 1.3V (specific value related to vehicle model); under empty load, slowly open throttle valve, and voltage of 4# pin is not greatly changed; quickly open throttle valve, and voltage of 4# pin could reach about 4V 104
Common Malfunction Diagnosis Flow of Geely Automobile
immediately (specific value related to vehicle model), and then reduced to about 1.5V (specific value related to vehicle model). Diagnosis flowchart for inlet pressure temperature sensor (inlet temperature sensor) 1. Ignition switch closed; remove ECU joint and check earth circuit (30-1) of sensor Y
is open circuited or shorted to B+?
N
2. Check signal circuit (44-2) of sensor is open circuited, shorted to earth or shorted Y
to B+?
Y N
3. Plug in ECU joint, and take out sensor plug, ignition turned on. Check socket N
connector terminal (2-1) has reference voltage of 5V? Repairs
Y
4. Replace intake temperature sensor
5. Replace ECU
Completed
105
Common Malfunction Diagnosis Flow of Geely Automobile
Diagnosis flowchart for inlet pressure temperature sensor (inlet pressure sensor) 1. Any following conditions occur? ---Vacuum booster or fuel pressure-regulating valve hose loosening or Y
damaged --- Intake manifold vacuum leaking and throttle valve leaking N Y
2. Disconnect sensor joint, and connect diagnosis instrument, and ignition turned on. Observe absolute pressure displayed on diagnosis instrument is N
N
3. Check lines between ECU terminal 7 of signal circuit of sensor and sensor
Y
terminal 4 is shorted circuited to B+?
4. Check lines between ECU terminal 7 of signal circuit of sensor and
Y
sensor terminal 4 is open circuited or shorted to earth? N 5. Check lines between ECU terminal 12 of 5V reference voltage and sensor
Y
terminal 3 is open circuited or shorted to earth or to power source?
N N
6. Check absolute pressure displayed on diagnosis instrument is 1013hpa after the following operations? Ignition switch closed; ECU terminal 7 shorted circuit to ECU terminal 3; ignition switch turned on Y 7. Check lines between ECU terminal 30 of earth circuit of sensor and
Y
sensor terminal 3 are open circuited, shorted to earth or to power source?
N N
8. With ignition switch turned on, check voltage between earth circuit (terminal 1) and reference voltage (terminal 3) is about 5V
Repairs
N 9. Replace manifold intake pressure sensor
10. Replace ECU
Completed
106
Common Malfunction Diagnosis Flow of Geely Automobile
No.060 Quick diagnosis for water temperature sensor Function: this sensor is for providing information about engine cooling liquid temperature, so that the controller could correct oil injection and ignition accordingly. Principle: this sensor is a heat variable resistor of negative temperature coefficient (NTC), with its resistance value reduced as the temperature rises, but not as linear relationship. This resistor is installed within copper heat guiding sleeve.
Definition of sensor pin: 1#45# temperature signal output; 2#30# earthing. Simple measuring method: 1. (remove the connector) place digital multimeter to ohm position, and two pens are respectively connected to 1#, 2# pins of sensor, and rated resistance is 2.5kΩ±5% under 20℃, and other corresponding resistance values could be measured from characteristic curve above. When measuring, use simulation method, specifically, put working area of the sensor into boiling water (soak time shall be sufficient), and observe changes of sensor resistance, which shall be reduced to 300Ω-400Ω (specific value up to temperature of boiling water); 2. Check water temperature parameter of engine diagnosis instrument is close to water temperature at the time, also with obvious changes; make judgment according to value displayed; Serial No.
Resistance Temperature tolerance Min.
Temperature Temperature tolerance
Max.
Min.
107
Max.
Common Malfunction Diagnosis Flow of Geely Automobile
Diagnosis flowchart for cooling liquid temperature sensor 1. Ignition switch closed: take out ECU joint and check earth circuit of sensor (2 pin – 30 pin) Y Y
is open circuited or shorted to B+?
N
2. Check signal circuit of sensor (1-45) is open circuited, shorted to B+ or shorted to ground?
Y
N
3. Plug in ECU joint, turn on ignition and check there is 5V reference voltage between two N
terminals of sensor joint?
Repairs
Y
4. Replace cooling liquid temperature sensor of the engine
5. Replace ECU
Completed
108
Common Malfunction Diagnosis Flow of Geely Automobile
No.061 Quick diagnosis for canister solenoid valve Function: for controlling flow of regenerated air flow of fuel evaporation control system. Principle: canister of fuel evaporation control system could absorb oil vapor of oil tank, till saturation. After canister control valve by electronic controller is opened, fresh air and fuel vapor saturated in the canister will form regenerated air flow, and reintroduce to engine inlet pipe. And electronic controller will change duty ratio of impulse signal transferred to magnet coil of canister control valve according to engine’s different conditions, thus controlling over flow of regenerated air flow. In addition, this flow is affected by pressure difference at two s ides.
Definitino of TEV pin: 1# TEV driver stage pin; 2#5# TEV control pin; Maintenance precautions: 1. When installing, airflow direction shall conform to specifications; 2. In case control valve becomes invalid due to black particle within valve body, and needed to be replaced, check canister; 3. During maintenance, avoid liquid such as water, oil from entering to valve; 4. To avoid transfer of solid borne noise, recommend to hang up canister control valve and install it at hose. Simple measuring method: 1. (remove the connector) place digital multimeter to ohm position, and two pens are respectively connected to two pins of canister control valve; rated resistance is 26Ω under 20℃; 2. Remove canister control valve, and absorb the air inside and check; canister control valve shall be stuffy; then apply battery voltage of 12V to two connecting terminals, and absorb the air to control valve, and the valve shall be airing. If upon check, status of canister control valve is not consistent with above check results, it indicates that it is malfunction, and replace it;
109
Common Malfunction Diagnosis Flow of Geely Automobile
Diagnosis flowchart for canister control valve Y
1. Ignition switch closed: remove joint of canister control valve, and turn on ignition switch, but unable to start the engine. Measure there is 12V voltage to ground at one terminal of socket connector?
N Y
2. Check lines between main relay terminal 87 and canister control valve are open circuited, shorted to ground or to power source?
Y N 3. Check resistance of canister control valve is 5-50Ω?
N
N
4. Ignition switch closed: remove ECU joint: check lines between ECU and canister control valve are open circuited, shorted to ground or to power source? Y
5. Replace canister control valve
6. Replace ECU, and confirm repairs are completed.
Repairs
110
Y Repairs
Common Malfunction Diagnosis Flow of Geely Automobile
No.062 Fuel injector EV
1.
O ring
2.
Filter screen
3.
Ejector body with electric plug
4.
Coil
5.
Spring
6.
Valve needle with coil
• Function: fuel injector ejects fuel within specified time according to instructions of ECU, and provides fuel to the engine and make it atomized. • Principle: ECU supplies power to coil of fuel injector, forming magnetic field force; when this force increases enough to overcome resultant of pressure of release spring, gravity of needle valve and friction force, needle valve starts to rise, and fuel injection starts. When injection impulse stops, pressure of release spring will make needle valve re-closed. • Mounting position: Intake manifold close to inlet valve. Malfunction: Poor idling speed, poor acceleration, unable to startup (difficult startup), etc. General causes: Colloid deposit within fuel injector due to lack of maintenance, causing it ineffective. Maintenance precautions: 1. There are many types of fuel injectors, and those with the same appearance and which could be installed may not be the proper one. Part number for injector during repairs must be the same with that of original injector. Do not mix up; 2. To ensure convenient installation, apply clean silicon-free oil at surface of upper O ring connected with fuel distribution pipe. Do not pollute inner of oil injector and jet orifice; 3. When removing and reassembling fuel injector, replace O ring; do not damage sealing surface of fuel injector; 4. If fuel injector has two slots, make it correct when installing clamps by referencing mounting position of original parts; 5. Do not remove, and clean or replace filter screen without permission; 6. After removing, make sure fuel injector seat is clean. Avoid foreign substances entering to the cylinder.
111
Common Malfunction Diagnosis Flow of Geely Automobile
Simple measuring method: (remove the connector) Place digital multimeter to ohm position, and two pens are respectively connected to two pins of oil injector, and rated resistance is 11-17Ω under 20℃. Suggestions: thoroughly clean oil injector with special cleaning analyzer for each 20000kM. Diagnosis flowchart for oil injector Y
1. Close ignition switch and disconnect joint of oil ejector; connect voltmeter to No. 1 terminal of the first cylinder ejector and earth between; switch on ignition switch, and observe voltage of No. 1 terminal of oil ejector is 12V instantaneously? For other oil ejectors, same steps.
N
2. Repair earthing, short circuit and open circuit between main relay, oil
Y
pump relay, oil ejector
3. Check lines between oil ejector and ECU terminal (17-2) are open circuited, shorted to ground or to power source?
N
N
4. Close ignition switch, and remove joint of oil ejector: measure resistance of each oil ejector is lower than 15.95Ω one by one with ohmmeter?
Y Y
5. Connect oil ejector joint of each cylinder and ground with ohmmeter; measure resistance between each oil ejector and ground is larger than 1MΩ?
N 6. Replace oil ejector
7. Replace ECU
Completed
112
Y Repairs
Common Malfunction Diagnosis Flow of Geely Automobile
No.063 Quick diagnosis for Hall sensor
Principle of hall sensor
Hall effect
When the current IS passes through semiconductor slice, hall voltage UH will occur at right-handed rotation direction, which is proportion to magnetic field induction B (vertical to current IS) and current. Hall voltage is affected by induction strength B. Hall element at (ON) status
Low level
UV
Hall element status
High level
UV UA output voltage UV input voltage
113
at
(LOCKED)
Common Malfunction Diagnosis Flow of Geely Automobile
Diagnosis flowchart for Hall sensor (ignition distributor) 1. Remove hall sensor, and measure resistance between terminal C of sensor joint and ground is between 0-2Ω?
N
Y 2. Ignition switch turned on, but unable to start the engine: measure voltage between terminal 3 and ground is between 1.0-1.5V?
N
Y N
3. Close ignition switch and remove ECU joint; measure resistance between terminal 1 of sensor joint and lines terminal 48 of ECU joint is between 0-2Ω? Y
N
4. Measure resistance between terminal 1 of sensor joint and ground is infinitely large? Y 5. Connect all joints, and clear malfunction code; as road testing, malfunction code is displayed? Y
Y
6. Replace hall sensor, and confirm malfunction code still exists after repairs are completed?
7. Repair open circuit of lines between sensor and ground, and confirm repairs are completed?
8. Repair problems such as open circuit or shorted to ground of lines between sensor and ECU, and confirm repairs are completed?
9. Repair problems such as open circuit between sensor and ECU, and confirm repairs are completed
10. Replace ECU
114
N
Troubleshooting tip
Common Malfunction Diagnosis Flow of Geely Automobile
No.064 Electric fuel pump EKP
1. Oil pump end cover 2. Armature 3. Oil duct 4. Impeller
• Function: Transfer fuel from oil tank to the engine, and provide sufficient fuel pressure and rich fuel. • Principle: Fuel pump is vane pump driven by DC motor, and placed within oil tank and immerged by fuel, using fuel for heat emission and lubrication. The battery supplies power to electric fuel pump through oil pump relay, which will only switch on lines of electric fuel pump when started and the engine is running. When the engine stops running due to accidents, fuel pump will stop running automatically. • Mounting position: Within fuel tank. Malfunction: Large running noise, poor acceleration, unable to startup (difficulty startup), etc. General causes: Due to uses of poor quality fuel, it will cause: 1. formation of insulating layer due to colloid accumulation; 2. locking of oil pump bushing and armature; 3. corrosion of oil level sensor elements, etc. Maintenance precautions: 1. according to needs of the engine, electric fuel pump is with different flows. Even mountable fuel pump with the same appearance is not proper. For maintenance, number of part of fuel pump shall be consistent with original one; 2. to prevent damages of fuel pump, do not operate it under dry condition for a long time; 3. if fuel pump is to be replaced, clean fuel tank and pipes and replace fuel filter. Simple measuring method: (remove the connector) Place digital multimeter to ohm position, and two pens are respectively connected to two pins of fuel pump, and measure internal resistance, which shall not be zero or infinite (i.e. non-short-circuited, off state). (connect the connector) for oil return system, connect the fuel pressure gauge at oil sucker, and start the engine, making it operate at idling speed status. Fuel pressure of the engine shall be around 260kPa at this time; take out vacuum tube of fuel pressure regulator, and fuel pressure shall be around 300kPa at this time.
115
Common Malfunction Diagnosis Flow of Geely Automobile
Diagnosis flowchart of oil pump circuit Y 1. Check fuse of oil pump relay is open circuited? N 2. Close inigtion and remove fuel pump relay: ignition switched on, and voltage of terminal 85, 30 of relay is larger than 10.7V?
N
Y N
3. Remove ECU joint, and measure resistance of lines between ECU terminal 3 and fuel pump relay is lower than 0.5Ω? Y N 4. Measure resistance between ECU terminal 3 and ground is infinitely large? Y N
5. Measure resistance of relay coil (85-86) is about 80-90Ω?
Y N
6. Check lines between fuel pump and fuse, and oil pump relay are normally connected?
Y
Y
7. Replace ECU and confirm repairs are completed.
Y
8. Repair “shorted to ground” of fuse of fuel pump relay, and confirm repairs are completed?
9. Repair malfunctions such as open circuit, short circuit of relay, fuse, power supply, and confirm repairs are completed?
Y
Y 10. Repair short circuit of lines between relay and ECU, and confirm repairs are completed?
11. Replace oil pump reay, and confirm repairs are completed?
116
Y
Repairs
Common Malfunction Diagnosis Flow of Geely Automobile
No.065 Fuel pressure regulator DR
• Function: For oil return system, fuel pressure regulator is used for regulating fuel pressure of fuel system, making difference with pressure of intake manifold kept at a constant value. • Principle: This pressure regulator is diaphragm type overflow valve. when system fuel pressure is increased, oil pressure within oil inlet exceeds resultant force of pre-tightening force of the spring and air pressure within spring chamber, the diaphragm will be jacked, and valve will be opened. Fuel is returned to fuel tank through oil return port in center of pressure regulator, and fuel pressure dropped, till the valve is closed. • Mounting position: Installed at fuel distribution pipe for oil return system. Malfunction: Fuel pressure too low or too high, difficult to startup, etc. General causes: Due to uses of poor quality fuel, it will cause: 1. blocked filter screen; 2. foreign substances causing large leakage. In addition, manually mechanical damages, etc. Maintenance precautions: during maintenance: 1. do not impact diaphragm element by high pressure gas; 2. do not clean it with strong corrosive liquid; 3. deformation is not allowed due to outside force. Simple measuring method: For oil return system, connect fuel pressure gauge at oil sucker, and start the engine, making it operate at idling speed status. Fuel pressure of the engine shall be around 260kPa at this time; take out vacuum tube of fuel pressure regulator, and fuel pressure shall be around 300kPa at this time.
117
Common Malfunction Diagnosis Flow of Geely Automobile
Diagnosis flowchart of fuel regulation 1. With the engine running at 1200rpm under normal temperature, N
check voltage of oxygen sensor displayed is kept at lower than 0.275V with the diagnosis instrument?
Y
2. Remove joint of oxygen sensor, and check its voltage is between 0.35-0.55V with the engine under idling speed?
N N
3. Check two lines connecting oxygen sensor (10-3; 28-4) are with
Y REPAIR
open circuit, shorted to ground or shorted to voltage source?
4. Check voltage of oxygen sensor displayed is kept larger than 0.75V
N
with the diagnosis instrument?
Y 5. Remove joint of oxygen sensor, and its voltage is lower than 0.35V Y
with the diagnosis instrument?
N
6. Remove oxygen sensor
7. Repair short circuit or open circuit
Completed
118
To troubleshooting tip
Common Malfunction Diagnosis Flow of Geely Automobile
No.066 Oxygen sensor LSH
1 cable conductor， 2 disk washer, 3 insulating bushing, 4 protective sleeve, 5 clamping connector of heating element 6 heating rod, 7 contact gasket 8 sensor seat, 9 ceramic probe, 10 protective tube
•
Function: Measure oxygen contents of engine exhaust, and determine gasoline and air are fully burnt. And electronic controller realizes closed-loop control using excess air coefficient =1 as the goal according to this information, to ensure maximum conversion efficiency of three-way catalytic converter on three pollutants such as HC, CO and Nox from the exhaust.
• Principle: Sensing element is ceramic tube, to exhaust externally and to atmosphere internally. When temperature of sensing ceramic tube reaches 350℃, it is with solid electrolyte. With this feature, convert concentration difference of oxygen to potential difference, reaching output of electrical signal. If mixture gas is too thick, concentration difference of oxygen in and out of ceramic tube is high, and potential difference is also high. And a great amount of oxygen is moved from inner side to outer side, and output voltage is high (close to 900mV); if mixture gas is too thin, concentration difference of oxygen in and out of ceramic tube is low, and potential difference is also low. And only a small amount of oxygen is moved from inner side to outer side, and output voltage is low(close to 100mV). Mounting position: Installed at front of exhaust pipe. Malfunction: poor idling speed, poor acceleration, tail gas exceeding standard, oil consumption too large, etc. Installation torque: 40~60 N•M General causes: 1. wet water vapor enters to inner of sensor, and temperature changes suddenly and probe is broken; 2. oxygen sensor “poisoning”.( Pb, S, Br, Si ). Maintenance precautions: do not use cleaning liquid, oily liquid or volatile solid at oxygen sensor during maintenance. Simple measuring method: (remove the connector) Place digital multimeter to ohm position, and two pens are respectively connected to 1# (white), 2# (white) pins of sensor, and resistance is 1~6Ω under normal temperature. (connect the connector) under idling speed status, when oxygen sensor reaches working temperature of 350℃, place digital multimeter to DC voltage position, and two pens are respectively connected to 3# (grey, 4# (black) pins of sensor, and voltage shall fluctuate quickly between 0.1-0.9V.
119
Common Malfunction Diagnosis Flow of Geely Automobile
Diagnosis flowchart of oxygen sensor
Y
1. Connect the diagnosis instrument, and start the engine to water temperature ＞ 80℃. Observe voltage of sensor signal is between 0.2-0.8? N
N
2. Check two lines connecting oxygen sensor (sensor 4-ECU28, sensor 3-ECU10) are with open circuit, shorted to ground or power source (＞1.098V for shorted to power source, ＜0.092 for shorted to ground)
Y
3. Close ignition, and plug in controller. Connect voltmeter to two white conductors of oxygen sensor, and the engine is started and running at idling speed, and check value displayed at voltmeter is between 12-14V?
N
Y
N
4. Close ignition and remove connection of socket connector of oxygen sensor. Connect two white conductors of oxygen sensor with multimeter, and check resistance is between 0.5-20ohm? Note: this value is related to temperature.
Y
N
5. Close ignition and remove connection of socket connector of oxygen sensor. Measure resistance of signal line (black) and signal cathode conductor (grey) of the sensor is within the following range: ＞30MΩ at -20℃; ＞10MΩ at 350℃; ＞100KΩ at 850℃.
Y 6. Close ignition and take out controller plug. Remove connection of socket connector of oxygen sensor, and connect the multimeter, and check resistance of cathode conductor is ＜0.5Ω?
N
Y 7. Steps same as 6; connect the multimeter to another terminal, andcheck resistance of anode conductor is ＜0.5Ω? Y N
8. Close ignition, plug in controller, and remove connection of socket connector of oxygen sensor. Connect black and central earthing with the voltmeter, with ignition turned on. Observe reading of voltmeter is between 0.4-0.6V?
Replace oxygen sensor, and confirm repairs N Replace ECU
Completed
120
No
Repairs
Common Malfunction Diagnosis Flow of Geely Automobile
No.067 JL376/378QE engine’s electric control system check Testing Testing terminal step
Component, part check
Preparations for testing conditions
Sealing of intake system
Ignition closed, take out plug of controller, and intake pipe in front of throttle valve is sealed with proper materials. Take out connecting pipe of canister control valve of throttle vavle body. No generation of bulb Apply compressed air, and make pressure within intake pipe as about 1-2bar. Check liquid leaking, and check all sealing seams. After check, reassemble connecting pipe of canister
02
Fuel device
Ignition closed, take out plug of controller, and connect pressure gauge at fuel high-tension loop. Take out fuel return pipe of the pressure regulator, and install auxiliary hose on the connector of pressure regulator. And auxiliary hose leads to one proper barrel (with capacity of at least 2 liters). 46 and 3 pins on the controller are earthed at the same time, making oil pmp rotate 30 seconds.
02.1
Oil supply of fuel pump
Carry out same as step 02
700-1000ccm
02.2
Fuel pressure
Carry out same as step 02
2.8—3 bar
02.3
Oil return pipe
Remove auxiliary hose, and connect return pipe to oil tank, and ignition is switched on, and 3 and 46 terminals of controller plug are earthed (with auxiliary cable). Read out pressure of Max. 2.9—3.1 bar pressure gauge, and disconnect earth connection, and ignition is closed.
02.4
pressure maintenance
After about 10 seconds, read pressure of the monograph again, and record dropped value of 0.2-0.3 bar the pressure.
02.5
pressure function
Plug in the controller, and the engine will start and operate at idling speed. Record fuel pressure at idling speed, and increase the throttle, and meanwhile observe pressure gauge, and pressure must be increased
01
02.6
regulator
Rated value
About 2.5 bar, About 2.8 bar
Ignition closed, and take out controller plug, and connect the voltmeter to plug of fuel pump, Power supply of fuel pump and make 3 and 46 terminals of controller plug earthed at the same time (with auxiliary cable). Min. 10.7V And fuel pump must be operating, and read out power supply voltage.
121
Common Malfunction Diagnosis Flow of Geely Automobile
02.7
Voltage drop of anode Same as description of 02.6, but multimeter placed to another terminal. side
Max. 0.5V
02.8
Voltage drop of cathode Same as description of 02.6, but multimeter placed to another terminal. side
Max. 0.5V
02.9
Total value of voltage drop Values calculated based on 02.7 and 02.8.
Max. 0.8V
03.0
Earth connection constant anode controller
of to Ignition closed, take out controller plug and connect multimeter
03.1
18．．．2
Constant anode, earthing Carry out same as step 3.0 terminal 2
About 12V
03.2
18. 14
Constant anode, earthing Carry out same as step 3.0 terminal 14
About 12V
03.3
18． 19
Constant anode, earthing Carry out same as step 3.0 terminal 19
About 12V
03.4
18…24
Constant anode, earthing Carry out same as step 3.0 terminal 24
About 12V
Anode to controller earth connection, voltage drop Ignition closed, take out controller plug, load resistance and voltmeter connection ignition switch
＜0.3V
Voltage drop terminal 18
Load resistance terminal 18 and 2
＜0．3V
04.0 04.1
B+
18
04.2
B- 2
Earth wire terminal 2
Load resistance terminal 18 and 2
＜0．3V
04.3
B- 4
Earth wire terminal 4
Load resistance terminal 18 and 4
＜0．3V
04.4
B- 19
Earth wire terminal 19
Load resistance terminal 18 and 19
＜0．3V
04.5
B- 24
Earth wire terminal 24
Load resistance terminal 18 and 24
＜0．3V
04.6
B+
27
Voltage drop terminal 27
Load resistance terminal 18 and 27, ignition turned on
＜0．3V
04.7
B+
37
Voltage drop terminal 37
Load resistance terminal 18 and 37, ignition turned on
＜0．3V
05.1
Hall sensor 1...3
Power supply hall sensor
Ignition closed, controller plug inserted. Connect voltmeter, and turn on ignition.
About 5
122
Common Malfunction Diagnosis Flow of Geely Automobile
Hall sensor signal
Close ignition, insert controller plug and connect voltmeter. Take out socket connector of When replacing shading ignition coil with ignition switch, and take out distributor cover. With ignition turned on, slowly rotor, one voltage larger rotate belt pulley of engine crankshaft manually, and observe shading rotor of measuring than 2V must be displayed instrument and hall sensor.
05.2
Hall sensor 1...2
05.3
Hall sensor based terminal 12 and ECU
on To anode conductor Close ignition, take out controller plug and connect the multimeter. connection of hall sensor
＜0.5Ω
05.4
Hall sensor based terminal 48 and ECU
on To cathode conductor Same as Step 5.3, with multimeter connected to another terminal connection of hall sensor
＜0.5Ω
05.5
Hall sensor based terminal 49 and ECU
on
Connection from hall sensor to controller Same as Step 5.3, with multimeter connected to another terminal conductor
＜0.5Ω
06.1
Pressure sensor terminal power supply from intake Ignition closed, and connect controller. Connect the voltmeter to plug of pressure sensor, and 约5 3...1 pipe pressure sensor ignition turned on
06.2
Pressure sensor terminal Intake pipe 4...1 sensor signal
06.3
Intake pipe pressure Pressure sensor terminal sensor signal when the Same as Step 6.2, with engine running at idling speed 4...1 engine is no-load running
10.8V 1.3
06.4
Intake pipe pressure Pressure sensor terminal sensor signal when 4...1 increasing throttle
电压变化
06.5
Anode Pressure sensor terminal connection 3 and ECU terminal 12 sensor
to
conductor pressure Ignition closed, take out controller plug, and connect resistance and measure
＜0.5Ω
06.6
Cathode Pressure sensor terminal connection 1 and ECU terminal 30 sensor
to
conductor pressure Same as Step 6.5; connect multimeter
＜0.5Ω
06.7
Pressure sensor terminal Signal conductor Same as Step 6.5; connect multimeter 4 and ECU terminal 7 connection to controller
07.1
Pressure sensor terminal Power supply from intake Close ignition, connect controller plug, and take out connection of socket connector of pressure About 5V 1...2 temperature sensor sensor, and connect voltmeter to plug of pressure sensor, ignition
07.2
Pressure sensor terminal Intake temperature sensor Same as Step 07.1, connect plug of pressure sensor. Note: this value is related to temperature 0.5…3V 1...2 signal
07.3
Pressure sensor terminal Intake temperature sensor Close ignition, take out plug of pressure sensor. Connect multimeter of pressure sensor. Note: At 20 1...2 resistance this value is related to temperature
pressure
Same as Step 6.1, with voltmeter connected to another terminal
Same as Step 6.2; step on the throttle, and observe voltmeter
123
3．8V 4.2V
＜0.5Ω
Common Malfunction Diagnosis Flow of Geely Automobile 07.4
Pressure sensor terminal Intake temperature sensor Close ignition, take out controller plug, and connect multimeter 2 to controller terminal 44 signal conductor
＜0.5Ω
08.1
Throttle position sensor Power supply from throttle Close ignition, connect controller plug, and connect voltmeter, ignition turned on terminal 1..2 sensor
About 5V
08.2
Throttle sensor signal Throttle position sensor voltage, throttle closed, Same as Step 8.1, voltmeter connected to throttle, closed terminal 2..3 throttle sensor signal voltage
0.1…0.9V
08.3
Throttle position sensor Throttle all opened terminal 2..3
3.0…4.8V
08.4
Throttle sensor signal voltage inspection. Note: Throttle position sensor Same as Step 8.2, but connect one oscillograph to replace voltmeter, with throttle quickly Oscillograph without this inspection only terminal 2..3 opened and closed sever voltage interference possible with connecting one oscillograph
08.5
Throttle position sensor Connection between terminal 1 and ECU anode conductor to Close ignition, take out controller plug, and connect resistance and measure terminal 12 throttle sensor
＜0.5Ω
Throttle position sensor Connection between terminal 2 and ECU cathode conductor to Same as Step 8.5, with multimeter connected to terminal terminal 30 throttle sensor
＜0.5Ω
Throttle position sensor Signal conductor terminal 3 and ECU controller conductor terminal 53
Same as Step 8.5, with multimeter connected to terminal
＜0.5Ω
Close ignition, take out controller plug, and connect multimeter
＜0.5Ω
08.6
08.7
Same as Step 8.2, whole throttle opened
to
09.1
Knocking sensor terminal Cathode conductor 2 and ECU terminal 30 controller conductor
to
09.2
Connection between Knocking sensor terminal signal conductor to Same as Step 9.1 1 and ECU terminal 11 controller
＜0.5Ω
09.3
Knocking sensor terminal Shielded 3 and ECU terminal 19 connection
Same as Step 9.1, with multimeter connected to another terminal
＜0.5Ω
09.4
Knocking sensor terminal Internal resistance 1…2 knocking sensor
Disconnect socket connector of knocking sensor, and connect multimeter
4.5…5.5V
10.1
Oxygen sensor terminal Power supply for heating Close ignition, plug in controller, with voltmeter connected to two white conductors connecting 12...14V 1…2 element of oxygen sensor to socket connector of oxygen sensor, and start the engine to be running at idling speed
10.2
Oxygen sensor terminal Internal resistance of PTC Close ignition, and disconnect socket connector of oxygen sensor, and connect multimeter to 0.2...20 1…2 heating element two white conductors of oxygen sensor. Note: this value is related to temperature.
10.3
Oxygen sensor 1…2
conductor of
Current consumption of Close ignition, ampere meter with suitable commutator conductor, connecting to one white 124
Common Malfunction Diagnosis Flow of Geely Automobile heating element of oxygen conductor. The engine is started and running at idling speed. Note: this value is related to sensor temperature. 10.4
Oxygen sensor
Insulated resistance heating element primary element
of Close ignition, disconnect socket connector of oxygen sensor. Measure signal line (black) and ＞30MΩ at -20℃; ＞10MΩ to signal cathode conductor (grey) of oxygen sensor and two white conductors one by one with at 350℃; ＞ 100KΩ at multimeter. Note: this value is related to temperature. 850℃.
10.5
Oxygen sensor
Reference voltage controller terminal 10
of Close ignition, plug in controller, and disconnect socket connector of oxygen sensor, and voltmeter connected to black wire and central earthing, with ignition turned on.
10.6
Oxygen sensor
Signal voltage of oxygen Close ignition, and connect socket connector of oxygen sensor. Connect voltmeter to black and Display slowly sensor grey cables of oxygen sensor. The engine is started and running at idling speed, and observe 0.2…0.8V display of measuring instrument after several minutes.
10.7
Oxygen sensor
Close-cycle control of Same as Step 10.6. When swinging at display, take out vacuum hose with fuel regulator and Display stable within short time. Then re-swing. oxygen sensor, seal it. After inspection, plug in hose at pressure regulator. interference identification of signal voltage
10.8
Grey cable
Cathode conductor signal Close ignition, take out controller plug, and disconnect socket connector of oxygen sensor, and connection connect multimeter/
10.9
Oxygen sensor Black cable
Anode conductor signal Same as Step 10.8; connect multimeter to black cable. After inspection, connect socket connection connector of oxygen sensor.
11.1
Cooling liquid temperature Supply voltage of cooling Close ignition, and turn on controller plug. Take out plug of cooling liquid temperature sensor. About 5V sensor liquid temperature sensor Connect voltmeter and turn on ignition.
11.2
Cooling liquid temperature Note: this value is related Same as Step 11.1, but connecting plug of cooling liquid temperature sensor. sensor to temperature
11.3
Cooling liquid temperature Connection sensor signal and conductor
11.4
Cooling liquid temperature Connection between Same as Step 11.3, with multimeter connected to another terminal. sensor cathode conductor and controller conductor
12.0
between Close ignition, take out controller, and take out plug of cooling liquid temperature sensor. <0.5Ω controller Connect the multimeter.
AC ready and compressor input
<0.5Ω
AC Close ignition, and take out controller plug. Open knife type panel of controller plug. Plug in controller, with voltmeter connected to the following terminals.
12.1
18...41
AC ready to input
The engine is started and running at idling speed. Close air conditioner.
About 12V
12.2
18...41
AC ready to input
Same as step 12.1, but with air conditioner turned on.
About 0V
12.3
18...40
AC compressor input
Same as step 12.1, with voltmeter connected to another terminal, and air conditioner closed
About 12V
12.4
18...40
AC compressor input
Same as step 12.3, but with air conditioner turned on.
About 0V
13.1
Ignition coil
Power supply from ignition Close ignition, and take out controller plug. Connect voltmeter. Ignition turned on. coil (ignition switch)
About 12V
125
between
Common Malfunction Diagnosis Flow of Geely Automobile 13.2
1...2
Ignition coil source input
Same as Step 13.1, with voltmeter connected to another terminal.
About 12V
13.3
Ignition coil conductor
13.4
B+… ignition coil
Ignition coil voltage F drop Same as Step 13.3. with voltmeter connected to B+ and ignition switch (load resistance). (ignition switch)
<0.5V
13.5
ECU terminal 1 Ignition coil terminal 1
Cathode conductor Same as Step 13.3. with voltmeter connected to controller terminal 1. voltage drop of ignition coil
<0.5V
connecting Power supply from ignition Close ignition, take out controller plug, and remove connecting conductor of ignition coil coil (with load) (ignition switch and terminal 1), and connect one load resistance to ignition switch and connecting conductor of terminal 1. Make bridge connection at controller plug (from 2 to 1. )
13.6
Ignition coil
Close ignition, and connect connecting conductor of ignition coil. Connect controller plug, and Intense blue spark seen remove conductor of ignition coil, and connect proper lightening distance, which is adjusted to during lightening 10mm. note: during inspection, do not hold or contact part 1 of ignition device with hands to operate the starter.
14.1
Ignition coil
Closed angle, angle control
closed Ignition “closed”, connect control plug. Connect conductor 4 of ignition coil. Turn on engine tester of ignition coil and adjust to closed angle for measurement. The engine is started and running at idling speed. Read out closed angle (measured value of the tester).
14.2
Ignition coil
Closed angle, angle selection
closed Same as Step 14.1, but with rotating speed slowly increased to about 3000rpm.
14.3
Ignition coil
Voltage drop of ignition Same as Step 14.1, with engine tester converted to dynamic voltage drop for measurement. final stage. Note: this measurement is only valid when using proper measuring instrument.
14.4
Ignition coil
Voltage drop of ignition Same as 14.2, but with engine slowly increased to about 3000rpm. final stage. Note: this measurement is only valid when using proper measuring instrument.
15.1
Ignition distributor
Basic arrangement distributor
15.2
Ignition timing correction Distributor arrangement of distributor
15.4
Ignition conductor of Digital idling-speed With the engine under hot running at idling speed, measure ignition advance angle. And When electric instruments induction thong (the first stabilization function connect electric instruments as much as possible, such as heating pad, high beam. And are turned on, adjust cylinder) or top dead observe ignition mark or ignition angle display of engine tester. ignition timing quickly.
Display larger
value
becomes
of Ignition “closed”, take out plug of hall sensor. The engine is placed at top dead center of the For basic adjustment, mark first cylinder (not rotating at camshaft). Take out ignition distributor cover, and evaluate marking on the distributor cover fit position of distributor rotor. with distributor rotor center. Ignition “closed”, connect plug of hall sensor, and install ignition distributor cover. optical disc Ignition time 6.75° lamp of tong sensor is connected to ignition conductor of the first cylinder. crankshaft angle (mark) Note: when engine tester is with dead center sensor, tong sensor is not needed to connect. With the engine under hot running, temperature of cooling liquid is larger than 80℃. Connect the diagnosis instrument, and choose ignition correction function, and at this point idling speed could be increased to about 1500rpm. If with ignition correction line (terminal 51), it could be selected. Ignition correction line (terminal 51) is earthed.
126
Common Malfunction Diagnosis Flow of Geely Automobile center sensor 16.1
Conductor connection of Close ignition, and take out controller plug. Remove fuse of oil pump and heating element of About 12V oil injector of the first oxygen sensor. Bridge connection with terminal 14, 3 and 46. Connect 2 (-) and 17 (+) with cylinder voltmeter.
16.2
Conductor connection of Same as 16.1, with voltmeter connected to 2 (-) and 16 (+). oil injector of the second cylinder
About 12V
16.3
2...35
Conductor connection of Same as 16.1, connect 2 (1) and 35 (+) with voltmeter oil injector of the third cylinder
About 12V
16.4
2...34
Conductor connection of Same as 16.1, connect 2 (1) and 34 (+) with voltmeter oil injector of the fourth cylinder
About 12V
17.1
B+...+EVl
Power supply under load
Close ignition, and take out controller plug. Remove all plugs of oil injector. Connect load ＜0.5V resistance to the first cylinder and terminal 14. voltmeter connects to positive connection of B+ and load resistance. Remove fuse of oil pump and heating element of oxygen sensor, with 2 bridge connected to 3 and 46.
17.2
B+...+EV2
Power supply under load
Same as 17.1, switching with another terminal for load resistance and voltmeter to positive ＜0.5V conductor (connecting plug for cylinder oil injector at cable side)
17.3
B+...+EV3
Power supply under load
Same as above-mentioned, but for cylinder 3
＜0.5V
17.4
B+...+EV4
Power supply under load
Same as above-mentioned, but for cylinder 4
＜0.5V
19.5
EV4+...
Startup control Note: this measuring instrument could be used at each oil injector.
Close ignition, and switch on controller plug. Connect closed angle tester to oil injector of fourth 25...35％ cylinder with switching conductor. Remove fuse of oil pump. Remove conductor of ignition coil 10...20％ (ignition switch). Remove plug of cooling liquid temperature sensor and connect one resistance 5…8％ with 30 thousand ohm to replace NTC. Operate starter for about 15 seconds, and observe display of closed angle tester. Display when startup: Display after startup for about 5 seconds: Display after startup for about 10 seconds:
20.1
4...26
Internal resistance stepper motor
of Close ignition, take out controller plug, and connect the multimeter. Note: resistance is related 35…95 ohm to temperature.
20.2
21...29
Internal resistance stepper motor coil
of Close ignition, take out controller plug, and connect the multimeter. Note: resistance is related 35…95 ohm to temperature.
20.3
4… stepper motor terminal B
Conductor connection
Same as 20.1, take out plug of stepper motor, with the multimeter switched to corresponding ＜0.3ohm terminal.
20.4
26… stepper motor terminal C
Conductor connection
Same as 20.1, take out plug of stepper motor, with the multimeter switched to corresponding ＜0.3ohm terminal.
20.5
21… stepper motor
Conductor connection
Same as 20.1, take out plug of stepper motor, with the multimeter switched to corresponding ＜0.3ohm 127
Common Malfunction Diagnosis Flow of Geely Automobile terminal D
terminal.
20.6
29… stepper motor terminal A
Conductor connection
Same as 20.1, take out plug of stepper motor, with the multimeter switched to corresponding ＜0.3ohm terminal.
20.7
Stepper motor
Control
Close ignition, turn on controller plug and turn on speed counter. Connect the tester to stepper About motor with switching conductor. The engine is started and running at idling speed. Display on 850rpm the speed counter: 60…80 step Display on the closed angle tester:
20.8
Stepper motor
Idling speed function
20.9
Stepper motor
Basic governing of idling Same as 20.7, the engine is still warm, and close all current consumption instruments. Connect Adjusted value speed diagnosis instrument and choose basic governing function. Choose maintenance connector terminal. and make terminal 39 (controller) earthed. Observe display on the speed counter and closed angle tester. Adjust bypass bolt. Running at idling speed.
21.1
51...
Connection between Close ignition, take out controller plug and connect the multimeter. ignition correction conductor to controller (terminal 51) conductor
＜0.5ohm
22.1
55...
Connection between fuel Close ignition, take out controller plug and connect the multimeter. conductor to controller (terminal 55) conductor
＜0.50ohm
23.1
3...2
Fuel pump relay control, Ignition “closed”, take out controller plug. Take out casing of controller plug, and turn on About 12V final stage controller plug, with voltmeter connected to terminal 1 and 2. “ignition” turned on, and starter not started.
23.2
3...2
Fuel pump relay control, Same as 23.1, but engine started and running at idling speed. driver stage
governing Same as 20.7, electric instruments such as heating pad shall be exact and turned on at the Rotating speed quickly same time. In case of servo steering, rotate to stopper and stop when the vehicle is at rest. reduced under the load, Observe display on the speed counter and closed angle tester. then increased to starting value
128
0.5...2.0V
Common Malfunction Diagnosis Flow of Geely Automobile
No.068 Diagnosis and solution of common malfunctions of JL376/378QE engine’s electric control system Serial No. Malfunction
Display by diagnosis instrument
Analytic procedure
Causes
Measures
1.
After startup, flame out after about 10s at idling λ integral quantity exceeding lower limit speed. Hard to start again, oil injection correction: -25% and flame out when voltage of oxygen voltage is 800mv throttling up the engine
2.
Unable to startup (started Key placed to the second position, and Diagnosis instrument ON, but unable to Fuse broken, causing ECU27 before); normally started check ECU27 pin is with 12V voltage, 19 Replace fuse communicate with ECU pin without voltage once during exhaust pin is connected to vehicle body
3.
Unable to startup
Diagnosis instrument without display
Electric injection system without power Fuse broken, causing ECU18 supply pin without power supply Replace fuse check ECUl8 pin is with 12V voltage, 19 voltage pin is connected to vehicle body
4.
Startup with burning, and flame out immediately after engine’s rotating speed rises
Two malfunctions: Throttle valve position sensor shorted to earth Pressure sensor shorted to earth
Measure connections between ECUl2 pin not ON with above-mentioned sensors and ECU, and above-mentioned sensors, Replace harness connections among them and with the but ON with hall element ground with multimeter.
5.
Instable idling speed, but actually operation very / normal
/
/
6.
Instable idling speed, sometimes high and / sometimes low
Not malfunction
Self-learning of stepper motor Flame out, wait for 10s, and not completed re-start
7.
Unable to start
Without malfunction. When the motor is working, diagnosis instrument displays Check hall element is working normally that rotating speed of the engine is 0rpm
8.
Unable to start
Without malfunction.
Obviously oil injection not normal; check ECU malfunction; malfunction hardware of oil supply system is working disappears after replacement Replace ECU normally of ECU
Hall element 48 pin broken
Oil pump relay is with closing sound, but Check fuse or lines from oil oil pump not working normally pump relay to oil pump
129
/
Improve harness quality
Common Malfunction Diagnosis Flow of Geely Automobile
No.069 Flashing code list of M1.5.4 series Serial No.
Designation of malfunction code
Flashing code
Malfunction type
Malfunction lamp
1
Knock sensor (zero measuring testing status)
1
1
1
2
Malfunction-free
11
-
-
3
Temperature sensor of AC condenser
13
1
0
4
Throttle valve position sensor
14
1
1
5
Condensing sensor
15
2
1
6
Intake pressure sensor
16
1
1
7
oxygen sensor
17
1
1
8
Intake temperature sensor
18
1
1
9
Cooling liquid temperature sensor
19
1
1
10
Oil injector-4 cylinders
21
1
1
11
Oil injector-1 cylinder
22
1
11
12
Oil injector-2 cylinders
23
1
1
13
Oil injector-3 cylinders
24
1
1
14
Canister control valve
25
1
1
15
Correction coefficient of air fuel ratio control
31
2
0
16
Maximum speed limit of the engine
33
2
0
17
Electronic control unit
34
2
1
18
Addition correction self-learning of air fuel ratio control (work when under idling speed range)
35
2
0
130
Common Malfunction Diagnosis Flow of Geely Automobile
19
Multiplication correction self-learning of air fuel ratio control (work when under driving conditions)
36
2
0
20
Addition correction self-learning of air leakage of air fuel ratio control
37
2
0
21
Battery
38
2
0
22
Vehicle speed signal
41
2
0
23
Cooling fan relay
42
1
1
24
Cylinder signal
43
2
0
25
Malfunction indicating lamp
45
1
0
26
Speed governor driver stage 1
61
1
1
27
Speed governor driver stage 2
62
1
1
Malfunction type: : “1” broken circuit or short circuited to ground or power source overrun
“2”
signal
Malfunction lamp: : “1”ON “0” OFF Steps for reading flashing code: 1. Switch on ignition switch of the engine, but unable to start the engine. 2. Connect K line (ECU-55# or OBDⅡ diagnosis connector -7#) to earth, and the time exceeds 2.5 seconds. 3. Malfunction stored in the malfunction memorizer is output in flashing mode through malfunction indicating lamp. 4. Each flashing code is made up of 2 numbers, and each number is made up of 0 or 1-9. 5. Number 0 flashes ten times, and numbers 1-9 flash respectively 1-9 times; interval of two numbers pauses (one second) when flashing, and neighboring malfunction code will pause for long time (3 seconds). 6. The same malfunction code flashes continuously for 3 seconds. And all malfunction codes flash continuously, till the engine is started or reading action of malfunction terminates. 7. If there is no malfunction stored within malfunction memorizer, then “without malfunction” flashes, i.e. “11”.
131
Common Malfunction Diagnosis Flow of Geely Automobile
Diagnosis flowchart of M7.9.7 system of 479Q/QA/481Q according to malfunction code Description: 1. check the following only when confirmed as current stable status malfunction; otherwise it will cause incorrect diagnosis. 2. “Multimeter” mentioned hereinafter refers to digital multimeter. Do not use pointer type multimeter to check lines of electric injection system. 3. Check vehicles with burglary protection system. If ECU to be replaced in the “Follow-ups”, make programming to ECU after replacement. 4. For this project: When P0171, P0172, P0335, P0336, P1651 malfunction codes exist, engine’s malfunction lamp is not ON. 5. If malfunction code indicates voltage of certain circuit is too low, it means that this circuit may be shorted to ground; if malfunction code indicates voltage of certain circuit is too high, it means that this circuit may be shorted to power source; if malfunction code indicates certain circuit is malfunction, it means that this circuit may be opened or there is malfunction to many lines. Diagnosis help: 1. Malfunction code could not be eliminated, malfunction is stable status malfunction; if chance failure, mainly check harness connector is loosening. 2. No unusual conditions are found after inspection according to above-mentioned steps; 3. During inspection, pay attention to effect of automobile maintenance, cylinder pressure, mechanical ignition timing on the system; 4. Replace ECU and test it. If malfunction code could be eliminated at this point, then malfunction part is located in ECU; if not eliminated, replace for original ECU, and repeat the flowchart, and recheck it.
No.070 Malfunction code: P0107 "voltage of intake pressure sensor circuit too low" Serial No.
Operation steps
Results
Follow-ups
1
Switch on diagnosis instrument and commutator, and place ignition switch to “ON”.
Next step
2
Observe “inlet pressure” of data flow, and check value is around 101kpa (specific Yes value related to the air pressure at that time). No
To step 5
Take out the connector of intake pressure sensor of the harness, and check voltage Yes between 3# and 1# pins of this connector is around 5V with multimeter. No
To step 5
3
4
5
Check lines respectively between 17#, 33#, 37# pins of ECU and 1#, 3#, 4# pins of sensor connector are shorted to ground.
Next step
Yes
Repair or replace harness
No
Next step
Start the engine and make it operate at idling speed. Step the throttle slowly to be close to full opening, and observe changes of value of “inlet pressure” on the Yes diagnosis instrument, and values shall not be largely changed at this time; step the throttle quickly to be close to full opening, and value shall reach above 90kpa No immediately at this time.
132
Next step
Diagnosis help Replace sensor
Common Malfunction Diagnosis Flow of Geely Automobile
No.071 Malfunction code: P0108 "voltage of intake pressure sensor circuit too high" Serial No.
Operation steps
Results
1
Switch on diagnosis instrument and commutator, and place ignition switch to “ON”.
2
Observe “inlet pressure” of data flow, and check value is around 101kpa (specific value related to the air pressure at that time).
Follow-ups
Next step Yes
To step 5
No
Next step
Yes
To step 5
No
Next step
Yes
Repair or replace harness
No
Next step
Take out the connector of intake pressure sensor of the harness, and check voltage between 3# and 1# pins of this connector is around 5V with multimeter.
3
Check lines respectively between 17#, 33#, 37# pins of ECU and 1#, 3#, 4# pins of sensor connector are opened or shorted to power source.
4
Start the engine and make it operate at idling speed. Step the throttle slowly to be Yes close to full opening, and observe changes of value of “inlet pressure” on the diagnosis instrument, and values shall not be largely changed at this time; step the throttle quickly to be close to full opening, and value shall reach above 90kpa immediately at this time. No
5
Diagnosis help
Replace sensor
No.072 Malfunction code: P0112 "temperature indicated by intake temperature sensor too low" Serial No.
Operation steps
1
Switch on diagnosis instrument and commutator, and place ignition switch to “ON”.
To step 5
2
Observe “intake temperature” of data flow, and check it is equal to Yes temperature within air inlet pipe (specific value related to engine temperature at that time). Note: if value is -40℃ at this point, then disconnection malfunction may occur to lines. No Take out connector of intake temperature sensor of the harness, and check Yes resistance between 1# and 2# pins of sensor is suitable to its temperature with multimeter (for details, refer to related parts of this maintenance manual). No
Next step
3
4
5
Results
Next step
Take out connector of intake temperature sensor of the harness, and check Yes voltage between 1# and 2# pins of this connector is around 5V. No Check lines between 17#, 40# pins of ECU and 1#, 2# pins of sensor Yes connector are opened or shorted to power source. No
6
Start the engine, and make it operate at idling speed. Observe changes of values of “intake temperature” on the diagnosis instrument, and values shall Yes rise as temperature of cooling liquid of the engine rises at this time 133
Follow-ups
Next step
Replace sensor To step 5 Next step Repair or replace harness Next step Diagnosis help
Common Malfunction Diagnosis Flow of Geely Automobile
No
Replace sensor
No.073 Malfunction code: P0113 "temperature indicated by intake temperature sensor too high" Serial No.
Operation steps
1
Switch on diagnosis instrument and commutator, and place ignition switch to “ON”.
To step 5
2
Observe “intake temperature” of data flow, and check it is equal to Yes temperature within air inlet pipe (specific value related to engine temperature at that time). Note: if value is -40℃ at this point, then disconnection malfunction may occur to lines. No
Take out connector of intake temperature sensor of the harness, and check Yes resistance between 1# and 2# pins of sensor is suitable to its temperature with multimeter (for details, refer to related parts of this maintenance manual). No
Next step
3
Results
Next step
Take out connector of intake temperature sensor of the harness, and check Yes voltage between 1# and 2# pins of this connector is around 5V. No
4
Start the engine, and make it operate at idling speed. Observe changes of values of “intake temperature” on the diagnosis instrument, and values shall rise as temperature of cooling liquid of the engine rises at this time.
6
Next step
Replace sensor To step 5 Next step
Yes
Repair or replace harness
No
Next step
Yes
Diagnosis help
No
Replace sensor
Check lines between 17#, 40# pins of ECU and 1#, 2# pins of sensor connector are shorted to ground.
5
Follow-ups
No.074 Malfunction code: P0117 "temperature indicated by cooling liquid temperature sensor too low" Serial No.
Operation steps
1
Switch on diagnosis instrument and commutator, and place ignition switch to “ON”.
2
Observe “temperature of cooling liquid” of data flow, and check it is equal to Yes engine temperature (specific value related to engine temperature at that time). Note: if value is -40℃ at this point, then disconnection malfunction No may occur to lines.
3
4
Results
Follow-ups
Next step To step 6 Next step
Take out connector of temperature sensor of cooling liquid of the harness, Yes and check resistance between 1# and 2# pins of sensor is suitable to its temperature with multimeter (for details, refer to related parts of this No maintenance manual).
Replace sensor
Take out connector of temperature sensor of cooling liquid of the harness, and check voltage between 1# and 2# pins of this connector is around 5V. Yes
To step 6
134
Next step
Common Malfunction Diagnosis Flow of Geely Automobile
Check lines between respectively 39#, 35# pins of ECU and 1#, 2# pins of sensor connector are opened, or shorted to power source.
5
No
Next step
Yes
Repair or replace harness
No
Next step
Start the engine, and make it operate at idling speed. Observe changes of Yes values of “temperature of cooling liquid” on the diagnosis instrument, and values shall rise as temperature of cooling liquid of the engine rises at this time. No
6
Diagnosis help
Replace sensor
No.075 Malfunction code: P0118 "temperature indicated by cooling liquid temperature sensor too high" Serial No.
Operation steps
1
Switch on diagnosis instrument and commutator, and place ignition switch to “ON”.
To step 6
2
Yes Observe “temperature of cooling liquid” of data flow, and check it is equal to engine temperature (specific value related to engine temperature at that time). Note: if value is -40℃ at this point, then disconnection malfunction No may occur to lines.
Yes Take out connector of temperature sensor of cooling liquid of the harness, and check resistance between 1# and 2# pins of sensor is suitable to its temperature with multimeter (for details, refer to related parts of this maintenance manual). No
Next step
3
Results
Take out connector of temperature sensor of cooling liquid of the harness, and check voltage between 1# and 2# pins of this connector is around 5V.
4
Next step
Replace sensor
To step 6
No
Next step
No Start the engine, and make it operate at idling speed. Observe changes of Yes values of “temperature of cooling liquid” on the diagnosis instrument, and values shall rise as temperature of cooling liquid of the engine rises at this time. No
6
Next step
Yes
Check lines between respectively 39#, 35# pins of ECU and 1#, 2# pins of Yes sensor connector are shorted to ground.
5
Follow-ups
Repair or replace harness Next step Diagnosis help Replace sensor
No.076 Malfunction code: P0122 "voltage of throttle valve position sensor circuit too low" Serial No.
Operation steps
Results
1
Switch on diagnosis instrument and commutator, and place ignition switch to “ON”. 135
Follow-ups
Next step
Common Malfunction Diagnosis Flow of Geely Automobile
Observe "absolute opening of throttle valve" of data flow, and value is between 4%-10% (specific value depends on vehicle model).
2
Step the throttle to full opening and observe "absolute opening of throttle valve" of data flow, and value will be increased to about 85-95% as opening of throttle valve is increased (specific value depends on vehicle model).
3
Repeat Step 3, and observe "absolute opening of throttle valve" of data flow, and value is abruptly changed during changes.
4
Take out connector of throttle valve position sensor of harness, and check lines between respectively 17#, 32#, 16# pins of ECU and 1#, 2#, 3# pins of sensor connector are shorted to ground.
5
Check voltage between 1# and 2# pins of this connector is around 5V with multimeter.
6
Yes
Next step
No
To step 5
Yes
Next step
No
To step 5
Yes
Replace sensor
No
Next step
Yes
Repair or replace harness
No
Next step
Yes
Replace sensor
No
Diagnosis help
No.077 Malfunction code: P0123 "voltage of throttle valve position sensor circuit too high" Serial No.
Operation steps
1
Switch on diagnosis instrument and commutator, and place ignition switch to “ON”.
2
Observe "absolute opening of throttle valve" of data flow, and value is between 4%-10% (specific value depends on vehicle model).
3
4
5
6
Results
Step the throttle to full opening and observe "absolute opening of throttle valve" of data flow, and value will be increased to about 85-95% as opening of throttle valve is increased (specific value depends on vehicle model).
Repeat Step 3, and observe "absolute opening of throttle valve" of data flow, and value is abruptly changed during changes.
Take out connector of throttle valve position sensor of harness, and check lines between respectively 17#, 32#, 16# pins of ECU and 1#, 2#, 3# pins of sensor connector are opened, or shorted to power source.
Check voltage between 1# and 2# pins of this connector is around 5V with multimeter.
136
Follow-ups
Next step Yes
Next step
No
To step 5
Yes
Next step
No
To step 5
Yes
Replace sensor
No
Next step
Yes
Repair or replace harness
No
Next step
Yes
Replace sensor
No
Diagnosis help
Common Malfunction Diagnosis Flow of Geely Automobile
No.078 Malfunction code: P0130 "signal circuit of upstream oxygen sensor malfunction" (Note: following diagnosis flowchart is applied when P0135 does not occur at the same time; if P0135 malfunctions exist at the same time, deal with P0135 malfunctions, and then check according to the following flowchart.) Serial No.
Operation steps
Results
1
Switch on diagnosis instrument and commutator, and place ignition switch to “ON”.
2
Yes Start the engine, and make it operate at idling speed, till temperature of cooling liquid reached normal value. Observe changes of value of “voltage of oxygen sensor” on the diagnosis instrument, and the value shall be changed quickly between 100mV~900mV at this time. No
Next step
Check lines respectively between 36#, 18# of ECU and A# (opposed to Yes grey connecting line of oxygen sensor), B# (opposed to black connecting line of oxygen sensor) of sensor connector are shorted to ground. No
3
A. Check admission system is severely leaking; B. Oil injector is blocked; C. Spark plug is with too large clearance; D. Resistance of sub live wire is too large; E. Tube of intake valve is worn; etc.
4
Follow-ups
Diagnosis help
Next step
Repair or replace harness Next step
Yes
Repair accordingly
No
Diagnosis help
No.079 Malfunction code: P0132 "voltage of upstream oxygen sensor circuit too high" (Note: following diagnosis flowchart is applied when P0135 does not occur at the same time; if P0135 malfunctions exist at the same time, deal with P0135 malfunctions, and then check according to the following flowchart.) Serial No.
Operation steps
1
Switch on diagnosis instrument and commutator, and place ignition switch to “ON”.
Diagnosis help
2
Start the engine, and make it operate at idling speed, till temperature of Yes cooling liquid reached normal value. Observe changes of value of “voltage of oxygen sensor” on the diagnosis instrument, and the value shall be changed quickly between 100mV~900mV at this time. No Yes Check lines respectively between 36#, 18# of ECU and A# (opposed to grey connecting line of oxygen sensor), B# (opposed to black connecting line of oxygen sensor) of sensor connector are shorted to power source. No
Repair or replace
3
Results
Follow-ups
Next step
Next step
Diagnosis help
No.080 Malfunction code: P0134 "upstream oxygen sensor signal malfunction" (Note: following diagnosis flowchart is applied when P0135 does not occur at the same time; if P0135 malfunctions exist at the same time, deal with P0135 malfunctions, and then check according to the following flowchart.) 137
Common Malfunction Diagnosis Flow of Geely Automobile
Serial No.
Operation steps
Results
1
Switch on diagnosis instrument and commutator, and place ignition switch to “ON”.
2
Start the engine, and make it operate at idling speed, till temperature of Yes cooling liquid reached normal value. Observe changes of value of “voltage of oxygen sensor” on the diagnosis instrument, and the value shall be changed quickly between 100mV~900mV at this time. No
Check lines respectively between 36#, 18# of ECU and A# (opposed to grey connecting line of oxygen sensor), B# (opposed to black connecting line of oxygen sensor) of sensor connector are opened.
3
Follow-ups
Next step
Diagnosis help Next step
Yes
Repair or replace harness
No
Diagnosis help
No.081 Malfunction code: P0135 "heating circuit of upstream oxygen sensor malfunction" Serial No.
Operation steps
Results
Follow-ups
1
Switch on diagnosis instrument and commutator, and place ignition switch to “ON”.
2
Take out connector of oxygen sensor of harness, and check voltage Yes between C# (opposed to white connecting line of oxygen sensor), D# (opposed to white connecting line of oxygen sensor) pins of this connector is around 12V with multimeter. No
To step 4
Yes
Next step
No
Replace sensor
Yes
Replace fuse
No
Next step
Next step
Next step
Check resistance between C# (white), D# (white) pins of oxygen sensor is between 2~5Ω under 20℃ with multimeter.
3
4
Check 8A fuse of heating circuit of oxygen sensor is blown.
Check lines respectively between 1# pin of ECU, 87# pin of main relay and Yes C# (opposed to white connecting line of oxygen sensor), D# (opposed to white connecting line of oxygen sensor) of sensor connector are opened, or shorted to power source or ground. No
5
Repair or replace harness Diagnosis help
No.082 Malfunction code: P0171 “self-adapting of closed-loop control of air fuel ratio shall exceed upper part” (Note: following diagnosis flowchart is applied when malfunction codes such as admission pressure sensor, canister control valve, oxygen sensor do not occur at the same time; if relevant malfunction codes exist at the same time, deal with other malfunctions, and then check according to the following flowchart.) Serial No.
Operation steps
Results
138
Follow-ups
Common Malfunction Diagnosis Flow of Geely Automobile
1
Switch on diagnosis instrument and commutator, and place ignition switch to “ON”.
2
Start the engine, and make it operate at idling speed, till temperature of cooling liquid reached normal value. Under full condition, observe changes of value of “voltage of oxygen sensor” on the diagnosis instrument, and check the value is around 100mV under some conditions for a long time.
Next step
Yes
Next step
No
Diagnosis help
Yes
Next step
No
Repair fuel system
Switch on fuel pressure gauge at oil inlet pipe of fuel system, and observe pressure is around 350kPa under full condition.
3
Check lines respectively between 36#, 18# pins of ECU and A# (opposed to Yes grey connecting line of oxygen sensor), B# (opposed to black connecting line of oxygen sensor) of sensor connector are shorted to power source. No
4
A. Check admission system is severely leaking; B. Oil injector is blocked; C. Spark plug is with too large clearance; D. Resistance of sub live wire is too large; E. Tube of intake valve is worn; etc.
5
Repair or replace harness Next step
Yes
Repair accordingly
No
Diagnosis help
No.083 Malfunction code: P0172 “self-adapting of closed-loop control of air fuel ratio shall exceed lower part” (Note: following diagnosis flowchart is applied when malfunction codes such as admission pressure sensor, canister control valve, oxygen sensor do not occur at the same time; if relevant malfunction codes exist at the same time, deal with other malfunctions, and then check according to the following flowchart.) Serial No.
Operation steps
1
Switch on diagnosis instrument and commutator, and place ignition switch to “ON”.
2
Yes Start the engine, and make it operate at idling speed, till temperature of cooling liquid reached normal value. Under full condition, observe changes of value of “voltage of oxygen sensor” on the diagnosis instrument, and check the value is around 900mV under some conditions for a long time. No
3
4
Results
Follow-ups Next step
Next step
Diagnosis help
Yes
Next step
No
Repair fuel system
Switch on fuel pressure gauge at oil inlet pipe of fuel system, and observe pressure is around 350kPa under full condition.
Check lines respectively between 36#, 18# pins of ECU and A# (opposed to grey connecting line of oxygen sensor), B# (opposed to black connecting Yes line of oxygen sensor) of sensor connector are shorted to power source.
139
Repair or replace harness
Common Malfunction Diagnosis Flow of Geely Automobile
A. Oil injector is leaking; B. Exhaust pipe is leaking; C. Ignition timing is incorrectly; etc.
5
No
Next step
Yes
Repair accordingly
No
Diagnosis help
No.084 Malfunction code: P0201 "one-cylinder oil injector circuit malfunction" Serial No.
Operation steps
Results
1
Switch on diagnosis instrument and commutator, and place ignition switch to “ON”.
2
Take out connector of one-cylinder oil injector of harness, and check Yes voltage between 1# pin of this harness and cathode of power source is around 12V. No
Check lines between 1# pin of connector of one-cylinder oil injector and main relay are opened or shorted to ground.
3
Check resistance between 1# and 2# pins of one-cylinder oil injector is between 11~13Ω under 20℃ with multimeter.
4
Next step
Check lines between 2# pin of one-cylinder oil injector connector and 27# pin of ECU are opened or shorted to power source or ground.
6
To step 4 Next step
Yes
Repair or replace harness
No
Next step
Yes
Next step
No
Replace oil injector
Check voltage between 2# pin of one-cylinder oil injector connector and Yes cathode of power source is around 3.7V with multimeter. No
5
Follow-ups
Diagnosis help Next step
Yes
Repair or replace harness
No
Diagnosis help
No.085 Malfunction code: P0202 "two-cylinder oil injector circuit malfunction" Serial No.
Operation steps
1
Switch on diagnosis instrument and commutator, and place ignition switch to “ON”.
2
Take out connector of two-cylinder oil injector of harness, and check voltage between 1# pin of this harness and cathode of power source is around 12V.
3
4
Results
Check lines between 1# pin of connector of two-cylinder oil injector and main relay are opened or shorted to ground.
Check resistance between 1# and 2# pins of two-cylinder oil injector is between 11~13Ω under 20℃ with multimeter.
140
Follow-ups Next step
Yes
To step 4
No
Next step
Yes
Repair or replace harness
No
Next step
Yes
Next step
No
Replace oil injector
Common Malfunction Diagnosis Flow of Geely Automobile
Check voltage between 2# pin of two-cylinder oil injector connector and cathode of power source is around 3.7V with multimeter.
5
Yes
Diagnosis help
No
Next step
Check lines between 2# pin of two-cylinder oil injector connector and 6# pin Yes of ECU are opened or shorted to power source or ground. No
6
Repair or replace harness Diagnosis help
No.086 Malfunction code: P0203 "three-cylinder oil injector circuit malfunction" Serial No.
Operation steps
Results
1
Switch on diagnosis instrument and commutator, and place ignition switch to “ON”.
2
Take out connector of three-cylinder oil injector of harness, and check Yes voltage between 1# pin of this harness and cathode of power source is around 12V. No
Check lines between 1# pin of connector of three-cylinder oil injector and main relay are opened or shorted to ground.
3
Check resistance between 1# and 2# pins of three-cylinder oil injector is between 11~13Ω under 20℃ with multimeter.
4
Next step
Check lines between 2# pin of three-cylinder oil injector connector and 7# pin of ECU are opened or shorted to power source or ground.
6
To step 4 Next step
Yes
Repair or replace harness
No
Next step
Yes
Next step
No
Replace oil injector
Check voltage between 2# pin of three-cylinder oil injector connector and Yes cathode of power source is around 3.7V with multimeter. No
5
Follow-ups
Diagnosis help Next step
Yes
Repair or replace harness
No
Diagnosis help
No.087 Malfunction code: P0204 "four-cylinder oil injector circuit malfunction" Serial No.
Operation steps
1
Switch on diagnosis instrument and commutator, and place ignition switch to “ON”.
2
Take out connector of four-cylinder oil injector of harness, and check voltage Yes between 1# pin of this connector and cathode of power source is around 12V with multimeter. No
3
4
Results
Check lines between 1# pin of connector of four-cylinder oil injector and main relay are opened or shorted to ground.
Next step
To step 4 Next step
Yes
Repair or replace harness
No
Next step
Check resistance between 1# and 2# pins of four-cylinder oil injector is Yes between 11~13Ω under 20℃ with multimeter. 141
Follow-ups
Next step
Common Malfunction Diagnosis Flow of Geely Automobile
Check voltage between 2# pin of four-cylinder oil injector connector and cathode of power source is around 3.7V with multimeter.
5
Check lines between 2# pin of four-cylinder oil injector connector and 47# pin of ECU are opened or shorted to power source or ground.
6
No
Replace oil injector
Yes
Diagnosis help
No
Next step
Yes
Repair or replace harness
No
Diagnosis help
No.088 Malfunction code: P0230 "oil pump control circuit malfunction" Serial No.
Operation steps
Results
1
Switch on diagnosis instrument and commutator, and place ignition switch to “OFF”.
2
Take out oil pump relay, and place ignition switch at “ON”. Check power supply terminal of oil pump relay, i.e. voltage between 30#, ,, , 86# pins of relay and cathode of power source is around 12V.
Check lines at power supply terminal of relay are opened or shorted to ground.
3
Check control terminal of oil pump relay with multimeter, i.e. voltage between 85# pin of relay and cathode of power source is around 3.7V.
4
Next step
Yes
To step 4
No
Next step
Yes
Repair or replace harness
No
To step 2
Yes
Replace oil pump relay
No
Next step
Yes
Repair or replace harness
No
Diagnosis help
Check control terminal of relay, i.e. lines between 85# pin of relay and 69# pin of ECU are opened or shorted to power source or ground.
5
Follow-ups
No.089 Malfunction code: P0325 "knock sensor circuit malfunction" Serial No.
Operation steps
1
Switch on diagnosis instrument and commutator, and place ignition switch to “OFF”.
2
Take out connector of knock sensor of harness, and check resistance between 1# and 2# pins of knock sensor is larger than 1MΩwith the multimeter.
3
Results
Next step
Yes
Next step
No
Replace sensor
Check lines respectively between 1#, 2# of knock sensor connector and Yes 19#, 20# of ECU are opened, or shorted to power source or to ground. 142
Follow-ups
Repair or replace harness
Common Malfunction Diagnosis Flow of Geely Automobile
According to the specification, replace knock sensor. Start the vehicle and make rotating speed of the engine exceed 2200 revolutions per minute. Recheck malfunction code P0325 will appear again.
4
No
Next step
Yes
Diagnosis help
No
Check as chance failure
No.090 Malfunction code: P0335 “crankshaft position sensor signal malfunction” Serial No.
Operation steps
Results
1
Switch on diagnosis instrument and commutator, and place ignition switch to “OFF”.
2
Take out connector of speed sensor of harness, and check resistance between 2# and 3# pins of speed sensor is between 770~950Ω under 20℃ with the multimeter.
Check lines respectively between 2#, 3# of speed sensor connector and 34#, 15# of ECU are opened, or shorted to power source or to ground.
3
4
Follow-ups
Next step
Yes
Next step
No
Replace sensor
Yes
Repair or replace harness
No
Next step
Yes
Diagnosis help
No
Replace panel
Check signal panel of flywheel is good. signal
No.091 Malfunction code: P0336 “crankshaft position sensor signal with unreasonable malfunction” Serial No.
Operation steps
1
Switch on diagnosis instrument and commutator, and place ignition switch to “OFF”.
2
Take out connector of speed sensor of harness, and check resistance between 2# and 3# pins of speed sensor is between 770~950Ω under 20℃ with the multimeter.
3
4
Results
Next step
Yes
Next step
No
Replace sensor
Yes
Repair or replace harness
No
Next step
Yes
Diagnosis help
Check lines respectively between 2#, 3# of speed sensor connector and 34#, 15# of ECU are opened, or shorted to power source or to ground.
Check signal panel of flywheel is good.
143
Follow-ups
Common Malfunction Diagnosis Flow of Geely Automobile
No
Replace panel
signal
No.092 Malfunction code: P0340 “Phase sensor signal malfunction” Serial No.
Operation steps
Results
1
Switch on diagnosis instrument and commutator, and place ignition switch to “ON”.
2
Take out connector of phase sensor of the harness, and check voltage between 3# and 1# pins of phase sensor connector is around 12V.
Check lines between 3# pin of phase sensor and 87# pin of main relay are opened or shorted to earth; Check 1# pin of phase sensor is poorly earthed.
3
Check voltage between 2# pin of phase sensor connector and cathode of power source is about 9.9V.
4
Next step
Yes
To step 4
No
Next step
Yes
Repair or replace harness
No
Next step
Yes
To step 6
No
Next step
Yes
Repair or replace harness
No
Next step
Yes
Diagnosis help
No
Replace panel
check lines between 2# pin of phase sensor connector and 79# pin of ECU are opened or shorted to power source or earth;
5
6
Follow-ups
Check signal panel of camshaft is good. signal
No.093 Malfunction code: P0342 “circuit voltage of phase sensor too low” Serial No.
Operation steps
1
Switch on diagnosis instrument and commutator, and place ignition switch to “ON”.
2
Take out connector of phase sensor of the harness, and check voltage between 3# and 1# pins of phase sensor connector is around 12V.
3
Results
Check lines between 3# pin of phase sensor and 87# pin of main relay are opened or shorted to earth; Check 1# pin of phase sensor is poorly earthed.
144
Follow-ups Next step
Yes
To step 4
No
Next step
Yes
Repair or replace harness
No
Next step
Common Malfunction Diagnosis Flow of Geely Automobile
Check voltage between 2# pin of phase sensor connector and cathode of power source is about 9.9V.
4
check lines between 2# pin of phase sensor connector and 79# pin of ECU are opened or shorted to power source or earth;
5
6
Yes
To step 6
No
Next step
Yes
Repair or replace harness
No
Next step
Yes
Diagnosis help
No
Replace panel
Check signal panel of camshaft is good. signal
No.094 Malfunction code: P0343 “circuit voltage of phase sensor too high” Serial No.
Operation steps
1
Switch on diagnosis instrument and commutator, and place ignition switch to “ON”.
2
Take out connector of phase sensor of the harness, and check voltage between 3# and 1# pins of phase sensor connector is around 12V.
3
4
5
6
Results
Check lines between 3# pin of phase sensor and 87# pin of main relay are opened or shorted to earth; Check 1# pin of phase sensor is poorly earthed.
Check voltage between 2# pin of phase sensor connector and cathode of power source is about 9.9V.
Follow-ups Next step
Yes
To step 4
No
Next step
Yes
Repair or replace harness
No
Next step
Yes
To step 6
No
Next step
Yes
Repair or replace harness
No
Next step
Yes
Diagnosis help
No
Replace panel
check lines between 2# pin of phase sensor connector and 79# pin of ECU are opened or shorted to power source or earth;
Check signal panel of camshaft is good.
145
signal
Common Malfunction Diagnosis Flow of Geely Automobile
No.095 Malfunction code: P0443 "Malfunction of control circuit of driver stage of canister control valve" Serial No.
Operation steps
Results
1
Switch on diagnosis instrument and commutator, and place ignition switch to “ON”.
2
Take out connector of canister control valve of the harness, and check voltage between 1# pin of this connector and cathode of power source is around 12V with the multimeter.
Check lines at power supply terminal of canister control valve are opened or shorted to ground.
3
Check resistance between 1# and 2# pins of canister control valve is between 22~30Ω under 20℃with the multimeter.
4
Check voltage between 1# pin of connector of canister control valve and cathode of power source is around 3.7V with the multimeter.
5
Check lines between 2# pin of connector of canister control valve and 46# pin of ECU are open shorted.
6
Follow-ups
Next step
Yes
To step 4
No
Next step
Yes
Repair or replace harness
No
To step 2
Yes
Next step
No
Replace valve
Yes
Diagnosis help
No
Next step
Yes
Repair or replace harness
No
Diagnosis help
control
No.096 Malfunction code: P0444 "voltage of control circuit of driver stage of canister control valve too low" Serial No.
Operation steps
1
Switch on diagnosis instrument and commutator, and place ignition switch to “ON”.
2
Take out connector of canister control valve of the harness, and check voltage between 1# pin of this connector and cathode of power source is around 12V with the multimeter.
3
Results
Next step
Yes
To step 4
No
Next step
Yes
Repair or replace harness
No
To step 2
Check lines at power supply terminal of canister control valve are opened or shorted to ground.
146
Follow-ups
Common Malfunction Diagnosis Flow of Geely Automobile
Yes
Next step
No
Replace valve
Yes
Diagnosis help
No
Next step
Yes
Repair or replace harness
No
Diagnosis help
Check resistance between 1# and 2# pins of canister control valve is between 22~30Ω under 20℃with the multimeter.
4
control
Check voltage between 1# pin of connector of canister control valve and cathode of power source is around 3.7V with the multimeter.
5
Check lines between 2# pin of connector of canister control valve and 46# pin of ECU are shorted to ground.
6
No.097 Malfunction code: P0445 "voltage of control circuit of driver stage of canister control valve too high" Serial No.
Operation steps
1
Switch on diagnosis instrument and commutator, and place ignition switch to “ON”.
2
Take out connector of canister control valve of the harness, and check voltage between 1# pin of this connector and cathode of power source is around 12V with the multimeter.
3
4
5
6
Results
Next step
Yes
To step 4
No
Next step
Yes
Repair or replace harness
No
To step 2
Yes
Next step
No
Replace valve
Yes
Diagnosis help
No
Next step
Yes
Repair or replace harness
No
Diagnosis help
Check lines at power supply terminal of canister control valve are opened or shorted to ground.
Check resistance between 1# and 2# pins of canister control valve is between 22~30Ω under 20℃with the multimeter.
Follow-ups
control
Check voltage between 1# pin of connector of canister control valve and cathode of power source is around 3.7V with the multimeter.
Check lines between 2# pin of connector of canister control valve and 46# pin of ECU are shorted to power source.
147
Common Malfunction Diagnosis Flow of Geely Automobile
No.098 Malfunction code: P0480 "malfunction control circuit of cooling fan relay of AC condenser" Serial No.
Operation steps
Results
1
Switch on diagnosis instrument and commutator, and place ignition switch to “OFF”.
2
Take out cooling fan relay of AC condenser, and place ignition switch at “ON”, and check voltage between power supply terminal of this relay, i.e. 30# and 85# pins of relay and cathode of power source is around 12V.
Check lines at power supply terminal of cooling fan relay of AC condenser are opened or shorted to ground.
3
Check voltage between control terminal of cooling fan relay of AC condenser this relay, i.e. 86# pin of relay and cathode of power source is around 3.7V.
4
Next step
Yes
To step 4
No
Next step
Yes
Repair or replace harness
No
To step 2
Yes
Replace relay
No
Next step
Yes
Repair or replace harness
No
Diagnosis help
Check lines between 86# pin of control terminal of relay and 50# pin of ECU are opened or shorted to power source or ground.
5
Follow-ups
No.099 Malfunction code: P0500 "unreasonable malfunction of speed signal" Serial No.
Operation steps
1
Switch on diagnosis instrument and commutator, and place ignition switch to “OFF”.
2
If vehicle is equipped with ABS system, check malfunction code.
3
4
Results
ABS system has
Follow-ups
Next step
Yes
Repair ABS system
No
Next step
Yes
Next step
No
Repair lines
Yes
Next step
No
Replace sensor
Check pointer of odometer works normally. instrument
Check speed sensor works normally.
148
speed
Common Malfunction Diagnosis Flow of Geely Automobile
Yes
Repair or replace harness
No
Diagnosis help
Check lines between sensor signal line and 59# pin of ECU are opened or shorted to power source or ground.
4
No.100 Malfunction code: P0506 "idling speed lower than target speed value" Serial No.
Operation steps
Results
1
Switch on diagnosis instrument and commutator, and place ignition switch to “OFF”.
Next step Yes
Next step
No
Repair maintain necessary
Yes
Next step
No
Repair maintain necessary
and as
Yes
Repair necessary
as
No
Diagnosis help
Check adjusting screw, throttle dragline and condition of throttle work normally.
2
3
Check idling speed governor works normally.
A. Check pressure of oil supply system is too low; B. Check oil injector is blocked; C. Check the system is well exhausted.
4
Follow-ups
and as
No.101 Malfunction code: P0507 "idling speed higher than target speed value" Serial No.
Operation steps
1
Switch on diagnosis instrument and commutator, and place ignition switch to “OFF”.
2
Check adjusting screw, throttle dragline and condition of throttle work normally.
3
Results
Follow-ups
Next step Yes
Next step
No
Repair and maintain as necessary
Yes
Next step
No
Repair and maintain as necessary
Yes
Repair as necessary
No
Diagnosis help
Check idling speed governor works normally.
A. Check the system is exhausted; B. Check oil injector is blocked; C. Check pressure of oil supply system is too high.
4
No.102 Malfunction code: P0508 "voltage of control circuit of idling speed governor too low" Serial No.
Operation steps
Results 149
Follow-ups
Common Malfunction Diagnosis Flow of Geely Automobile 1
Switch on diagnosis instrument and commutator, and place ignition switch to “ON”.
2
Take out connector of idling speed governor, and check resistance between A and D, B and C pins is around 53±5.3Ω under 20℃ with the multimeter.
Check lines among A, B, C D pins of idling speed governor and 65#, 66#, 67#, 64# pins of ECU are shorted to ground.
3
Next step Yes
Next step
No
Replace motor
Yes
Repair or replace harness
No
Diagnosis help
stepper
No.103 Malfunction code: P0509 "voltage of control circuit of idling speed governor too high" Serial No.
Operation steps
Results
1
Switch on diagnosis instrument and commutator, and place ignition switch to “ON”.
2
Take out connector of idling speed governor, and check resistance between A and D, B and C pins is around 53±5.3Ω under 20℃ with the multimeter.
Next step Yes
Next step
No
Replace motor
Check lines among A, B, C D pins of idling speed governor and 65#, 66#, Yes 67#, 64# pins of ECU are shorted to power source. No
3
Follow-ups
stepper
Repair or replace harness Diagnosis help
No.104 Malfunction code: P0511 "malfunction control circuit of idling speed governor" Serial No.
Operation steps
1
Switch on diagnosis instrument and commutator, and place ignition switch to “ON”.
2
Take out connector of idling speed governor, and check resistance between A and D, B and C pins is around 53±5.3Ω under 20℃ with the multimeter.
3
Results
Follow-ups
Next step
Yes
Next step
No
Replace motor
Yes
Repair or replace harness
No
Diagnosis help
Check lines among A, B, C D pins of idling speed governor and 65#, 66#, 67#, 64# pins of ECU are opened.
stepper
No.105 Malfunction code: P0560 "unreasonable system voltage signal" Serial No.
Operation steps
Results
1
Switch on diagnosis instrument and commutator, and place ignition switch to “OFF”.
2
Check battery voltage is around 12V with the multimeter.
150
Follow-ups
Next step Yes
Next step
No
Replace battery cell
Common Malfunction Diagnosis Flow of Geely Automobile
3
Check lines among 44#, 45#, 63# pins of ECU and 87# pin of main relay Yes are opened or shorted to ground. No
4
5
Start the engine, and check charging voltage of generator is between 9-16V Yes within different speed range. No
Repair or replace harness Next step Next step Replace generator
Yes
Diagnosis help
No
Repair or replace harness
Check earth point of engine harness is good.
No.106 Malfunction code: P0562 "system voltage too low" Serial No.
Operation steps
1
Switch on diagnosis instrument and commutator, and place ignition switch to “OFF”.
2
3
4
5
Results
Follow-ups
Next step
Yes
Next step
No
Replace battery cell
Yes
Repair or replace harness
No
Next step
Yes
Next step
No
Replace generator
Yes
Diagnosis help
No
Repair or replace harness
Check battery voltage is around 12V with the multimeter.
Check resistance of lines between 44#, 45#, 63# pins of ECU and 87# pin of main relay are too large.
Start the engine, and check charging voltage of generator is between 9-16V within different speed range.
Check earth point of engine harness is good.
No.107 Malfunction code: P0563 "system voltage too high" Serial No.
Operation steps
1
Switch on diagnosis instrument and commutator, and place ignition switch to “OFF”.
2
Results
Follow-ups
Next step
Yes
Next step
No
Replace battery cell
Check battery voltage is around 12V with the multimeter.
151
Common Malfunction Diagnosis Flow of Geely Automobile
Yes
Next step
No
Replace generator
Yes
Diagnosis help
No
Repair or replace harness
Start the engine, and check charging voltage of generator is between 9-16V within different speed range.
3
4
Check earth point of engine harness is good.
No.108 Malfunction code: P0601 "error of check code of electronic control unit" Serial No.
Operation steps
1
Switch on diagnosis instrument, and place ignition switch at “ON”.
2
Eliminate malfunction code, and reconfirm this malfunction is stable status malfunction.
3
Results
Replace ECU.
Follow-ups
Next step Yes
Next step
No
System normal
End
No.109 Malfunction code: P0602 "error of identification code of diagnosis data of electronic control unit" Serial No.
Operation steps
1
Switch on diagnosis instrument and commutator, and place ignition switch to “ON”.
2
Eliminate malfunction code, and reconfirm this malfunction is stable status malfunction.
3
Results
Replace ECU.
Follow-ups Next step
Yes
Next step
No
System normal
End
No.110 Malfunction code: P0645 "malfunction of relay control circuit of AC compressor" Serial No.
Operation steps
Results
1
Switch on diagnosis instrument and commutator, and place ignition switch to “OFF”.
152
Follow-ups
Next step
Common Malfunction Diagnosis Flow of Geely Automobile
Take out relay of AC compressor, and place ignition switch at “ON”. Check voltage of power supply terminal of relay, i.e. 30# and 85# pins and cathode of power source is around 12V.
2
Yes
To step 4
No
Next step
Yes
Repair or replace harness
No
To step 2
Yes
Replace relay
No
Next step
Yes
Repair or replace harness
No
Diagnosis help
Check lines at power supply terminal of relay are opened or shorted to ground.
3
Check voltage of control terminal of AC compressor relay, i.e. between 86# pin of relay and cathode of power source is around 3.7V with the multimeter.
4
Check lines of control terminal of AC compressor relay, i.e. 86# pin of relay and 70# pin of ECU are opened.
5
No.111 Malfunction code: P0646 "voltage of relay control circuit of AC compressor too low" Serial No.
Operation steps
1
Switch on diagnosis instrument and commutator, and place ignition switch to “OFF”.
2
Take out relay of AC compressor, and place ignition switch at “ON”. Check voltage of power supply terminal of relay, i.e. 30# and 85# pins and cathode of power source is around 12V.
3
4
Results
Check lines at power supply terminal of relay are opened or shorted to ground.
Follow-ups
Next step
Yes
To step 4
No
Next step
Yes
Repair or replace harness
No
To step 2
Yes
Replace relay
No
Next step
Check voltage of control terminal of AC compressor relay, i.e. between 86# pin of relay and cathode of power source is around 3.7V with the multimeter.
153
Common Malfunction Diagnosis Flow of Geely Automobile
Yes
Repair or replace harness
No
Diagnosis help
Check lines of control terminal of AC compressor relay, i.e. 86# pin of relay and 70# pin of ECU are shorted to ground.
5
No.112 Malfunction code: P0647 "voltage of relay control circuit of AC compressor too high" Serial No.
Operation steps
1
Switch on diagnosis instrument and commutator, and place ignition switch to “OFF”.
2
3
4
5
6
Results
Follow-ups Next step
Yes
To step 4
No
Next step
Yes
Repair or replace harness
No
To step 2
Yes
Replace relay
No
Next step
Yes
Repair or replace harness
No
Next step
Yes
Diagnosis help
No
Repair or replace electro-magnetic clutch
Take out relay of AC compressor, and place ignition switch at “ON”. Check voltage of power supply terminal of relay, i.e. 30# and 85# pins and cathode of power source is around 12V.
Check lines at power supply terminal of relay are opened or shorted to ground.
Check voltage of control terminal of AC compressor relay, i.e. between 86# pin of relay and cathode of power source is around 3.7V with the multimeter.
Check lines of control terminal of AC compressor relay, i.e. 86# pin of relay and 70# pin of ECU are shorted to power source.
Check electromagnetic clutch of AC compressor works normally.
154
Common Malfunction Diagnosis Flow of Geely Automobile
No.113 Malfunction code: P1508 "voltage of control circuit of idling speed governor too high" Serial No.
Operation steps
Results
1
Switch on diagnosis instrument and commutator, and place ignition switch to “ON”.
2
Take out connector of idling speed governor (EWD) of the harness, and Yes check voltage between 2# pin of this connector and cathode of power source is around 12V with the multimeter. No
Check lines at power supply terminal of idling speed governor (EWD) are opened and shorted to ground.
3
Check resistance between 1# and 2# pins of idling speed governor (EWD) is around 17.6Ω under 20℃ with the multimeter.
4
Next step
To step 4
Next step
Yes
Repair or replace harness
No
Next step
Yes
Next step
No
Replace EWD
Yes
Repair or replace harness
No
Diagnosis help
Check lines between 1# pin of connector of idling speed governor (EWD) and 26# pin of ECU are shorted to power source.
5
Follow-ups
No.114 Malfunction code: P1651 "malfunction of control circuit of engine malfunction lamp (SVS)" Serial No.
Operation steps
1
Switch on diagnosis instrument and commutator, and place ignition switch to “ON”.
2
Carry out action testing on malfunction lamp of the engine via “actuator Yes action testing” of the diagnosis instrument, and observe it is at OFF status or ON status. No
3
4
5
Results
Check lines at power supply terminal of malfunction lamp of the engine is open circuited or shorted to ground.
Check lines between pin of control terminal of malfunction lamp and 28# pin of ECU is open circuited or shorted to power source or the ground.
Check bulb of malfunction lamp is working normally.
155
Follow-ups
Next step Next step System normal
Yes
Repair or replace harness
No
Next step
Yes
Repair or replace harness
No
Next step
Yes
Diagnosis help
No
Replace bulb
Common Malfunction Diagnosis Flow of Geely Automobile
Diagnosis flowchart of M7 system based on malfunction Before executing steps of malfunction diagnosis based on malfunction of the engine, carry out preliminary inspection: 1. Confirm malfunction indicator lamp of the engine is working normally; 2. Check and confirm there is no malfunction information recorded with the malfunction diagnosis instrument; 3. Confirm malfunction claimed by the vehicle owner exists and confirm conditions why this malfunction appears. Appearance inspection: （1）Check fuel pipe is leaking; （2）Check vacuum pipe is broken, kinked, or correctly connected; （3）Check inlet pipe is blocked, air leaking, squashed or damaged; （4）Check high tension line of ignition system is broken, aging, and ignition sequence is correct; （5）Check earthing location of harness is clean, firm; （6）Check connector of each sensor, actuator is loosening or poorly contacted. Important: in case of above-mentioned malfunctions, carry out care and maintenance accordingly, otherwise it will affect following malfunction diagnosis and maintenance. Diagnosis help: 1. Confirm the engine is free of malfunction records; 2. Confirm malfunction that is claimed exists; 3. Carry out according to above-mentioned steps and find out nothing unusual; 4. Pay attention to the effect of automobile maintenance, cylinder pressure, mechanical ignition timing, fuel conditions on the system during inspection; 5. Replace ECU and test it. If malfunction is eliminated at this time, then malfunction part is in ECU; if malfunction still exists at this point, replace for original ECU, and repeat the flowchart, and re-inspect.
156
Common Malfunction Diagnosis Flow of Geely Automobile
No.115 Engine not running or slowly running while startup General malfunction part: 1. battery; 2. startup motor; 3. harness or ignition switch; 4. mechanical parts of the engine. General diagnosis flowchart: Serial No.
Operation steps
1
Check voltage between two binding posts of battery is around 8-12V while the engine is started with the multimeter.
2
3
4
5
Results
Follow-ups
Yes
Next step
No
Replace battery
Yes
Next step
No
Repair or replace harness
Yes
Repair or replace starting motor
No
Next step
Yes
Replace for lubricating oil with proper grade
No
Next step
Yes
Check internal resistance of engine
No
Diagnosis help
With ignition switch at starting position, check binding post of anode of startup motor is with voltage above 8V with the multimeter.
Remove startup motor, and check its working conditions. Mainly check it is open circuited or jammed due to poor lubrication.
If malfunction only occurs in winter, check resistance of startup motor is too large due to improper selection of lubricating oil and gear case oil.
Check internal mechanical resistance of the engine is too large, causing startup motor not running or slowly running.
157
Common Malfunction Diagnosis Flow of Geely Automobile
No.116 While startup, engine running, but unable to start General malfunction part: 1. oil tank without oil; 2. fuel pump; 3. speed sensor; 4. ignition coil; 5. mechanical part of engine. General diagnosis flowchart: Serial No.
Operation steps
1
Connect fuel pressure gauge (access point is front end of oil sucker of fuel distribution pipe assembly), and start the engine, and check fuel pressure is around 350kPa.
2
3
4
5
Results
Follow-ups
Yes
Next step
No
Repair oil supply system
Yes
Next step
No
Repair speed sensor lines
Yes
Next step
No
Repair system
Yes
Eliminate mechanical failure
No
Next step
Yes
Diagnosis help
No
Repair corresponding lines
Connect diagnosis instrument of electric injection system and observe “engine speed”. Start the engine and observe speed signal is output.
Take out line of one cylinder, and connect spark plug, making spark plug electrode about 5mm away from engine body. Startup the engine and check there is high pressure spark. ignition
Check pressure of each cylinder of the engine, and observe engine cylinder is with insufficient pressure.
Connect commutator of electric injection system, and open ignition switch, and check power supply of 12#, 13#, 44#, 45#, ,63# pins are normal; check bonding of 3#, 51#, 53#, 61#, 80# pins are normal.
158
Common Malfunction Diagnosis Flow of Geely Automobile
No.117 Difficult to start for hot startup General malfunction part: 1. fuel containing water; 2. fuel pump; 3. cooling liquid temperature sensor; 4. fuel pressure regulator vacuum pipe; 5. ignition coil. General diagnosis flowchart: Serial No.
Operation steps
1
Connect fuel pressure gauge (access point is front end of oil sucker of fuel distribution pipe assembly), and start the engine, and check fuel pressure is around 350kPa.
2
3
4
5
6
Results
Follow-ups
Yes
Next step
No
Repai r oil supply system
Yes
Next step
No
Repair system
Take out line of one cylinder, and connect spark plug, making spark plug electrode about 5mm away from engine body. Startup the engine and check there is high pressure spark.
Take out connector of cooling liquid temperature sensor, and start the Yes engine. Observe the engine is successfully started at this point. (or connect one 300ohm resistance in series at connector of this sensor to replace cooling liquid temperature sensor and observe the engine is successfully started at this point.) No
ignition
Repair lines replace sensor
or
Next step
Yes
Repair or replace
No
Next step
Yes
Replace fuel
No
Next step
Yes
Diagnosis help
No
Repair corresponding lines
Check fuel pressure regulator vacuum pipe is loosening or air leaking.
Check fuel condition and observe malfunction is caused just after refueling.
Connect commutator of electric injection system, and open ignition switch, and check power supply of 12#, 13#, 44#, 45#, ,63# pins are normal; check bonding of 3#, 51#, 53#, 61#, 80# pins are normal.
159
Common Malfunction Diagnosis Flow of Geely Automobile
No.118 Difficult to start for cold startup General malfunction part:1. fuel containing water; 2. fuel pump; 3. cooling liquid temperature sensor; 4. oil injector; 5. ignition coil; 6. throttle valve body and idling speed bypass duct; 7. mechanical parts of engine. General diagnosis flowchart: Serial No.
Operation steps
1
Connect fuel pressure gauge (access point is front end of oil sucker of Yes fuel distribution pipe assembly), and start the engine, and check fuel pressure is around 350kPa. No
2
3
4
5
6
7
8
Results
Take out line of one cylinder, and connect spark plug, making spark plug Yes electrode about 5mm away from engine body. Startup the engine and check there is high pressure spark. No Take out connector of cooling liquid temperature sensor, and start the Yes engine. Observe the engine is successfully started at this point. (or connect one 300ohm resistance in series at connector of this sensor to replace cooling liquid temperature sensor and observe the engine is No successfully started at this point.)
Step on the throttle lightly, and observe it is easily started.
Next step Repai r oil supply system Next step Repair system
ignition
Repair lines replace sensor
or
Next step
Yes
Clean throttle valve and idling speed duct
No
Next step
Remove oil injector, and check it is leaking or blocked with special Yes cleaning and analysis instrument. No Check fuel condition and observe malfunction is caused just after refueling.
Follow-ups
Replace malfunctiony ones Next step
Yes
Replace fule
No
Next step
Yes
Eliminate mechanical failure
No
Next step
Yes
Diagnosis help
No
Repair corresponding lines
Check pressure of each cylinder of the engine, and observe engine cylinder is with insufficient pressure.
Connect commutator of electric injection system, and open ignition switch, and check power supply of 12#, 13#, 44#, 45#, ,63# pins are normal; check bonding of 3#, 51#, 53#, 61#, 80# pins are normal.
160
Common Malfunction Diagnosis Flow of Geely Automobile
No.119 Difficulty startup at any time though with normal speed General malfunction part: 1. fuel containing water; 2. fuel pump; 3. cooling liquid temperature sensor;4. oil injector; 5. ignition coil; 6. throttle valve body and idling speed bypass duct; 7.intake duct; 8. ignition timing; 9. spark plug;10. mechanical parts of engine. General diagnosis flowchart: Serial No.
1
Operation steps
Results
Follow-ups
Yes
Repair air system
No
Next step
Check air filter is blocked, and intake duct is air leaking.
2
Connect fuel pressure gauge (access point is front end of oil sucker of Yes fuel distribution pipe assembly), and start the engine, and check fuel pressure is around 350kPa. No
3
Take out line of one cylinder, and connect spark plug, making spark plug Yes electrode about 5mm away from engine body. Startup the engine and check there is high pressure spark. No
4
5
6
7
8
9
10
11
Check spark plug of each cylinder, and observe its type and clearance conform to the specifications.
Take out connector of cooling liquid temperature sensor, start the engine and observe it is successfully started at this time.
Step on the throttle lightly, and observe it is easily started.
Remove oil injector, and check it is leaking or blocked with special cleaning and analysis instrument.
Check fuel condition and observe malfunction is caused just after refueling.
Check pressure of each cylinder of the engine, and observe engine cylinder is with insufficient pressure.
Check ignotion sequence and ignition timing of the engine conform to the specifications.
Next step Repair oil supply system Next step Repair system
ignition
Yes
Next step
No
Adjust or replace
Yes
Repair lines replace sensor
No
Next step
Yes
Clean throttle valve and idling speed duct
No
Next step
Yes
Replace malfunctiony ones
No
Next step
Yes
Replace fuel
No
Next step
Yes
Eliminate mechanical failure
No
Next step
Yes
Next step
No
Repair timing
Connect commutator of electric injection system, and open ignition Yes switch, and check power supply of 12#, 13#, 44#, 45#, ,63# pins are normal; check bonding of 3#, 51#, 53#, 61#, 80# pins are normal. No
161
intake
or
ignition
Diagnosis help Repair corresponding lines
Common Malfunction Diagnosis Flow of Geely Automobile
No.120 Normal startup with instable idling speed at any time General malfunction part:1. fuel containing water; 2. oil injector; 3. spark plug; 4. throttle valve body and idling speed bypass air duct; 5. intake duct; 6. idling speed regulator; 7. ignition timing; 8. spark plug; 9. mechanical parts of the engine. General diagnosis flowchart: Serial No.
1
2
3
4
5
6
7
8
9
Operation steps
Results
Follow-ups
Yes
Repair air system
No
Next step
Yes
Clean or replace
No
Next step
Yes
Next step
No
Adjust or replace
Check air filter is blocked, and intake duct is air leaking.
Check idling speed regulator is jammed.
Check spark plug of each cylinder, and observe its type and clearance conform to the specifications.
Check throttle valve body and idling speed bypass air duct is with carbon Yes deposit. No Remove oil injector, and check it is leaking or blocked, or flow with out of tolerance with special cleaning and analysis instrument.
Check fuel condition and observe malfunction is caused just after refueling.
Check pressure of each cylinder of the engine, and observe cylinder pressure has too large differences.
Check ignition sequence and ignition timing of the engine conform to the specifications.
Connect commutator of electric injection system, and open ignition switch, and check power supply of 12#, 13#, 44#, 45#, ,63# pins are normal; check bonding of 3#, 51#, 53#, 61#, 80# pins are normal.
162
intake
Clean Next step
Yes
Replace malfunction ones
No
Next step
Yes
Replace fuel
No
Next step
Yes
Eliminate mechanical failure
No
Next step
Yes
Next step
No
Repair timing
Yes
Diagnosis help
No
Repair corresponding lines
ignition
Common Malfunction Diagnosis Flow of Geely Automobile
No.121 Normal startup, with instable idling speed during warming up General malfunction part: 1. fuel containing water; 2. cooling liquid temperature sensor; 3. spark plug; 4. throttle valve body and idling speed bypass air duct; 5. intake duct; 6.idling speed regulator; 7. mechanical parts of engine. General diagnosis flowchart: Serial No.
1
2
3
4
5
6
7
8
Operation steps
Results
Follow-ups
Yes
Repair air system
No
Next step
Yes
Next step
No
Adjust or replace
Yes
Clean parts
No
Next step
Yes
Repair lines replace sensor
No
Next step
Yes
Replace malfunctiony ones
No
Next step
Yes
Replace fuel
No
Next step
Yes
Eliminate mechanical failure
No
Next step
Check air filter is blocked, and intake duct is air leaking.
Check spark plug of each cylinder, and observe its type and clearance conform to the specifications.
Remove idling speed regulator, and check throttle valve body, idling speed regulator and idling speed bypass air duct are with carbon deposit.
Take out connector of cooling liquid temperature sensor, start the engine and observe the engine's idling speed is instable during warming up.
Remove oil injector, and check it is leaking or blocked, or flow with out of tolerance with special cleaning and analysis instrument.
Check fuel condition and observe malfunction is caused just after refueling.
Check pressure of each cylinder of the engine, and observe cylinder pressure has too large differences.
Connect commutator of electric injection system, and open ignition Yes switch, and check power supply of 12#, 13#, 44#, 45#, ,63# pins are normal; check bonding of 3#, 51#, 53#, 61#, 80# pins are normal. No
163
intake
concerned
or
Diagnosis help Repair corresponding lines
Common Malfunction Diagnosis Flow of Geely Automobile
No.122 Normal startup, with instable idling speed after warming up General malfunction part:1. fuel containing water; 2.cooling liquid temperature sensor; 3. spark plug; 4. throttle valve body and idling speed bypass air duct; 5.intake duct;6. idling speed regulator; 7. mechanical parts of engine. General diagnosis flowchart: Serial No.
1
2
3
4
5
6
7
8
Operation steps
Results
Follow-ups
Yes
Repair air system
No
Next step
Yes
Next step
No
Adjust or replace
Yes
Clean parts
No
Next step
Yes
Repair lines replace sensor
No
Next step
Yes
Replace malfunctiony ones
No
Next step
intake
Check air filter is blocked, and intake duct is air leaking.
Check spark plug of each cylinder, and observe its type and clearance conform to the specifications.
Remove idling speed regulator, and check throttle valve body, idling speed regulator and idling speed bypass air duct are with carbon deposit.
Take out connector of cooling liquid temperature sensor, start the engine and observe the engine's idling speed is instable during warming up.
Remove oil injector, and check it is leaking or blocked, or flow with out of tolerance with special cleaning and analysis instrument.
Check fuel condition and observe malfunction is caused just after Yes refueling.
Check pressure of each cylinder of the engine, and observe cylinder pressure has too large differences.
Connect commutator of electric injection system, and open ignition switch, and check power supply of 12#, 13#, 44#, 45#, ,63# pins are normal; check bonding of 3#, 51#, 53#, 61#, 80# pins are normal.
164
concerned
or
Replace fuel
No
Next step
Yes
Eliminate mechanical failure
No
Next step
Yes
Diagnosis help
No
Repair corresponding lines
Common Malfunction Diagnosis Flow of Geely Automobile
No.123 Normal startup, idling speed is instable or the vehicle will flame out when partially loaded (such as: when air conditioner is on) General malfunction part: 1. air conditioning system; 2、idling speed regulator; 3. oil injector. General diagnosis flowchart: Serial No.
Operation steps
1
Remove idling speed regulator, and check throttle valve body, idling speed Yes regulator and idling speed bypass air duct are with carbon deposit.
2
3
4
5
6
Results
Observe output power of the engine is increased while air conditioner is on, i.e. observe changes of ignition advance angle, oil injection pulse width and air input with diagnosis instrument of electric injection system.
Connect commutator of electric injection system, and disconnect connecting line of 75# pin of electronic control unit. Check there is high level signal at harness end when air conditioner is on.
Check pressure of air conditioning system, electromagnetic clutch of air compressor and AC compression pump are normal.
165
Clean parts
concerned
No
Next step
Yes
To step 4
No
Next step
Yes
Next step
No
Repair conditioning system
Yes
Next step
No
Repair conditioning system
Remove oil injector, and check it is leaking or blocked, or flow with out of tolerance Yes with special cleaning and analysis instrument.
Connect commutator of electric injection system, and open ignition switch, and check power supply of 12#, 13#, 44#, 45#, ,63# pins are normal; check bonding of 3#, 51#, 53#, 61#, 80# pins are normal.
Follow-ups
air
air
Replace malfunction ones
No
Next step
Yes
Diagnosis help
No
Repair corresponding lines
Common Malfunction Diagnosis Flow of Geely Automobile
No.124 Normal startup, the idling speed is too high General malfunction part: 1. throttle valve body and idling speed bypass air duct; 2. vacuum pipe; 3. idling speed regulator; 4. cooling liquid temperature sensor; 5. ignition timing. General diagnosis flowchart: Serial No.
Operation steps
1
Check throttle cable is jammed or too tightening.
2
3
Check vacuum pipe of intake system and connection is leaking.
Results
Follow-ups
Yes
Adjust
No
Next step
Yes
Repair system
No
Next step
Remove idling speed regulator, and check throttle valve body, idling Yes speed regulator and idling speed bypass air duct are with carbon deposit. No
4
5
6
Take out connector of cooling liquid temperature sensor, start the engine Yes and observe the engine's idling speed is too high at this time.
air
intake
Clean concerned parts Next step Repair lines or replace sensor
No
Next step
Yes
Next step
No
Repair ignition timing
Yes
Diagnosis help
No
Repair corresponding lines
Check ignition timing of the engine conforms to the specification.
Connect commutator of electric injection system, and open ignition switch, and check power supply of 12#, 13#, 44#, 45#, ,63# pins are normal; check bonding of 3#, 51#, 53#, 61#, 80# pins are normal.
166
Common Malfunction Diagnosis Flow of Geely Automobile
No.125 Unable to rotating speed or flameout while accelerating General malfunction part:1. fuel containing water; 2. intake pressure sensor and throttle valve position sensor; 3. spark plug; 4. throttle valve body and idling speed bypass air duct; 5.intake duct; 6. idling speed regulator; 7. oil injector; 8. ignition timing; 9. exhaust pipe. General diagnosis flowchart: Serial No.
Operation steps
1
Check air filter is blocked.
2
3
4
5
6
7
8
9
10
Connect fuel pressure gauge (access point is front end of oil sucker of fuel distribution pipe assembly), and start the engine, and check fuel pressure is around 350kPa during accelerating.
Check spark plug of each cylinder, and observe its type and clearance conform to the specifications.
Remove idling speed regulator, and check throttle valve body, idling speed regulator and idling speed bypass air duct are with carbon deposit.
Check intake pressure sensor, throttle valve position sensor and its lines are normal.
Remove oil injector, and check it is leaking or blocked with special cleaning and analysis instrument.
Check fuel condition and observe malfunction is caused just after refueling.
Check ignotion sequence and ignition timing of the engine conform to the specifications.
Results
Follow-ups
Yes
Repair air intake system
No
Next step
Yes
Next step
No
Repair oil supply system
Yes
Next step
No
Adjust or replace
Yes
Clean concerned parts
No
Next step
Yes
Next step
No
Repair lines or replace sensor
Yes
Replace ones
No
Next step
Yes
Replace fuel
No
Next step
Yes
Next step
No
Repair ignition timing
Yes
Next step
No
Repair or exhaust pipe
Yes
Diagnosis help
No
Repair lines
Check exhaust pipe is smoothly exhausted.
Connect commutator of electric injection system, and open ignition switch, and check power supply of 12#, 13#, 44#, 45#, ,63# pins are normal; check bonding of 3#, 51#, 53#, 61#, 80# pins are normal.
167
malfunction
replace
corresponding
Common Malfunction Diagnosis Flow of Geely Automobile
No.126 Slow reaction while accelerating General malfunction part:1. fuel containing water; 2. intake pressure sensor and throttle valve position sensor; 3. spark plug;4. throttle valve body and idling speed bypass air duct; 5.intake duct;6. idling speed regulator; 7. oil injector; 8. ignition timing; 9. exhaust pipe. General diagnosis flowchart: Serial No.
1
Operation steps
Results
Follow-ups
Yes
Repair system
No
Next step
Check air filter is blocked.
2
Connect fuel pressure gauge (access point is front end of oil sucker of Yes fuel distribution pipe assembly), and start the engine, and check fuel pressure is around 350kPa during accelerating. No
3
Check spark plug of each cylinder, and observe its type and clearance conform to the specifications.
4
5
6
7
8
9
10
Remove idling speed regulator, and check throttle valve body, idling speed regulator and idling speed bypass air duct are with carbon deposit.
Check intake pressure sensor, throttle valve position sensor and its lines are normal.
Remove oil injector, and check it is leaking or blocked with special cleaning and analysis instrument.
Check fuel condition and observe malfunction is caused just after refueling.
Check ignition sequence and ignition timing of the engine conform to the specifications.
intake
oil
supply
Next step Repair system
Yes
Next step
No
Adjust or replace
Yes
Clean concerned parts
No
Next step
Yes
Next step
No
Repair lines or replace sensor
Yes
Replace ones
No
Next step
Yes
Replace fuel
No
Next step
Yes
Next step
No
Repair ignition timing
Yes
Next step
No
Repair or exhaust pipe
Check exhaust pipe is smoothly exhausted.
Connect commutator of electric injection system, and open ignition Yes switch, and check power supply of 12#, 13#, 44#, 45#, ,63# pins are normal; check bonding of 3#, 51#, 53#, 61#, 80# pins are normal. No
168
air
malfunction
replace
Diagnosis help Repair corresponding lines
Common Malfunction Diagnosis Flow of Geely Automobile
No.127 Weak with poor performance while accelerating General malfunction part:1. fuel containing water; 2. intake pressure sensor and throttle valve position sensor;3. spark plug;4. ignition coil; 5. throttle valve body and idling speed bypass air duct; 6. intake duct;7、idling speed regulator; 8 oil injector; 9. ignition timing; 10. exhaust pipe. General diagnosis flowchart: Serial No.
Operation steps
1
Check there are malfunctions such as clutch skidding, low tire Yes pressure, braking dragging, incorrect tire dimension, incorrect No positioning of four wheels, etc.
2
Results
Check air filter is blocked.
Follow-ups Repair Next step
Yes
Repair system
No
Next step
air
intake
oil
supply
3
Connect fuel pressure gauge (access point is front end of oil sucker Yes of fuel distribution pipe assembly), and start the engine, and check fuel pressure is around 350kPa during accelerating. No Take out line of one cylinder, and connect spark plug, making spark Yes plug electrode about 5mm away from engine body. Startup the engine and check strength of high pressure spark is normal. No
Next step
4
Check spark plug of each cylinder, and observe its type and Yes clearance conform to the specifications. No
Next step
Remove idling speed regulator, and check throttle valve body, idling Yes speed regulator and idling speed bypass air duct are with carbon No deposit.
Clean concerned parts
5
6
7
8
9
10
11
12
Check intake pressure sensor, throttle valve position sensor and its lines are normal.
Next step Repair system
Repair ignition system
Adjust or replace
Next step
Yes
Next step
No
Repair lines or replace sensor
Remove oil injector, and check it is leaking or blocked with special Yes cleaning and analysis instrument. No
Replace
Check fuel condition and observe malfunction is caused just after Yes refueling. No
Replace fuel
Check ignition sequence and ignition timing of the engine conform to the specifications.
Next step
Next step
Yes
Next step
No
Repair ignition timing
Yes
Next step
No
Repair or exhaust pipe
Check exhaust pipe is smoothly exhausted.
Connect commutator of electric injection system, and open ignition Yes switch, and check power supply of 12#, 13#, 44#, 45#, ,63# pins are normal; check bonding of 3#, 51#, 53#, 61#, 80# pins are normal. No
169
malfunction
replace
Diagnosis help Repair lines
corresponding
Common Malfunction Diagnosis Flow of Geely Automobile
No.128 Malfunction code with EOBD system Description
Malfunction level
NO
Malfunction code
1
P0030
Open-circuit of heating control circuit of upstream oxygen sensor
3
2
P0031
Short-circuit to earth of heating control circuit of upstream oxygen sensor
3
3
P0032
Short-circuit to power source of heating control circuit of upstream oxygen sensor
3
4
P0036
Open-circuit of heating control circuit of downstream oxygen sensor
3
5
P0037
Short-circuit to earth of heating control circuit for downstream oxygen sensor
3
6
P0038
Short-circuit to power source of heating control circuit for downstream oxygen sensor
3
7
P0053
Unreasonable heating internal resistance, upstream oxygen sensor
3
8
P0054
Unreasonable heating internal resistance, downstream oxygen sensor
3
9
P0105
Unchanged signal (icing) of intake pressure sensor
3
10
P0106
Intake pressure sensor unreasonable
3
11
P0107
Intake pressure sensor short circuit to earth
3
12
P0108
Intake pressure sensor short circuit to power source
3
13
P0112
Too low signal voltage of intake temperature sensor
3
14
P0113
Too high signal voltage of intake temperature sensor
3
15
P0116
Unreasonable temperature signal of engine coolant
3
16
P0117
Too low circuit voltage of temperature sensor of engine coolant
3
17
P0118
Too high circuit voltage of temperature sensor of engine coolant
3
18
P0122
Circuit voltage exceeding minimum value, throttle position sensor
3
19
P0123
Circuit voltage exceeding maximum value, throttle position sensor
3
20
P0130
Unreasonable signal upstream oxygen sensor
3
21
P0132
Circuit voltage too high, upstream oxygen sensor signal
3
22
P0133
Upstream oxygen sensor aging (signal slows down)
3
170
Common Malfunction Diagnosis Flow of Geely Automobile 23
P0134
Circuit signal malfunction, upstream oxygen sensor
3
24
P0136
Unreasonable signal of downstream oxygen sensor
3
25
P0138
Circuit voltage too high, downstream oxygen sensor signal
3
26
P0140
Circuit signal malfunction, downstream oxygen sensor
3
27
P0170
Unreasonable self-learning of closed-loop control of air fuel ratio for off-line test
7
28
P0171
Over-thin of self-learning of closed-loop control of air fuel ratio for off-line test
7
29
P0172
Lower cable inspection air/fuel ratio closed circuit self-adaptation too thick
7
30
P0201
Open circuit of 1st cylinder fuel injector controlling circuit
3
31
P0202
Open circuit of 2nd cylinder fuel injector controlling circuit
3
32
P0203
3rd cylinder fuel injector controlling circuit open circuit
3
33
P0204
Open circuit of 4th cylinder fuel injector controlling l circuit
3
34
P0261
Short circuit to earth of 1st cylinder fuel injector controlling circuit
3
35
P0262
Short circuit to power supply of 1st cylinder fuel injector controlling circuit
3
36
P0264
37
P0265
Short circuit to power supply of 2nd cylinder fuel injector controlling t circuit
3
38
P0267
Short circuit to earth of 3rd cylinder fuel injector controlling circuit
3
39
P0268
Short circuit to power supply of 3rd cylinder fuel injector controlling circuit
3
40
P0270
Short circuit to earth of 4th cylinder fuel injector controlling circuit
3
41
P0271
Short circuit to power supply of
3
42
P0300
Several cylinders misfire
2
43
P0301
1st cylinder misfire
2
Short circuit to earth of 2nd cylinder fuel injector controlling circuit
171
4th cylinder fuel injector controlling circuit
3
Common Malfunction Diagnosis Flow of Geely Automobile
44
P0302
2nd cylinder misfire
2
45
P0303
3rd cylinder misfire
2
46
P0304
4th cylinder misfire
2
47
P0318
Damaged circuit inspection accelerating sensor signal failure
3
48
P0321
Crankshaft signal error
3
49
P0322
No engine speed sensor pulse signal (open or short circuit)
4
50
P0324
Knock signal processing chip and other circuit malfunction
6
51
P0327
Knock sensor signal circuit voltage lower than normal value
3
52
P0328
Knock sensor signal circuit voltage over normal value
3
53
P0340
Improper phase sensor mounting position
3
54
P0341
Poor phase sensor conduction
3
55
P0342
Phase sensor short circuit with earth
3
56
P0343
Phase sensor short circuit with power supply
3
57
P0420
3 way catalytic converter ageing (emission over standard level)
3
58
P0444
Canister valve controlling circuit open circuit
3
59
P0458
Canister valve controlling circuit voltage lower than normal value
3
60
P0459
Canister valve controlling circuit voltage over normal value
3
61
P0480
Cooling fan relay controlling circuit open circuit (low speed)
5
62
P0481
Cooling fan relay controlling circuit open circuit (high speed)
5
63
P0501
Vehicle speed sensor signal unreasonable
3
172
Common Malfunction Diagnosis Flow of Geely Automobile
64
P0506
Idle controlling speed lower than target
3
65
P0507
Idle controlling speed higher than target
3
66
P0508
Stepping motor driving pin short circuit with earth
3
67
P0509
Stepping motor driving pin short circuit with power supply
3
68
P0511
Stepping motor driving pin failure
3
69
P0560
System battery voltage signal unreasonable
5
70
P0562
System battery voltage lower than normal value
5
71
P0563
System battery voltage over normal value
5
72
P0602
Electrical Control Unit (ECU) code error
3
73
P0627
Pump relay controlling circuit open circuit
3
74
P0628
Short circuit to earth of pump relay controlling circuit
3
75
P0629
Short circuit to power supply of pump relay controlling circuit
3
76
P0645
Open circuit of A/C compressor relay controlling circuit
5
77
P0646
Short circuit to earth of A/C compressor relay controlling circuit
5
78
P0647
Short circuit to power supply of A/C compressor relay controlling circuit
5
79
P0650
MIL lamp driving circuit failure
3
80
P0691
Short circuit to earth of cooling fan relay controlling circuit (low speed)
5
81
P0692
short circuit to power supply of cooling fan relay controlling circuit (low speed)
5
82
P2177
Air/fuel ratio closed circuit self-adaptation over upper limit (middle loading area)
11
83
P2178
Air/fuel ratio closed circuit self-adaptation below lower limit (middle loading area)
11
173
Common Malfunction Diagnosis Flow of Geely Automobile
84
P2187
Air/fuel ratio closed circuit self-adaptation over upper limit (low loading area)
11
85
P2188
Air/fuel ratio closed circuit self-adaptation below lower limit (low loading area)
11
86
P2195
Upper oxygen sensor ageing (signal deviation over upper limit)
3
87
P2196
Upper oxygen sensor ageing (signal deviation below lower limit)
3
88
P2270
Lower oxygen sensor ageing (over upper limit)
3
89
P2271
Lower oxygen sensor ageing (below lower limit)
3
No.129 Malfunction code without EOBD system NO
Malfunction code
1
P0107
Low circuit voltage of intake pressure sensor
2
P0108
High circuit voltage of intake pressure sensor
3
P0112
Low signal of intake temperature
4
P0113
High signal of intake temperature
5
P0116
Incorrect water temperature signal
6
P0117
Water temperature signal too low
7
P0118
Water temperature signal too high
8
P0120
Malfunction of throttle position sensor circuit
9
P0130
Signal voltage too low, upstream oxygen sensor
10
P0132
Signal voltage too high, upstream oxygen sensor
11
P0134
Malfunction of upstream oxygen sensor signal (0.4V≤usvk_w≤0.6V)
12
P0135
Malfunction of heating circuit of oxygen sensor
13
P0201
Malfunction of one-cylinder oil nozzle circuit
14
P0202
Malfunction of two-cylinder oil nozzle circuit
15
P0203
Malfunction of three-cylinder oil nozzle circuit
16
P0204
Malfunction of four-cylinder oil nozzle circuit
Description
174
Common Malfunction Diagnosis Flow of Geely Automobile
17
P0230
Malfunction of oil pump control circuit
18
P0325
Malfunction of knock sensor circuit
19
P0335
Reference point signal malfunction, crankshaft position sensor
20
P0443
Malfunction of canister control valve driver-stage control circuit
21
P0444
Voltage too low, driver-stage control circuit of canister control valve
22
P0445
Voltage too high, driver-stage control circuit of canister control valve
23
P0480
Malfunction of cooling fan relay of AC condenser control circuit
24
P0500
Unreasonable speed signal
25
P0506
Idling speed lower than target idling speed value
26
P0507
Idling speed deviated from target value
27
P0508
Short-circuit to earth,of control circuit idling speed governor
28
P0509
short circuit to power supply of idle speed adjustor controlling circuit
29
P0511
Open circuit of idle speed adjustor controlling circuit
30
P0560
System voltage signal unreasonable
31
P0562
System voltage lower than normal value
32
P0563
System voltage over normal value
33
P0601
Electrical Control Unit (ECU) check code error
34
P0602
Electrical Control Unit (ECU) programming error
35
P0630
Vehicle Identification Number (VIN) discode or mismatch - Electrical Control Unit (ECU)
36
P0645
AC compressor relay controlling circuit failure
37
P0646
AC compressor relay controlling circuit voltage lower than normal value
38
P0647
AC compressor relay controlling circuit over normal value
39
P0650
MIL controlling circuit malfunction
175
Common Malfunction Diagnosis Flow of Geely Automobile
Transmission No. 130 Transmission hard to put into gear Malfunction
Causes
Solution 1. Check the pedal’s free clearance, keeping at 1-3mm; clearance between release bearing and clutch pressure plate better at 2-3mm; if too large, adjust it within range above (empirical data);
Clutch not fully separated
2. Check whether crankshaft has too large play; if unusual, repair the engine to make play accurate; 3.
Clutch pressure plate spring too soft; replace it;
4.
Clutch disk excessively worn; replace it;
5. Clutch pressure plate and flywheel surface warped and deformed (replace it if deformed amounts above 0.5 mm) 1. Upper, lower play of gear shifting lever kept at large, replace gear shifting lever assembly; Gear shifting lever incorrectly adjusted
1-2mm, if too
2. Check whether rubber pillar of support base is broken; replace gear shifting lever assembly if so; 3. Check whether cover at connections of shift lever and transmission is too loose; replace the cover if so; 1． Check whether quantity of transmission gear oil reaches oil filler; add it if not enough;
ansmission hard to put into gear Check transmission oil
2．Check whether gear oil within transmission turns black or white, which indicates deterioration if so. Replace it and clean transmission; 3． Check viscosity of gear oil within transmission, and replace for those suitable for local weather; 1. Check whether shift shaft within transmission bends, and could reach maximum stroke by drawing front and back, without jamming; replace shift shaft if so;
Shifting parts block within transmission
2. Check whether support shaft falls or deforms, and replace it if so; 3. Check whether interlocking slide block abrades, and moving left and right within interlocking is smooth. burnish it if jamming; 4. Check whether interlocking groove of shifter fork shaft is too deep, whether its depth fits for extruded part of interlocking block. If too deep, burnish it;
Check synchronizer in transmission
Check whether clearance on the gear pressed by synchronizer ring of each gear is between 0.85-1.45. If clearance less than 0.5mm, replace synchronizer ring;
176
Common Malfunction Diagnosis Flow of Geely Automobile Transmission hard to put into gear
Abnormal Clutch not fully separated
Adjust and repair
Normal Abnormal
Shift bar incorrectly adjusted
Adjust and repair
Normal Abnormal
Transmission oil
Check and replace
Normal Shifting parts block within transmission
Abnormal
Adjust and replace
Abnormal
Adjust and replace
Normal Synchronizer within transmission
No. 131 Park position fails Malfunction
Parking gear fails
Causes
Solution
Gear cable incorrectly adjusted
Check whether gear cable is drawn to P gear; adjust cable position if not so, making shifting bar below transmission reach the furtherest point. Manual shift ball placed at P-position fastening blot;
P-position locking device fails or broken
If manual brake released at P-position and this vehicle moved to-and-fro freely, it is assumed locking device of P-position fails, or P locking plate wears, ruptures. Replace locking plate or repair locking device;
Auto transmission malfunction
Check whether P-position tie rod within transmission bends or deforms; check whether P-position locking block ruptures, making it unable to lock output shaft;
177
Common Malfunction Diagnosis Flow of Geely Automobile Parking gear fails
Incorrectly
Gear cable incorrectly adjusted
Adjust
Normal P-position locking device fails or broken
Ruptures
Replace
Normal Abnormal
Auto transmission malfunction
Repair
No. 132 Gear indicator lamp off sometimes Malfunction
Gear indicator lamp off sometimes
Causes
Solution
Combined instrument malfunction
Take out N-position switch plug, short-connected N-position or P-position tie-line, with long-time check; check whether position lamp short-connected is normal. If malfunction exists, check whether tie-line of N-position switch and combination instrument is normal; replace combination instrument if normal; shake combination instrument properly, and check normal or not; replace combination instrument if abnormal (other positions and the like)
A/T switch malfunction
Check contact on A/T switch, and replace A/T switch if necessary; check earth wire is falsely connected; fix earth wire.
Gear contact sheet within transmission
Remove oil drip pan; check gear contact sheet is poorly contacted;
Line malfunction
Check line is worn or broken, and earth wire is poorly contacted;
178
Common Malfunction Diagnosis Flow of Geely Automobile Gear indicator lamp off sometimes
Abnormal Replace
Combination instrument malfunction
Normal Abnormal Replace
A/T switch malfunction
Abnormal Repair
Line malfunction
No.133 Auto transmission with abnormal sound Malfunction
Auto transmission with abnormal sound
Causes
Solution
Oil quantity and quality
Oil filled between 2-4 holes of dip stick. Oil is too much, causing abnormal sound with parts rotation. Oil too little, and each friction pair lack of lubrication, causing abnormal sound. Check idling speed is normal and engine temperature is normal. For N-position, check oil level is normal, and fill transmission oil if not sufficient. If dirty, replace transmission oil.
Torque converter malfunction
Check abnormal sound of transmission is in front or at rear. If in front, start vehicle, step on brake, and put into driving position. If noise too large, check turbo pulley within torque converter works normally. Listen carefully unusual noise is from crankshaft rear, transmission front, and if noise is wheezy, it is abnormal sound of torque converter; replace torque converter assembly;
Oil pump malfunction
Abnormal sound in middle, slow shifting, oil pressure insufficient. Check clearance between oil pump rotor and casing, plate, which shall be within standard range;
Planet gear mechanism
Check planet gear mechanism is worn or broken, and thrust bearing, thrust disc is damaged. Replace it if so.
Out shaft axle differential with abnormal sound
Check meshing mark of output shaft and gear ring is normal; replace output shaft and gear ring if abnormal; check whether differential bearing is loosening. Shaking with hands shall be without loosening sound, and ball bearing track not flaked; replace differential bearing if abnormal; check differential planet gear, shaft could grind step. Replace differential assembly if worn.
179
Common Malfunction Diagnosis Flow of Geely Automobile Auto transmission with abnormal sound
Oil quantity and quality
Abnormal
Check or repair
Normal Torque converter
Replace
Abnormal
Normal Oil pump
Replace
Abnormal
Normal Planet gear mechanism
Repair
Abnormal
Normal Outshaft axle differential with abnormal sound
Abnormal
Repair
180
Common Malfunction Diagnosis Flow of Geely Automobile
No.134 Transmission shaking during driving Malfunction
Causes
Solution
Engine malfunction
Engine power output not balanced; some cylinder not working; check operations of each cylinder through cylinder breaks;
Engine suspension malfunction
Check each cushion of suspension deforms, ages, ruptures; change cushion if any.
Drive shaft malfunction
Check ball cage inside and outside the drive shaft is excessively worn or loosening, drive shaft bends, and upper and lower runout within 2mm; replace drive shaft assembly if too large.
Tire or steel ring malfunction
Check tire is bubbling, line broken, and upper and lower runout is within 1-3mm. replace tire, steel ring, front hub if too large;
Transmission inner malfunction
Check whether tooth of driving gear and driven gear of each position falls out individually; check meshing clearance of driving gear and driven gear of each position is too deep, and check meshing mark and ensure middle part is well meshed; check tooth of output shaft and differential gear ring falls out individually;
Transmission shaking during driving
181
Common Malfunction Diagnosis Flow of Geely Automobile Transmission shaking during driving
Engine
Abnormal
Repair
Normal Engine suspension
Replace
Abnormal
Normal Drive shaft
Replace
Abnormal
Normal Tire or steel ring
Dynamic balancing or replace
Abnormal
Normal Within transmission
Abnormal
Repair
182
Common Malfunction Diagnosis Flow of Geely Automobile
No. 135 Auto transmission case oil temperature rises, reverse gear fails Malfunction
Causes
Solution Check manual shifting valve is worn, or blocks. If abnormal, replace control valve plate assembly or grind control valve, making it normal;
Control valve plate fails
Check each relevant control valve is leaking; replace valve body assembly if abnormal; Auto transmission case oil temperature rises, reverse gear fails
Check piston seal of control brake is damaged, leaking; replace seal if abnormal; Reversing control brake malfunction Check reversing control piston blocks; adjust or replace piston if abnormal;
Auto transmission case oil temperature rises, reverse gear fails
Control valve plate fails
Fails
Replace
Abnormal
Repair
Normal Reversing control brake malfunction
183
Common Malfunction Diagnosis Flow of Geely Automobile
No. 136 Auto transmission upshifts too late Malfunction
Causes
Solution 1. Check throttle tie-line, and step to the end, and throttle shall at maximum position. If not possible, adjust throttle tie-line;
Throttle tie-line malfunction 2. Check tie-line of throttle position of auto transmission; there shall be 2-8mm clearance between tie-line bottom and pedestal, and adjust it if not so;
Control valve plate malfunction
Check each control valve is worn, or blocks; if abnormal, grind it or replace control valve assembly;
Governor valve malfunction
Check speed control valve blocks or leaks; if abnormal, repair or replace governor valve;
Friction disk skids
Check friction disk clearance is normal; if not, replace friction disk or flange, and adjust it normally;
Auto transmission upshifts too late
1. Check filter is obstructed; if abnormal, clean or replace;
Oil pressure insufficient 2. Check main adjusting valve; if abnormal, check oil pump gear clearance and strength of relief spring inside the oil pump conforms to requirement; if abnormal, replace oil pump;
Throttle valve malfunction
Check throttle valve blocks or is worn, leaking; if abnormal, grind it or replace valve plate assembly;
Shifting valve malfunction
Check shifting valve blocks, or is worn, leaking; if abnormal, grind it or replace it;
Accumulator malfunction
Check accumulator blocks, or is worn, leaking; check accumulator spring conforms to requirement; if abnormal, adjust or replace seal or spring;
184
Common Malfunction Diagnosis Flow of Geely Automobile Auto transmission upshifts too late
Abnormal Throttle tie-line
Adjust
Normal Control valve plate
Abnormal
Repair or replace
Normal Abnormal
Repair or replace
Governor valve
Normal Friction disk skids
Abnormal
Replace
Normal Oil pressure insufficient
Abnormal
Repair
Normal Throttle valve
Abnormal
Repair
Normal Shifting valve
Abnormal
Replace
Normal Accumulator
Abnormal
Replace
185
Common Malfunction Diagnosis Flow of Geely Automobile
No. 137 Auto transmission unable to upshift Malfunction
Causes
Auto transmission unable to upshift
Solution
Auto transmission oil
Check auto transmission oil is too little, and oil level shall be between 2-4 holes of dipstick; if too little, it will not generate oil pressure, making it unable to upshift;
Throttle tie-line malfunction
Check throttle tie-line, and step to the end, and throttle shall at maximum position. If not possible, adjust throttle tie-line; Check tie-line of throttle position of auto transmission; there shall be 2-8mm clearance between tie-line bottom and pedestal, and adjust it if not so;
Governor valve malfunction
Check speed control valve blocks or leaks or fails; if abnormal, repair or replace governor valve;
Auto shifting valve malfunction
Check auto shifting valve blocks or leaks; if abnormal, adjust or replace valve plate assembly;
Accumulator malfunction
Check accumulator blocks, or is worn, leaking; check accumulator spring conforms to requirement; if abnormal, adjust or replace seal or spring;
Drive-gear control valve malfunction
Check drive-gear clutch piston blocks or leaks; if abnormal, adjust or replace drive-gear clutch parts;
Auto transmission unable to upshift
Abnormal Check and fill
Auto transmission oil liquid Normal Abnormal
Throttle tie-line
Adjust
Normal Governor valve
Abnormal
Repair
Normal Auto shifting valve Normal
Abnormal
Repair
Abnormal
Replace
Accumulator Normal Drive-gear control valve
Abnormal
Repaiar or replace
186
Common Malfunction Diagnosis Flow of Geely Automobile
No. 138 Auto transmission unable to force downshift Malfunction
Auto transmission unable to force downshift
Causes
Solution
Throttle tie-line malfunction
Check throttle tie-line, and step to the end, and throttle shall at maximum position. If not possible, adjust throttle tie-line; Check tie-line of throttle position of auto transmission; there shall be 2-8mm clearance between tie-line bottom and pedestal, and adjust it if not so;
Control valve malfunction
Check control valve plate blocks or leaks inside; if abnormal, repair or replace;
Governing valve malfunction
Governing valve severely worn, causing pressure relief, thus unable to downshift; replace governing valve assembly;
Forced downshift switch malfunction
Check forced downshift switch is ok; if abnormal, replace it, and if normal, check tie-line from downshift switch to control unit is normal, and if so, check control unit is ok, and if not so, replace it;
Forced-gear solenoid valve damaged
Check solenoid valve switch is damaged; by referencing circuit drawing, check there is open circuit, short circuit; replace solenoid valve;
Auto transmission unable to force downshift
Abnormal Adjust
Throttle tie-line
Normal Abnormal Repaiar or replace
Control valve
Normal Forced downshift switch
Abnormal Replace
Normal Forced-gear solenoid valve damaged
Abnormal Replace
187
Common Malfunction Diagnosis Flow of Geely Automobile
No. 139 Engine shuts down after putting into gear Malfunction
Causes
Solution
Idling speed too low or clutch too low; Clean idling motor or replace, and adjust clutch height, or throttle blocks replace throttle tie-line; Idling motor poorly operates
Clean or replace idling motor;
Rotating signal panel loosens or engine unusually operates
Check signal panel loosens; repair or replace parts and components; Repair the engine, making it normal or replace damaged parts and components;
Engine shuts down after putting into Gear inside transmission worn, damaged or Disassemble gear inside transmission; adjust or replace gear jammed, blocked damaged parts and components; Clutch disk and flywheel locked or not fully Repair or replace parts and components; repair and separate separated fully or replace damaged parts and components; With power on, test locking clutch solenoid valve is normal; check resistance of control solenoid valve is up to standard; if not so, replace solenoid valve; if so, check tie line of solenoid valve and control unit is normal; if so, check control unit is ok; if not so, replace it; if solenoid valve and control unit tie-line, control unit are all normal, clean or replace torque converter;
Torque converter (with locking clutch) malfunction
Engine shuts down after putting into gear
Abnormal Repair
Idling speed too low or clutch too low; throttle blocks
Normal Idling motor poorly operates Abnormal
Clean or replace
Normal Rotating signal panel loosens or engine unusually operates
Abnormal
Repair
Normal Gear inside transmission worn, damaged or jammed, blocked
Abnormal
Repair
Normal Torque converter
Abnormal Replace
188
Common Malfunction Diagnosis Flow of Geely Automobile
No. 140 No forward gear Malfunction
Causes
Solution
1. Check oil pressure of drive gear, which shall be within standard value. If oil pressure too low, check whether oil pressure valve is Forward gear clutch malfunction jammed, and clutch oil plug is damaged; 2. Check clutch friction disk is excessively worn; 1. Check drive-gear clutch oil pressure; Forward gear brake malfunction 2. Check drive-gear brake friction disk is excessively worn; 3. Check brake driving piston is jammed; No forward gear
Forward gear one-way clutch malfunction
Check one-way clutch is damaged, and functionally abnormal;
Control valve malfunction
Check valve body of control valve plate is worn, leaking or blocked; if abnormal, clean, adjust or replace valve plate assembly.
Governing valve malfunction
Check governing valve is blocked, worn or leaking; if abnormal, adjust or replace governing valve assembly;
No forward gear
Unusual Replace
Forward gear clutch
Normal Unusual Forward gear brake
Replace
Normal Abnormal Forward gear one-way clutch
Replace
Normal Abnormal Control valve
Replace
Normal Governing valve
Abnormal
Replace
189
Common Malfunction Diagnosis Flow of Geely Automobile
No. 141 Transmission oil easily deteriorate Malfunction
Transmission oil easily deteriorate
Causes
Solution
Transmission oil quality problem
Transmission must be filled with qualified gear oil (degree of API GL-4, SAE 80W-85 viscosity);
Transmission oil severely insufficient
Oil level flush with lower plane of oil filler bolt; quality of gear oil not good, and its quantity severely insufficient, causing poor heat emission and excessive wearing of the bearing. Mating surface of constant meshing gear falls out due to high temperature causing transmission oil turning black and deteriorating; replace damaged parts and components and clean transmission, and replace gear oil;
Transmission vent hole falls out
Vent hole falls out, causing entry of dust and moisture from the atmosphere, and turning transmission oil white or dirty;
Transmission inner malfunction
Check meshing clearance of each gear pair within transmission is too small, which shall be between 0.1-0.35. If too small, it will cause transmission oil temperature too high, thus facilitating gear oil deteriorating;
Disassemble transmission, and remove oil sludge and Gear oil not replaced according to specified foreign substance. Clean scraps on the gear and bearing time for a long time causing too much oil thoroughly. Refill gear oil with specified model, and sludge, and oil easily deteriorates replace it according to specified time and mileage.
190
Common Malfunction Diagnosis Flow of Geely Automobile Transmission oil easily deteriorate
Normal Abnormal
Transmission oil quality problem
Refill accordingly
Normal Abnormal
Transmission oil severely insufficient
Refill accordingly
Normal Abnormal Transmission vent hole falls out
Repair
Normal Abnormal Repair transmission
Transmission inner malfunction Normal Abnormal
Gear oil not replaced according to specified time
Replace oil
No. 142 Auto transmission oil easily deteriorate Malfunction
Auto transmission oil easily deteriorate
Causes
Solution
Transmission oil quality and quantity problem
Auto transmission must be filled with qualified ATF (degree of DEXRONⅡ or DEXRON Ⅲ). Oil level shall be between the third or fourth hole of dipstick;
Torque converter inner malfunction
Replace torque converter assembly;
Transmission inner malfunction
Check ablation of each clutch and brake within auto transmission, making auto transmission oil deteriorate; replace clutch and brake friction disk;
Auto transmission heat-removal system malfunction
Check heat-removal oil tank of auto transmission leaks, and there shall be no auto transmission oil within water tank; if any, replace radiator assembly; check heat-removal control valve is jammed, making transmission oil unable to remove heat circularly. Too high oil temperature will cause easy deterioration;
191
Common Malfunction Diagnosis Flow of Geely Automobile Transmission oil easily deteriorate
Normal Abnormal
Transmission oil quality problem
Replace
Normal Abnormal Torque converter inner
Replace
Normal Abnormal
Repaiar or replace
Transmission inner
Normal Abnormal Repair
Auto transmission heat-removal system
No. 143 No reversing gear Malfunction
Causes
Shifting operation mechanism incorrectly No reversing adjusted gear, reversing not possible or Reversing locking mechanism worn, automatic damaged jump-out while reversing Reverse gear malfunction
Solution Adjust shifting operation mechanism (gear shifting lever or shift tie-line); Check reversing shift fork is severely worn, or fails; if abnormal, replace swing link support; Check reverse gear ruptures or fails; if abnormal, replace gear;
192
Common Malfunction Diagnosis Flow of Geely Automobile No reversing gear
Shifting operation mechanism incorrectly adjusted
Abnormal
Adjust
Normal Reversing locking mechanism worn, damaged
Abnorma Replace
Normal Reverse gear malfunction
Abnormal Replace
No. 144 Trip stop of fourth gear of transmission case Malfunction
Causes
Solution
Shifting operation mechanism incorrectly adjusted
Adjust shifting operation mechanism (gear shifting lever o shift tie-line);
Check adapting of synchronizer ring and drum of third, fourth gear loosens, and replace it if abnormal; check slide block of synchronizer of third, fourth gear is excessively worn, and replace it if abnormal;
Synchronizer of third, fourth gear loosens
Auto trip stop of Check self-locked groove of shift fork shaft of fourth gear of synchronizer of third, fourth gear and transmission transmission housing are incorrectly positioned; check shift fork shaft if Shift fork shaft of third, fourth gear self-locked, case abnormal; check grooving position of self-locked groove is interlocking mechanism poor correct; replace shift fork shaft if abnormal; check position of transmission housing hole is up to standard; replace transmission housing if abnormal;
Shift fork of third, fourth gear excessively worn Check shift fork shaft is deformed or worn; replace it if (4-gear end face) abnormal; Fourth-gear of output, input shaft worn, appearing severe taper
193
Replace fourth-gear of output, input shaft;
Common Malfunction Diagnosis Flow of Geely Automobile Trip stop of fourth gear of transmission case
Shifting operation mechanism incorrectly adjusted
Abnormal Adjust
Normal Unusual Synchronizer of third, fourth gear loosens
Repaiar or replace
Normal Abnormal Shift fork shaft of third, fourth gear self-locked, interlocking mechanism poor
Repair
Normal Abnormal Shift fork of third, fourth gear excessively worn
Replace
Normal Fourth-gear of output, input shaft worn, appearing severe taper
Abnormal
194
Replace
Common Malfunction Diagnosis Flow of Geely Automobile
No. 145 Transmission with abnormal sound Malfunction
Causes
Solution
Check viscosity of transmission oil is too small, and quantity is too Poor transmission oil quality, quantity little. Fill in API GL-4 SAE and oil level is flush with lower plane of oil filler;
Transmission with abnormal sound
Bearing within transmission worn
If any gear is sounding and park gear not sounding during driving, check each bearing within transmission is worn or loosening, and bearing shall move stably without abnormal sound. Shaking with hands shall be without loosening sound;
Gear worn
Meshing clearance of each gear pair within transmission is too large or too small, which shall be within 0.1-0.35mm. Measure it with several points, with measuring error at different positions not exceeding 0.15mm;
Input shaft or bearing malfunction
If any gear is sounding, and clutch disappears, check bearing is damaged; replace it if abnormal; check input shaft and output shaft is bent and measured with dial indicator, and with upper and lower runout no more than 0.1mm;
Gear moving interfere
Check chamfer of reversing cock wheel and driving and driven gear of the second gear is too small, making reverse gear scratch driving and driven gear of the second gear, and grind chamfer to make it larger; push reverse gear to the highest position with hands, making it not scratch driving and driven gear of the second gear;
Differential malfunction
If any gear is sounding during driving, and park gear not sounding, check differential bearing or planet gear mechanism is damaged or clearance incorrect; if damaged, adjust or replace parts concerned; check bearing is damaged, and replace it if so;
195
Common Malfunction Diagnosis Flow of Geely Automobile Transmission with abnormal sound
Transmission oil quality, quantity poor
Abnormal
Replace or add
Normal Abnormal Bearing within transmission worn
Replace
Normal Abnormal Gear worn
Replace
Normal Abnormal Input shaft or bearing
Replace
Normal Gear moving interfere
Abnormal
Repair
Normal Differential
Abnormal
Adjust or replace
196
Common Malfunction Diagnosis Flow of Geely Automobile
No. 146 Gear shifting lever swinging, hard to shift Malfunction
Causes
Solution
Gear shifting lever loosens, shifting Check nylon cover of gear shifting lever is unusually worn; if so, replace it; Gear shifting incorrect; lever swinging, hard to shift Gap between shift ball head and swing lever Check shift ball head and swing lever loosen; if so, replace it; too large, shifting incorrect; Gear shifting lever swinging, hard to shift
Shift bar loosens, shifting incorrect
Abnormal
Repair
Normal Clearance between shift ball head and swing lever too large, shifting incorrect
Abnormal
197
Repaiar or replace
Common Malfunction Diagnosis Flow of Geely Automobile
No. 147 Sounding when releasing throttle of third, fourth gears and decelerating Malfunction
Causes
Transmission oil quality, quantity
Solution Check viscosity of transmission oil is too small, and quantity is too little. Fill API GL-4 SAE 80W-85, and oil level shall be flush with lower plane of oil filler.
Check driving gear and driven gear of third, fourth gear. Abrasion of tooth shall not exceed 30% of original tooth length, Gear clearance of third, fourth gear too large and abrasion of its depth no more than 0.5mm. Meshing area of gear shall be no less than 2/3 of working surface; meshing clearance no larger than 0.5mm; change gear pair if too large;
Sounding when releasing throttle of third, fourth gears and Bearing with abnormal sound(major decelerating inspection)
Mainly check abrasion of bearing of input shaft 6205 (without slot), output shaft 6305 (with slot). And the bearing shall be operating without abnormal sound or jamming. Ball track with the bearing shall not be fallen. Shaking with hands shall be without loosening sound. In case of above-mentioned problems, change bearing;
Large play of one shaft
If play of one shaft is too large, check bearing of one shaft is loosening; replace it if so;
Synchronizer malfunction
Check synchronizer of third, fourth gear is loosening; replace it if so;
Sounding when releasing throttle of third, fourth gears and decelerating
Transmission oil quality, quantity
Abnormal
Fill up accordingly
Normal Abnormal Repair
Gear clearance of third, fourth gear too large
Normal Abnormal Bearing with unusual noise
Normal
Replace
Abnormal
Large play of one shaft
Repair
Normal Synchronizer malfunction
Abnormal
198
Repaiar or replace
Common Malfunction Diagnosis Flow of Geely Automobile
No. 148 Fifth gear not easily shifted up Malfunction
Causes
Solution
Shift lever malfunction
Check gear shifting lever is bent or deformed, rubber sleeve is aging, loosening
Transmission shift operation mechanism malfunction
Check swing link support is worn, loosening or deformed, and shift shaft and device of fifth gear is smoothly put into gear; if not, replace swing link support assembly; check shift fork of fifth gear is vertical to shift fork shaft; if not, replace shift fork of fifth gear;
Synchronizer assembly of fifth gear malfunction
1. Toothed ring of fifth-gear synchronizer is excessively worn, and clearance of toothed ring pressed at gear no less than 0.5mm, with specified value between 0.85-1.45; area of joint face of fifth-gear synchronizer and gear shall be larger than 80%; replace synchronizer ring if not; 2. Check height of slide block of synchronizer is no less than 5mm; replace slide block of synchronizer if less than 5mm; 3. Check synchronizer hub and cover is too loosening or too tightening. Hub shall be assembled within the cover freely. Joint part of cover and gear shall be triangular. Replace synchronizer assembly if damaged, worn, or its edge angle turning round;
Transmission input, output shaft fifth-gear malfunction
Replace transmission input, output shaft fifth-gear;
Fifth gear not easily shifted up
199
Common Malfunction Diagnosis Flow of Geely Automobile Fifth gear not easily shifted up
Abnormal
Shift lever
Replace
Normal Unusual Repair
Transmission shift operation mechanism
Normal
Abnormal
Fifth-gear synchronizer
Replace
Normal Abnormal Repair
Transmission input, output shaft fifth-gear
No. 149 Fifth gear, first gear blocks, relieved only when the vehicle stops Malfunction
Causes
Solution
⑴ Gear shifting lever malfunction
① Check gear shifting lever is bent or deformed, rubber cover is aging or loosening;
⑵Clutch not fully separated
① Check free clearance of pedal is at 1-3mm; clearance of bearing and pressure plate is better at 2-3mm; if too large, adjust accordingly; (empirical data) ② If clutch spring is too soft, replace it; ③ If clutch friction disk is excessively worn, replace it; ④ Check clutch plate and flywheel surface is bent, deformed (replace it if amount of deformation is above 0.5mm);
⑶Transmission inner malfunction
① Check swing link support, right-angle shaft is deformed, loosening. Right angle is 90 degree by visual measurement, and if bending angle diminishes, replace swing link support; ② Check fifth-gear synchronizer, and cover within hub is too loosening and slanted around; if too loosening, replace synchronizer assembly; ③ Check height of slide block of synchronizer; if less than 5mm, replace slide block; ④ Check soldered tooth of driven gear of one gear is too far from engaging tooth of another gear, and clutch collar may be too deep inside. Press soldered tooth by forcing machine; Check clearance between rear end plate of fifth gear synchronizer and hub is too large; after fifth-gear is put, slide block turns up, and blocks when to be relived. clearance shall be within 2mm; if too large, replace rear end plate;
Fifth gear, first gear blocks, relieved only when the vehivle stops
200
Common Malfunction Diagnosis Flow of Geely Automobile Fifth gear, first gear blocks, relieved only when the vehivle stops
Abnormal Check gear shifting lever
Replace
Normal Abnormal Clutch not fully separated
Repair
Normal Abnormal Transmission inner malfunction
Repair
No. 150 Hiss sound when put into gear during driving Malfunction
Hiss sound when put into gear during driving
Causes
Solution
Gear shifting lever malfunction
Check tightening torque at connections of gear shifting lever and transmission is too tightening, and rubber cover is not isolating vibration, making sound introduced to cab;
Fourth-gear shift shaft and fork malfunction
Check working face of fourth-gear shift shaft and fork is vertical; if not, replace fourth-gear fork. Check working face of fork is worn unilaterally; if so, replace fourth-gear fork;
Fourth-gear synchronizer malfunction
② Check fourth-gear synchronizer spring and ring are damaged; if conical surface turns small or deformed, replace synchronizer toothed ring;
201
Common Malfunction Diagnosis Flow of Geely Automobile Hiss sound when put into gear during driving
Abnormal
Check shift bar
Repair
Normal
Fourth-gear shift shaft and fork
Abnormal
Replace
Normal Abnormal Check fourth-gear synchronizer
Replace
202
Common Malfunction Diagnosis Flow of Geely Automobile
No. 151 Transmission gear runout Malfunction
Causes Fixed bolt loosens
of
Solution transmission
Gear shifting lever deforms
Check fixed bolt of transmission; fasten it if loosening; Gear shifting lever deformed causing gear abnormally or not well jointed; 1. If gear runout found at any gear, gear lever is switched to this gear, then remove transmission cover and check gear meshing; if normal, check locking mechanism of shift fork shaft; 2. Push positioning device of shifting fork with hands; if poor, remove shift fork shaft and check positioning ball and spring; if the spring is too soft or broken, replace it. If groove of shift fork shaft is excessively worn, repair or replace it; 3. Check screws of fixing plate of shifting fork are loosening, and clearance between fork end and gear groove is too large; correct it if shifting fork bends; if lower end of shifting fork is worn and sliding gear groove is too loosening, remove and repair it;
Shift fork within transmission is excessively worn, self-locked spring breaks or too softens; During driving, replace self-locked spring and gear lever fork automatically jumps to neutral position, which may occur when driving at medium, Axle head of swing link support transmission is high speed, load within Weld up shaft end of swing link support, and grind it to stand dimension; suddenly changes excessively worn, making all or automotive is gears not well positioned vibrating severely, and most trip stop Bearing and shaft unusually Check abrasion of bearing and shaft; if the shaft is severely worn, bearing during at high worn is loosening or shift shaft plays axially, then remove, repair or replace; speed.
Spline clearance between transmission clutch collar and spline hub too large; clearance Check operation of synchronizer; if malfunction found, repair or replace it; between clutch collar and tooth of put gear too large
Soldered tooth bent or deformed, Check meshing of gear; if not fully meshed, check gear is worn or in abrasion smaller taper; replace it if severely worn;
203
Common Malfunction Diagnosis Flow of Geely Automobile Transmission gear runout
Abnormal
Fixed bolt of transmission loosens
Fasten
Normal Abnormal Shift fork within transmission worn
Replace
Normal Abnormal
Swing link support within transmission
Repair
Normal Abnormal Unusual abrasion of bearing and shaft
Replace
Normal Abnormal
Synchronizer clutch collar and spline hub
Replace
Normal Abnormal
Soldered tooth bent, deformed, worn
Replace
No. 152 Hiss sound when second, third, fourth gear upshift Malfunction
Causes
Solution
Second, third, fourth gear synchronizing ring malfunction Hiss sound when second, third, fourth gear upshift
check back clearance of synchronizing ring of second, third, fourth gear is not proper; if not normal, check end face of synchronizing ring is excessively worn; if abnormal, replace synchronizing ring;
Contact face of gear end face and synchronizing ring is excessively worn; if abnormal, replace gear;
Second, third, fourth gear malfunction
204
Common Malfunction Diagnosis Flow of Geely Automobile Hiss sound when second, third, fourth gear upshift
Second, third, fourth gear synchronizing ring
Abnormal
Repaiar or replace
Normal Abnormal
Second, third, fourth gear
Repaiar or replace
No. 153 Chug sound in transmission case at idling speed Malfunction
Causes
Solution Clearance between hub and torsional spring within clutch friction disk is too large. Concentricity of transmission one shaft and engine crankshaft is out of true. Clutch friction disk and hub bent and deformed, and rotated causing abnormal sound. Connecting plane of transmission and engine shall be adjusted with adjusting pad;
Clutch malfunction
Chug sound in transmission case at iding speed Transmission malfunction
Bearing within transmission is excessively worn; clearance driving and driven gear of first, second gear is too large. Meshing clearance at 0.1-0.15; adjusting pad of output shaft is broken, making output shaft move forward; first gear scratches and differential generating abnormal sound; Check lubricating oil is poor or deteriorating. If abnormal, supplement or replace lubricating oil;
Lubricating oil malfunction Chug sound in transmission case at iding speed
Check clutch
Abnormal
Repair
Normal Check transmission
Abnormal
Repair
Normal Unusual Check transmission lubricating oil
Fill or replace
205
Common Malfunction Diagnosis Flow of Geely Automobile
No. 154 Da-da sound in transmission at idling speed Malfunction
Da-da sound in transmission at idling speed
Causes
Solution
Clutch malfunction
Gap between spline hub and one shaft spline within clutch friction disk is too large; replace clutch friction disk and one shaft;
Transmission inner malfunction
Check bearing ball of input shaft is crushed; tooth of driving and driven gear of first, second gear of input shaft is fallen individually; chamfer of reversing middle wheel and second-gear driving and driven gear is too small, making reversing gear scratch second-gear driving and driven gear; grind chamfer to make larger, and push reversing gear to the highest position with hands, making it not scratch second-gear driving and driven gear; check whether reversing gear and transmission housing collide; if abnormal, repair transmission housing. Check swing link support is loosening, causing reversing gear collide with transmission housing; if abnormal, replace support;
Lubricating oil malfunction
check lubricating oil is insufficient; if not sufficient, fill up;
206
Common Malfunction Diagnosis Flow of Geely Automobile Da-da sound in transmission at idling speed
Check clutch
Abnormal
Repair
Normal
Check transmission
Abnormal
Repair
Normal Check transmission lubricating oil
Unusual
207
Add or replace
Common Malfunction Diagnosis Flow of Geely Automobile
No. 155 Buzz sound during driving at high speed Malfunction
Causes
Solution
Check viscosity of transmission oil is too small, and Viscosity of transmission oil too small, quantity too quantity is too little. Fill in API GL-4 SAE 80W-85 little and oil level is flush with lower plane of oil filler; Check tightening torque at connections of gear shifting Tightening torque at connection of transmission lever and transmission is too tightening, and rubber lever cover is not isolating vibration, making sound introduced to cab; Mainly check meshing mark of differential gear ring and output shaft, which is adjusted between 0.1-0.15mm. Meshing mark shall be in middle of tooth, with area no Meshing mark of differential gear ring and output less than 80%. Meshing point not falling out; differential shaft abnormal, and differential bearing worn bearing worn or loosening. Ball, track within bearing not falling out. Inner and outer cover not obviously loosening while shaking bearing. Buzz sound during driving at high Transmission cone bearing incorrectly adjusted speed
check cone bearing is adjusted too tighten; if not normal, adjust and check differential;
① Toothed ring of synchronizer is excessively worn. Clearance on the gear pressed by synchronizer ring is no less than 0.5mm. Specified value is between 0.85-1.45. Area of joint face of fifth-gear synchronizing ring and gear shall be larger than 80%; if lower, replace synchronizing ring; ② Check fit clearance of hub, cover, which shall be no obvious clearance while shaking from left to right. Hub shall be assembled within the cover freely. Joint part of cover and gear shall be triangular. Replace synchronizer assembly if damaged, worn, or its edge angle turning round; ③ Check height of slide block of synchronizer; if less than 5mm, replace slide block;
Transmission synchronizer malfunction
208
Common Malfunction Diagnosis Flow of Geely Automobile Buzz sound during driving at high speed
Transmission oil viscosity, quantity
Abnormal
Fill up accordingly
Normal
Tightening torque at connection of transmission lever
Abnormal
Tighten the torque accordingly
Normal Meshing mark of differential gear ring and output shaft, and differential bearing abrasion
Normal
Abnormal
Abnormal
Transmission cone bearing adjustment
Adjust or repair
Adjust according to standard gap
Normal Transmission synchronizer, hub, cover, slide block
Abnormal
209
Repaiar or replace
Common Malfunction Diagnosis Flow of Geely Automobile
No.156 Transmission with abnormal sound while shifting Malfunction
Causes
Clutch tie-line malfunction
Solution Clutch tie-line (improved version) having too small bending; while shifting, clutch sound introduced to cab via tie-line; replace old version of clutch tie-line;
Check tightening torque at connections of gear shifting lever and transmission is Tighten connections of gear shifting lever and transmission too tightening, and rubber cover is not according to standard torque; isolating vibration, making sound introduced to cab;
Transmission with abnormal sound while shifting
① Toothed ring of synchronizer is excessively worn. Clearance on the gear pressed by synchronizer ring is no less than 0.5mm. Specified value is between 0.85-1.45. Area of joint face of fifth-gear synchronizing ring and gear shall be larger than 80%; if lower, replace synchronizing ring; Synchronizer gear ring, hub, cover ② Check fit clearance of hub, cover, which shall be no obvious excessively worn or clearance clearance while shaking from left to right. Hub shall be assembled within the cover freely. Joint part of cover and gear shall be incorrectly triangular. Replace synchronizer assembly if damaged, worn, or its edge angle turning round; ③ Check height of slide block of synchronizer; if less than 5mm, replace slide block;
Transmission inner malfunction
Transmission input, output shaft bearing, gear severely worn, or long-term impact causing burr at meshing of gear; replace damaged parts;
210
Common Malfunction Diagnosis Flow of Geely Automobile Transmission with abnormal sound while shifting
Abnormal
Check clutch tie-line
Replace tie-line
Normal Abnormal Check tightening torque at connection of transmission lever
Tighten accordingly
Normal Abnormal Check transmission synchronizer gear ring, hub, cover, slide block
Replace
Normal Check transmission gear, shaft and bearing, etc.
Abnormal
Replace damaged parts
No. 157 Transmission gear disorder Malfunction
Causes
Solution
Lock frame, pin of interlocks deformed or Replace interlock ball, pin and spring of severely worn. transmission
When clutch not fully separated, put into gear at start or shifting during driving; not switched to the gear needed; unable to return to neutral position after put into gear; put into two gears while vehicle is static.
Lower end of gear lever (automotive) is not sufficient in length, and working face of Replace shift operation mechanism lower end greatly worn or fork, guide block greatly deformed, worn.
Location pin of gear lever ball head worn, loosening broken, or ball head, hole greatly Replace gear lever assembly worn.
211
Common Malfunction Diagnosis Flow of Geely Automobile
Gear disorder
Try to put into gear but cannot or try to shift down but cannot?
Put into different gear. Hold gear lever with hands and shake around. Check swing angle of gear lever (automotive)
No Yes
Swing or not
Put into two gears at the same time? No
No
No
Malfunction caused by broken or leaked location pin
Yes
But swinging angle of gear lever exceeds normal range
Malfunction caused by damaged locking device, such as severely deformed, worn lock pin, frame
Malfunction caused by loosening mating of location pin and slot or severe abrasion of ball head and seat
Interlocjing
End
212
Yes
Malfunction caused as shifting swing lever falls out from fork groove, such as severely worn lever or groove
Common Malfunction Diagnosis Flow of Geely Automobile
No. 158 Shaking startup Malfunction
Causes
Solution
1. Get off the vehicle and check flywheel, flywheel casing, transmission connection is Inner end of releasing lever not within the loosening, engine support is fixed, bolt is same plane loosening? If loosening, fasten it; 2. check pressing spring or circlip of release bearing is broken; replace it; When the vehicle starts at low speed, release clutch gradually according to operation rules, and Driven disk or clutch plate deformed or slowly step down accelerator warped; end face of flywheel severely pedal. Clutch could not jointed jumps stably and cause shaking, even buffeting to whole vehicle.
1. Check if any large abrasion sound is heard during rotation, even rotating resistance is larger? 2. A. Check cushion sheet on clutch plate is broken, damping spring is fatigue or broken; B. friction rivet on clutch plate is loosening; Repair or replace it if malfunctions exist.
Check driven disk is with uneven depth, oil Friction disk of driven disk with uneven sludge, scorching, uneven surface, hardened depth, oil sludge, scorching, uneven surface, exposed rivet head, loosening or surface, hardened surface, exposed rivet broken rivet head, loosening or broken rivet Replace it if exist.
213
Common Malfunction Diagnosis Flow of Geely Automobile
214
Common Malfunction Diagnosis Flow of Geely Automobile
Chassis No.159 Shaking startup Malfunction
Causes
Solution
(1) Clutch pedal has too large free stroke, diaphragm spring force fully or partially acting on operation mechanism, making Adjust free stroke of clutch; driven disk unable to well separated with flywheel and clutch plate;
(2) Clutch housing or transmission housing loosening (3) Rivet on driven disk loosening or driven disk too thick; Malfunction: while startup, clutch (4) Driven friction disk, clutch plate and flywheel’s working face could not be warped, deformed; jointed stably, causing shaking. (5) Spring annealing, diaphragm spring fatigue, with uneven and insufficient elastica, or broken;
Fasten loosening parts; Clinch or replace driven disk; Replace warped driven disk, clutch plate or flywheel; Replace clutch plate assembly;
(6) Fixed screws for clutch plate and flywheel loosening;
Fasten bolt;
(7) Space between release bearing sleeve and its guide pipe with oil sludge, dust or blocked, unable to return;
Clean guide pipe;
215
Common Malfunction Diagnosis Flow of Geely Automobile
Diagnosis flowchart of shaking startup
216
Common Malfunction Diagnosis Flow of Geely Automobile
No. 160 Clutch slipping Malfunction When releasing clutch, the vehicle could not be started; during accelerating, rotating speed of engine rises, and vehicle speed not rising accordingly; when going against long slope, clutch smoking with pasting smell. When pulling on parking brake for startup test, engine shall stall; if not, it indicates that the clutch slips.
Causes
Solution
(1) Free stroke of clutch pedal too small or zero, diaphragm spring force fully or partially acting on operation mechanism, making driven disk Adjust free stroke of clutch; unable to well pressed with flywheel and clutch plate; (2) Driven disk with oil sludge, causing reduced Remove oil sludge and eliminate oil its surface friction force or its hardened; leaking; or replace driven disk; (3) Working face of driven friction disk, clutch plate and flywheel severely worn, thickness Replace driven disk; reduced; (4) Spring annealing, diaphragm spring fatigue Replace clutch plate assembly; or broken; (5) Fixed screws for clutch plate and flywheel Fasten bolt; loosening; (6) Space between release bearing sleeve and Clean guide pipe; its guide pipe with oil sludge, dust or blocked, unable to return; Diagnosis program for clutch driving, slipping
217
Common Malfunction Diagnosis Flow of Geely Automobile
No. 161 Heavy clutch Malfunction
Causes
1. Clutch jammed;
drive
mechanism
Solution
deformed, Check drive mechanism is deformed or jammed; correct and repair if so;
2. Clutch tie-line jammed;
Feel heavy and 3. Clutch hard when blocked; stepping down clutch pedal
master
cylinder
Clean or replace clutch tie-line;
damaged, Check clutch master cylinder is damaged, blocked; replace it if so;
Check clutch wheel cylinder is damaged, blocked; replace it if so;
4. Clutch wheel cylinder damaged, blocked;
4. Foreign substances or rust at pivoting of Check any foreign substances or rusts at pivot; clean them or diaphragm spring of clutch plate; lubricate rusts if so; Heavy clutch
Unusual
Clutch drive mechanism deformed, jammed
Correct and repair
Normal Unusual Clutch tie-line jammed or fouling
Clean or replace
Normal Clutch master cylinder damaged, blocked
Damaged Replace
Normal Damaged Clutch wheel cylinder damaged, blocked
Replace
Normal Foreign substances or rust at pivoting of diaphragm spring of clutch plate
218
Unusual
Clean or lubricate
Common Malfunction Diagnosis Flow of Geely Automobile
No. 162 Not fully separated Malfunction
Causes
Solution
(1) Free stroke of clutch too large, diaphragm spring force fully or partially acting on operation mechanism when stepping down the pedal, making Adjust it; diaphragm spring not fully compressed, and driven disk unable to well separated with flywheel and clutch plate; Malfunction: when the engine is operating at idling speed, step on clutch pedal, impact sound of gear occurs when put into gear at original position, and hard to put into gear; if severe, engine will stall
(2) Clutch plate diaphragm uneven, not within the same plane;
Replace clutch plate;
(3) Driven disk incorrectly installed, causing friction between driven disk Reassemble; and flywheel; (4) Driven disk warped, deformed, causing friction between driven disk Correct driven disk; and flywheel or clutch plate; replace driven disk of standard thickness;
(5) Clutch driven disk too thick;
(6) Spline hub of driven disk not flexibly moved at one shaft (output shaft) of transmission, causing friction between driven disk and flywheel or Replace driven disk; clutch plate, and making clutch not fully separated;
219
Common Malfunction Diagnosis Flow of Geely Automobile
Diagnosis program for not fully separated clutch
220
Common Malfunction Diagnosis Flow of Geely Automobile
No. 163 Clutch with abnormal sound Malfunction
Causes
Solution
1. Fixed screws of clutch operation mechanism Check fixed screws of clutch operation mechanism are loosening or damaged; loosening or damaged; fasten or replace it if any;
2. Clutch release bearing worn, damaged;
Check clutch release bearing is worn, damaged; replace it if any;
Abnormal sound when stepping on 3. Torsion spring of clutch plate loosening or Check torsion spring of clutch plate is loosening or broken; broken; replace it if any; clutch pedal
4. Spline hub of clutch plate worn, loosening;
4. Check spline hub of clutch plate is worn, loosening; replace it if any;
5. Screws of clutch housing loosening;
5. Check fixed screws of clutch housing are loosening; fasten it if any;
221
Common Malfunction Diagnosis Flow of Geely Automobile Clutch with abnormal sound
Abnormal
Fixed screws of clutch operation mechanism loosening or damaged
Fasten or replace
Normal Abnormal
Clutch release bearing worn, damaged
Replace
Normal Abnormal
Torsion spring of clutch plate loosening or broken
Replace
Normal Abnormal Replace
Spline hub of clutch plate worn, loosening
Normal Screws of loosening
clutch
housing
Abnormal
222
Fasten screws
Common Malfunction Diagnosis Flow of Geely Automobile
No. 164 Shock absorber with abnormal sound Malfunction
Vehicle with sound
Causes
Solution
1. Fixed bolts loosening or damaged;
Check fixed bolts are loosening or damaged; fasten or replace if any;
2. Upper and lower rubber covers damaged;
Check upper and lower rubber covers are damaged; replace if any;
bumping abnormal 3. Buffer block damaged;
Check buffer block is damaged; replace if any;
4. Oil leaking;
Check it is oil leaking; replace it if any;
5. Spring too soft or broken;
Check spring is too soft or broken; replace it if any;
6. Internally worn, loosening;
Check it is oil leaking; replace it if any;
223
Common Malfunction Diagnosis Flow of Geely Automobile Shock absorber with abnormal sound
Normal Fixed bolts loosening or damaged
Fasten replace
Abnormal
Normal Damaged
Upper and lower rubber covers damaged
Replace
Normal Damaged
Buffer block aged, damaged
Replace
Normal Oil leaking
Oil leaking
Replace
Normal Abnormal
Spring too soft or broken
Replace
Normal Abnormal Internally worn, loosening, core axle warped, not straight, friction face warped, uneven
224
Replace
or
Common Malfunction Diagnosis Flow of Geely Automobile
No. 165 Front wheel with abnormal sound when turning Malfunction
Causes
Solution
1. Front suspension bolt loosening or damaged;
Check front suspension bolt is loosening or damaged; fasten or replace it if any; Check ball head of tie rod, lower swing arm are loosening; replace it if any;
2. Ball head of tie rod, lower swing arm loosening; Abnormal sound occur to front wheel when turning, while 3. Rubber cover of lower swing arm damaged; normally when driving straightly
Check ball head of lower swing arm is loosening; replace it if any; Check rubber cover of lower swing arm is damaged; replace it if any;
4. Pressure bearing of front wheel lack of Check pressure bearing of front wheel lacks of lubricating oil or damaged; lubricating oil or damaged; lubricate or replace it if any;
5. Outer ball cage of front wheel worn, loosening;
225
Check outer ball cage of front wheel is worn, loosening; replace it if any;
Common Malfunction Diagnosis Flow of Geely Automobile Front wheel abnormal sound turning
with when
Front suspension bolt loosening or damaged?
Abnormal Fasten or replace
Normal Ball head of tie rod, lower swing arm loosening
Loosening
Replace
Normal Rubber cover of lower swing arm damaged
Damaged
Replace
Normal Abnormal Pressure bearing of front wheel lack of lubricating oil or damaged
Lubricate replace
Normal Abnormal
Outer ball cage of front wheel worn, loosening
226
Replace
or
Common Malfunction Diagnosis Flow of Geely Automobile
No.166 Heavy steering Malfunction
Causes
Solution
(1) Ttire pressure not enough;
Tire inflation
(2) Fixed screws of steering knuckle loosening or Re-fasten falling out; (3) Inner, outer tie rod ball head adjusted too Adjust their matching clearance or lubricate tighten or lack of oil;
Driver feels heavy and difficult while turning steering wheel to left or right during driving; when the vehicle is turning corner or turning around at low speed, hard or even unable to turn steering wheel.
(4) Bearing of drive part of steering gear having too large pretightening force, or driven part and Adjust clearance lining matched too tighten; (5) Meshing of drive, driven parts adjusted too Adjust gap tighten; (6) Steering gear is oil-free or lack of oil;
Fill up lubricating oil
(7) Thrust bearing of steering knuckle lack of oil or Replace thrust bearing damaged;
(8) Steering shaft bent or its sleeve collapsed Replace steering gear causing scratchin;
(9) Kingpin rear inclination or inclination too large Four wheels positioning or front wheel with negative outer inclination;
(10) Vehicle frame deformed causing incorrect Correct vehicle frame or four wheels positioning positioning of front wheel.
227
Common Malfunction Diagnosis Flow of Geely Automobile
Fig 4 Diagnosis chart for heavy steering
228
Common Malfunction Diagnosis Flow of Geely Automobile
No. 167 Steering wheel not well back to original position Malfunction
Causes
Solution Check tire pressure is too low; if so, add pressure to specified scope;
1. Tire pressure too low;
2. Tie-rod ball head, and ball head of lower swing arm rusty, jammed;
Steering wheel not well back to original position
Check tie-rod ball head is rusty, jammed; if so, lubricate or replace it; Check ball head of lower swing arm is rusty, jammed; if so, lubricate or replace it;
3. Pressure bearing lack of lubrication or damaged;
Check pressure bearing is lack of lubricating oil or damaged; if so lubricate or replace it;
4. Meshing clearance of steering gear too small;
Check meshing clearance is too small; if so, adjust it;
5. Steering column bent or blocked;
Check steering column is bent or blocked; if so, correct or replace it;
6. Positional parameter of front wheel incorrect
229
Check positional parameter of front wheel is incorrect; if so, adjust it;
Common Malfunction Diagnosis Flow of Geely Automobile Steering wheel not well back to original position
Too low
Tire pressure too low
Fill
Normal Unusual Tie-rod ball head, and ball head of lower swing arm rusty, jammed
Lubricate replace
or
Normal Unusual Lubricate or replace
Pressure bearing lack of lubrication or damaged
Normal Meshing clearance of steering gear too small
Too small Adjust
Normal Damaged Steering column bent or blocked, cracked, too soft
Correct replace
Normal Unusual Positional parameter of front wheel incorrect
230
Positional adjustment
or
Common Malfunction Diagnosis Flow of Geely Automobile
Malfunction
Causes
Shaking steering
1. Power steering pump belt too loosening; 2. Lack of steering oil; 3. Power steering pump damaged;
Abnormal steering
sound
while
4. Power steering gear clearance too large or damaged 5. Ball head of lower swing arm malfunction
Power
steering
Solution Check power steering pump belt is too loosening; if so, adjust it. Check it is lack of steering oil; if so, add it; Check power steering pump is damaged; if so, replace it Check power steering gear clearance is too large or damaged; if so, adjust or replace it; Check ball head is rusty or jammed; if so, lubricate or replace it;
with
abnormal sound
Too loosening Power steering pump belt too loosening
Adjust
Normal Lack of power steering oil?
Lack
Fill
Normal Power steering pump damaged
Damaged
Replace
Normal Abnormal Power steering gear clearance too large or damaged
Adjust or replace
Normal Ball head of lower swing
Abnormal Replace
arm faulty
231
Common Malfunction Diagnosis Flow of Geely Automobile
Malfunction
Causes
Solution
1. Connecting screws of front suspension Check connecting screws of front suspension loosening or loosening or damaged; damaged; if so, fasten or replace it;
Steering shaking steering driving
wheel while during
2. Wheel and wheel parts abraded while Check wheel and wheel parts are abraded while steering; if steering so, adjust and repair it;
3. Steering gear looseningly installed;
Check steering gear is looseningly installed; if so, fasten it;
4. Front wheel incorrectly positioned;
Check front wheel is incorrectly positioned; if so adjust it;
5. Electric power assisted steering motor Replace steering column with motor assembly; shaking
No. 170 Steering power insufficient (hydraulic) Malfunction
Causes 1. Power-assisted steering loosening or damaged;
Solution pump
belt
2. Lack of power steering oil;
too Check power-assisted steering pump belt is too loosening or damaged; if so, adjust or replace it;
Check it is lack of power steering oil; if so, add it; Check power steering pump is damaged; if so, replace it;
Steering wheel not 3. Power steering pump damaged; well back to original position 4. Hydraulic booster system with air
Empty the air inside the hydraulic booster system;
5. Hydraulic pipe distorted, scrimped or cracked, Repair abnormal parts; oil leaking; 6. Power steering gear damaged;
Check power steering gear is damaged; if so, replace it;
232
Common Malfunction Diagnosis Flow of Geely Automobile Steering power insufficient
Abnormal
Power-assisted steering pump belt too loosening or damaged
Adjust or replace
Normal Lack of power steering oil
Lack
Fill
Normal Damaged
Power steering pump damaged
Replace
Normal Damaged
Power steering gear damaged
Replace
No. 171 Power-assisted pump with abnormal sound Malfunction
Causes
Solution
1. Power-assisted oil insufficient
Check power-assisted oil is insufficient; if so, add it;
2. Power-assisted pump belt pulley loosening
Check power-assisted pump belt pulley is loosening; if so, replace it;
Power-assisted pump with abnormal sound 3. Power-assisted pump belt loosening or severely Check power-assisted pump belt is loosening or after vehicle worn severely worn; if so, adjust or replace it; started; and worsen when steering Check screws of power-assisted pump are loosening; if 4. Screws of power-assisted pump loosening so, fasten them. 5. Power-assisted pump worn or damaged Check power-assisted pump is worn or damaged internally; internally; if so, replace it.
233
Common Malfunction Diagnosis Flow of Geely Automobile Power-assisted pump with abnormal sound
Lack
Power-assisted oil insufficient
Add
Normal Loosening Fixed screws loosening
of
power-assisted
Fasten
pump
Normal Power-assisted pump belt pulley loosening or worn
Damaged
Replace
Normal Power-assisted pump belt loosening or worn
Damaged
Replace
Normal Damaged Power-assisted pump severely worn internally
Replace
234
Common Malfunction Diagnosis Flow of Geely Automobile
No. 172 Direction running out Malfunction
Causes
Solution
(1) Front wheel’s rotating mass (including tire, hub, Dynamic balancing of front wheel brake drum or disk, hub, etc.) imbalanced; (2) Front wheel’s radial circle or end face circle running Positional adjustment for tire, dynamic balancing of out too large; the wheel (3) Front wheel using retread tire;
Replace tire
(4) Front wheel’s camber angle too small, toe-in too Adjust toe-in or four-wheel positioning large, kingpin negative caster or caster angle too large; (5) Kingpin caster angle or kingpin angle inconsistent Four-wheel positioning for two front wheels; When the vehicle is running within certain low or high speed range, sometimes angular oscillation occurs around kingpin at two front wheels, as called front wheel yawing; especially when yawing at high speed, two front wheels are severely pendulating left to right, and hands holding steering gear feels sense of numbness, or even whole nose is seen to be shaking from the cab.
(6) Front beam or front suspension bent, distorted, Correct front body or replace front suspension deformed; (7) Action of steering system and front suspension Correct toe-in; adjust tie-rod; replace tie-rod, ball interferes each other; head (8) Steering system’s rigidity too low (including Replace steering tie-rod, lower swing arm; steering tie-rod, lower swing arm, etc.); (9) Meshing clearance of drive, driven parts or bearing Adjust clearance; clearance of steering engine too large; (10) Gear looseningly;
rack
of
steering
engine
matched
Adjust matching clearance;
(11) Ball head of inner and outer steering tie-rods Replace ball head; connected looseningly; (12) Front support loosening or deformed;
Fasten or replace front support
(13) Front wheel hub bearing loosening;
Replace bearing
(14) Steering engine looseningly connected at the Fasten or adjust frame; (15) Vibration damper of front suspension fails or its Replace vibration damper efficiency at left and right different; (16) Front suspension height or rigidity (thickness, length, or extent of new, old of spring surface) Replace spring inconsistent; (17) Road roughness too large; when blow frequency of road surface on the wheel is inconsistent with natural frequency of angular oscillation of front beam, Drive on favorable road surface yawing of front wheel is caused under gyroscope effect;
235
Common Malfunction Diagnosis Flow of Geely Automobile
Diagnosis flowchart of front-wheel yawing
236
Common Malfunction Diagnosis Flow of Geely Automobile
No. 173 Steering wander during normal driving Malfunction
Causes
Solution
Tire pressure of two front wheels not equal, diameter not Inflate the tire, adjust loading; equal or ca loading uneven;
One of tire or hub of two front wheels deformed
Replace deformed tire or hub;
One ball head of steering tie-rod loosening or jammed
Replace loosening or jammed ball head;
Toe-in too large or negative toe-in
Correct toe-in;
one ball head of lower swing arm loosening or jammed
Replace loosening or jammed ball head of lower swing arm;
Front spiral spring at two sides with unequal height or Replace spring; elasticity; One lower swing arm bent or lining loosening Automatically run to Lower joist of front suspension deformed another side during driving. Straight driving only ensured with hands forcibly holding Wheelbase of two sides of frames unqual steering wheel
Replace lower swing arm assembly;
Replace lower joist of front suspension;
Adjust wheelbase at two sides of frame;
Hub bearing or oil seal of two front wheels with unequal Adjust degree of tightness of hub bearing degree of tightness or oil seal of two front wheels;
Wheels at two sides of front, rear axles with braking or Correct breaking of wheels at two sides dragging at one side; of front, rear axle;
Correct camber angle of two front camber angle of two front wheels, kingpin caster angle or wheels, kingpin caster angle or kingpin kingpin toe-in angle unequal; toe-in angle Front beam, rear axle tube or frame with bending with Correct front beam, rear axle tube or horizontal plane; frame; Camber of paving too large or with cross wind.
Choose road for driving;
Electric power-assisted steering pitch sensor incorrectly Adjust or adjusted assembly;
237
replace
steering
column
Common Malfunction Diagnosis Flow of Geely Automobile
Automatic steering wandering diagnosis flow chart
238
Common Malfunction Diagnosis Flow of Geely Automobile
No. 174 Front wheel tire abnormally worn Malfunction
Causes
Solution
(1) Tire pressure not conforming to requirements;
Inflate or discharge to the standard
(2) Tire not changed for long time;
Replace the tire
(3) Front wheel incorrectly positioned, especially Make four-wheel positioning toe-in and camber incorrectly matched
(4) Hub bearing loosening
Replace the bearing
(5) Steering inner, outer tie-rod or steering engine Replace ball head or fasten screws loosening; (6) Radial circle or end face circle of front wheel Balance the tire or replace tire with too large runout; (7) Rotating quality of front wheel imbalanced;
Balance the tire
(8) Front wheel yawing;
Fasten nuts of tie-rod ball head, replace the tire
(9) Longitudinal center line of front axle and frame not vertical, or wheelbase at two sides of frame Correct or adjust frame and wheelbase Tire increasingly unequal; worn, with unusual tread shape (10) Front axle or frame bent, deformed; Correct or adjust frame and wheelbase (11) Front axle with insufficient rigidity;
Replace front axle
(12) Steering tie-rod or ball joint with insufficient Replace steering tie-rod rigidity; (13) Front wheel unbracing, braking slowly back, Adjust braking or braking dragging; (14) Tire bolt loosening;
Fasten screws
(15) Overloading, uneven loading, startup too fast, turning or braking at high-speed with too strong Reduce loading or reduce braking rush; (16) Often drive on the road with larger camber;
Reduce driving on unfavorable road
(17) Turning angle unable to ensure pure rolling of Eliminate incorrect driving behaviors each wheel, with too much or insufficient steering; (18) Poor tire quality;
Choose high-quality tire
239
Common Malfunction Diagnosis Flow of Geely Automobile
Diagnosis flowchart of unusual abrasion of front wheel
240
Common Malfunction Diagnosis Flow of Geely Automobile
No. 175 Normally when driving straightly, but with abnormal sound while turning Malfunction
Causes
Solution
Wheel abraded with body parts while turning;
Normally when Outer cage of two front wheels without lubricating driving straightly, oil or damaged; but with abnormal sound while turning Pressure bearing lack of lubricating oil or damaged;
Check wheel is abraded with body parts while turning; if so, adjust and repair it; Check outer cage of two front wheels are with lubricating oil or damaged; Check pressure bearing is lack of lubricating oil or damaged; if so, lubricate or replace it;
Thrust bearing of slide column lack of lubricating Lubricate or replace thrust bearing of slide column; oil or with damaged ball; Normally when driving straightly, but with unusual noise while turning
Wheel abraded with body parts while turning
Abnormal
Adjust and repair
Normal Outer cage of two front wheels without lubricating oil or damaged
Abnormal
Fill up oil or replace
Normal Oil leaking Pressure bearing lack of lubricating oil or damaged
Lubricate replace
241
or
Common Malfunction Diagnosis Flow of Geely Automobile
No. 176 Braking wandering Malfunction
Causes
Solution
(1) Materials for friction disk of brake shoe of left, right wheels not the same or degree of new, old not the Replace brake disk and brake drum same;
(2) Closing area, position of friction disc of brake shoe and brake drum (disk) of left, right wheels not the same Adjust the clearance or braking clearance not the same;
(3) Technical conditions for left, right wheel cylinders not Replace left, right wheel cylinders the same, causing different action time or opening size;
(4) Pulling force of release spring of brake shoe of left, Replace release spring of brake shoe right wheels not the same; (5) Tire of left, right wheels with different pressure, While braking, wandering different diameter, different pattern, or different pattern Adjust tire, and charge the tire occurs to driving direction; depth; while emergency braking, swerving occurs. (6) Brake drum of left, right wheels with different thickness, diameter, extent deformation, and roughness Replace brake drums of left, right wheels of working surface;
(7) Brake pipe at single side collapsed, blocked or oil Clean brake oil pipe leaking; (8) Brake pipe at single side or wheel cylinder with air Replace brake oil resistance; (9) Brake shoe at single side and support pin closely Adjust clearance of brake shoe or remove matched or rusty; dust
(10) Frame, axle bent within horizontal plane, and wheelbase at two sides of frame unequal, or rigidity of Adjust frame, wheelbase or replace spring front plate spring unequal.
242
Common Malfunction Diagnosis Flow of Geely Automobile
243
Common Malfunction Diagnosis Flow of Geely Automobile
No. 177 Braking dragging Malfunction
Causes
Solution
(1) Brake pedal without free stroke;
Adjust free stroke of brake pedal
(2) Matching between brake pedal and other axles lack of Apply oil, remove dust, or solve other oil, rusty, or release spring of pedal falls out, snapped off, problems accordingly; or with too small pulling force, etc.;
(3) Release spring of master cylinder piston ruptured or Replace release spring of master cylinder with too small pretightening force; piston;
(4) Master cylinder piston, leather cup with too large length Replace master cylinder piston, leather cup or leather cup bloating, sticking;
(5) Compensation hole of master cylinder obstructed by Clean pollutants; pollutants; After releasing brake pedal, braking actions on individual or all wheels could not be fully released, thus affecting re-startup, accelerating driving or free running of vehicles.
(6) Leather cup of wheel cylinder bloating, sticking, or Replace wheel cylinder leather cup piston blocking;
(7) Release spring of brake shoe falling out, snapped off or Replace release spring of brake shoe; with too small pulling force;
(8) Brake shoe and support pin rusty;
Repair brake shoe and support pin;
(9) clearance between brake shoe and brake drum (disk) Adjust clearance between brake shoe and incorrectly adjusted; after releasing brake, local abrasion brake drum (disk); still exists; (10) Oil pipe through wheel cylinder collapsed or Clean oil pipe of wheel cylinder obstructed; (11) While not braking, center hole of auxiliary cylinder Repair center hole of auxiliary cylinder piston of supercharger could not be opened; piston of supercharger
(12) Brake hose distorted, deformed or partially obstructed Replace brake hose
(13) Hub bearing loosening;
Fasten hub bearing
244
Common Malfunction Diagnosis Flow of Geely Automobile
245
Common Malfunction Diagnosis Flow of Geely Automobile
No. 178 Braking with abnormal sound Malfunction
Causes
Solution
Fixed screws for suspension connection of Check fixed screws for suspension connection of brake brake system loosening or damaged; system are loosening or damaged; if so, fasten or replace;
Fixed bolt of front brake tongs loosening or with Fasten or replace front brake tongs assembly; worn lining;
Braking with abnormal sound while vehicle is driving normally
Vacuum booster internally damaged;
Check vacuum booster is internally damaged; if so, replace it;
Brake disk severely worn;
Check brake disk is severely worn; if so, replace it;
Material of brake disk too hard;
Check material of brake disk is too hard; if so, grind or replace it;
Brake hub or disk severely worn with groove;
Replace brake hub or disk;
Rubber cover of front and rear suspensions Replace rubber cover of front and rear suspensions; loosening, aging;
246
Common Malfunction Diagnosis Flow of Geely Automobile Braking unusual noise
with
Unusual Material of brake disk too hard
Grind or replace
Normal Abnormal Vacuum booster internally damaged
Replace
Normal Abrasion Brake disk severely worn
Replace
Normal Abnormal Fixed bolt of front brake tongs loosening or with worn lining
Grind or replace
Normal Abnormal Brake hub or disk severely worn with groove
Grind or replace
Normal Abnormal Rubber cover of front and suspensions loosening, aging
rear
Replace
Normal Abnormal Check fixed screws for suspension connection of brake system are loosening or damaged;
247
Fasten or replace
Common Malfunction Diagnosis Flow of Geely Automobile
No. 179 Braking sideslipping, swerving Malfunction
Causes
Solution
Tire worn smoothly
Check tire is worn smoothly; if so, replace it;
Tire of the same axle not consistent
Check tire of the same axle is consistent; if not, adjust it;
Tire pressure too low or too high
Check tire pressure is too low or too high; if so, adjust to specified pressure;
While braking, vehicle slips to one Brake shoe, brake disk with oil sludge; Check brake shoe, brake disk are with oil sludge; if so, clean it; side or swerves Air in the pipeline;
Check air is in the pipeline; if so, empty it;
Pressure dividing valve incorrectly Check pressure dividing valve is incorrectly adjusted; if so, readjust adjusted it; Rubber cover of chassis suspension Check rubber cover of chassis suspension is loosening; if loosening necessary, replace rubber cover;
248
Common Malfunction Diagnosis Flow of Geely Automobile Braking sideslipping, swerving
Replace Check tire is worn smoothly
Abnormal
Normal Check tire of the same axle is consistent
Abnormal
Adjust or replace
Normal Abnormal
Check tire pressure is too low or too high
Adjust
Normal Abnormal
Clean
Check brake shoe, brake disk are with oil sludge
Normal Check air is in the pipeline
Abnormal
Empty the air
No. 180 Braking intermittently stiffening Malfunction
Causes
Solution
Vacuum tube of vacuum booster with cracks, or air Check vacuum tube of vacuum booster is with cracks, leakage or air leakage; if so, replace it;
Check non-return valve of booster is obstructed or When stepping on Non-return valve of booster obstructed or blocked blocked; if so, clean or replace it; brake pedal, sometimes normal, sometimes Vacuum booster damaged Check vacuum booster is damaged; if so, replace it; stiffening Machinery parts of brake pump blocked
Check machinery parts of brake pump are blocked; if so, repair;
Brake pipe obstructed
Check brake pipe is obstructed; if so, unclog it.
249
Common Malfunction Diagnosis Flow of Geely Automobile Braking intermittently stiffening
Abnormal
Check vacuum tube of vacuum booster is with cracks, or air leakage
Replace
Normal Abnormal Check non-return valve of booster is obstructed or blocked
Clean or replace
Normal Abnormal Check vacuum booster is damaged
Replace
Normal Abnormal Check machinery parts of brake pump are blocked
Repair
Normal Check brake pipe is obstructed
Abnormal Unclog the pipe
250
Common Malfunction Diagnosis Flow of Geely Automobile
No. 181 Braking ineffective Malfunction
Causes
Solution
(1) Master cylinder, wheel cylinder, pipe or pipe Eliminate oil leaking or fasten joint screws joint with oil leakage; (2) Master cylinder liquid chamber (tank) with Add brake liquid insufficient oil or without oil; (3) Brake liquid deteriorates (thinning down or thickening) or fouling within inner pipe wall too Replace brake liquid or clean brake pipe thick; (4) Air inside the brake liquid;
Empty the air
(5) Master cylinder leather cup, piston or cylinder Replace leather cup piston or replace brake master severely worn; cylinder (6) Wheel cylinder leather cup, piston or cylinder Replace brake wheel cylinder severely worn; (7) Oil inlet, compensation hole of master cylinder Clear obstructed substances or vent hole of liquid chamber (tank) obstructed; While braking, the driver feels deceleration insufficient; while emergency braking, braking distance too long.
(8) Delivery valve, spill valve of master cylinder or pretightening force of piston release spring too Replace master cylinder small; (9) Through hole at front end of master cylinder Replace master cylinder piston obstructed or leather cup sticking, bloating; (10) Leather cup of wheel cylinder sticking, Replace wheel cylinder bloating; (11) Supercharger or booster with poor efficiency Replace supercharger or ineffective; (12) Oil pipe collapsed or hole inside the hose Unclog the pipe obstructed; (13) Brake pedal with too large free stroke;
Adjust free stroke
(14) Friction disk of brake shoe and brake drum (disk) not favorably closed or brake clearance Replace brake disk and brake drum or adjust clearance incorrectly adjusted; (15) Friction disk of brake shoe with poor quality, or hardened surface, scorching, oil sludge or Replace friction disk of brake shoe exposed rivet head during uses, (16) Brake drum severely worn or deformed while Replace friction disk and brake drum braking;
251
Common Malfunction Diagnosis Flow of Geely Automobile
Diagnosis flowchart of ineffective braking
252
Common Malfunction Diagnosis Flow of Geely Automobile
No. 182 Brake fails Malfunction
Causes
Solution
(1) Severely insufficient brake liquid or without Add brake liquid brake liquid; When stepping (2) Leather cup of master cylinder severely Replace leather cup of master cylinder or eliminate oil on brake pedal, ruptured or severe leakage of brake system; leakage the vehicle is not decelerating; even with Replace brake hose or metal pipe; stepping on (3) Brake hose or metal pipe ruptured; continuously, not obviously decelerating. (4) Connection between brake pedal and master Repair brake pedal; cylinder falls off.
253
Common Malfunction Diagnosis Flow of Geely Automobile
254
Common Malfunction Diagnosis Flow of Geely Automobile
No. 183 Steering wheel with too large free stroke Malfunction
Causes
Solution
(1) Drive, driven meshing part of steering gear Adjust drive, driven meshing part of steering gear or loosening or bearing of drive, driven parts bearing clearance of drive, driven parts; loosening;
(2) Connecting parts of steering gear and steering Adjust clearance of connecting parts of steering gear shaft loosening; and steering shaft; When the vehicle keeps driving (3) Ball joint of steering gear loosening; straightly, shaking steering gear to and fro slightly, it (4) Connecting part of tie-rod ball head loosening feels play angle very large.
Replace ball joint of steering gear;
Fasten or replace tie-rod ball head;
(5) Ball head of lower swing arm loosening
Fasten or replace ball head of lower swing arm assembly;
(6) Steering thrust bearing loosening
Replace steering thrust bearing;
(7) Hub bearing loosening
Adjust clearance of hub bearing;
255
Common Malfunction Diagnosis Flow of Geely Automobile
256
Common Malfunction Diagnosis Flow of Geely Automobile
No. 184 Buzzing noise at rear wheel while driving at high speed Malfunction
Causes
Solution Check bearings of two rear wheels are worn, damaged; if so, replace;
Bearings of two rear wheels worn, damaged Buzzing noise at rear wheel while driving at high Positioning misadjustment of rear wheel speed
Check positioning of rear wheel is misadjusted; if so, make positioning adjustment; Check pressure of two rear wheels is normal; if abnormal, adjust it to standard value;
Pressure of two rear wheels normal
Buzzing noise at rear wheel while driving at high speed
Abnormal
Bearings of two rear wheels worn, damaged
Replace
Normal Positioning misadjustment of rear wheel
Abnormal
Positioning adjustment
Normal Pressure of two rear wheels normal
Abnormal
257
Adjust
Common Malfunction Diagnosis Flow of Geely Automobile
No. 185 Braking force of brake master cylinder insufficient Malfunction
Causes
Solution
Gas within brake pipe
Check if the air exists; empty the air at exhaust hole of wheel cylinder;
Brake pipe with leakage
Check if leakage occurs, usually at connections; properly increase torque.
Brake pedal with too long stroke; when stepping on Brake master cylinder valve with poor sealing the pedal, no obvious braking effect, with braking distance larger Main leather ring of brake master cylinder worn than standard
After long-time uses and abrasion with cylinder body, main leather ring of brake master cylinder is worn; thus replace main leather cup; Due to long-time uses and sanitation within the vehicle, brake master cylinder body is filled with hard substances such as sandstone. During working, inner wall of cylinder body is ragged, causing poor sealing with leather ring, and internal leakage; replace brake master cylinder.
Brake master cylinder body ragged
Braking insufficient
After uses for a certain time, due to increase of foreign substances within brake liquid and abrasion of valve, sealing of valve becomes poor; thus replace the valve.
force
Leakage
Pipe with leakage
Eliminate leakage
No Brake master cylinder valve with poor sealing
Poor sealing
Replace valve
Poor Main leather ring of brake master cylinder worn
Worn
Replace main leather ring
No Main leather ring of brake master cylinder worn
Worn
Replace main leather ring
No Inner wall of brake master cylinder body ragged
Ragged
Replace brake master cylinder
258
Common Malfunction Diagnosis Flow of Geely Automobile
No. 186 Stepping on pedal too heavily Malfunction
Causes
Solution As near to the engine, rubber hose is increasingly aged due to its high temperature, easily causing cracks, leaking vacuum, and reducing degree of vacuum of vacuum booster, making function of booster ineffective.
(1) Vacuum connecting hose leaking;
Stepping on pedal (2) Non-return valve of booster ineffective; too heavily, with ineffective or semi-ineffective booster function
As non-return valve of booster is the valve from the engine to booster, if non-return valve is ineffective, then vacuum chamber of the booster is equal to vacuum source pressure, when the engine is with low revolution, degree of vacuum will be insufficient, and causing booster semi-effective.
Connection between booster and brake master cylinder is one important sealing point of booster, as O-ring (3) Leakage at connection of brake master sealing. After uses for long time, O-ring is aging, with cylinder reducing sealing performance, causing function of booster ineffective. As the booster has generally rubber sealing parts inside, leakage will easily occur, causing function of booster ineffective.
(4) Leakage of booster assembly;
Stepping on pedal too heavily
Leaking
Eliminate leakage
Vacuum connecting hose leaking
No Non-return ineffective
valve
of
booster
Ineffective
Replace valve
non-return
No Leakage at connection of brake master cylinder
Air leakage
Replace O ring
No Leakage assembly
of
booster
Air leakage Replace booster
259
Common Malfunction Diagnosis Flow of Geely Automobile
No. 187 Common malfunction diagnosis and Solution for Geely automobile tire Serial No.
Malfunction
symptom
Causes
Prevention
1
1. After the tire crown is damaged by sharp articles, the steel wire is rusty and snapped off, with reduced Drive on favorable Tire tread torn, blown strength. road or drive at low Bar blows up up And under impact of outside force, it is blown up; also speed blown up under strong impact during driving at high speed.
2
Steel wire of bracing Tire tread ply of tire tread rusty, Steel wire of bracing ply damaged by sharp articles on Avoid sharp articles deformed and tire casing the road, causing rusty and deformed tire casing. deformed.
3
Bar cracked
Tire sidewall bulges out under charging Cord thread broken as tire is under strong impact of road Avoid barriers or status, and barriers, etc. causing low power at this point, and the drive at low speed corresponding inner surface is bulging out. cord thread broken.
4
Tire is cut through Cut through Tire stabbed by sharp articles on the road; repairs from outside, and Avoid sharp articles (repair) needed. with repair marks
5
Pattern bruising
6
Tire crown rubber as in soybean curd Spongy residue type, and surface of rubber is squeezed the pattern with broken stone inside
7
Racially cracked, Tire sidewall cord thread broken, stabbed or or even blown up if Tire stabbed (cut through) by sharp articles. severe with bruising cut through marks.
8
Rubber chapped
10
Rubber between tire Driving under lower pressure, excess flections caused by Tire bead bead and sidewall frequent steering, braking with a rush, it causes cracks cracked, and cord cracked with fatigue. thread broken.
Drive on favorable Tire crown rubber Tire stabbed by sharp articles on the road, and rubbing road or drive at low and casing torn, and with the road surface if continue driving. speed fallen out
Tire is running under low temperature in winter. As temperature is too low, rubber’s performance is reduced, Replace winter tire and also squeezed with broken stone on the road, causing cracks of rubber.
Drive on favorable road and avoid sharp articles
With being placed for long time under charging status, Avoid direct sun Rubber surface with ultraviolet radiation, erosion by ozone and heat, rubber shining, ozone, turtleback cracks. surface of the tire is cracked, but tire structure is not heat source damaged, which could be used later.
260
Keep standard pressure inside the tire, and have good driving habits
Common Malfunction Diagnosis Flow of Geely Automobile
11
Tire fabric and tire Tire bead bead slip off; if Incorrect assembling: severe, steel wire assembling. prized up could be seen.
12
Tire bead’s steel wire cracked, blown up
13
Tire casing deformed, tire cavity with high Worn and temperature damaged scorching, and tire sidewall circumferentially
Steel wire cracked in order, and those at cracks having its radius reduced.
damage
tire
bead
Apply lubricating oil during while assembling, and avoid barbaric behaviors
Use improper hub or tire seat. Rim is not effectively lubricated. When assembling, tire bead is not fully closed with rim. To complete assembling, charge too high pressure, causing high shear force locally at tire bead, making its steel wire broken in order, and tearing the tire sidewall, even causing severe accidents.
Lubricate effectively, and avoid charging too high pressure and forced assembly
While driving under insufficient pressure or pressure loss, causing contact surface of the tire too large, and Keep unusual heating, and also causing reduced tire pressure performance and rolling, till blown up; if severe, accidents may occur.
normal
With obvious rolling traces and scorification of cord thread; if severe, cord thread and tire casing rolled and cracked.
14
Pattern of one side of Unusual tire crown is abrasion circumferentially (one side at worn too quickly than shoulder) other parts
15
Unusual abrasion (local)
Local pattern of tire crown is When emergency braking or braking locking, tire is Avoid emergency circumferentially instantly abraded with road surface locally, causing local braking worn more quickly abrasion too quick. than other parts
16
Unusual abrasion
Check mechanical Local pattern of tire system of the Caused by driving habit of mechanical system (caster crown is worn as in vehicle, and avoid angle too large, hub eccentric) lumpy rapid steering, braking, startup
17
Pattern at two sides Unusual of tire crown is abrasion circumferentially Driving under relatively low pressure (two sides at worn too quickly than shoulder) other parts
A. Toe-in too large or positive camber angle too large, and tire shoulder of outer side is worn. B. Toe-in too large Correct toe-in or negative camber angle too large, and tire shoulder of camber angle inner side is worn.
261
or
Check pressure and use standard pressure
Common Malfunction Diagnosis Flow of Geely Automobile
No. 188 Causes analysis for common manufacturing defects of Geely automobile tire Serial No.
Malfunctions
Malfunction
Causes
1. Steel wire of bracing ply not well bound with tire casing; ply separation may occur. 2. While driving at high-speed for long time ply Tire casing not stabbed, but cord thread loosens with with low pressure, frictional force between tire casing. tire and road surface increases, and tire crown unusually heats up, causing reduced adhesive force among parts, and ply separation may occur.
1
Bracing separates
2
Joint slips off
3
Tire sidewall Side bulged out; foreign substances inside while Other substances loosening dissecting. manufacturing
4
Inner loosening
Surface layer between tire sidewall rubber and Tire rubber and sidewall not well bound rubber cracked during manufacturing.
Cord plies bulged out, loosened with tire casing.
262
mixed
during
1. Inner lining or cord plies and tire casing ply not well bound during manufacturing. 2. While driving at high-speed for long time with low pressure, frictional force between tire and road surface increases, and tire crown unusually heats up, causing reduced adhesive force among parts, and ply separation may occur.
Common Malfunction Diagnosis Flow of Geely Automobile
Electrics No. 189 CD-player disk boot malfunction (without MP3) Malfunction
CD-player disk Boot malfunction
Cause
Solution
Power source malfunction
Inspect +B and GND, which normal value shall be 10V to 14V. When ACC and GND ignition switch locating at ACC or ON, the voltage shall be 10V to 14V. If it indicates no powers supply, then check whether the fuse is burnt or not, and replace it if necessary. In common condition, GND and vehicle earth lead shall be conducted.
CD inserted in wrong direction
Check if the disk is inserted in wrong direction, and correct it if necessary.
Wrong CD format or too dirty disk
Firstly inspect the disk format, and change disk if necessary. Then check whether it contains dirt or scratch mark and replace it if necessary.
CD not reset yet
Press RESET button to reset CD-player
Shock proof removed
screw
not
The laser head of CD-player is too dirty or aged and too high resistance
Internal CD-player malfunction
circuit
Remove the shock proof screw on housing The laser head is too dusty and dirty, which affect reading ability of the lens. And it needs to be cleaned. Clean method: clean with special disk. Laser head ageing, this results low laser power. That is, the beam from laser head can not focus correctly, which causes reading ability reduction or losing. Replace CD-player assembly. Replace CD-player assembly.
263
Common Malfunction Diagnosis Flow of Geely Automobile CD-player disk boot failure (without MP3)
Normal Using non-CD disk
Abnormal
Please use CD disk, rather than VCD, DVD or PC disk etc.
Normal Dust on CD laser head
Abnormal
Clean laser head
Abnormal
Clean disk
Normal Dirt on disk
Normal Power source malfunction
Abnormal
Inspect +B and GND, which normal value shall be 10V to 14V. When ACC and GND ignition switch locating at ACC or ON, the voltage shall be 10V to 14V. Inspect and replace the fuse.
Normal Abnormal CD-player not reset
Press RESET button to reset CD-player
Normal CD inserts in wrong direction
Abnormal Correct the disk direction
Normal Disk contains scrapes or deformation abnormal
Abnormal Replace disk
Normal Shockproof screw not removed
Not removed Remove the shockproof screw on housing
Normal Abnormal Internal CD-player malfunction
Replace CD-player assembly
264
Common Malfunction Diagnosis Flow of Geely Automobile
No. 190 CD-player fails to work when activating Malfunction
CD-player fails to work when activating
Cause
Solution
Power source circuit malfunction or fuse damaged;
Inspect +B and GND, which normal value shall be 10V to 14V. When ACC and GND ignition switch locating at ACC or ON, the voltage shall be 10V to 14V. In common condition, GND and vehicle earth lead shall be conducted. If it indicates no powers supply, then check whether the fuse is burnt or not, and replace it if necessary.
CD-player power switch malfunction or damage
① Check the power switch on CD panel; operate the power switch by hand, if there is no response then replace the CD-player
Internal CD-player power source circuit malfunction
④ Check the voltage of internal CD-player power source end, if the value is between 10~14V as normal, then replace the CD-player assembly
CD-player fails to work when activating
Abnormal
External CD-player power source
Inspect the circuit and replace the fuse
Normal Abnormal
CD-player switch
Replace CD assembly
Normal
Internal CD-player power source circuit
Abnormal
Replace CD assembly
No. 191 CD-player keeps soundless under all modes Malfunction
Cause
Solution
① CD-player power source malfunction
Inspect +B and GND, which normal value shall be 10V to 14V. When ACC and GND ignition switch locating at ACC or ON, the voltage shall be 10V to 14V. If it indicates no powers supply, then shall confirm whether the fuse is burnt or not, and replace it if necessary.
② Loudspeaker malfunction
Check whether the appearance of loudspeaker is damaged, as well as the coil whether it is burnt. Method: Measure the resistance by multimeter setting at ohms range, and the value shall be 4 Ohm, if it indicates to infinite, then the loudspeaker is burnt and need to be replaced.
③ Wires and connector
Check loudspeaker and CD-player connection whether there is open/short circuit. Measure two ends of same colour respectively by multimeter setting to Ohms range, and the value shall be 0 which means conducted. Check CD-player rear plug whether it is loose, and the power source voltage whether it is normal. In generally condition, GND and body earthlead shall be conducted.
④ CD-player sound controller damaged
Check whether CD-player sound controller is damaged, and track adjustment whether it is correct, as well as sound adjusting variable voltage regulator whether it is badly worn. Replace CD-player assembly.
CD-player keeps soundless under all modes
265
Common Malfunction Diagnosis Flow of Geely Automobile CD-player keeps soundless under all modes
Check LCD screen illumination
Abnormal Check wires, connector and power source voltage.
Normal Abnormal
CD –player power source malfunction
Check and replace the fuse
Normal Abnormal
Check loudspeaker
Replace loudspeaker
Normal Abnormal
Check CD-player sound adjusting button
Replace CD-player assembly
Normal
Internal CD-player circuit
Abnormal
Replace CD-player assembly
266
Replace CD-player assembly
Common Malfunction Diagnosis Flow of Geely Automobile
No. 192 CD-player/radio gains no power Malfunction
Cause
CD-player gains no power when pressing POWER button, after the ignition switch opened,
Solution
①Vehicle ignition switch closed
①Turn ignition device to ON or ACC position
②Fuse burnt
②Replace fuse of same specification
③Power source output line loose
③Replace it with new connector of same specification if abnormal
④Dirt in connector conducting point.
④Clean the conducting point with special cleaning solution or replace it with a new one.
⑤Connector wire (open circuit)
⑤Check loudspeaker output line with multimeter whether it is disconnected, replace it with new connector of same specification if necessary
⑥Poor fuse sometimes)
core
contact
disconnected
(open
circuit
⑥Connect vehicle battery earthlead and speaker housing by lead wire, if CD-player regains normal operation, which indicates the earth lead open circuit, then replace it with new connector of same specification.
⑦Connector earth lead open circuit
⑦Replace it specification
with new connector of same
⑧Internal CD-player/radio short circuit
⑧Replace CD-player/radio assembly
CD-player/radio gains no power Abnormal
Turn to ON or ACC position
Vehicle ignition switch closed Normal Fuse burnt
Abnormal Replace with fuse of same specification
Normal
Abnormal
Power source output line loose Normal
Replace with fuse of same specification Abnormal
Clean or replace connector with same specification
Dirt in connector conducting point Normal Connector wire core disconnected (open circuit) Normal Poor fuse contact (open circuit sometimes) Normal
Abnormal
Replace connector with same specification
Abnormal Replace connector with same specification
Abnormal
Replace connector with same specification
Connector earth lead open circuit Normal
Short circuit
Internal CD-player/radio short circuit
Replace CD-player/radio assembly
267
Common Malfunction Diagnosis Flow of Geely Automobile
No. 193 A loudspeaker of CD-player/radio is soundless Malfunction
A loudspeaker is soundless when CD/FM operating
Cause
Solution
Panel function setting inaptitude
In SEL menu, on panel, BAL and FDA shall be set to 0
Loudspeaker damaged
Replace loudspeaker of same specification. (Note: Firstly, connect the output line of front right loudspeaker to the other one, and check the sound output, which can indicate whether the loudspeaker is broken.)
Loudspeaker output line wrong connected
Check output line connection whether it is correct. (Please refer to the connecting method shows on nameplate.)
Connector conducting point and output line connection containing dirt or oxide.
Clean the connector with special cleaning solution or replace it with a new one of same specification.
Connector wire core disconnected (open circuit)
Measure loudspeaker output line by multimeter, whether it is disconnected. And replace it with a new one of same specification when necessary.
Internal CD-player/radio loudspeaker output disconnected
Replace CD-player/radio assembly
A loudspeaker of CD-player/radio is soundless
Loudspeaker output line wrong connected Normal
Abnormal
Abnormal
Panel function setting inaptitude
Normal
Abnormal
Loudspeaker damaged
Please refer to the connecting method shows on nameplate
In SEL menu, on panel, BAL and FDA shall be set to 0
Replace a new loudspeaker of same specification
Normal Loudspeaker outputline connection oxide
Abnormal
Clear the oxide or replace with new outputline of same specification
Normal Dirts on connector conducting point Normal
Abnormal
Abnormal
Connector wire core disconnected (open ciercuit) Normal Internal CD-player/radio loudspeaker output
Clean the connector or replace it with a new one of same specification
Replace with new connector of same specification
Disconnected Replace CD-player/radio assembly
268
Common Malfunction Diagnosis Flow of Geely Automobile
No. 194 Onboard hand-free phone has no sound output (MK) Malfunction
No sound output when using onboard hand-free phone
Cause
Solution
①Low sound volume set
①Set it louder
②Unmatch cell phone type or interface
②Replace it with cell phone or interface matching with the vehicle
③Phone mute outputline switch or external controlling circuit damaged
③Remove phone mute outputline to inspect the damaged part, internal or external controlling circuit
④Dirt on connector conducting point
④Clean conducting point by special cleaning solution or replace with new connector of same specification.
⑤Connector wire core disconnected (open circuit)
⑤Measure loudspeaker outputline by multimeter, to check whether it is disconnected. Replace with new connector of same specification.
⑥Short circuit between phone mute outputline and earthlead
⑥Measure the connection between phone mute outputline and earthlead by multimeter, to check whether there is short circuit. (Remove phone mute outputline to inspect the damaged part, internal or external controlling circuit)
⑦Internal CD-player malfunction
⑦Replace CD-player assembly
⑧Onboard hand-free phone controller malfunction
⑧Replace onboard hand-free phone controller
269
Common Malfunction Diagnosis Flow of Geely Automobile No sound output when using onboard hand-free phone
Abnormal
Set it louder
Low sound volume set Normal Phone mute outputline switch or external controlling circuit damaged
Abnormal
Replace switch or external controlling circuit
Normal Dirts on connector conducting point
Abnormal
Clean or replace with new connector of same specification
Normal Cell phone or interface unmatch Normal Short circuit between phone mute outputline and earthlead
Abnormal
Replace with cell phone matching with vehicle
Abnormal
Check phone mute outputline external controlling circuit whether it is short circuit.normal
Normal Controller wire core disconnected (open circuit) Normal
Abnormal
Replace with new connector of same specification
Normal
Internal CD-player failure
Abnormal
Replace CD-player assembly
Normal Onboard hand-free phone controller failure
Abnormal
Replace onboard hand-free phone controller
270
Common Malfunction Diagnosis Flow of Geely Automobile
No. 195 CD-player/radio button out of control Malfunction
Cause
CD-player/radio button out of control
Solution
①Button stuck
Rock around of the button until it senses normal
②Improper operation
Press RST button by sticker to reset the player, then it will be recovered.
③CD-player/radio inner malfunction
Replace CD-player/radio assembly
CD-player/radio button out of control
Rock around of the button until it senses normal
Button stuck
Abnormal
Normal Abnormal
Improper operation
Normal
Press RST button by sticker to reset the player, then it will be recovered
Abnormal
Replace CD-player/radio assembly
CD-player/radio inner malfunction
No. 196 CD-player/radio button indicator malfunction Malfunction
Cause
Solution
①Fuse disconnected
①Replace fuses
②Lamp controlling line loose
②Fix the wire
③ Lamp controlling switch fails or not locates at ON position.
③Directly connect the lamp controlling outputline to positive pole of vehicle battery, for inspecting the switch. If the lamp lightened then the switch damaged. The switch shall turn to ON position.
CD-player/radio button indicator malfunction ④Lamp controlling wire core disconnected (open circuit)
⑤Check dirt on connector conducting point, and clean it if necessary.
⑤Dirt on connector conducting point ⑥CD-player/radio connected
inner
circuit
271
④Measure lamp controlling outputline with multimeter, to check whether it is disconnected. If there is open circuit, replace connector of same specification.
short
⑥Replace CD-player/radio assembly
Common Malfunction Diagnosis Flow of Geely Automobile CD-player/radio button lamp malfunction
Abnormal
Fuse disconnected
Replace fuse
Normal
Abnormal
Lamp controlling line loose
Fix lamp controlling line
Normal
Abnormal
Lamp controlling switch fails or not locates at ON position.
Replace switch with same specification or turn lamp controlling switch to ON position.
Normal Abnormal
Lamp controlling wire core disconnected (open circuit)
Replace connector with same specification
Normal Dirts on connector conducting point
Abnormal Clean or replace with new connector of same specification
Normal Abnormal CD-player/radio inner circuit short/open circuit
Replace CD-player/radio assembly
272
Common Malfunction Diagnosis Flow of Geely Automobile
No.197 CD-player/radio memory function malfunction Malfunction
Cause
Solution
①Power outputline B+ (memory line) and ①Check power source outputline B+ (memory ACC (ignition line) wrong connected to line) and ACC (ignition line), whether they are each other wrong connected, and correct it when necessary. ②Check power source output line B+ (memory CD-player/radio memory ②Power outputline B+ (memory line) line) whether it is connected on ACC (ignition function malfunction line), and correct it when necessary. (Note: please connected on ACC (ignition line ) connect according the method showing on nameplate) ③CD-player/radio inner memory circuit Replace CD-player/radio assembly. ` short or open CD-player/radio memory function failure
Abnormal
Power outputline B+ (memory line) and ACC (ignition line) wrong connected to each other
Correct B+ (memory line) and ACC (ignition line)
Normal Power outputline B+ (memory line) connected on ACC (ignition line )
Normal
Abnormal Connect B+ (memory line) back to memory power end
Abnormal
Replace CD-player/radio assembly
CD-player/radio inner memory short or open circuit
No. 198 CD-player/radio no signal Malfunction
CD-player/radio no signal
Cause
Solution
①Antenna cable disconnected
①Check antenna cable whether it is disconnected
②Dirt on antenna cable conducting point
②Clean conducting point with special cleaning solution
③Antenna cable deformed and results poor ③Replace with new antenna assembly of same conduct specification ④CD-player/radio inner short circuit, open circuit
antenna
273
cable
④Replace CD-player/radio assembly
Common Malfunction Diagnosis Flow of Geely Automobile CD-player/radio no signal
Antenna cable disconnected
Abnormal
Check antenna cable whether it is disconnected
Abnormal
Clean conducting point with special cleaning solution
Normal Dirts on antenna cable conducting point Normal
Antenna cable deformed and results poor contact
Abnormal
Replace antenna assembly with same specification
Abnormal
Replace CD-player/radio assembly
Normal CD-player/radio inner antenna cable short circuit
No.199 CD-player/radio sound distortion at large volume Malfunction
Cause
Solution
Loudspeaker retaining screw loose
Check loudspeaker retaining screws whether they are loose, and tighten them when necessary.
Loudspeaker diaphragm deglue
Check loudspeaker diaphragm whether it is deglue, and repair or replace loudspeaker when necessary.
CD-player/radio sound distortion at large volume Loudspeaker damage or disable to sustain Replace loudspeaker or turn down the volume high power A loudspeaker rectifier burnt
Replace damaged loudspeaker
CD-player/radio inner short or open circuit
Replace CD-player/radio assembly；
CD-player/radio sound distortion at large volume
Abnormal Loudspeaker retaining screw loose
Tighten the screws
Normal Abnormal Loudspeaker damaged or disable to sustain high power
Replace loudspeaker or turn down the volume
Abnormal CD-player/radio inner short or open circuit
274
Replace CD-player/radio assembly
Common Malfunction Diagnosis Flow of Geely Automobile
No. 200 CD-player/radio tuner can’t stop Malfunction
Cause
Solution
①Antenna cable disconnected
①Check antenna cable whether it is disconnected
②Dirt on antenna cable conducting point
②Clean conducting point with special cleaning solution. (Note: May clean with soft cloth, but neve use solvents such as benzene or alcohol )
CD-player/radio tuner can’t stop
③Antenna cable deformed and results poor ③Replace antenna assembly of same specification conduct ④CD-player/radio inner antenna cable short ④Replace CD-player/radio assembly。 or open circuit CD-player/radio tuner can’t stop
Antenna cable disconnected
Abnormal
Connect antenna cable
Normal
Dirts on antenna cable conducting point
Abnormal
Clean or replace antenna cable with same specification
Normal Replace new atenna cable of same specification
Antenna cable deformed and results poor
Abnormal
conduct
Normal CD-player/radio inner antenna cable short or open circuit
Abnormal
275
Replace CD-player/radio assembly
Common Malfunction Diagnosis Flow of Geely Automobile
No. 201 CD-player/radio has noise when receiving signal Malfunction
Cause
Solution
Check antenna cable earth lead whether it is loose, replace i Antenna cable earth lead loose or of same specification or clean earth lead conducting point with poor contact special clean solution if necessary.
Poor local radio signal
CD-player/radio has noise when receiving signal
Change channel and test
Antenna cable earth lead deformed Replace with new antenna cable of same specification and results poor conduct
Antenna retaining screw loose
Check antenna cable retainig screws whether they are loose, and tighten them if necessary.
Loudspeaker malfunction
Check loudspeaker, circuit and connector, and remove the malfunctions according to different appearances.
CD-player/radio inner malfunction
Replace CD-player/radio assembly
CD-player/radio has noise when receiving signal
Abnormal Replace antenna cable with same specification
Antenna cable earth lead loose or poor contact abnormal
Normal Poor local radio signal
Abnormal Change channel and test
Normal Abnormal Loudspeaker malfuction
Check and maintain loudspeaker and circuit
Normal Abnormal
Tighten the screws
Antenna retaining screw loose Normal CD-player/radio inner malfunction
Abnormal
Replace CD-player/radio assembly
276
Common Malfunction Diagnosis Flow of Geely Automobile
No. 202 CD-player fails to insert disk Malfunction
Cause
Solution
①Another disk in CD-player
①Press popup button and insert another disk
②Two disk inserted
②It can insert one disk only.
③Disk coating is too thin
③Disk coating is too thin (transparent) to catch infrared signal. The photod on CD core is over conducted and results CPU out of control.
④Disk coating scuffed seriously
④If disk coating scuffed seriously where aligning to photod, then fault ③ will appear, that is, CPU out of control
⑤Function improper operated
⑤Don’t press two buttons at same time when operating the panel, which may result CPU out of control sometimes. When it appears, press RST button by sticker to reset CD-player and remove the malfunction.
CD-player fails to insert disk
⑥Don‘t operate CD-player when CD hatch exposures ⑥Sun or glare projectivity causes CD under sun or glare projectivity. Replace CD-player hatch deformation assembly.
⑦Disk broken
⑦Broken disk can not be applied, please replace disk.
⑧Shockproof screw not removed
⑧Remove the shockproof screw on housing.
⑨CD -player inner circuit malfunction
⑨Replace CD-player assembly
277
Common Malfunction Diagnosis Flow of Geely Automobile CD-player fails to insert disk
Another disk remains in CD-player
Abnormal
Press popup button and insert another disk
Normal Two disks inserted
Abnormal
It can insert one disk only
Normal Disk coating is too thin
Abnormal
Replace disk
Normal Disk coating scuffed seriously
Abnormal
Replace disk
Normal Function improper operated
Abnormal
Press RST button by sticker to reset CD-player and remove the failure.
Normal Sun or glare projectivity causes CD hatch deformation
Abnormal
Don‘t operate CD-player when CD hatch exposures under sun or glare projectivity. Replace CD-player assembly.
Normal Disk broken
Abnormal
Replace disk
Normal Shockproof screw not removed
Abnormal
Remove the shockproof screw on housing
Normal CD -player inner circuit failure
Abnormal
Replace CD-player assembly
278
Common Malfunction Diagnosis Flow of Geely Automobile
No. 203 CD-player fails to popup disk Malfunction
Cause
CD-player fails to popup disk
Solution
Disk with improper type
Replace with CD-player
disk
of
proper
type,
matching
Disk coating scuffed seriously
If disk coating scuffed seriously where aligning to photod, then CPU will be out of control. Replace disk.
Function improper operated
When CPU is out of control, press RST button by sticker to reset CD-player and press popup button for a while.
Sun or glare projectivity shines on CD hatch Don‘t operate CD-player when CD hatch exposures directly under sun or glare projectivity.
Disk broken
Broken disk can not be applied, please replace disk
CD –player inner circuit malfunction
Replace CD-player assembly
CD-player fails to popup disk
Disk with improper type
Abnormal
Replace with disk of proper type, matching CD-player
Abnormal
Press RST button by sticker to reset CD-player and press popup button for a while.
Abnormal
Don‘t operate CD-player when CD hatch exposures under sun or glare projectivity.
Abnormal
Replace disk
Normal Function improper operated
Normal Sun or glare projectivity shines on CD hatch directly
Normal Disk broken or disk coating scuffed seriously
Normal CD –player inner circuit malfunction
Abnormal
Replace CD-player assembly
279
Common Malfunction Diagnosis Flow of Geely Automobile
No. 204 CD-player with poor vibration resistance performance Malfunction
Cause
Solution
①CD –player vibration resistance switch ①Press SEL button over 3 sec, until menu popup and improper set select ESP 12/45, 45s is better. CD-player with poor vibration resistance performance, and fails to work on rough road
②Mounting bracket screws loose
②Ensure each fix position is mounted according to dimension drawings, and tightened the retaining screws.
③CD –player inner poor welded
③Replace CD-player assembly。
CD-player with poor vibration resistance performance
CD –player vibration resistance switch improper set
Abnormal
Press SEL button over 3 sec, until menu popup and select ESP 12/45, 45s is better.
Abnormal
Tighten retaining screws, as well as CD-player
Normal Mounting bracket screws loose
normal CD –player inner poor welded
Abnormal
Replace CD-player assembly
280
Common Malfunction Diagnosis Flow of Geely Automobile
No. 205 USB interface of CD –player malfunction (U-disk) (MK) Malfunction
USB interface of CD –player malfunction (U-disk)
Cause
Solution
①No music stores in U-disk
①Copy MP3 music to U-disk
②No MP3 music stores in U-disk
②Check music format on PC, whether it stores MP3 files.
③Improper operation
③Static or pulse voltage, appears when insert U-disk repeatedly, results CPU error. (Don't pull out U-disk when playing music. It must turn to other MODE first.) Press RST button by sticker to reset CD-player and remove malfunction.
④U-disk broken
④Check U-disk by applying another normal U-disk.
⑤U –disk improper inserted
⑤Insert U-disk until the indicator lightened. (The flat surface of U-disk shall be upwards, and the groove surface shall be downwards.)
⑥Clean with special clean solution (Note: may clean ⑥Dirt on U-disk interface conducting with soft cloth, never use solvent such as benzene or point alcohol.) ⑦CD –player interface contacting point ⑦Replace CD-player assembly deformed ⑧U-disk malfunction results data loss and affects music play, inspect with another normal U-disk on same CD-player. Replace U-disk when necessary.
⑧Data loss
⑨CD-player inner program ⑨Replace CD-player assembly, including USB malfunction, which affects USB loading
281
Common Malfunction Diagnosis Flow of Geely Automobile USB interface of CD –player failure (U-disk)
No music stores in U-disk
Copy MP3 music to U-disk
Abnormal
Normal No MP3 music stores in U-disk
Abnormal
Copy MP3 music to U-disk
Normal Improper operation
Abnormal
Press RST button by sticker to reset CD-player and remove failure.
Abnormal
Replace with U-disk of same specification
Abnormal
Insert U-disk until the indicator lightened.
Abnormal
Clean interface contacting point
Abnormal
Replace CD-player assembly
Abnormal
Replace U-disk with same specification
Normal U-disk broken
Normal U –disk improper inserted
Normal CD –player interface conducting point deformed
Normal Dirts on U-disk interface conducting point Normal Data loss
Normal CD-player inner program failure, which affects USB loading
Abnormal
Replace CD-player assembly, including USB
282
Common Malfunction Diagnosis Flow of Geely Automobile
No. 206 CD-player burns out when connecting power source Malfunction
Cause
Solution
CD-player power source or Check CD-player power source, whether the voltage is between 12V and 14V. If the voltage is over normal standard, then check generator and circuit malfunction external power source, whether they operating normally.
CD-player burns out when connecting power source
CD-player short circuit between housing and earth
CD –player over load
Check the resistance value between the positive pole of CD-player power supply circuit and CD-player housing, with multimeter, whether the value is between 5kOhm and 10kOhm. If the circuit is conducting and the resistance value is 0, then it indicates there is short circuit between positive pole of power source and CD-player housing. Check CD-player inner stabilized voltage supply and all components of protective circuit, whether there is short circuit. The principle inspecting points are as follows: the inductive choke of stabilized voltage supply end, the dynatron of controlling switch power supply and protective diode. Check the components above, whether they were burnt out, and replace them or the CD-player when necessary. Connect multimeter to positive pole of CD-player, and set to current measure mode. Turn on CD-player and operate in common condition, test current whether it is over normal value. Check power source circuit and corresponding loads one by one, whether they are over load or consist leakage.
CD-player burns out when connecting power source
Check CD-player power supply voltage
Normal
Over load Inspect and maintain generator
Abnormal
Check the resistance value between the positive pole of CD-player inner power source and CD-player housing.
Inspect and maintain power source circuit
stabilitized
Normal CD-player over load Abnormal
Inspect and maintain power amplifying circuit
Normal Replace CD-player assembly
283
Common Malfunction Diagnosis Flow of Geely Automobile
No. 207 CD-player consists back drop Malfunction
Cause
Solution ① Check disk surface, whether it consists scuffing or wearing seriously, which results fuzziness sound when playing.
CD –player disk malfunction
② Check whether there is problem of disk quality.
③Check engine high voltage wire, whether it is Engine high voltage wire or other electric damaged. As well as the resistance value, whether it is appliances normal. Replace when necessary.
④ Check shield wire between CD-player housing and earth lead, whether it consists disconnection or loose. CD-player shield wire malfunction ⑤ Check the connection condition between radio antenna pin and CD-player housing.
CD-player consists back drop when operating
⑦ Check the transfer switch between CD-player and radio, whether it consists virtual link, or in place. The alternation switch of CD-player and Inspect the mechanical part of corresponding radio not in place. connection or replace CD-player assembly when necessary.
CD-player stabilized power source components and loudspeaker circuit components
⑧Check the filter in CD-player stabilized circuit. For the filters with inductive choke, shall inspect leakage. Replace CD-player when necessary.
⑨ Check the capacitor in circuit, whether it is damaged. Replace CD-player when necessary.
⑾ Check power source, if it is low power, which results CD-player inner components operate abnormally. Replace CD-player assembly when abnormal.
CD –player inner malfunction
284
Common Malfunction Diagnosis Flow of Geely Automobile CD-player consists back drop when operating
Abnormal Check enigne high voltage wire or other electric appliances
Check CD disk
Replace disk
Normal
Check CD shield wire
Abnormal
Check and maintain, bonding again
Normal Check the transfer switch between CD-player and radio
Abnormal Adjust or replace
Normal Check CD-player stabilitized power source and loudspeaker circuit
Normal Replace CD-player assembly
285
Normal
Adjust or replace
Common Malfunction Diagnosis Flow of Geely Automobile
No. 208 Cassette stuck or failed to popup Malfunction
Cause
Solution
Cassette deformed or damaged
Hatch mechanism contains dirt
stuck
①Check cassette surface, whether it is damaged or deformed, and replace it when necessary.
②Check the hatch, whether it is deformed. As well as the track, whether it or consist dirt. Maintain them when necessary. ③Check hatch track, whether it is too dusty, which results mechanism stuck. Clean and lubricate when necessary.
Cassette stuck or failed to popup ④Press and check hatch button, whether it is functional. Inspect the Cassette hatch button “EJECT” button, whether it is cracked or dropped from loader. Replace radio malfunction or damaged assembly when necessary.
Loader stuck or damaged
⑤Press hatch popup button, inspect the operating condition of hatch link mechanism and loader. Remove radio cover, press popup button and indicate the malfunction position. Replace radio assembly when necessary.
Cassette stuck or failed to popup
Abnormal Replace cassette
Check cassette whether it is deformed
Abnormal Hatch mechanism stuck or contains dirts
Check hatch button “ EJECT”
Adjust or replace
Abnormal Replace radio assembly
Abnormal Check link mechanism of loader
Replace radio assembly
Replace radio assembly
286
Common Malfunction Diagnosis Flow of Geely Automobile
No. 209 Cassette speed abnormal, turned over automatically and chewed Malfunction
Cause
Solution ①Check external power supply, whether the voltage is over load and results inner appliances operating unstably. The normal value shal between 12V and 14V approximately.
① Power supply malfunction
② Sentus or cassette housing
Cassette speed abnormal, turned over automatically and chewed
deformation
on
②Sentus or deformation on cassette housing affects cassette operating and results low speed, unstably or chewed. Check and replace the cassette.
③ Button switch not in place
③Button switch not in place, resulting all the link mechanism operating unreliably, and further causes cassette speed unstably or chewed. Check operating conditions of all buttons and link mechanism, and implement modification.
④ Drive gear worn
④Drive gear worn seriously, resulting clearance increased between each gear, and further causes speed differential. As a result the cassette speed becomes abnormal, and may turn over automatically or chewed. Replace recorder assembly.
⑤ Drive belt skid or dropped
⑤Drive belt skid or dropped, that is, the friction reduced between belt and motor/flywheel, which results motor speed lowered and unstably. Check drive belt, whether it is loose or dropped, and replace recorder assembly when necessary.
⑥Drive motor brush worn seriously and fallen graphite powder results partly short circuit between the copper plates of commutator, and ⑥ Drive motor brush worn seriously. further causes motor speed lowered. Check the clearance and wearing condition between brushes, and replace recorder assembly when necessary.
⑦Guide pulley low pressure or deformed, wearing or poor bearing ⑦ Guide pulley low pressure or lubrication will cause cassette speed lowered and unstably. Check deformed guide pulley wearing and operating condition, and lubricate or replace recorder assembly when necessary.
⑧The resistance of speed regulator potentiometer, electric governor, increased or decreased, as well as delayed diode open circuit or short ⑧ Speed regulator potentiometer of circuit will result motor voltage raised or reduced, which causes motor electric governor damaged speed unstable. Check the speed regulator potentiometer of electric governor circuit, whether it is damaged, and replace recorder assembly when necessary.
287
Common Malfunction Diagnosis Flow of Geely Automobile Cassette speed abnormal, turned over automatically and chewed
Normal Abnormal Power supply
Maintain power supply
Normal Abnormal Cassette housing, damaged or not
Replace cassette
Normal Abnormal Recorder button, damaged or not
Inspect and replace
Normal Abnormal Drive gear wearing condition
Replace recorder
Normal Abnormal Drive belt, loose or not
Replace recorder
Normal Drive motor wearing condition
Abnormal
Replace recorder
Normal Abnormal Inspect guide pulley operating condition
Inspect and replace recorder
Normal Inspect speed regulator potentiometer electric governor circuit
Abnormal Inspect and replace recorder
Normal Replace CD-player/radio assembly
288
Common Malfunction Diagnosis Flow of Geely Automobile
No. 210 Poor timbre, low volume or noise jump when playing CD Malfunction
Cause
Solution
① CD disk is too dirty or poor quality
② Loudspeaker damaged
poor
contact
③ Volume controlling knob damaged
Poor timbre, low volume or noise jump when playing CD
④ Power supply unstable
①Check CD disk surface, if it is too dirty or scuffed, then must be replaced. ②Check CD disk quality, if it is deformed or piratic, then must be replaced.
③Check loudspeaker exterior, whether it is damaged, as well as coil, whether it is burnt. Method: Measure the resistance by or multimeter, and the normal value shall be 4 Ohm. If the value shows as infinite, then the loudspeaker was burnt and must be replaced.
④Check CD player volume controlling knob, whether it is damaged. As well as track controlling, whether it operates correctly. And variable potentiometer of volume controller, whether it is seriously worn, Replace CD-player assembly when necessary.
⑤Check voltage of CD-player power supply, generally +B and GND voltage shall between 10V and 14V. When ACC and GND ignition switch locating at ACC or ON position, the value shall between 10V and 14V. ⑥Check CD-player laser head serve motor driving voltage, whether it is in normal range. Maintain it when necessary.
⑤ Laser head is too dirty or aging
⑦After CD disk was inserted, inspect by infrared illuminator, load motor action, when the disk positioned survey up/down focus action of laser head, whether it radiates red/blue beam. Check laser head component, clean laser head or replace CD-player assembly when abnormal.
⑧Power amplifier is a component of the vehicle sonic equipmen with most malfunction rate. It is mostly caused by integrated package puncture.
⑥ CD-player inner power amplifying ⑨Check power amplifier circuit supply voltage and load, as well circuit malfunction as the transient peak voltage generated by motor, whether they are under normal value. Maintain and replace CD-player assembly when necessary.
289
Common Malfunction Diagnosis Flow of Geely Automobile Poor timbre, low volume or noise jump when playing CD
Check CD disk, whether it is too dirty
Abnormal
Replace CD disk
Normal Check loudspeaker, whether it is poor conducted
Abnormal Maintain, modify or replace
Normal Check volume adjusting knob
Abnormal Replace CD-player assembly
Normal Check CD-player supply voltage
Abnormal
Maintain, modify
Normal Check laser head, whether it is too dirty or aging
Abnormal Clean or replace CD-player assembly
Normal Check the voltage between each pin of power amplifier
Abnormal
Inspect and maintain circuit or replace CD-player assembly
normal Replace CD-player assembly
290
Common Malfunction Diagnosis Flow of Geely Automobile
No. 211 Low loudspeaker volume Malfunction
Cause
Solution
①Loudspeaker poor performance, magnetic of alnico reduced. The sensitivity of loudspeaker is mainly determined by the magnetic of permanent magnet, the quality of cone diaphragm and the level of assembly process. Contact alnico with ferromagnetic and estimate the magnetism, replace loudspeaker when necessary.
Loudspeaker poor performance
Loudspeaker circuit poor contact or short circuit.
② Check loudspeaker and CD-player external connection, whether they are damaged. Measure with multimeter, the resistance shall be 0 Ohm, disconnect the connectors on both ends, and measure the resistance between connection and body (earth lead), of which value shall be infinite. If not, the circuit shall be maintained or replaced. ③Check loudspeaker exterior, whether it is damaged, as well as coil, whether it is burnt. Measure the resistance by multimeter, and the normal value shall be 4 Ohm. If the value shows as infinite, then the loudspeaker was burnt and must be replaced.
All or single loudspeaker low volume
④Check CD disk quality, whether it is piratic. Replace to genuine CD disk.
CD disk damaged
Volume controlling damaged
⑤Check disk format or surface wearing level, and replace timely when necessary.
potentiometer
worn
⑥Measure the resistance between both ends of volume controlling potentiometer. Connect multimeter or and rotate potentiometer slowly, meanwhile survey the resistance variation, if there is no change or shows as infinite, which indicates damage, then shall replace CD-player
⑦Check power amplifying circuit, measure the voltage between each pin by multimeter. Check the signal from front amplifying circuit. Mainly inspect the capacitance, CD -player inner power amplifier open or short resistance of power amplifying circuit, as well as the circuit circuit and integrated package of circuit panel, whether they are burnt. Replace CD-player when necessary. power amplifying circuit, measure the voltage between each pin by multimeter.
291
Common Malfunction Diagnosis Flow of Geely Automobile Loudspeaker low volume
Abnormal Replace loudspeaker
Loudspeaker poor performance
Normal Loudspeaker connecting wire poor
Abnormal
Check and maintain
conducted or short circuit
Normal
loudspeaker circuit
Abnormal Replace CD disk
Poor CD disk quatily
Normal
Volume controlling potentiometer damaged
Abnormal Replace volume potentiometer
Normal CD-player assembly inner short circuit or open
Abnormal
circuit
292
Replace CD player
Common Malfunction Diagnosis Flow of Geely Automobile
No. 212 Large loudspeaker noise Malfunction
Cause
Dirts in clearance cracked.
Solution
①Check loudspeaker magnet clearance and cone diaphragm, loudspeaker magnet whether there is dirt in the clearance or the diaphragm cracked. With or cone diaphragm that problems voice will be distortion when voice coil vibrating, and results raucity voice.
②Check loudspeaker circuit, whether it is damaged or short circuit to earth, as well as virtual connection between circuit and CD-player/loudspeaker. Maintain or replace it when necessary. Loudspeaker circuit poor contact
External appliances affection
③Pull out the pins of CD-player and loudspeaker, measure the resistance by multimeter, the value between both ends of circuit shall be 0 Ohm, the resistance to earth shall be infinite, and the resistance of loudspeaker shall be 4 Ohm. Inspect or replace when necessary.
④Check the appliances in engine cabin, high voltage wire for example, mainly inspect the electromagnetic frequency, generated when the appliances operating, which may affect the normal operation of CD-player and loudspeaker.
Large loudspeaker noise ⑤Check the filter of CD-player stabilized voltage, some may equips with inductive choke filter, then shall check current leakage in inductive choke. Replace CD-player when necessary. CD –player stabilized voltage supply ⑥Check capacitor of circuit, whether it is damaged. Remove the components malfunction capacitor and measure it by multimeter setting at voltage range, survey value variation between straight polarity and reverse polarity. If the variation range is too narrow, which indicates the capacitor is damaged, then replace CD-player.
⑦Most malfunctions in voice circuit appear on capacitor, cause CD –player voice circuit short or current leakage or sealing-off always affect voice affection when damaged playing, with load noise. Measure it by multimeter, replace CD-player or implement welding when necessary.
⑧Check power amplifying circuit, measure the voltage between each pin by multimeter, survey the signal from front amplifying CD –player power amplifying circuit circuit, mainly inspect the capacitor, resistance, circuit and short or damaged integrated package on circuit panel, whether there are evidences of burning. Replace CD-player when necessary.
293
Common Malfunction Diagnosis Flow of Geely Automobile Large loudspeaker noise
Abnormal Replace loudspeaker Dirts in loudspeaker magnet clearance or cone diaphragm cracked.
Normal
Abnormal
Maintain loudspeaker circuit
Loudspeaker circuit poor contact
Normal
Abnormal
Maintain modify replace
External appliances affection
Normal CD –player stabilized voltage supply components malfuction
Abnormal
Replace CD-player
Normal Abnormal Replace CD-player
CD –player voice short circuit or damaged
Normal CD –player power amplifiying circuit short or damaged
Abnormal
Normal Replace CD-player assembly
294
Replace CD-player
Common Malfunction Diagnosis Flow of Geely Automobile
No. 213 Loudspeaker susurrates when pressing horn Malfunction
Cause
Solution
Loudspeaker damaged or screws loose
①Check whether loudspeaker cone diaphragm is cracked. Check whether the loudspeaker retaining screws are loose. Since the vehicle horn mounting at front cross member, body will be vibrated when pressing horn, meanwhile, cracked diaphragm or loose screws will result CD-player loudspeaker voice distortion, as well as voice raucity when pressing horn. Solution: replace horn and tighten loudspeaker retaining screw.
Loudspeaker short circuit
②Check loudspeaker circuit, whether it is damaged or short circuit to earth, as well as short circuit between loudspeaker circuit and horn circuit. Measure the resistance between loudspeaker and earth, whether it is under normal range. Maintain or replace it when necessary.
③Check the screws of CD-player earth lead, horn earth lead and body connecting position, whether they are loose. When pressing horn, earth lead will be virtually conducted, because The screw of CD-player and horn earthlead screws loose, the friction between body and earth lead will loose cause weak spark and generates interfering signal, which results loudspeaker raucity. Solution: Clean earth leads, and tighten the retaining screws. Loudspeaker susurrates when pressing horn CD-player short circuit
④Check the resistance between terminal A3, at CD-player pin, and body. Disconnect CD-player pin and rear view mirror pin, measure the resistance from A3 terminal to fuse by multimeter, the value shall be infinite, that is under non-conduction. Otherwise, shall maintain CD-player power supply circuit. ⑤When pressing horn, loudspeaker susurrates, then shall mainly inspect short circuit between horn circuit, earth lead connecting with CD-player earth lead, and CD-player circuit. Maintain circuit when necessary.
⑥Check CD-player power supply circuit and inner stabilitized power supply, whether there is burnt or short circuit. Mainly inspect the capacitor between power supply and circuit, whether there is current leakage or damage. Maintain or replace it when necessary. ⑦Check anti-interference or wireharness direction on CD-player inner magnet interference may CD-player. As well as screen condition of CD-player, whether it result loudspeaker noise is interfered by screen wire damage. Maintain or replace it when necessary. ⑧Check CD-player high frequency receiving circuit, whether there is damaged component, short circuit in circuit, or current leakage in high frequency capacitor. Maintain circuit or replace CD-player assembly when necessary.
295
Common Malfunction Diagnosis Flow of Geely Automobile Loudspeaker susurrates when pressing horn
Normal
Abnormal
Loudspeaker damage or screws loose
Maintain, tighten and replace
Normal Abnormal Loudspeaker short circuit
Replace loudspeaker
Normal
The screw of CD-player and horn earthlead loose
Abnormal Maintain and tighten
Normal Abnormal Horn and CD-player short circuit
Maintain and replace
Normal
CD-player inner short circuit or burnt
Abnormal Maintain and replace CD-player
Replace CD-player assembly
296
Common Malfunction Diagnosis Flow of Geely Automobile
No. 214 Speedometer non-display Malfunction
Cause
Solution Lift vehicle with two-post lift then start engine，geared, and accelerate, survey sensor pulse signal by oscilloscope. If there is no pulse signal on display screen, then the sensor is malfunction and must be replaced. Measure the voltage between both ends of speed sensor, open ignition switch, and rotate wheel slowly. The voltage between speed sensor pin 1 and pin 3 shall be 0.5~9V, between pin 2 and pin 3 shall be 8V approximately. Otherwise, shall inspect speed sensor circuit.
Speed sensor poor operation
Speed sensor malfunction
Speedometer non-display, sc. odometer non-display
connecting
Measure the resistance between pin 2 of speed sensor and body, earth end, by multimeter, the value shall be 0 Ohm, sc. circuit conducted. Set ignition switch to ON position, measure the voltage between pin 3 and body, earth end, the value shall be 7.5~9V. Otherwise, shall maintain circuit or replace instrument assembly.
Lift vehicle with two-post lift, then turn shift lever to neutral gear and set ignition switch at ON position. Rotate front Speed sensor power supply circuit wheel slowly, measure the voltage between pin 1 and pin 2 malfunction by multimeter, the value shall between 0.5V and 9V. Otherwise, replace speed sensor.
Lift vehicle with two-post lift, then start engine, geared, and accelerate. Survey sensor pulse signal by oscilloscope, if there is no pulse signal on display screen, then shall inspect Speed sensor drive or driven gear speed sensor firstly. If it finds no damage in sensor inspection, then shall remove driven gear from speed sensor damaged rear end, as well as drive gear from gearbox output shaft, and survey whether it appears gear hit and miss. Replace it when necessary.
Open fuse box and check CLUSTER (10A) AM1 (30A) and fuse MAIN (80A), whether they are burnt. Replace them when necessary. Disconnect connector from grouped LCD odometer power supply and instrument assembly, measure the resistance between B7 instrument connecting circuit (GND) and body (earth end) by multimeter, as well as the malfunction resistance between B8 (GND) and body (earth end), and the value shall be 0 Ohm, sc. conducted. Otherwise, shall maintain connecting circuit.
Grouped instrument inner short and Replace grouped instrument open circuit
297
Common Malfunction Diagnosis Flow of Geely Automobile Speedometer non-display
Survey instrument indicating condition
Abnormal
Normal
Maintain instrument power supply fuse and fuse box. Check CLUSTER (10A) AM1 (30A) and fuse MAIN (80A), whether they are burnt.
Lift vehicle with two-post lift, then start engine, geared, and accelerate. Survey sensor pulse signal by oscilloscope
Normal
Abnormal Lift front wheel and rotate slowly, then measure the voltage between speed sensor pin 1 and pin 2 by multimeter, the value shall be 0.5~9V.
Normal
Check instrument operating condition. Maintain instrument, speed sensor connecting harness and connecting pin etc.
Abnormal
Measure the resistance between speed sensor pin 2 and body by multimeter, the value shall be 0 Ohm. Measure the voltage between pin 3 and body (earth end), the value shall be 7.5~9V.
Maintain sensor
speedometer
Replace drive or driven gear Replace assembly
instrument
298
Abnormal
Replace speedometer sensor
Common Malfunction Diagnosis Flow of Geely Automobile
No. 215 Freedom ship speedometer malfunction, indicates automatically when pressing horn Malfunction
Cause
Solution
Battery positive pole wire poor ①Check battery positive pole pin, whether it is poor contacted. Clean contact and tighten it when necessary. ②Set multimeter to voltage range, connect the red probe to terminal A11 on instrument panel pin, the black probe to body earth lead, turn ignition switch to ON position, press horn button, and survey the variation of voltage indicator. If the indicator swings greatly, which indicates short circuit between speedometer and center integrated controlling circuit, Instrument connecting cable short then shall implement maintaining work. circuit ②Pull out instrument pin and center integrated controller pin, measure the resistance between two ends of wire harness and earth lead, of which value shall be infinite, sc. non-conducted. Otherwise, shall maintain or replace wire harness. ③Check center integrated controller surface, whether it is burnt. Smell center integrated controller, whether there is burnt taste. Replace center integrated controller when necessary.
Freedom ship speedometer malfunction, indicates automatically when pressing horn
④Disconnect center integrated controller and speedometer connecting pin, measure the resistance respectively between terminal A11 on Center integrated controller inner instrument connector and terminal A3 of center integrated controller, the short circuit or damage value shall be 0 Ohm, sc. conducted. And the resistance between any terminal and earth shall be infinite. Otherwise, shall replace wire harness ⑤Set multimeter to voltage range, turn ignition switch to ON position, connect the red probe to terminal A3 on center integrated controller, the black probe to body earth lead, then press horn button and survey the variation of multimeter indicator. Maintain center integrated controller or replace it when necessary. ⑥Since the horn button switch is integrated in grouped switch on Freedom ship; therefore, once there is short circuit between horn button and grouped switch, they will affect each other. ⑦Disconnect center integrated controller and grouped switch connector, measure the resistance between A21 and A2, as well as A22 and A3, by multimeter, and the value shall be 0 Ohm. Measure the resistance Horn button cable and grouped between any terminal and body earth lead, the value shall be infinite. switch inner short circuit ⑧Check circuit between grouped switch and horn button, whether there is short circuit. Disconnect center integrated controller connector, and measure it by multimeter. The resistance between C6 and A21, C6 and A22, C6 and B11, C6 and B22 shall be infinite, sc. non-conducted. Press horn button, the multimeter indicator shall stand still. Otherwise, it indicates grouped switch inner short circuit or burnt, and shall be replaced.
Grouped instrument inner circuit
Replace instrument assembly
299
Common Malfunction Diagnosis Flow of Geely Automobile speedometer moves automatically when pressing the horn (CK)
Check instrument connecting wire.
Pull out instrument connector and center integrated controller pin; inspect the harness by multimeter, whether there is short circuit.
Abnormal
Check horn button circuit and grouped switch.
Check center integrated controller, whether it is burnt.
Disconnect center integrated controller and grouped switch connector, measure the resistance between A21 and A2, as well as A22 and A3, by multimeter.
Abnormal Inspect, maintain, replace
Connect multimeter to terminal A11 on instrument panel connector, set ignition switch to ON position, press horn button, and survey the variation of voltage indicator.
Swing
Check center integrated controller inner circuit, whether there is short circuit or damage
Connect multimeter to terminal A3 on center integrated controller, set ignition switch to ON position, press horn button, and survey the variation of voltage indicator.
Inspect and maintain speedometer and center integrated controller connecting wire, whether there is short circuit. Replace center integrated controller when necessary.
Swing
Inspect, maintain, replace
Abnormal
Measure the resistance between C6 and A21, C6 and A22, C6 and B11, C6 and B22, by multimeter, press horn button, and survey the variation of multimeter indicator.
Swing Replace grouped switch assembly
300
Inspect, maintain, replace
Common Malfunction Diagnosis Flow of Geely Automobile
No. 216 Incorrect indication of speedometer Malfunction
Cause
Speed sensor fails or damaged
Solution 1) Lift the vehicle with double props lifter, and shift the gear to accelerate; view the waveform of the pulse signal from sensor by oscilloscope; if the pulse signal is disconnected, then the speed sensor should be replaced; 2) While measuring the voltage between terminals of speed sensor, place igniting switch to ON and turn the wheel slowly; the voltage between #1 and #3 terminal of speed sensor should be varied from 0.5 to 9 V and voltage between #2 and #3 should be about 8 V; #2 terminal is earthing wire; the resistance between #2 terminal and body (earth) measured by Ohm grade of multi-meter is zero, which is in conducting state; if all the measured values are in normal range, speedometer sensor should be replaced.
3) Lift the vehicle with double props lifter, and shift the gear to accelerate; view the waveform of the pulse signal from sensor by oscilloscope; if the pulse signal is disconnected or broken Drive or driven gear of speedometer is down, then the speedometer should be checked first for worn out broken sensor; the final driven gear in speed sensor and drive gear of transmission output shaft should be dismantled and checked if there is broken tooth; if yes, the gear should be replaced. 4) Check the cable of speed sensor connection and instrument loop if there is broken sleeve resulting in short-circuit; if yes, harness should be repaired or replaced; 5) Remove plugs of speed sensor instrument PCB and Conducting state or poor contact between measure their resistance separately with multi-meter; the speed sensor connection and instrument resistance between #2 terminal of speed sensor and A9 loop terminals of instrument plug should be zero as conducting Incorrect indication state; so as the resistance between #3 terminal of speed of speedometer sensor and A10 of instrument plug, and between #1 terminal of speed sensor and A11 of instrument plug; 6) Check the rear connections of instrument panel, please re-connect or replace if there is loose or poor contact; Measure voltage of terminal B4 for normal 12V; instrument Fluctuation of power supply for instrument connectors B7 and B8 are bond straps; place igniting switch to loop ON position, measure the voltage between A10t A9, which should be about 8V; connector A9 is bond strap and A11 is signal cable for speedometer. 7) Check PCB of speedometer for signs of sealing-off or burning. Because the electronic circuit of speedometer converts the frequency signal from wheel speed sensor to useful voltage signal to control circuit of speedometer and drive the motor of odometer, if there is sealing-off or poor Malfunction of internal electronic circuit for contact, the discontinuous power supply for electronic circuit speedometer or stuck actuating will result in unstable speedometer due to irregular swing of mechanism speedometer pointer. Test the combined instrument with testing bench; 8) Check the internal actuating mechanism of speedometer for dropping off or check the drive motor and pointer for blocking by dirt, which may result in blocked or damaged speedometer; if yes, clean or replace instrument assembly.
The types of tyres for front wheels are Replaced with tyres of same specification as original different.
301
Common Malfunction Diagnosis Flow of Geely Automobile Incorrect indication speedometer
of
Lift the vehicle with lifter, and shift the gear to accelerate the engine; connect oscilloscope to #1 pin of speed sensor to view the waveform of the pulse signal
Normal
Abnormal Measure the voltage between terminals of speed sensor, place igniting switch to ON and turn the wheel slowly; the voltage between #1 and #3 terminal of speed sensor should be varied from 0.5 to 9 V
Check the rear connections of instrument panel and power supply of instrument
Check, repair
and
Yes
No Check speedometer damaged
adjust
if is
Replace sensor
Check if there is conducting state or break between speed sensor connection and instrument loop
speed
Check drive or driven gear of speedometer
Normal
Replace drive driven gear speedometer
or of
Abnormal
Check malfunction of internal electronic circuit for speedometer or stuck actuating mechanism
Replace instrument assembly
302
Repair connection replace harness
or
Common Malfunction Diagnosis Flow of Geely Automobile
No. 217 Kilometrage on LCD of odometer will accumulate automatically after the engine starts Malfunction
Cause
Solution
Short-circuit of instrument PCB
1) Check PCB of speedometer whether it is burnt or of short-circuit; because the electronic circuit of speedometer converts the frequency signal from wheel speed sensor to useful voltage signal to control circuit of speedometer and drive the motor of odometer; if the PCB is short-circuit, will result in discontinuous power supply for electronic circuit and then affect to speedometer; 2) Check PCB of instrument for short-circuit due to soldering sealing-off of dropping-off; if yes, check and repair or replace instrument assembly;
Short-circuit of odometer drive motor circuit
3) Place igniting switch to ON position, measure with voltage grade of multi-meter if voltage of odometer drive motor is in normal range; measure if resistance of drive motor is in normal range; check if short-circuit of drive circuit results in abnormal working of odometer motor and moving of odometer kilometrage; repair drive circuit or replace drive motor; 4) Check centralized controller for “always-ON" of A3 speed signal to instrument due to internal short-circuit or burn-out, which will result in automatic moving of odometer kilometrage; 5) Switch multi-meter to voltage grade and igniting switch to ON; connect red probe to A3 terminal of centralized controller and black probe to bond strap of body; the voltage measured should be between 0.5 – 9 V; start up engine and view pointer of multi-meter; there will be no obvious variation; otherwise, check and repair centralized controller or replace centralized controller;
Kilometrage on LCD of odometer will move Short-circuit of centralized controller automatically after start-up of engine
6) Besides odometer, the pulse signal from speed sensor is also provided for centralized controller and EPS, so the normal working of speedometer will be affected by damage or short-circuit of any module of them; 7) Firstly, check speedometer under normal working condition: Lift the vehicle with double props lifter, and Internal short-circuit or damage of ECU for EPS shift the gear to accelerate the engine; view the (Electrical Power-assisted Steering) waveform of the pulse signal from sensor by oscilloscope; if speedometer works normally, remove plugs of speed sensor and centralized controller, start up engine and view if there is pulse signal on oscilloscope; if yes, the ECU internal circuit for EPS is broken and should be replaced. Wrong connection of harness
Connect the harness again;
Malfunction of speed sensor
Replace speed sensor
303
Common Malfunction Diagnosis Flow of Geely Automobile Kilometrage on LCD of odometer will accumulate automatically after start-up of engine
Lift the vehicle with lifter, remove speed sensor and start up engine; connect oscilloscope on signal wire (#1 terminal) of speed sensor and view the signal from sensor
Wrong connection of harness
With signal Check centralized controller; remove plugs of speed sensor and EPS; switch multi-meter to voltage grade and igniting switch to ON; connect red probe to A3 terminal of centralized controller and black probe to bond strap of body; measure if there is pulse signal
With signal Replace centralized control module
Connect the harness again
Without signal Check PCB of instrument and odometer drive motor circuit for short-circuit due to soldering sealing-off of dropping-off
Replace assembly
Without signal Check EPS ECU internal circuit for short-circuit or break
Replace EPS ECU
304
instrument
Malfunction of speed sensor
Replace sensor
speed
Common Malfunction Diagnosis Flow of Geely Automobile
No. 218 Automatic movement of odometer pointer after start-up of engine Malfunction
Cause
Solution
1) Remove plugs of speed sensor and instrument plug; measure wire resistance between terminals by multi-meter separately; the resistance between #1 terminal of speed sensor and A11 terminal of instrument Conducting state or poor contact plug should be zero as conducting state; the resistance between speed sensor connection and measured by the multi-meter should be infinite, instrument loop, poor contact between otherwise, there is short-circuit and should be repaired; instrument PCB and bond strap 2) Check connection cable of instrument panel; Measure voltage of terminal B4 by multi-meter for normal 12V; instrument connectors B7 and B8 are bond straps; check fixing screws of B7 and B8 earth wire and body for loosing; if yes, tighten it firmly;
3) Check PCB of instrument for short-circuit due to soldering sealing-off of dropping-off; if yes, check and repair or replace instrument assembly; 4) Check tachometer for normal working; if there is Short-circuit of internal electronic circuit internal short-circuit or break for tachometer, the of instrument or tachometer circuit connection between tachometer and speedometer on PCB should be checked for short circuit or wrong transmission signal which results in fault of odometer and instrument assembly should be replaced; 5) Remove plugs of centralized controller, EPS and speedometer sensor, etc , start up engine and connect oscilloscope on A11 terminal of instrument plug wire or #9 terminal of engine ECU to view waveform; if there is still waveform of signal after removing plugs, the engine ECU fails internally and should be replaced;
Automatic moving of odometer pointer after ECU of engine start-up of engine
Short-circuit of centralized controller
6) Switch multi-meter to voltage grade and igniting switch to ON; connect red probe to A3 terminal of centralized controller and black probe to bond strap of body; the voltage measured should be between 0.5 – 9 V; start up engine and view pointer of multi-meter; there will be no obvious variation; otherwise, should check and repair centralized controller loop and instrument connection or replace centralized controller;
7) Firstly, check speedometer under normal working condition: Lift the vehicle with double props lifter, and shift the gear to accelerate the engine; view the waveform of the pulse signal from sensor by Internal short-circuit or damage of EPS oscilloscope; if speedometer is working normally, remove ECU plugs of speed sensor and centralized controller, start up engine and view if there is pulse signal on oscilloscope; if yes, the ECU internal circuit for EPS is broken and should be replaced. Internal short-circuit of speed sensor
Replace speed sensor assembly
Wrong connection of harness
Check and sort out the harness connection again.
305
Common Malfunction Diagnosis Flow of Geely Automobile Automatic movement of odometer pointer after start-up of engine
Remove plug of speed sensor; lift the vehicle with double props lifter, and start up the engine; connect oscilloscope on A11 terminal of instrument harness to view for signal
Yes
No Short-circuit of internal electronic circuit of instrument or tachometer circuit
Wrong connection of harness
Check if there is conducting state or bad contact of bond strap between speed sensor connection and instrument loop
Internal short-circuit speed sensor
Connect the harness again Replace instrument assembly
Replace assembly
Normal
Abnormal
Check engine ECU for internal short-circuit or break
Check, replace
repair
and
Normal
Abnormal Replace ECU
engine
Check centralized controller for internal short-circuit or damage
Normal
Abnormal Check EPS
Replace centralized controller
Replace EPS module (ECU)
306
speed
of
sensor
Common Malfunction Diagnosis Flow of Geely Automobile
No. 219 Incorrect indication or no indication of engine tachometer Malfunction
Cause
Solution
1) Open fuse unit and check if CLUSTER(10A) AM1(30A) and MAIN(80A) in fuse unit is broken; replace if necessary; 2) Place igniting switch to ON and measure voltage of instrument connector B4 with voltage grade of multi-meter; the voltage should be equal to the voltage of battery Malfunction of power supply circuit for (standard voltage: 12V); measure resistance of instrument instrument connectors B7 and B8 to bond strap; the resistance should be zero because B7 and B8 are bond straps of instrument; if power supply voltage for B4 and resistances for B7 and B8 are different from normal values, circuit should be checked and repaired or fuse should be replaced; 3) Check PCB of tachometer for short-circuit due to soldering Conducting state or break of tachometer PCB sealing-off of dropping-off; if yes, check and repair or replace instrument assembly; 4) Remove engine ECU connecting harness and instrument harness; measure by resistance grade of multi-meter between #54 terminal or engine ECU and B11 connector of Short-circuit or poor contact of engine ECU Incorrect indication connecting harness, power supply and instrument board; the resistance should be zero as conducting state; and measure resistance between engine or failure of engine tachometer connecting wire #54 or B11 on instrument board and body (bond strap); the tachometer resistance should be infinite, otherwise there must be short-circuit in this loop. Blocked mechanical part of tachometer
5) Check tachometer coil for blow-out or break; check if hairspring blocks with panel while rotating and if there is break of hairspring of tachometer coil; if yes, tachometer or instrument assembly should be replaced;
Internal malfunction of tachometer
6) Dismantle combined instrument assembly with connectors connected; connect oscilloscope on B11 terminal of instrument connector; start up engine and view if the displayed waveform of pulse signal is correct; if yes, the tachometer should be checked, repaired or replaced; 7) Check rotating speed output signal of engine ECU; dismantle engine ECU with connectors connected; connect oscilloscope on #54 terminal and start up engine to view if the displayed waveform of pulse signal is correct; if without pulse display, engine control system should be checked and repaired or engine ECU should be replaced;
Malfunction of engine control system
307
Common Malfunction Diagnosis Flow of Geely Automobile Incorrect indication or no indication of engine tachometer
Start up engine and view if pointer of tachometer is swinging
Without swinging
swinging
Check power supply loop for instrument; measure voltage of B4 instrument connector for normal about 12 V with voltage grade of multi-meter; check fuse for burn-out
Abnormal
Check tachometer short-circuit or break
PCB
Check tachometer coil for blow-out or break; check if hairspring blocks with panel while rotating and if there is break of hairspring of tachometer coil
Replace instrument
fuse
of
for
Replace tachometer or instrument assembly
Abnormal Check, replace
repair
and
Check connecting harness of engine ECU and tachometer for short-circuit or break
Abnormal
Check, replace
repair
and
Connect oscilloscope on B11 terminal of instrument connector; start up engine and view if the displayed waveform of pulse signal is correct
Normal Check, repair or replace tachometer
Abnormal Connect oscilloscope on #54 terminal; start up engine and view if the displayed waveform of pulse signal is normal
Check and repair engine system or replace ECU
308
control
Common Malfunction Diagnosis Flow of Geely Automobile
No. 220 Incorrect indication (or no indication) of fuel gauge Malfunction
Cause
Solution
1) Open fuse unit and check if CLUSTER(10A) AM1(30A) and MAIN(80A) in fuse unit is broken; replace if necessary; 2) Place igniting switch to ON and measure voltage of instrument connector B4 with voltage grade of multi-meter; the voltage should be 1) Malfunction of power supply equal to the voltage of battery (standard voltage: 12V); measure circuit for instrument resistance of instrument connectors B7 and B8 to bond strap; the resistance should be zero because B7 and B8 are bond straps of instrument; if power supply voltage for B4 and resistances for B7 and B8 are different from normal values, circuit should be checked and repaired or fuse should be replaced; 3) Dismantle instrument panel and then switch on igniting switch; check output voltage between “+12V” and “-“ terminals of instrument 2) Malfunction of stabilizing circuit stabilizer for normal 11.5 – 12.5 V; if the voltage is lower than 11.5 V for fuel gauge or higher than 12.5 V or no voltage output, the stabilizer should be replaced;
Incorrect indication 3) Fuel gauge in poor operation (or no indication) of fuel gauge
4) Check fuel gauge condition: disconnect sensor of fuel gauge and open igniting switch; using external resistor instead of resistor of sensor for detection and identification, the fuel gauge will indicate out of fuel with 110Ω resistor, one-fourth tank of fuel with 75Ω resistor, half tank of fuel with 40Ω resistor, three-fourth tank of fuel with 20Ω resistor and full of fuel with 3Ω resistor; if the results indicated by fuel gauge are different from above values, fuel gauge or instrument assembly should be replaced;
5) Disconnect fuel sensor and combined instrument; measure resistance of connecting wire between fuel gauge sensor and 4) Short-circuit or break of combined instrument with multi-meter and the standard is 0 Ohm; the connecting wire between fuel resistance between the wire and bond strap should be infinite as gauge sensor and combined break status; otherwise the wire is short-circuit or broken and should instrument be replaced; 6) Floater of fuel sensor is blocked: check if there has been crash on bottom of tank and if there is bulge or other object which prevents 5) Floater of fuel sensor is blocked floater from moving upward and downward, so that the fuel gauge is incorrect; if yes, clear, repair or replace it; 7) Check fuel gauge sensor with resistance grade of multi-meter: the resistance measured by multi-meter should be 3±2Ω when floater of 6) Fuel gauge sensor in poor sensor is at full position, and 32.5±3Ω for middle (1/2 position) of tank, operation 110±6Ω for out of fuel position; if measured results for floater of sensor are different from standard values, fuel gauge sensor should be replaced;
309
Common Malfunction Diagnosis Flow of Geely Automobile Incorrect indication (or no indication) of fuel gauge
Disconnect sensor of fuel gauge and open igniting switch; use external resistor instead of resistor of sensor to detect and view if fuel gauge actuate
Yes
No
Check if pointer position of fuel gauge is met with external resistors
No
Check if there is short-circuit or break of connecting wire between fuel gauge sensor and combined instrument
Check power supply loop for instrument; open fuse unit and check fuse for burn-out; measure voltage of B4 instrument connector for normal voltage of battery
Yes
Replace fuel gauge instrument assembly
or
Check if fuel gauge sensor is blocked
No
Yes Check bottom of tank for distortion and internal surface of tank for bulge or other blocking
Replace sensor
fuel
Check, repair or replace
Abnormal Replace fuse
Check fuel stabilizing circuit; dismantle instrument panel and then switch on igniting switch; check output voltage between “+12V” and “-“ terminals of instrument stabilizer
gauge
Clear or replace
Abnormal Replace fuel gauge instrument assembly
310
or
Replace stabilizer
Common Malfunction Diagnosis Flow of Geely Automobile
No. 221 No indication of water temperature gauge Malfunction
Cause
Solution
Water temperature gauge in poor operation
Check water temperature gauge condition: disconnect sensor of water temperature gauge and open igniting switch; using external resistor instead of resistor of sensor for detection and identification, the water temperature gauge will indicate around “C” area with 165Ω resistor, around “1/2 C” area with 56Ω resistor, around “H” area with 28.7Ω resistor; if the results indicated by water temperature gauge are different from above values, water temperature gauge or instrument assembly should be replaced;
Place igniting switch to ON and measure voltage of instrument connector B4 with voltage grade of multi-meter; the voltage should be equal to the voltage of battery (standard voltage: 12V); measure resistance of instrument connectors B7 and B8 to bond strap; the resistance should be zero because B7 and B8 are bond straps of instrument; if Malfunction of power supply circuit for power supply voltage for B4 and resistances for B7 and B8 are different from normal values, circuit should be checked instrument and repaired or fuse should be replaced; Dismantle instrument panel and then switch on igniting switch; check output voltage between “+12V” and “-“ terminals of instrument stabilizer for normal 11.5 – 12.5 V; if the voltage is lower than 11.5 V or higher than 12.5 V or no voltage output, the stabilizer should be replaced;
No indication of water temperature gauge
5) While checking water temperature sensor, the sensor can be dismantled from engine and put into coolant or water with certain temperature, in the meantime, check if the resistance value is met with standard value. When temperature of coolant is 60℃, the resistance of water temperature sensor Water temperature gauge sensor in poor is 164.5±5Ω; and when temperature of coolant is 90℃, the operation resistance of water temperature sensor is 56±3Ω; when temperature of coolant is 115℃, the resistance of water temperature sensor is 28.7±2Ω; if measured resistance values of water temperature sensor are different from standard values, water temperature sensor should be replaced; 4) Disconnect water temperature sensor and combined instrument; measure resistance of connecting wire between Short-circuit or open-circuit of connecting water temperature gauge sensor and combined instrument wire between water temperature gauge with multi-meter and the standard is 0 Ohm; the resistance sensor and combined instrument between the wire and bond strap should be infinite as break status; otherwise the wire is short-circuit or broken and should be replaced;
311
Common Malfunction Diagnosis Flow of Geely Automobile No indication of water temperature gauge
Disconnect sensor of water temperature gauge and open igniting switch; use external resistor instead of resistor of sensor to detect and view if water temperature gauge actuate
Yes
No
Check if pointer position of water temperature gauge is met with external resistors
Yes Check water temperature sensor with multi-meter to measure resistances in different temperatures
Normal Check connecting wire of water temperature sensor or replace instrument assembly
Check if there is short-circuit or break of connecting wire between water temperature gauge sensor and combined instrument
Abnormal Check, repair or replace
No Replace water temperature gauge or instrument assembly
Abnormal Replace water temperature sensor
Check power supply loop for instrument; open fuse unit and check fuse for burn-out; measure voltage of B4 instrument connector for normal voltage of battery
Abnormal
Replace fuse
Check water temperature gauge stabilizing circuit; dismantle instrument panel and then switch on igniting switch; check output voltage between “+12V” and “-“ terminals of instrument stabilizer
Abnormal Replace water temperature gauge or instrument assembly
312
Replace stabilizer
Common Malfunction Diagnosis Flow of Geely Automobile
No. 222 Electric mirror can’t work Malfunction
Cause Switch parts damaged
Solution of
Check contacts of mirror control switch and contacts of left and right adjusting mirror switches for circuit break due to burn-out or too dirty; if yes, clean them or replace switch parts; Check left and right adjusting switches for blocking; if yes, switch parts should be replaced.
Poor contact, short-circuit or open circuit of harness, Check connector of mirror switch parts for loosing or dropping-off; Check connecting wire and connector of mirror motor for loosing or dropping-off; connectors
Electric mirror Power supply for mirror can’t work
Malfunction of mirror motor
Disconnect connectors of mirror switch parts and measure voltage of its power supply; find power supply wire and measured voltage should be 12 – 14 V; if there is no voltage, fuse should be checked for burn-out; check if the resistance between bond strap at mirror switch parts and body should be zero, otherwise look for the line or tighten it up again; check if there is break between points of harness connection and measure the resistance; it should be zero as conducting state. Check mirror motor for sign of burn-out and measure by multi-meter if the resistance of motor is in normal range; if the resistance is infinite, thus the motor is burnt or broken internally and should be replaced; check with power on: disconnect connector of mirror motor; connect positive and negative poles of external power supply to connectors of motor output and view if motor is actuating; if not, it shows that motor has been broken internally and the electric mirror should be replaced.
Electric mirror can’t work
Switch of mirror damaged
Abnormal Replace fuse
Normal Poor contact, short-circuit or break of harness, connecting wire and connectors
Abnormal Replace switch part
Normal Abnormal Short-circuit or open circuit of power supply for mirror
Check, repair and replace
Normal Replace motor of electric mirror
313
Common Malfunction Diagnosis Flow of Geely Automobile
No. 223 Always-On or failure of water temperature alarm indicator Malfunction
Cause
Solution Check cooling system for sufficient coolant and normal recirculation of coolant;
Malfunction of cooling system Water temperature alarm indicator is Malfunction of temperature sensor always on or isn’t on
The water temperature sensor is negative thermostat-type; measure its water resistance variation under different temperature and working condition and compare them to standard values; check, repair or replace water temperature sensor;
Malfunction of wire Internal malfunction combined instrument
2) Check, repair or replace electric harness; of
3) Check, repair or replace combined instrument;
Water temperature alarm indicator is not on or always on
Cooling system
Is electric fan working?
Abnormal
Normal Abnormal
Measure with multi-meter resistance variation
Malfunction of water temperature sensor
Normal
Malfunction of wire
Abnormal Check, repair or replace electric harness;
Normal Abnormal
Check if broken
of Malfunction combined instrument
314
instrument
is
for
Common Malfunction Diagnosis Flow of Geely Automobile
No. 224 Safety & alarm indicator is always on or not on Malfunction
Cause
Solution
Safety & alarm Seat belt unlocked (always-on) Snap-on the seat belt indicator is always Break (not on) or short-circuit (always-on) of 1) Check and repair internal circuit board for seat belt on or not on internal circuit board for seat belt snap-on lock snap-on lock, or replace seat belt assembly Malfunction of loop
3) Check if switching loop for snap-on lock of seat belt is broken or short-circuit;
Internal fault of combined instrument
2) Check, repair or replace instrument assembly;
Safety & alarm indicator is not on or always on
Safety & alarm indicator for driver is not on
Abnormal
GAUGE instrument assembly
insurance, and front-left
Normal Alarm indicator is always on
Normal function
Snap-on seat belt
Abnormal Check loop or replace seat belt lock assembly
315
combined belt lock
Common Malfunction Diagnosis Flow of Geely Automobile
No. 225 Brake fluid level alarm indicator is always on or can’t alarm Malfunction
Cause
Solution
Insufficient brake fluid results in always-on of brake Fill sufficient brake fluid fluid level alarm indicator Short-circuit or open circuit of brake fluid level Replace brake fluid level sensor sensor Short-circuit or open circuit of connection between Failure of brake fluid level brake fluid level sensor and instrument results in Short-circuit of brake fluid level alarm indicator results in always-on of its indicator. alarm indicator is always always-on of brake fluid level alarm indicator on or can’t alarm Break of circuit for brake fluid level alarm indicator or failure of Brake fluid level alarm indicator can’t alarm buzzer for alarm circuit Internal fault of combined instrument
Check, repair or replace combined instrument.
Fault of ABS system (indicated together with ABS Repair ABS system fault indicator)
Brake fluid level alarm indicator is always on or can’t alarm
Insufficient brake fluid
Insufficient oil
Check if oil is sufficient and fill sufficient brake fluid
Normal Short-circuit or open circuit of brake fluid level sensor Normal Short-circuit or open circuit of connection between brake fluid level sensor and instrument
Broken
Short-circuit or break Repair the connection
Normal Short-circuit instrument
of
combined
Broken
Replace combined instrument
Normal Malfunction of ABS system
Broken
Repair ABS system
316
Brake sensor
fluid
level
Common Malfunction Diagnosis Flow of Geely Automobile
No. 226 Oil alarm indicator is always on Malfunction
Cause
Solution
Insufficient lubricating oil
Check and eliminate oil leakage and fill lubricating oil according to specification
Block of lubricating oil tube
Dismantle oil pressure sensor and insert a flat bar to internal diaphragm of sensor. Open start-up switch, if oil pressure gauge actuates normally, thus the lubricating oil tube is blocked;
Oil pressure alarm indicator is always on or Oil pressure sensor damaged can’t alarm
Connect terminal of oil pressure sensor to bond strap with wire, if the oil alarm is normal, then oil pressure sensor is fault and may be replaced;
Break or short-circuit of connecting Check the break or short-circuit of connecting wire for oil wire for oil pressure alarm indicator pressure alarm indicator with multi-meter and repair it; Over-low oil pressure
Remove the fault according to diagnosis process in engine section;
Internal fault of combined instrument
Replace combined instrument
Oil alarm indicator is always on or can’t alarm
Insufficient lubricating oil
Insufficient Fill lubricating oil
Normal Blocked Repair
Block of lubricating oil tube
Normal Oil pressure sensor damaged
Blocked Replace
Normal Over-low Over-low oil pressure
Check and repair
Normal Abnormal Break or short-circuit of connecting wire for oil pressure alarm indicator
Check and repair
Normal Short-circuit instrument
of
combined
Abnormal
317
Replace combined instrument
Common Malfunction Diagnosis Flow of Geely Automobile
No. 227 Headlight is always on or not on Malfunction
Cause
All headlights can’t work; all headlights is always on or not on
Solution
Broken fuse for headlights
Check if fuse is broken and replace it if necessary;
Burn-out of headlight
Replaced burnt headlight
Headlight relay is broken
If fuse is intact, check if headlight relay is poor contact or burnt off and repair or replace it according to condition.
Broken combined switch for headlight
Check combined switch for headlight; measure conductivity of switch with multi-meter; if the resistances are both infinite when switch is placed on either lower beam or main beam position, thus the switch for headlight is broken and should be replaced;
Broken harness or poor contact with Check circuits section by section to eliminate short-circuit bond strap or break; If fuse is normal, check if headlight lamp holder is poor Burnt bulb or poor contact of lamp contact or if filament is burnt out and repair or replace it holder according to condition. Internal fault of centralized controller Replace centralized controller (CK and MK) Failure of light controller (Vision)
Replace light control module;
Headlight is always on or not on
Broken fuse for headlight
Burnt out
Replace
Normal Headlight relay is broken
Burnt out
Replace
Normal Broken switch for headlight
Burnt out
Replace
Normal Broken harness or poor contact with bond strap
Abnormal
Repair or replace
Normal Broken bulb or poor contact of lamp socket
Abnormal
Repair or replace
Normal Malfunction of centralized controller or light controller
Abnormal
Replace centralized controller or light controller
318
Common Malfunction Diagnosis Flow of Geely Automobile
No. 228 Weak running of starter Malfunction
Cause
Solution
Malfunction of battery
Check if the voltage of battery reaches to 12.5 – 12.9V, if not, charge or replace the battery;
Malfunction of harness
Check the connecting end of starter harness for fine contact, if it's abnormal, the starter harness should be checked and repaired; Check if the internal bearing bush of starter is over-worn and thus results in fractional drag between rotator and stator and subsequent Weak running of starter; then bearing bush or starter assembly should be replaced;
Weak running of Internal starter starter
Measure length of internal brush of starter with vernier caliper; the standard length of brush should be 15.5 mm and the minimum worn length is 10 mm; if the brush is shorter than the minimum value, the brush or starter assembly should be replaced; malfunction
of Check if the no load current of starter is smaller than 90A under 11.5V; if it's abnormal, then starter assembly should be replaced; Check the grounding situation of starter commutator; check connection between armature coil and spindle with Ohm meter; it should be disconnected, if it’s connected, the commutator or starter should be replaced; Check if the undercutting depth of commutator should be 0.60 mm and the minimum depth should be 0.20 mm. if the depth is smaller than the minimum value, then the commutator or starter assembly should be replaced;
Malfunction of engine
Check if the crankshaft of engine can be rotated or if it’s run heavily, if it’s abnormal to cause Weak running of starter, the engine should be checked and repaired internally;
Weak running of starter
Too low
Voltage of battery
Charge or replace battery
Normal Does starter work normally?
Abnormal
Check, repair or replace starter
Normal Malfunction of starter harness
Bad contact
Repair or replace
Normal Engine works abnormally
Abnormal
Repair or replace
319
Common Malfunction Diagnosis Flow of Geely Automobile
No. 229 Starter can’t work Malfunction
Cause
Solution
Malfunction battery
of Check if the voltage of battery reaches to 12.5 – 12.9V, if not, recharge or replace the battery;
Malfunction fuse
of
Malfunction starter relay
of Check if internal contacts of starter relay is conducting with power on, and replace the relay if it’s broken;
Malfunction harness
of Check the harness of starter for short-circuit or poor contact, if it's abnormal, the starter harness should be checked and repaired;
Check the fuse of starting loop for break and replace fuse if it’s broken;
Check if the coil of electromagnetic switch for starter is OK, and replace the electromagnetic switch if the coil is broken; Check the stator coil of starter for break or short-circuit, and replace starter assembly if the coil is abnormal; Measure length of internal brush of starter with vernier caliper; the standard length of brush should be 15.5 mm and the minimum worn length is 10 mm; if the brush is shorter than the minimum value, the brush or starter assembly should be replaced;
Starter can’t work Internal malfunction starter
of
Internal malfunction engine
of
Check the condition of commutator: 1. Check with Ohm meter if it’s connected between two commutators, and replace commutators or starter assembly if one of them is disconnected. 2. Check the grounding situation of starter commutator; check connection between armature coil and spindle with Ohm meter; it should be disconnected, if it’s connected, the commutator or starter should be replaced. 3. Check if the undercutting depth of commutator should be 0.60 mm and the minimum depth should be 0.20 mm. if the depth is smaller than the minimum value, then the commutator or starter assembly should be replaced. Check connecting condition of exciting coil: 1. Check with Ohm meter if it’s connected between conductor and exciting coil brush, and replace starter assembly if it’s disconnected. 2. Check the grounding condition of exciting coil; it should be disconnected between end of exciting coil and magnetic pole armature frame measured by Ohm meter, and replace starter assembly if it’s connected. Check if the crankshaft of engine can be rotated normally, if it’s blocking or blocked, the engine should be checked and repaired.
320
Common Malfunction Diagnosis Flow of Geely Automobile Starter can’t work
Low voltage of battery
Charge or replace battery
Too low
Normal Broken fuse of starter
Change starter fuse
Broken
Normal Malfunction of starter relay
Change starter relay
Abnormal
Normal Open circuit or poor contact of connector loop for starter
Abnormal
Check and starter loop
repair
Normal Blocking or incapable rotating or crankshaft for engine
Broken
Check and repair engine
Normal Starter in poor operation
Abnormal
321
Replace assembly
starter
Common Malfunction Diagnosis Flow of Geely Automobile
No. 230 Idling of starter Malfunction
Cause Malfunction switch
of
Check coil poles of electromagnetic switch for short-circuit, which will result electromagnetic in idling of starter due to positive pole of power supply connecting to exciting coil of starter; replace electromagnetic switch or starter assembly if necessary;
Malfunction of one-way clutch
Idling of starter
Solution
Check working, wearing-out and damaging condition of clutch planetary gear. Hold starter clutch with hand and rotate planetary gear clockwise to check free rotating of this gear; and try to rotate planetary gear counterclockwise; it should not be rotated; replace starter assembly if it’s abnormal;
Check starter fastening bolt for loosing, which will result that one-way clutch Malfunction of starter fastening can’t engage with ring gear of flywheel to drive torque and that the starter is bolt idling; bolt should be tightened or replaced; Check ring gear of flywheel for worn-out or damage and loosing, which will result that torque can’t be driven through starter and that the starter is idling; flywheel assembly should be replaced; Malfunction of flywheel
Check fastening bolt of flywheel for loosing and dropping-off; if it’s abnormal, it should be tightened or flywheel assembly should be replaced; Check the engaging gears of starter and flywheel for over worn-out or damaged tooth, which will result that gears can’t engage to drive torque and that the starter is idling; pinion of starter or starter assembly should be replaced;
Idling of starter
Short-circuit of internal contacts of electromagnetic switch for starter
Short-circuit
Replace electromagnetic switch or starter assembly
Normal Broken Slipping or broken tooth of starter one-way clutch
Replace one-way clutch
Normal Loosing of starter fastening bolt
Loosing
Tightening
Normal Damage or loosing of ring gear for starter and flywheel
Abnormal
322
Tighten or flywheel
replace
Common Malfunction Diagnosis Flow of Geely Automobile
No. 231 Abnormal sound during start-up of starter Malfunction
Cause
Malfunction of one-way clutch
Solution Check bearing and pinion of one-way clutch for damage, which may result in “breaking” between gear of one-way clutch and ring gear of flywheel and subsequent abnormal sound during start-up; thus one-way clutch should be replaced; Check if pinion of one-way clutch return well after start-up; if not, the pinion will contact to ring gear of flywheel after start-up and result in abnormal sound; one-way clutch should be dismantled for checking and greasing or replaced;
Abnormal sound Malfunction of battery during start-up of starter Internal malfunction of starter
Check if voltage of battery reaches to 12.5 – 12.9 V; if the voltage is over-low, starter will be unable to drive torque to flywheel and electromagnetic switch of starter will snap-on and generate abnormal sound due to no energy; thus battery should be recharged or replaced; Check internal bearing bush of starter for wearing condition; if it’s over-worn, stator and rotator of starter will contact and result in abnormal sound; thus starter assembly should be replaced;
Malfunction of electromagnetic Check coil of electromagnetic switch for short-circuit or poor contact; if it’s switch abnormal, electromagnetic switch should be replaced;
Malfunction of flywheel
Check ring gear of flywheel for over worn-out or damage and loosing, which may result in bad engaging between one-way gear of starter and ring gear of flywheel for driving torque and subsequent abnormal “breaking” sound; thus ring gear of flywheel or flywheel assembly should be replaced;
Abnormal sound during start-up of starter
Broken
Damage of one-way clutch bearing and pinion
Replace one-way clutch
Normal Low voltage of battery
Over-low
Recharge or replace battery
Normal Over worn-out of internal bearing bush for starter
Abnormal
Replace starter
Normal Damage or loosing of ring gear for engine flywheel
Abnormal
323
Replace flywheel
Common Malfunction Diagnosis Flow of Geely Automobile
No. 232 Over-high or over-low recharging voltage from generator Malfunction
Cause
Solution
Check generator belt for tension and wearing condition and if there is 10 mm of Malfunction of generator flexibility at middle of belt under 50 N pressure; if the belt is over-loosing or belt over worn-out, the generator belt should be adjusted or replaced; Malfunction of fuse
Check fuse of generator (60A) for poor contact; if it’s broken, the generator fuse should be replaced;
Poor contact of harness
Check and remove fault of bad wire contact;
Malfunction of generator Check if generator regulator is able to adjust generated voltage; if it’s regulator abnormal, regulator or generator assembly should be replaced; 1. Check forward rectifying: Connect one probe of Ohm meter to positive pole of rectifying diode, and the other probe to every end of rectifiers; changeover the polarity of probes and repeat above procedure; the Ohm meter will show conducting for one and cutoff for the other; if the conductivity is different from above description, the rectifier or generator assembly should be replaced;
Over-high or over-low recharging voltage from generator
Malfunction of generator 2. Check backward rectifying: Connect one probe of Ohm meter to negative rectifier pole of rectifying diode, and the other probe to every end of rectifiers; changeover the polarity of probes and repeat above procedure; the Ohm meter will show conducting for one and cutoff for the other; if the conductivity is different from above description, the rectifier or generator assembly should be replaced. Malfunction of battery
Check internal plate of battery for sulfurization or short-circuit, which may result in over recharging current and subsequent over recharging energy from generator, thus the battery should be replaced;
324
Common Malfunction Diagnosis Flow of Geely Automobile Over-high or over-low recharging voltage from generator
Loosing or over worn-out of generator belt
Abnormal
Replace belt
generator
Normal Loosing or bad contact of fuse of generator
Change fuse Abnormal
Normal Malfunction of generator regulator
Replace regulator
Abnormal
generator
Normal Malfunction of generator rectifier
Replace generator rectifier or generator assembly
Abnormal
Normal Sulfurization or short-circuit of internal battery plate
Sulfurization or short-circuit
325
Replace battery
Common Malfunction Diagnosis Flow of Geely Automobile
No. 233 Generator can’t work Malfunction
Cause
Solution
Check generator belt for tension and wearing condition and if there is 10 mm of Malfunction of generator flexibility in the middle of belt under 50 N pressure; if the belt is over-loosing or over belt worn-out, the generator belt should be adjusted or replaced; Check fuse of generator (60A) for break; if it’s broken, the generator fuse should be replaced;
Malfunction of fuse
Malfunction of generator Check if generator regulator is able to adjust generated voltage; if it’s abnormal, regulator or generator assembly should be replaced; regulator 1. Check forward rectifying: Connect one probe of Ohm meter to positive pole of rectifying diode, and the other probe to every end of rectifiers; changeover the polarity of probes and repeat above procedure; the Ohm meter will show conducting for one and cutoff for the other; if the conductivity is different from above Malfunction of generator description, the rectifier or generator assembly should be replaced; rectifier 2. Check backward rectifying: Connect one probe of Ohm meter to negative pole of rectifying diode, and the other probe to every end of rectifiers; changeover the polarity of probes and repeat above procedure; the Ohm meter will show conducting for one and cutoff for the other; if the conductivity is different from above description, the rectifier or generator assembly should be replaced. Generator can’t work 1. Place multi-meter to Rx1 grade and connect two probes to any two leads of armature windings; they should be connected; if the resistance is infinite, it indicates that the break results in failure of generator, thus the coil or generator Malfunction of stator coil of assembly should be replaced; 2. Check windings with bond strap: Place multi-meter to Rx1 grade and connect one probe to any lead of armature winding generator and the other probe to core of stator; if the resistance is infinite, the insulation of armature windings is good, otherwise the coil or generator assembly should be replaced; 1. Check resistance of rotator windings: Place multi-meter to Rx1 grade and connect two slip rings; the standard resistance should be 2.7 – 3.1 Ohm; if the Malfunction of rotator coil resistance is different from standard, the rotator or generator assembly should be of generator replaced; 2. Check flexibility of rotator: The radial swinging standard should be less than 0.5 mm; if it's abnormal, the generator assembly should be replaced; Malfunction of brush for engine
internal
Malfunction of harness
The length standard of exposed brush measured by vernier caliper should be 10.5 mm and the minimum length should be 1.5 mm; if the length is smaller than the minimum length, the brush or generator assembly should be replaced; Check the harness of generator for short-circuit or poor contact, if it's abnormal, the generator harness should be checked and repaired;
326
Common Malfunction Diagnosis Flow of Geely Automobile Generator work
can’t
Adjust or replace generator belt Loosing or over worn-out of generator belt
Broken fuse of generator
Replace fuse
Loosing or break of wire for connectors of generator Check and generator loop
repair
Generator rectifier in poor operation
Replace rectifier or generator
Generator regulator in poor operation
Replace assembly
starter
Open circuit or short-circuit of stator coil of generator
Replace assembly
generator
Damage of internal brush or rotator for generator
Replace assembly
327
generator
Common Malfunction Diagnosis Flow of Geely Automobile
No. 234 Charging indicator of generator is always on or not on Malfunction
Cause Malfunction generator belt
Solution of
Check generator belt for tension and wearing condition and if there is 10 mm of flexibility at middle of belt under 50 N pressure; if the belt is over-loosing or over worn-out, the generator belt should be adjusted or replaced;
Malfunction of Check if generator regulator is able to adjust generated voltage; if it’s abnormal, generator regulator regulator or generator assembly should be replaced;
Charging indicator of Malfunction generator is generator rectifier always on or not on
Malfunction generator fuse
1. Check forward rectifying: Connect one probe of Ohm meter to positive pole of rectifying diode, and the other probe to every end of rectifiers; changeover the polarity of probes and repeat above procedure; the Ohm meter will show conducting for one and cutoff for the other; if the conductivity is different from above description, the rectifier or of generator assembly should be replaced. 2. Check backward rectifying: Connect one probe of Ohm meter to negative pole of rectifying diode, and the other probe to every end of rectifiers; changeover the polarity of probes and repeat above procedure; the Ohm meter will show conducting for one and cutoff for the other; if the conductivity is different from above description, the rectifier or generator assembly should be replaced; of Check positive pole fuse of generator for conducting; if it’s broken, the generator fuse should be replaced;
Malfunction of Check indicating diode of combined instrument for mixed connection or breakdown; if combined instrument it’s abnormal, the combined instrument should be replaced; Malfunction of harness Check charging loop for good contact; if it’s abnormal, check or repair the loop; Malfunction of battery
Replace battery assembly;
Charging indicator of generator is always on or not on
Loosing or over worn-out of generator belt
Worn-out
Replace generator belt
Normal Broken fuse of generator
Broken
Change fuse
Normal Generator regulator in poor operation Normal
Abnormal Replace regulator
generator
Normal Generator rectifier in poor operation Normal
Abnormal Replace rectifier or generator assembly
Normal Short-circuit or open circuit of charging indicator loop of generator
Abnormal
Check or repair charging indicator loop of generator
Normal Short-circuit or open circuit of internal charging indicator of combined instrument
Abnormal
328
Replace combined
Common Malfunction Diagnosis Flow of Geely Automobile
No. 235 Flashing of charging indicator of generator Malfunction
Cause
Solution Check generator belt for tension and wearing condition and if there is 10 mm of flexibility at middle of belt under 50 N pressure; if the belt is over-loosing or over worn-out, the generator belt should be adjusted or replaced;
Malfunction belt
of
generator
Malfunction fuse
of
generator Check if the poor contact of fuse for battery positive pole results in insufficient charging of battery, thus the fuse should be tightened or replaced;
Malfunction regulator
of
generator Check if generator regulator is able to adjust generated voltage; if it’s abnormal, regulator or generator assembly should be replaced.
Malfunction Flashing of rectifier charging indicator of generator
of
generator
1. Check forward rectifying: Connect one probe of Ohm meter to positive pole of rectifying diode, and the other probe to every end of rectifiers; changeover the polarity of probes and repeat above procedure; the Ohm meter will show conducting for one and cutoff for the other; if the conductivity is different from above description, the rectifier or generator assembly should be replaced; 2. Check backward rectifying: Connect one probe of Ohm meter to negative pole of rectifying diode, and the other probe to every end of rectifiers; changeover the polarity of probes and repeat above procedure; the Ohm meter will show conducting for one and cutoff for the other; if the conductivity is different from above description, the rectifier or generator assembly should be replaced;
Check magnetic field diode of generator with Ohm grade of multi-meter for short-circuit or break; if the magnetic field diode is short-circuit or broken, the Malfunction of magnetic field voltage will be lower than voltage of charging indicator, and formed field diode of generator potential difference will result in lower-than-normal brightness of charging indicator; Malfunction instrument
of
combined Check indicating diode of combined instrument for mixed connection; if it’s abnormal, the combined instrument should be replaced;
Malfunction of harness
Check charging loop for good contact; if it’s abnormal, check or repair the loop;
329
Common Malfunction Diagnosis Flow of Geely Automobile Flashing of generator
charging
indicator
of
Abnormal
Loosing or over worn-out of generator belt
Replace belt
generator
Normal Broken fuse of generator
Abnormal
Replace fuse
Normal Abnormal
Generator regulator in poor operation
Replace regulator
generator
Normal Abnormal
Generator rectifier in poor operation
Replace rectifier or generator assembly
Normal
Short-circuit or open circuit of charging indicator loop of generator
Abnormal
Check or repair charging indicator loop of generator
Normal Short-circuit or open circuit Short-circuit or open circuit of magnetic field diode
Check, repair or replace generator
Normal Short-circuit or open circuit of internal charging indicator of combined instrument
Abnormal
330
Replace combined
Common Malfunction Diagnosis Flow of Geely Automobile
No. 236 Abnormal sound of generator Malfunction
Cause Abnormal sound of generator belt
Abnormal sound of generator
Solution Check generator belt for tension and wearing condition and if there is 10 mm of flexibility at middle of belt under 50 N pressure; if the belt is over-loosing or over worn-out and results in abnormal sound, the generator belt should be adjusted or replaced;
Check if the fastening bolts of generator belt pulley are loosing or the Malfunction of generator belt pulley distortion of pulley results in abnormal frictional sound with other parts; thus the generator belt pulley or generator assembly should be replaced; Malfunction of generator bearing
Check working condition of generator bearing; if it’s over-worn or lubricated badly, the generator bearing or generator assembly should be replaced;
Malfunction of generator brush
Check working and worn condition of internal brush for generator; if uneven worn-out of brush results in abnormal frictional sound with rotator of generator, the generator assembly should be replaced;
Other faults
Check if other objects enter to generator internally and result in abnormal bumping sound, thus the generator should be checked and repaired;
Abnormal sound of generator
Malfunction generator belt
of
Adjust replace
Friction of generator belt pulley with other object
Check, repair or replace generator
Malfunction of generator brush
Loosing of break generator bearing
or
Replace generator assembly
of
Replace generator bearing or generator assembly
331
Common Malfunction Diagnosis Flow of Geely Automobile
No. 237 Failure of battery storage Malfunction
Cause
Solution Check internal plates of battery for sulfurizing or short-circuit which will result in automatic discharging of battery, thus the battery should be replaced;
Internal malfunction of battery
Check if the battery is undercharged normally and results in subsequent failure of battery, thus the generator or loop should be checked; Check if the electrolyte level of battery is met to standard; the battery should be filled or replaced if the electrolyte level is too low;
Failure of battery storage
Check if the density of electrolyte for every battery cell is between 1.25 to 1.29 under 20 degree; if not, the distilled water should be filled or the battery should be replaced;
Other faults
Check the battery loop for short-circuit or connecting to bond strap, if it's abnormal, the loop should be checked and repaired; Check all switches for light for normal working; if there are abnormal, the switches for light should be replaced;
Fault of battery storage
Sulfurizing or short-circuit of internal battery plate
Replace battery
Short-circuit or open circuit of battery loop
Check and repair battery loop
Battery is undercharged normally
Charge or replace
Insufficient electrolyte or incorrect electrolyte density for battery
Filling
Malfunction of loop or switch
Check, replace
332
or
Common Malfunction Diagnosis Flow of Geely Automobile
No. 238 Weak running of blower Malfunction
Cause Malfunction of battery
Weak running of blower
Solution Check if the voltage of battery reaches to 12.5 – 12.9V, if the over-low voltage results in weak running of blower, the battery should be charged or replaced ;
Worn-out or poor contact of Replace blower assembly blower carbon brush Malfunction of blower coil
Check blower coil for short-circuit; check and measure if over-big adjusting resistance of blower results in weak running; if it’s abnormal, the blower assembly should be replaced;
Malfunction of blower adjusting Replace blower adjusting resistance; resistance Weak running of blower
Over-low Over-low voltage for blower
Charge or replace battery
Normal Abnormal Over-big resistance or short-circuit of blower coil
Replace motor
blower
Replace assembly
blower
Normal Abnormal Blocking or unsmooth running of blower blades
333
Common Malfunction Diagnosis Flow of Geely Automobile
No. 239 Blower can’t work Malfunction
Cause
Solution
Malfunction of fuse
Check the fuse of blower for break and replace blower fuse if it’s broken;
Check #1 and #2 terminal of relay for conducting; if so, check #3 and #4 terminal of Malfunction of blower relay for conducting while applying positive voltage to #1 and #2 terminal; if not, relay the relay should be replaced; Malfunction of blower Check every coil of blower adjusting resistance for conducting; if not, the blower adjusting resistance adjusting resistance should be replaced; Blower work
can’t Malfunction of blower Check blower coil for short-circuit or conducting; if it’s not conducted, the blower coil motor should be replaced; Malfunction of blower Check every connector of blower switch for conducting; if there is abnormal switch connector, the blower switch should be replaced; Malfunction harness
of Check the harness of blower for short-circuit or break; if it's abnormal, the harness of blower should be checked and repaired;
Malfunction of blower Check blower fan for blocking or other object resulting in blocking, thus the blower fan should be dismantled and checked; Blower can’t work
Over-low Low voltage of battery
Charg or replace battery
Normal Break Broken fuse of blower
Replace blower fuse
Normal Abnormal
Malfunction of blower relay
Replace blower relay
Normal Open circuit resistance
of
blower
speed
governing
Open circuit
Replace
blower
speed
governing resistance; Normal
Short-circuit or open circuit of blower coil
Abnormal
Replace blower motor
Normal Normal working of blower switch
Abnormal
Replace switch
blower
Normal Blocking or blocked blower fan
Normal
Abnormal
Replace blower fan
Abnormal
Open circuit or poor contact of connector loop for blower
Check and repair blower loop
334
Common Malfunction Diagnosis Flow of Geely Automobile
No. 240 Abnormal sound of blower Malfunction
Cause
Internal malfunction of blower
Solution Check working condition of brush for worn-out and if the friction between brush and rotator of blower results in abnormal sound; if it's abnormal, the blower motor or blower assembly should be replaced; Check bearing bush of blower for over-worn; if it's abnormal, the blower motor or blower assembly should be replaced;
Abnormal sound of blower Other malfunctions
Check blower internally for other object; if so, the blower should be dismantled to take other object out; Check fixing bolt of blower blades and fastening bolt of blower for loosing; tighten them if it’s abnormal;
Abnormal sound of blower
Impurity enters into blower
Abnormal Dismantle blower
Normal Loosing of internal blower blades
Abnormal
Dismantle blower
Normal Internal brush and bearing for blower in poor operation
Abnormal
335
Replace blower
Common Malfunction Diagnosis Flow of Geely Automobile
No. 241 Continuous running of cooling fan Malfunction
Cause Malfunction relay
of
Solution Check #1 and #2 terminal of relay for conducting; if so, check #3 and #4 terminal of relay fan for conducting while applying positive voltage to #1 and #2 terminal; the #3 and #4 terminal should be conducted; if the two contacts are still normal-close resulting in continuous running of fan, the relay should be replaced;
Malfunction thermostat Continuous running of cooling fan
of
1. Check if the opening temperature of thermostat is 80 – 84 degree; if not, recirculation and heat dispersion of cooling water will be bad and the high water temperature will result in continuous running of fan; then the thermostat should be replaced; 2. Check thermostat valve for lift; when water temperature is about 93 degree, the lift should bigger than 8 mm; if not, insufficient recirculation and heat dispersion of cooling water will result in high water temperature and subsequent continuous running of fan; then the thermostat should be replaced;
Check if the resistance of coolant temperature sensor varies according to water Temperature sensor temperature; check if the resistance of sensor is 2.5 kOhm +/- 5% under 20 degree; if it's for coolant abnormal, the temperature sensor for coolant should be replaced; Other malfunctions
Check if there is leakage of coolant for radiator and cooling system; if so, it will result in insufficient cooling water and high water temperature and subsequent continuous running of fan, thus the leaking parts should be replaced or treated for sealing;
Malfunction harness
of Check harness of fan motor for short-circuit or mixed connection; if it’s abnormal, the fan loop should be checked and repaired;
Malfunction engine ECU
of Check internal program of engine ECU for short-circuit or mixed connection; if it’s abnormal, thus the engine ECU should be replaced;
Continuous running of cooling
Leaking or insufficient coolant
Leakage
Check cooling system
Normal No recirculation and heat dispersing for coolant of radiator
Abnormal
Check, repair or replace thermostat
Normal Fan relay in poor operation
Abnormal
Replace relay
fan
Normal Water temperature sensor in poor operation
Abnormal
Replace water temperature
Normal Short-circuit or break of fan loop
Abnormal
Check and repair fan loop
Normal Engine ECU in poor operation
Abnormal
Replace engine
336
Common Malfunction Diagnosis Flow of Geely Automobile
No. 242 Cooling fan can’t work Malfunction
Cause
Solution
Malfunction of fan Check fan blades for distortion which may contact with fan guard and prevent fan from blades rotating; if it’s abnormal, thus fan blades should be replaced; Malfunction of fuse Check fuse of cooling fan for conducting; if it’s broken, the fuse of cooling fan should be for cooling fan replaced; Check #1 and #2 terminal of relay for conducting; if so, check #3 and #4 terminal of relay Malfunction of relay for conducting while applying positive voltage to #1 and #2 terminal; if not, the relay should be replaced;
Cooling can’t work
Malfunction of Check if the resistance of coolant temperature sensor varies according to water cooling temperature; check if the resistance of sensor is 2.5 kOhm +/- 5% under 20 degree; if it's fan temperature sensor abnormal, the temperature sensor for coolant should be replaced; Check internal coil of cooling fan motor for break or short-circuit; disconnect connectors of fan and connect battery and ammeter to the connectors; check if the current of cooling fan Malfunction of while running should be 5.7 – 7.7 A; if it’s abnormal, the motor assembly of cooling fan motor for cooling should be replaced; fan Check internal brush of cooling fan motor for worn-out; if it’s abnormal or over-worn, the motor assembly of fan should be replaced; Malfunction harness
of Check the harness of cooling fan for short-circuit or break; if it's abnormal, the harness of cooling fan should be checked and repaired;
Engine ECU
Check engine ECU internally for fault; if so; detect and clear code with diagnostic equipment and then reset it; if it doesn’t work, then replace engine ECU;
Cooling fan can’t work
Blocked Fan blades blocked due to contacting with fan guard
Replace fan blades
Normal Open circuit
Broken fuse of fan
Change fuse of fan
Normal Fan relay in poor operation
Abnormal
Replace fan relay
Normal Water temperature sensor in poor operation
Abnormal
Replace water temperature sensor
Normal Short-circuit or open circuit of cooling fan motor
Abnormal
Replace fan motor
Break
Check and repair fan motor loop
Normal Open circuit of cooling fan motor loop Normal Engine ECU
Abnormal
337
Replace engine ECU
Common Malfunction Diagnosis Flow of Geely Automobile
No. 243 Weak running of cooling fan Malfunction
Cause Malfunction of battery
Solution Check if the voltage of battery reaches to 12.5 – 12.9V, if the over-low voltage results in weak running of fan, the battery should be charged or replaced ;
Malfunction of cooling fan Check fuse of cooling fan for good contact; if it’s broken, the cooling fan fuse fuse should be replaced; Check if fan relay is well power-on; or check if corrosion of pins will result in Malfunction of cooling fan weak running of cooling fan; if it’s abnormal, the cooling fan relay should be relay replaced; Check if internal bearing bush of cooling fan is over-worn resulting in loosing or blocking of motor rotator and subsequent weak running; thus the motor assembly of cooling fan should be replaced;
Weak running of cooling fan
Check internal coil of cooling fan motor for break or short-circuit; disconnect connectors of fan and connect battery and ammeter to the connectors; check if Internal malfunction of motor the current of cooling fan while running should be 5.7 – 7.7 A; if it’s abnormal, for cooling fan the motor assembly of cooling fan should be replaced; Check internal brush of cooling fan motor for worn-out; if it’s over-worn, the motor assembly of cooling fan should be replaced; Check if the fastening bolts for cooling fan blades are loosing or loose fitting; tighten or replace fan blades;
Weak running of cooling fan
Over-low Low voltage of battery
Charge or replace battery
Normal
Poor contact of fan fuse
Abnormal
Replace fuse of fan
Normal
Poor power-on of fan relay
Abnormal
Replace fan relay
Normal
Short-circuit of fan motor
Abnormal
338
Replace fan motor
Common Malfunction Diagnosis Flow of Geely Automobile
No. 244 Wiper can’t work Malfunction
Cause Malfunction of fuse
Solution Check fuse of wiper for break or short-circuit; if it’s abnormal, the fuse should be replaced or the loop should be checked and repaired;
Malfunction of wiper Check internal contacts of wiper switch for short-circuit or open circuit; if it’s switch abnormal, the wiper switch should be replaced; Malfunction of wiper Check internal coil of wiper motor for short-circuit; if it’s abnormal, the wiper motor motor assembly should be replaced; Malfunction of fuse for Check fuse of centralized controller for conducting; if it’s broken or short-circuit, the centralized controller fuse of centralized controller should be replaced; Wiper can’t work
Internal malfunction of Check centralized controller for normal working; if it’s abnormal, the centralized centralized controller controller assembly should be replaced; Malfunction of harness
Mechanical malfunction
Check wiper loop for break or short-circuit; if it’s abnormal, the loop should be checked and repaired; 1. Check if there is dropping-off at connection of wiper link and wiper motor; if so, and the dropping-off results in malfunction of wiper, the link should be checked for damage; thus the wiper link should be replaced; 2. Check connection of wiper link for bad lubrication resulting in blocking and subsequent malfunction or continuous turning of wiper; thus the link should be greased or replaced;
Wiper can’t work
Broken
Broken fuse of wiper
Change fuse
Normal Short-circuit or break of internal contacts of wiper switch
Abnormal
Replace switch
wiper
Abnormal
Replace wiper motor
Normal Short-circuit of internal coil of wiper
Normal
Dropping-off of connection between wiper link and wiper motor
Abnormal
Check, repair or replace link
Normal Short-circuit or open circuit of wiper loop
Abnormal
339
Check and repair wiper loop
Common Malfunction Diagnosis Flow of Geely Automobile
No. 245 Wipe doesn’t work at intermitting position Malfunction
Cause
Solution
Malfunction of wiper switch
Check if internal contacts of wiper switch are contacted well; if it’s short-circuit or poor contact, the wiper switch should be replaced;
Malfunction of wiper relay
Check intermitting relay of wiper for normal working; if it’s abnormal, then the intermitting relay of wiper should be replaced;
Malfunction of fuse for centralized Wipe doesn’t controller work at intermitting Malfunction of wiper motor position Malfunction of harness Malfunction controller
of
Check fuse of centralized controller for conducting; if it’s broken or short-circuit, the fuse of centralized controller should be replaced; Check internal coil of wiper motor for short-circuit or break; if it’s broken, then check if the wiper works normally at other position; if it doesn't work too, the motor assembly of wiper should be replaced; Check wiper harness for break or short-circuit; if it’s abnormal, the loop should be checked and repaired;
centralized Check centralized controller for normal working; if it’s abnormal, the centralized controller assembly should be replaced;
Wipe doesn’t work at intermitting position
Internal open circuit of wiper switch
Abnormal
Replace wiper switch
Normal
Short-circuit or open circuit of wiper motor coil
Abnormal
Replace wiper motor
Broken
Change fuse
Normal
Broken fuse of centralized controller
Normal
Open circuit of wiper loop
Open circuit
Repair the loop
Normal
Centralized controller in poor operation
Abnormal
340
Replace controller
centralized
Common Malfunction Diagnosis Flow of Geely Automobile
No. 246 Electric fuel pump can’t work Malfunction
Cause
Solution
Over-low voltage of battery Malfunction of fuse for fuel pump
Check the fuse of fuel pump for conducting and replace fuse if it’s broken;
Malfunction of fuel pump relay
Check relay of electric fuel pump for normal working; if it can’t work normally, then the relay of fuel pump should be replaced;
Electric fuel pump Internal Malfunction of fuel pump can’t work
Check if the resistance of pump is 0.20 – 3.0 Ohm under 20 degree; and check internal coil of electric fuel pump for break or short-circuit; if it's different, the electric fuel pump assembly should be replaced;
Malfunction of harness
Check if harness of electric fuel pump is able to conduct, and if connectors and relay sockets are well contacted; if not, the fuel pump loop should be checked and repaired;
Malfunction of main relay
Check main relay for normal working; if it’s abnormal, the main relay should be replaced;
Malfunction of engine ECU
Check engine ECU for normal working; if it’s abnormal, the engine ECU should be replaced;
Electric fuel pump can’t work
Broken fuse of fuel pump
Broken
Change fuse
Normal Fuel pump relay in poor operation
Abnormal
Replace fuel pump relay
Normal Open circuit of fuel pump loop
Open circuit
Repair fuel pump loop
Normal Main relay in poor operation
Abnormal
Replace main relay
Normal Open circuit or short-circuit of internal coil for fuel pump
Abnormal
Replace pump
electric
Normal Engine ECU in poor operation
Abnormal
341
Replace engine ECU
fuel
Common Malfunction Diagnosis Flow of Geely Automobile
No. 247 Insufficient pressure of electric fuel pump Malfunction
Cause Malfunction of fuel pipeline
Solution Check fuel pipeline for leakage; if so, the fuel pipeline should be replaced;
Malfunction of strainer for fuel Check strainer for fuel pump for blocking; if so, the strainer should be pump cleaned or replaced; Internal malfunction of fuel Check electric fuel pump for internal pressure discharging; if so, the pump electric fuel pump assembly should be replaced;
Insufficient pressure of electric Malfunction of fuel regulator fuel pump
Check fuel pressure regulator for normal working; if it’s abnormal, the fuel pressure regulator should be replaced;
Malfunction of fuel filter
Check fuel filter for blocking; if so, the fuel filter assembly should be replaced;
Malfunction of fuel injector
Check injector for good sealing; if it’s leaking, the injector assembly should be replaced;
Over-quick pressure discharging of electric fuel pump
Leakage Distortion or leakage of fuel pipeline
Replace or repair
Normal Abnormal Malfunction of fuel pressure regulator
Replace regulator
pressure
Normal Abnormal Internal pressure discharging or bad sealing for electric fuel pump
Replace electric fuel pump
Normal Abnormal Bad sealing of injector
Replace injector
342
Common Malfunction Diagnosis Flow of Geely Automobile
No. 248 Positive pressure of fuel tank too high Malfunction
Cause
Solution
Malfunction of Check fuel tank cover and gasket for distortion or damage; if resulting in blocking or fuel tank cover damage of check valve on the cover, the fuel tank cover should be replaced; Malfunction of Check if the venting tube for fuel tank is bent, distorted or vented smoothly; if in case venting tube for of blocking or venting hardly and resulting in over-pressure of fuel tank, then it fuel tank should be replaced; Malfunction of Check if the venting check valve for fuel tank is blocked or unavailable resulting in venting check over-pressure of fuel tank, thus the check valve should be replaced. valve for fuel tank 1. Inspect visually if the canister is cracked or broken; if so, the canister assembly Positive pressure should be replaced; of fuel tank too high Malfunction of 2. Blocking the outlet of canister, blow air (4.71 kPa) into adsorbing entry and check the air discharged from desorbing outlet; if it doesn’t conform to regulation, the control canister canister should be replaced; 3. Blow the air to adsorbing entry, and check the air should discharge through other outlet freely; if not, the canister assembly should be replaced; Malfunction of Check canister control valve for resistance; the rating resistance under 20 degree canister control should be 22- 30 Ohm; if not, the canister control valve should be replaced; valve Malfunction engine ECU
of Check engine ECU for pulse signal controlling solenoid of control valve; if it results in malfunction of control valve, the engine ECU should be replaced;
Positive pressure of fuel tank too high
Broken Malfunction of venting check valve for fuel tank
Replace
Normal Abnormal
Malfunction of venting tube for fuel tank
Replace
Normal Malfunction of fuel tank cover
Abnormal
Replace
Normal Malfunction of control canister
Abnormal
Replace
Normal Malfunction of canister control valve
Abnormal Replace
Normal Abnormal
Malfunction of engine ECU
343
Check, replace
repair
or
Common Malfunction Diagnosis Flow of Geely Automobile
No. 249 Failure of remote controller Malfunction
Cause
Solution
Malfunction of Are indicators on keys bright or dark while emitter is working? If they are dark, then the remote controller battery is low or in poor contact and should be checked, repaired or replaced; battery Malfunction battery
Failure remote controller
of
of Check if the voltage of battery is enough, if it’s over-low, the battery should be charged or replaced;
Malfunction of fuse Check fuse of centralized controller for conducting; if it’s broken, the fuse of centralized for centralized controller should be replaced; controller Mismatch of remote Check remote controller for matching to centralized controller; if not, the remote controller type controller should be coded or replaced for coding process; Internal Malfunction Check internal electronics of remote controller for short-circuit or break; if it’s broken, the of remote controller remote controller should be replaced; Malfunction harness
of Check centralize controller loop for conducting to every connector; if it’s conducted, the harness of centralize controller should be checked and repaired;
Internal Malfunction Check if the centralized controller is able to receive signal from remote controller of centralized normally and control every actuating component; if it’s abnormal, the centralized controller controller assembly should be replaced;
344
Common Malfunction Diagnosis Flow of Geely Automobile Failure of remote controller
Is voltage of remote controller battery too low?
Over-low
Replace remote controller battery
Normal Is voltage of battery too low?
Over-low
Charge or replace battery
Normal Broken fuse of centralized controller
Broken
Change fuse
Normal Broken internal part of remote controller
Broken
Replace controller
remote
Normal Is remote controller matched to centralized controller?
Mismatch
Coding
Normal Short-circuit or break of centralized controller loop
Abnormal
Check and repair centralized controller loop
Normal Centralized controller in poor operation
Abnormal
345
Replace centralized controller
Common Malfunction Diagnosis Flow of Geely Automobile
No. 250Door lock is not self-locked after driving 30 feet Malfunction
Cause
Solution
Malfunction of fuse centralized controller
for Check fuse of centralized controller for conducting; if it’s broken, the fuse of centralized controller should be replaced;
Internal malfunction centralized controller
of Check centralized controller for normal working; if it’s abnormal, the centralized controller assembly should be replaced;
Check normal function of speedometer and then check if the signal is transferred to centralized controller; if it’s not working normally, the speed Door lock is not Malfunction of speed sensor sensor should be replaced; self-locked after driving 30 feet Locking latch for left-front door Check, repair or replace locking latch for left-front door; in poor operation Failure of indication
speedometer Check why the speedometer indicates abnormally, or replace combined instrument;
Malfunction of harness
Check loop of centralized controller and relative central control locking; if it’s abnormal, the loop should be checked and repaired;
Door lock is not self-locked after driving 30 feet
Broken fuse of centralized controller
Break
Change fuse
Normal Short-circuit or open circui of centralized controller loop
Abnormal
Check and repair centralized controller loop
Normal No signal from speed sensor to centralized controller
Abnormal
Repair speed sensor
Normal Door locking in poor operation
Abnormal
Replace door lock locking
Normal Speedometer indication in poor operation
Abnormal
Replace combined instrument
Normal Centralized controller in poor operation
Abnormal
Replace centralized
346
Common Malfunction Diagnosis Flow of Geely Automobile
No. 251 Failure of central control locking while driving Malfunction
Cause
Solution 1. Check if the lockup unit is firm and free of dropping-of; if not, it should be repaired;
1. Malfunction of lockup unit 2. Check the lockup unit for blocking; it should be moved freely during normal working; if it’s blocked, the lockup unit should be replaced; 3. Check motor of lockup unit and measure its resistance for short-circuit or break; if so, it should be replaced;
Failure of central control either by manual control or by remote control 2. Malfunction of circuit
4. Check fuse of central control for break; if so, the loop should be checked for short-circuit, grounding and over-current; if so, the fuse should be replaced after repairing; 5. Check connector for loosing or dropping-off; if so, it should be repaired;
3. Centralized controller
6. Centralized controller is damaged internally; the centralized controller assembly should be replaced;
Failure of central control locking while driving
Loosing or dropping-off of the lockup unit
Abnormal
Repair
Normal Blocking of lockup unit
Abnormal
Check, replace
repair
Normal Short-circuit or open circuit of lockup unit motor
Abnormal
Replace
Normal Poor contact, short-circuit or open circuit of loop
Abnormal
Check and repair
Normal Internal malfunction of centralized controller
Abnormal
347
Replace
or
Common Malfunction Diagnosis Flow of Geely Automobile
No. 252 Flashing CGQ alarm indicator for speedometer Malfunction
Cause
Solution 1. Check if the resistance of sensor is in normal range; replace it if necessary;
1. Malfunction of speed sensor
2. Lift front wheels and shift the gear; check speed sensor for signal; replace it if necessary;
3. Check speed sensor for dropping-off or poor contact; repair it if Flashing CGQ necessary; alarm indicator for speedometer during 2. Malfunction of drive assembly Check speedometer for blocking or damage, otherwise replace it if driving for speedometer necessary; 2. Malfunction of circuit 3. Malfunction instrument
of
4. Check sensor combined instrument loop and all connectors for short-circuit, open circuit or poor contact; otherwise repair it if necessary; combined Check internal PCB of combined instrument for fault; otherwise replace it if necessary;
Flashing CGQ alarm indicator for speedometer
Speed sensor
Abnormal
Replace
Normal Drive assembly for speedometer
Abnormal
Replace
Normal Abnormal
Circuit
Check repair
Normal Combined instrument
Abnormal
348
Replace
and
Common Malfunction Diagnosis Flow of Geely Automobile
No. 253 Window lifter can’t work Malfunction
Cause
Solution
Fuse burnt
Check if fuse of lifter burnt; if so, check if the circuit connects to earth wire and results in fuse burning because of over-current; replace fuse after repairing.
Circuit
Check all connectors of circuit for poor contact, short-circuit or open circuit; Check switch of lifter for loosing or poor contact; if so, repair it.
Switch of lifter
Check if the voltage of power supply for switch of lifter is 12V and there is power output after pressing switch; if not, replace the switch of lifter. Dismantle internal decorating plate of door; Check motor of window lifter for normal working after power-on; if it’s abnormal, replace it;
Window can’t work
lifter
Motor of lifter
Check if the resistance of glass along the sliding groove is too big and if the sliding groove is distorted; if it’s abnormal, it should be checked and repaired; Check motor of lifter and measure the resistance between terminals of motor with Ohm meter; if the resistance is infinite, the lifter should be replaced; Check fuse and relay of centralized controller harness; if they are abnormal; replace them;
Centralized controller
Check if connector of centralized controller is firm; if it's abnormal, it should be checked and repaired; Check centralized controller for normal working with displacement method, otherwise replace it if necessary;
Window lifter can’t work
Malfunction of fuse
Abnormal
Checking, replacing
repairing
Normal Abnormal
Malfunction of circuit
Check and repair
Normal Malfunction of lifter switch
Abnormal
Check, repair or replace
Normal Malfunction of lifter motor
Abnormal
Check, repair or replace
Normal Malfunction of centralized controller
Abnormal
Check, repair or replace
349
or
Common Malfunction Diagnosis Flow of Geely Automobile
No. 254 Blocking Door lock Malfunction
Cause
Solution Rusty internal mechanism of Door lock can't be moved. Clear, lubricate or replace it on rusty condition.
Rusty Door lock
Check if the lockup unit is firm and free of dropping-of; if not, it should be repaired; Malfunction of opener Check the lockup unit for blocking; it should be moved freely during normal working; if it’s blocked, the lockup unit should be replaced; of Door lock Check motor of lockup unit and measure its resistance for short-circuit or break; if so, it should be replaced; Door can’t opened due blocking latch
Check if the door is distorted and if there is sign of squeezing or bumping; if it’s abnormal, the door should be calibrated;
be Door to Over-abrading lock
Door
Check if the blocking of internal mechanism of Door lock is because of over-abrading; if so, it should be replaced;
Dislocation of Door Check Door lock for loosing; if so, adjust or replace it. lock due to external Check Door lock for distortion; if so, replace it. force Dismantle internal decorating plate of door and check supporting bar for knob of Supporting bar for Door lock for blocking or distortion; if it's abnormal, it should be calibrated or knob of Door lock replaced.
Blocking door latch
Rusting blocking
or
Blocking or rusting of door latch
Check, replace
repair
or
Check, replace
repair
or
Check, replace
repair
or
Normal Malfunction of door opener
Normal Distortion or dislocation of door
Abnormal
Distortion or dislocation
Normal Over-abrading door latch
Normal Blocking or interference of door latch knob
Worn-out
Replacing
Blocking interference
350
or Checking repairing
and
Common Malfunction Diagnosis Flow of Geely Automobile
No. 255 Failure of door lock Malfunction
Cause
Solution 1. Check if internal knob is too tight and unable to return; if so, it should be adjusted or replaced;
1. Internal knob of door is blocked and unable 2. Check if internal knob of door is unable to return to return because of distortion or dislocation; if so, it should be adjusted or replaced;
3. Check if core of door lock is unable to return because of rusting or over-abrading, so that the Door lock can’t be sprung back; if so, clear or replace it;
Door can’t be 2. Blocking of core of door lock closed because of failure of door lock 3. Broken body of door lock
4. Check internal structure of Door lock body for damage; if so, it should be replaced;
4. Distortion of door
5. Check door for distortion due to external bumping; If so, it should be adjusted or replaced;
5. Distorted or blocking knob of door lock
6. Check operating knob of door lock for distortion or interference; otherwise it should be repaired or replaced;
Failure of door lock
Blocking of internal knob of door
Yes
Repair or replace
No Blocking or damage of core of door lock
Yes
Replace
No Broken body of door lock
Yes
Replace
No Yes
Distortion of door
Check, repair or replace
No Distortion of door lock knob
Yes
Replace
351
Common Malfunction Diagnosis Flow of Geely Automobile
No. 256 If four doors of vehicle are not closed, the anti-theft alarm will be activated automatically and central control will be locked automatically Malfunction
Cause
Solution
If four doors of vehicle are not closed, the anti-theft alarm will be activated automatically and central control will be locked automatically
Is triggering switch of door control Check if the triggering switch of door control is unable to return broken? or blocked; repair or replace it according to condition; Is centralized controller broken? Malfunction of circuit
Check if there is signal outputted from centralized controller; repair or replace it according to condition; Check loops among all doors for break, short-circuit or poor contact, otherwise repair them;
If four doors of vehicle are not closed, the anti-theft alarm will be activated automatically and central control will be locked automatically
Blocking or non-return of door control
Yes
Replace
switch
No Centralized controller is broken
Replace
Yes
No Poor contact, short-circuit or open circuit
Yes
352
Check and repair
Common Malfunction Diagnosis Flow of Geely Automobile
No. 257 Reversing radar can’t work while reversing Malfunction
Cause
Solution
Failure of switch for Replace reversing switch; reversing light Failure of sensor of Check, repair or replace reversing sensor; reversing radar 2) Check if connection between body harness and controller is reliable; Poor contact between if the connection is normal, slight vibration should be touched by hand harness and controller on sensor. If not, check if the voltage of power supply for controller harness is normal. No display or alarm of Poor contact between reversing radar harness and display while reversing
3) Check if connection between body harness and controller is reliable; if the connection is normal, all LEDs will be on for about 1s when power is on. If not, check if the voltage of power supply for controller harness is normal.
4) If display works normally when power is on and slight vibration has Broken connecting been touched on sensor connected to controller when reversing, but no harness between reversing data are showed on display, the connection between display controller and display and controller should be checked for correct conducting; the break and short circuit test may be conducted with multi-meter. 5) After inspections stated above, if there is still fault, it can be Broken reversing radar determined that controller or display is broken. External power supply controller or display mode can be used to check and determine the parts to be replaced. Reversing radar can’t work
Abnormal
Failure of switch for reversing light
Check
and
Check
and
Normal Failure of sensor of reversing radar
Abnormal
repair Normal Poor contact between harness and display
Abnormal
Checking
and
Normal Broken connecting harness between controller and display
Abnormal
Check and repair
Normal Broken reversing radar controller or display
Abnormal
353
Replace
Common Malfunction Diagnosis Flow of Geely Automobile
No. 258 Wrong information from the reversing radar Malfunction
Cause 1) Sensor incorrectly;
is
Solution 1) Failed sensor is determined according to direction indicators of display (When obstacle is detected by two left sensors, left indicator is on; and right installed indicator is on per contra; when obstacle is detected by two middle sensors, both left and indicators are on.). Please adjust sensor promptly if inclined installation of sensor is inspected.
Figures which don’t change according to the distance of obstacle are 2) Broken harness showed on display sensor connecting when reversing. 3) broken controller
Wrong
information
sensor
for 2) The connected harness between sensors and controller should be checked for short circuit or break with multi-meter. 3) After inspections stated above, if there is still fault, it can be determined that controller or sensors are broken. Corresponding sensor can be replaced by or good one, if there is still fault, then it can be determined that controller is broken.
from
Abnormal installation for sensor
Abnormal
Adjust
Normal Short-circuit or break f connecting harness between controller and sensor
Short-circuit or break
Check, repair or replace
Normal Broken sensor or controller
Broken
354
Replace
Common Malfunction Diagnosis Flow of Geely Automobile
No. 259 Sunroof can’t move, including malfunction of automatic closing and anti-nip Malfunction
Cause
Solution
Broken fuse
Check if fuse is burnt-out; if so, replace it;
Poor contact of switch
Check switch for poor contact with multi-meter; if so, replace the switch;
Sunroof can’t Disordered memory for move, including control module malfunction of automatic closing Malfunction of control and anti-nip module
Sunroof operation
in
Check if the sunroof has functions such as automatic shutting and jam-preventing; if not, power-off the sunroof, and power-on again after 30 s to reset; Check control module for burn-out; if so, the control module should be replace;
Reverse connection
Connect the harness again;
Malfunction of motor
Check motor for normal working; if it’s abnormal, replace the motor;
poor
Burnt
Fuse burnt
Change fuse
Normal Poor contact of switch
Broken
Replace switch
Normal Power-off the sunroof, and power-on again after 30 s to reset
Disordered memory for control module
Normal Control module burnt
Burnt Replace control module
Normal Malfunction of motor
Burnt
Replace motor
355
Common Malfunction Diagnosis Flow of Geely Automobile
No. 260 Abnormal sound and vibration of sunroof while operating Malfunction
Cause
Solution
Obstacle or blocking of sliding Check sliding groove for obstacle; if so, clear it and lubricate the sliding groove groove;
Abnormal sound and vibration of Broken moving mechanism sunroof while operating Internal malfunction of motor Distorted window frame
Dismantle the glass and slide and check moving mechanism manually for damage; if so, the moving mechanism should be replaced; Replace sunroof and motor assembly; Replace sunroof and motor assembly;
Abnormal sound and vibration of sunroof while operating
Impurity or blocking of sliding groove
With impurity
Clearing impurity and lubricating
Normal Broken or mechanism
blocking
moving
Broken
Replace mechanism
moving
Normal Internal malfunction of motor
Normal
Over-low
Replace sunroof and motor assembly
Distorted
Distorted window frame
Replace sunroof assembly;
356
and
motor
Common Malfunction Diagnosis Flow of Geely Automobile
No. 261 Leaking of sunroof (water on internal decoration of roof) Malfunction
Water internal decoration roof
Cause
Solution
1) Check if one side of the clearance between glass of sunroof and roof is 1) Uneven clearance around too big; if so, dismantle left and right decorating bars for sunroof and release glass of sunroof and opening of on fastening bolt for glass; insert shim to the clearance around glass of sunroof roof and roof to even the clearance; of 2) Clog-up of sunroof drain 2) Check drain for clog-up; if so, the drain should be cleaned; 3) Dropping-off of sealant at rear 3) Check sealant at rear drain for dropping-off; if so, the rear drain should be drain re-installed;
Leaking of sunroof (water in internal decoration of roof)
One side of the clearance between glass of sunroof and roof is too big
Adjust the clearance around glass of sunroof and roof evenly
Too-big
Even Clog-up
Clog-up of drain
Clear the drain
Unblocked Dropping-off of sealant at rear drain
Drooping-off Re-install rear drain
357
Common Malfunction Diagnosis Flow of Geely Automobile
No. 262 Air-conditioner can’t work Malfunction Air-conditioner can’t work
Cause
Solution
Undercharge of refrigerant
Undercharge of refrigerant results in insufficient refrigerating capacity;
Overdose of refrigerant
Undercharge or overdose of refrigerant results in insufficient refrigerating capacity;
Air in system
Air in system results in insufficient refrigerating capacity;
Leakage in system
Check and remove leakage in system;
Over-loose compressor
belt
for Over-loose belt for compressor results in over-low rotating speed of compressor, warm air outlet and abnormal sound; stretch or replace the belt;
Open-circuit of AC pressure Replace AC pressure switch; switch Clog-up of drying filter
Replace AC clog-up of drying filter;
Less amount of cooling air for Less amount of cooling air for condenser results in over-pressure at LP and condenser HP side; check if the rotating speed of fan is normal and if the voltage is low; The fins of condenser blocked by dust
is Blocked fins of condenser by dirt results in over-high HP and bad heat radiating effect; clean the dust on condenser;
Dirt in system
Dirt in system will result in vacuum or very low pressure at LP side, high pressure at HP side, frost or dew deposited on pipeline near drying reservoir or heat expansion valve and warm air outlet; if the condition is not improved after power-off, then it can be determined that the system is clogged up by dirt. Then the drying reservoir should be replaced and heat expansion valve should be cleaned;
Moisture in system
After certain working duration, moisture in system will result in obvious lower and lower pressure at LP side, clog-up of hest expansion valve by ice, frost deposited on evaporator and warm air outlet; and system will be normal if power-on again after certain duration of shut-down; but the malfunction of intermitting cooling will occur repeatedly;
Low rotating speed or failure of blower will result in frost deposited on Low rotating speed or failure of evaporator, warm air outlet and insufficient refrigerating capacity; check blower blower speed adjusting switch, relay and speed adjusting resistance for damage and replace it, or replace blower assembly if necessary; Electromagnetic clutch compressor is slipping
of
Slipping of compressor electromagnetic clutch will result in abnormal running of compressor and insufficient refrigerating capacity; electromagnetic clutch can be replaced separately or compressor will be replaced;
Too much refrigerating oil in system will result in turbid streaking on sight Too much refrigerating oil in glass and insufficient refrigerating capacity; discharge exceed refrigerating system oil; Clogging of air inlet duct by other object will decrease air amount and result in Air inlet duct of AC is clogged insufficient cooling capacity and increased noise; clear clogging object from by other object air duct; Unclosed fresh air damper of AC will result in higher temperature of air outlet Fresh air damper of AC is not and insufficient refrigerating capacity; check the cause of unclosed fresh air closed tightly damper and treat it; Air filter screen of evaporator Blocking of air filter screen of evaporator by dust or other object will result in is blocked by dust or other decreased air amount and insufficient refrigerating capacity; clean air filter object screen; The fins of evaporator is Blocking of fins of evaporator by dust will result in decreased air amount and blocked by dirt insufficient refrigerating capacity; clean it by compressed air; Malfunction of evaporator
Malfunction of evaporator will resulting in failure of AC;
Bad packing of temperature wrap for heat expansion valve will result in Bad packing of temperature loosing of heat isolating layer and insufficient refrigerating capacity; pack it wrap for heat expansion valve properly again; Incorrect adjusting temperature controller
of Incorrect adjusting of temperature controller; replace the temperature controller;
Exceed or less opening of Replace expansion valve assembly, pump for vacuum and fill refrigerant; 358
Common Malfunction Diagnosis Flow of Geely Automobile expansion valve Malfunction of compressor
Malfunction of compressor will resulting in failure of AC;
Short-circuit or break of loop Check and repair loop and harness; and harness Malfunction of engine ECU
Replace engine ECU;
359
Common Malfunction Diagnosis Flow of Geely Automobile
Air-conditioner can’t work
Abnormal
Dirt in system
Repair or clear
Normal Abnormal
Malfunction of air duct
Check, repair or replace
Normal Undercharge refrigerant
or
overdose
Abnormal
of
Check repair
and
Check repair
and
Normal Abnormal
Air or moisture in system
Normal
Abnormal
Too much refrigerating oil or dirt in system
Check and repair
Normal Abnormal
Malfunction of evaporator
Check and repair
Normal Abnormal
Electromagnetic clutch of compressor is slipping or belt is loosing
Check, replace
repair
or
Check, replace
repair
or
Check, replace
repair
or
Check, replace
repair
or
Normal Abnormal
Malfunction of blower
Normal Malfunction evaporator
of
condenser
Abnormal
or
Normal Malfunction of temperature controller or temperature wrap
Abnormal
Normal Malfunction compressor
of
Abnormal
Check, replace
repair
or
Normal Short-circuit or circuit of circuit and harness
Abnormal
Check and repair loop and harness;
Normal Malfunction of engine ECU
Abnormal Replace engine ECU
360
Common Malfunction Diagnosis Flow of Geely Automobile
No. 263 Normal suction pressure and too high exhaust pressure for AC compressor Malfunction
Cause
Solution
Air in system
1) Air in system: Drain refrigerant and vent air out; pump vacuum and fill refrigerant again.
Too much refrigerant
2) Too much refrigerant: Discharge exceeding refrigerant. 3) Clog-up of condenser: Clean or replace condenser; pump vacuum and fill refrigerant again.
Normal suction Condenser blocked pressure and too high exhaust pressure for AC Drying reservoir blocked compressor while running of vehicle Pipeline blocked AC Insufficient air condenser fan
amount
4) Clog-up of drying reservoir: Replace drying reservoir; pump vacuum and fill refrigerant again. 5) Clog-up of pipeline: Clear clog-up; pump vacuum and fill refrigerant again. of
6) Insufficient air amount of condenser fan: Replace fan.
High temperature of engine 7) High temperature of engine water tank: find the cause and remove it. water tank Normal suction pressure and too high exhaust pressure for AC compressor
Abnormal
Air in system
Check and repair
Normal Too much refrigerant
Abnormal
Discharge
Normal Condenser blocked
Abnormal
Check, repair or replace
Normal Drying reservoir blocked
Abnormal
Check, repair or replace
Normal Abnormal Abnormal
Pipeline blocked
Check, repair or replace
Normal Insufficient air amount of condenser fan
Abnormal
Check, repair or replace
Normal High temperature of engine water tank
Abnormal
361
Check, repair or replace
Common Malfunction Diagnosis Flow of Geely Automobile
No. 264 Too high suction pressure and exhaust pressure for AC compressor Malfunction
Cause
Solution
Overdose of refrigerant
1) Overdose of refrigerant: Discharge exceeding refrigerant.
Malfunction of heat expansion 2) Malfunction of heat expansion valve: Replace heat expansion valve. valve Broken suction valve segment 3) Broken suction valve segment of compressor: Replace compressor. of compressor Too high suction pressure and exhaust pressure for AC compressor while running of vehicle AC
Over-high temperature of inlet 4) Over-high temperature of inlet air for evaporator: Check if fresh air damper air for evaporator is closed tightly; find the cause and remove it. Air in system Poor heat condenser Insufficient air condenser fan
5) Air in system: Vent air in system out; pump vacuum and fill refrigerant again. radiating amount
for 6) Poor heat radiating for condenser: Check if fins of condenser are blocked by dirt and if fins are bent or distorted; clean or replace them. of
7) Insufficient air amount of condenser fan: Check if fan circuit is in poor contact, if the rotating speed of fan is normal and if there is too much dust on fins of condenser; find out the cause and remove it.
8) Loose fixing of temperature wrap: The temperature wrap contacts badly with Loose fixing of temperature outlet of evaporator or outer heat isolating part of temperature wrap is broken; wrap fix the temperature wrap again to ensure good heat isolating and contact of temperature wrap for heat expansion valve. Too-high suction pressure and exhaust pressure for AC compressor
Abnormal
Overdose of refrigerant
Check repair
and
Normal Abnormal
Fault of heat expansion valve
Replace
Normal Abnormal
Broken suction valve segment of compressor
Check, repair or replace
Normal Too-high temperature evaporator
of
inlet
air
for
Abnormal
Check repair
and
Check repair
and
Normal Abnormal
Air in system Normal Poor heat radiating for condenser
Abnormal
Check, repair or replace
Normal Insufficient air amount of condenser fan
Abnormal
Check, repair or replace
Normal Loose fixing of temperature wrap
Abnormal
362
Check repair
and
Common Malfunction Diagnosis Flow of Geely Automobile
No. 265 Too high suction pressure and normal exhaust pressure for AC compressor Malfunction
Cause
Solution
Too high temperature of inlet air for evaporator Too high suction pressure and normal Malfunction of heat expansion exhaust pressure for valve AC compressor Broken compressor while AC running Loosing or bad heat isolating of temperature wrap for heat expansion valve
1)
Too high temperature of inlet air for evaporator: Check fresh air damper for leakage; the doors and windows should be closed to keep outside warm air away from carriage;
2) Malfunction of heat expansion valve: Replace heat expansion valve; 3) Broken compressor: Replace compressor; 4) Loosing or bad heat isolating of temperature wrap for heat expansion valve: Tighten it to ensure good contact and enhance isolating protection;
Too high suction pressure and normal exhaust pressure for AC compressor
Too high temperature of inlet air for evaporator
Abnormal
Malfunction valve
Abnormal
of
heat
expansion
Broken compressor
Abnormal
Loosing or poor heat isolating of temperature wrap for heat expansion valve
Abnormal
363
Check repair
and
Check, repair or replace
Replace
Check repair
and
Common Malfunction Diagnosis Flow of Geely Automobile
No. 266 Too low suction pressure and exhaust pressure for AC compressor Malfunction Too low suction pressure and exhaust pressure for AC compressor while running of vehicle AC
Cause
Solution
Insufficient refrigerant in 1) Insufficient refrigerant in system: Check system for leakage; repair it and system supplement refrigerant again; Malfunction of expansion valve
heat
2) Malfunction of heat expansion valve: Replace heat expansion valve;
Moisture in system
3) Moisture in system: Discharge refrigerant, replace drying filter and pump vacuum repeatedly (not less than 30 min) and fill refrigerant again;
Broken compressor
4) Broken compressor: Replace compressor;
Too low suction pressure and exhaust pressure for AC compressor
Insufficient
Insufficient refrigerant in system Normal
Filling
Abnormal
Malfunction valve
of
heat expansion Normal
Checking, repairing or replacing Abnormal
Moisture in system
Checking and repairing
Normal Abnormal
Broken compressor
Checking, repairing or replacing
364
Common Malfunction Diagnosis Flow of Geely Automobile
No. 267 Air conditioning has abnormal sound Malfunction t The compressor has abnormal sound during the operation
Cause
Solution (1)The driving belt has not been tensioned. It will be prolonged in the process of usage and thus cause the abnormal sound; the belt shall be re-tensioned in case of this situation occurs; (2).The pulley and the tensioner bearing break down with rumbling sound during the operation; a harsh feeling is showed when rotating the pulley by hand: replace the bearing, check the tensioner and the pulley, replace them in case they are out of service. (3)The abnormal sound may be caused by the looseness of the mounting bolt between the engine and the compressor bracket as well as untightening of the bolt when mounting the compressor bracket; the bolt shall be checked and retightened to ensure its reliable connection;
The compressor has abnormal (4).The compressor is oil shortage that causes the piston seizure, the piston scraping and sound also the abnormal sound: the refrigeration oil shall be added; (5).Too much or too little refrigerant, which causes the malfunction or the liquid impact of the compressor; the refrigerant must be refilled; (6).Failure of compressor electromagnetic clutch; replace the electromagnetic clutch or the compressor assembly; (7).Undersupply of the sedan generator battery that causes the insufficiency in the compressor electromagnetic clutch coil suction resultant; the electromagnetic clutch is in nearly sucking condition, which may cause the abnormal sound; the generator battery shall be checked or replaced; (8).The pulley is un-tightened: tightening the fastening screw; (1).The abnormal sound is generated owing to the mismatch of the thermo expansion valve structure with the system; it normally occurred when opening or closing the air conditioning; here opening of the thermo expansion valve can be lowered (clockwise fasten the set screw by half turn to 3/4 turn; over low fastening has no effect and over high fastening will influence the performance); replace the thermo expansion valve if the above method is invalid; (2)Performance of the thermo expansion valve does not mate with the system. The thermo The thermo expansion valve will have an abnormal sound under certain operation mode if the capacity of expansion valve the thermo expansion valve is too large; replace into a thermo expansion valve of suitable has abnormal capacity. sound (3).Resonance of the thermo expansion valve will be caused if the thermo expansion valve structure does not mate with the system; the thermo expansion valve shall be replaced under this condition; (4). It is caused by the quality problem of the thermo expansion valve such as ultra low of the spring force; the thermo expansion valve shall be replaced; The air (1) abnormal sound of the blower, imbalance of the blower fan blade, abnormal sound conditioning has caused by excessive wear of the blower motor: replace the blower; other abnormal sound (2) Looseness of the clamp or the knock during the operation: tighten the clamping stirrup, eliminate the friction or the vibration between the hoses and other parts; (3) There has chatter in the pressure line caused by overfilling of the refrigerant; surplus refrigerant shall be discharged; (4) There has hissing sound at inlet of the thermo expansion valve caused by inadequate filling of the refrigerant; the refrigerant shall be supplied;
365
Common Malfunction Diagnosis Flow of Geely Automobile
Abnormal noise of the auto air conditioning reversing servomotor of generation II Vision and Leading; replace the servomotor
The air conditioning has abnormal sound
Abnormal Abnormal noise compressor
of
Overhaul or replace
the
Normal Abnormal Abnormal
noise expansion valve
of
the
Replace
thermo
Normal Abnormal Overhaul or replace
Other abnormal sounds of the air conditioning
No. 268 The air conditioning has no heating supply or the heating air is not warm Malfunction Cause t Malfunction of the blower switch
Solution 1) Malfunction of the blower switch: replace the blower switch;
2). Air leak of the heating radiator shell or the blower shell: tighten the connection Air leak of the heating radiator screw and replace the sealing gasket; shell or the blower shell The cooling fin of the hot-water pipe inside the heating radiator is 3). Cooling fin of the hot-water pipe inside the heating radiator is squeezed and deformed, which blocks the wind passing through the heater: straighten the squeezed and deformed. The air cooling fin with a nipper pliers; it shall be replaced by a new heater in case that conditioning the cooling fin is unable to be straightened. has no heating supply or Hot air outlet is blocked by the 4). Hot air outlet is blocked by the heater felt gasket: readjust the felt gasket the heating heating radiator felt gasket position; air is not warm The water valve switch is in Reopen it in correct position; wrong open position
Improper adjustment to the mix 5). Improper adjustment to the mix air throttle: re-adjust the air throttle; air throttle
366
Common Malfunction Diagnosis Flow of Geely Automobile The air conditioning has no heating supply or the heating air is not warm
Malfunction Overhaul or replace
The blower switch is out of service
Normal The heating radiator shell or the blower shell is air leakage
Air leakage Overhaul or replace
Normal The cooling fin of the hot-water pipe inside the heating radiator is squeezed and deformed.
Deformation Overhaul or replace
Normal Block Adjust
Hot air outlet is blocked by the heating radiator felt gasket
Normal The mix air throttle is in improper adjustment
Improper adjustment
367
Adjust
Common Malfunction Diagnosis Flow of Geely Automobile
No. 269 A/C compressor fails to start Malfunction symptom A/c compressor assembly fails to start when the a/c is in operation
Cause
Solution
Fuse, electric appliance relative fuse is blown, the electric appliance element is of poor contact, the relay element and relay are coil is broken: check the service condition of each electric appliance element and malfunction replace damaged one; The belt is over loose
Readjust or replace the belt
Failure of low voltage Low temperature protection switch takes effect; when the environment switch temperature is lower than 15oC, the low temperature protection switch will automatically cut out the circuit controlling the compressor: check if the environment temperature is lower than 15oC and if the low temperature protection switch is in normal operation; Water temperature is too Check and eliminate the failure of ultra high in water temperature; high The idle speed is too low Eliminate it per the preclusion method of too low idle speed of engine;
The temperature Performance parameter of the temperature controller is over proofed while the controller is failure temperature inside the car is ultra high, but the temperature controller is incapable of being switched on to operate the compressor: replace the temperature controller; The thermo sensitive The thermo sensitive resistance is damaged and incapable of sensing the resistance is damaged temperature correctly: check and replace the thermo sensitive resistance; High pressure switch
The high pressure switch takes the protection effect so that the compressor fails to start; check if the high pressure is too high and the system is blocked;
The electromagnetic The electromagnetic clutch can not be sucked together and is incapable of being clutch can not be sucked operated along with the compressor: check if the clearance of the electromagnetic together clutch is too large, replace the electromagnetic clutch; The electromagnetic The electromagnetic clutch can’t work: check if the electromagnetic clutch coil is clutch can’t work broken, replace the electromagnetic clutch; The refrigerant is leaking The refrigerant is leaked to the set value of low pressure switch, the low pressure protection switch takes effect so that the compressor fails to start: check the system leaking position and eliminate it; The compressor bearing The compressor bearing is damaged or oil shortage: replace the compressor and is damaged or oil fill up the refrigeration oil as required; shortage Cylinder sticking compressor
Malfunction of interior short control
of Cylinder sticking of compressor; there may have foreign materials inside the cylinder or the piston position maybe changed after long-term abrasion that causes the seizure or the oil shortage: remove the compressor for replacement;
ECU Replace the ECU assembly circuit
368
Common Malfunction Diagnosis Flow of Geely Automobile A/C compressor fails to start
Fuse, electric appliance element and relay are in trouble
Abnormal
Overhaul or replace
Normal Malfunction switch
of
low
pressure
Malfunction of temperature controller
Abnormal
Abnormal
Abnormal
High pressure switch
The electromagnetic clutch can not be sucked together
Unable to suck
Overhaul or replace
Replace
Overhaul or replace
Overhaul or replace
Leaking The refrigerant leaking
Overhaul
is
The compressor bearing is damaged or oil shortage
The electromagnetic clutch can’t work
Damaged
Cylinder sticking
Replace
Replace
Abnormal Overhaul or replace
The compressor is of piston seizure Abnormal Short circuit of ECU
Replace assembly
369
the
ECU
Common Malfunction Diagnosis Flow of Geely Automobile
No. 270 The A/C control mechanism is hard to operate Malfunction symptom
Cause
Solution
Manipulating key of the control 1).Manipulating key of the control mechanism and rocker on the shell mechanism and rocker on the shell body are heavy: spread lubrication oil at the sliding part of each The A/C control body are heavy revolving member. mechanism is hard to operate The air throttle is ineffective in 2).The air throttle is ineffective in rotation: repair the air throttle. rotation
The A/C control mechanism is hard to operate
Manipulating key of the control mechanism
Heavy Overhaul
and rocker on the shell body are heavy
Normal Blocked
The air throttle is ineffective in
Overhaul
rotation
No. 271 The A/C evaporator is frosting Malfunction symptom
Cause
Solution
The thermo expansion 1).The thermo expansion valve is in abnormal operation: replace the valve can’t work thermo expansion valve; .Thermo sensitive resistance of the 3). Thermo sensitive resistance of the temperature controller is temperature controller is mounted in incorrect position, so it is incapable of sensing the surface mounted in incorrect temperature of the evaporator. Install the resistance in correct position; position The A/C evaporator is frosting during the operation Malfunction of thermo sensitive resistance of the temperature controller
4). Thermo sensitive resistance of the temperature controller fails so that the compressor can not stop; uninterrupted refrigeration will lower down the surface temperature of the evaporator. when the temperature is below 0 degree, water vapor in the air flowing through the evaporator will be frosting on external surface of the evaporator: replace the thermo sensitive resistance;
Temperature of the 5).Temperature of the temperature controller thermo sensitive temperature controller resistance is set so low, causing surface temperature of the evaporator thermo sensitive below 0 degree to frost: replace the thermo sensitive resistance; resistance is set too low
370
Common Malfunction Diagnosis Flow of Geely Automobile The a/c evaporator is frosting
Abnormal The thermo expansion valve is in abnormal operation
Replace
Normal Deficient The evaporator is deficiency in draught
Overhaul
Normal
Thermo sensitive resistance of the temperature controller is in incorrect mounting position
Incorrect Re-mount
Correct Abnormal Replace
Thermostat of the temperature controller is out of service
Normal
Design temperature of the temperature controller thermostat is over low
Abnormal Replace
371
Common Malfunction Diagnosis Flow of Geely Automobile
No. 272 Constant malfunction and solution of A/C components Spare parts name A/C relay
Compressor
Constant malfunction
Preclusion method
1).The contact is superficial charring; 1).Connection check: bridge a wire at the suction position 2).The relay coil is burnt out; of the relay. If the compressor or the fan is in normal 3).The spring leaf is damaged and incapable of operation after the bridging, it means there is failure in the sucking; relay; 2) Displacement method check: replace into a new relay of the same type and specification to make the judgment of the original relay. When replacing the damaged relay, it shall adopt the relay of the same model and specification and the relay position shall not be changed randomly; 1).Cylinder sticking and cylinder scoring of Replace into a new compressor of the same model; compressor; the link rod is breakout; the pulley does not rotate or is hard to rotate; there has abnormal sound; 2).Valve leaf and valve plate of the compressor is damaged and there has abnormal sound; 3).The compressor sealing gasket is breakdown that result in coalition between high and low pressures; high pressure is the same as the low pressure; 4).The compressor shaft seal is leaked that causes large leakage of the refrigerant; 5).Pulley bearing is damaged. Ultra large belt Replace the electromagnetic clutch and adjust the belt tension will generate too much radial bearing tensioning force; force, and the suction cup will be seized with the pulley thus damage the bearing; 6).Coil of the electromagnetic clutch is short or Replace the electromagnetic clutch; broken so that the suction can not be generated; 7).Clearance between the suction cup and the pulley is too small that causes the sticking or the seizure between the suction cup and the belt surface, or even the pulley charring; 8).Fuse of the electromagnetic clutch is blown out; 9). The electromagnetic clutch is slipping; Reason of insufficient suction and its preclusion method: suction between the pulley and the suction cup (1).The electromagnetic clutch is insufficient in the power is inadequate that causes the slippage; supply voltage: recharge the battery; (2).A/C relay is in poor contact: check the relay and replace it if anything wrong with it. (3).There has too much refrigerant or the compressor is of piston seizure that causes excessive load; discharge the surplus refrigerant or replace the compressor; (4).The electromagnetic clutch has slipping sound caused by the belt slippage; re-tension the belt;
Evaporator
1).The evaporator is leaking that causes the Replace the evaporator assembly or the evaporator. shortage of refrigerant or no refrigerant; the result is that the evaporator is insufficient in the cooling volume or does not refrigerate.
372
Common Malfunction Diagnosis Flow of Geely Automobile
2).The evaporator is frosting;
Frosting on the sedan A/C evaporator can be treated according to the following aspects: 1).The thermo expansion valve is in abnormal operation: replace the thermo expansion valve; 2).The evaporator is deficiency in draught: find out the reason and eliminate it; 3). Thermo sensitive resistance of the temperature controller is in incorrect mounting position, so it is incapable of sensing the surface temperature of the surface temperature. Install the thermo sensitive resistance per correct position; 4). Thermo sensitive resistance of the temperature controller is out of service so that the compressor can not stop; uninterrupted refrigeration will lower down the surface temperature of the evaporator. When the temperature is below 0℃, water vapor in the air flowing through the evaporator will be frosted on external surface of the evaporator: replace the thermo sensitive resistance; 5).Design temperature of the temperature controller thermostat is over low that causes surface temperature of the evaporator below 0℃ to frost: replace the thermostat;
3) The ice block is caused by the moisture in the system and the dirty block is caused by the impurities such as the aluminium chips in 3)The evaporator assembly is the system; result of the ice block is that the evaporator is not cool blocked sometimes, while the result of the dirty block is that the evaporator is not cool or is inadequate in the cooling volume: eliminate the moisture or the impurities. 4).Constant malfunction of the thermo expansion valve: power head (gas phase head) of the thermo expansion valve is leaked that 4)The thermo expansion valve causes inadequate opening or incapable of being opened of the is blocked or leaked; thermo expansion valve, thus the evaporator is not cool or is inadequate in cooling volume: replace the thermo expansion valve.
1).There has dirt on the condenser flat pipe and the heat emission fin, which will Clean out dirt and impurities on the flat pipe and the heat emission reduce the heat transfer fin; capability and increase the high pressure in the refrigeration system; Condenser
2).There is impurity blockage on the condenser heat Purge them with compressed air; emission fin; 3).The condenser heat Calibrate it with the nipper pliers and replace the condenser if it is emission fin is of flexural severe; deformation; 4).The condenser is leaking;
Dry reservoir
Replace the condenser
The block reason is the pulverizing of the drier as well as too many impurities in the system; the phenomena is that the high pressure is 1)Dry reservoir assembly is increased and there has apparent temperature difference between blocked; inlet and outlet of the dry reservoir assembly: replace the dry reservoir; Thermo expansion valve maybe blocked so that the a/c will not 2)Filter screen inside the dry refrigerate: replace the dry reservoir and check the thermo reservoir assembly is damaged; expansion valve;
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Common Malfunction Diagnosis Flow of Geely Automobile
1).The hose is aging damaged; Replace damaged hose assembly; 2).The connection is loose; Pipeline assembly
Retighten the connection or replace the hose assembly;
3).The connection thread is Replace the hose assembly; damaged;
4).O seal ring is damaged;
Replace O seal ring. The above failures will cause the refrigerant leaking;
1).Wire of the blower or the fan Reconnect the fan wire; is broke off; 2).Motor of the fan or the Replace the blower or the fan; blower is damaged 3). Fuse of the blower or the fan is blown out or the switch is in Check and replace the fuse, eliminate the switch bad contact; Blower and condenser bad contact; fan 4).Governing resistance of the Replace the governing resistance; blower is damaged;
5).The fan blade is battered
Replace the condenser fan (the above failure will cause deficiency in fan draught or no draught of the fan so that the high pressure will be abnormally high; deficiency in the blower draught or no draught of the blower will cause the evaporator to frost, deficiency in heating air or no heating air);
374
Common Malfunction Diagnosis Flow of Geely Automobile
Diagnoses flow of air-conditioning system constant malfunction
375
Common Malfunction Diagnosis Flow of Geely Automobile
Solution to auto a/c Constant malfunction: Auto air-conditioning system of Vision and Leading models are provided with failure self-diagnostic function. Some basic failures can be checked by the self checking function. In addition, we have enumerated some familiar failure symptoms and treatment processes, according to which you can find out the failure reasons and help your clients to solve the problems.
No.273 Vehicle temperature sensor is in poor condition (code display 01) Yes Power on and test if the voltage between B3 and B2 is0.5V≤Vi≤4.8V
The a/c controller is in poor condition
Pull out B plug behind the control panel
Vehicle interior temperature sensor
Test the ohmic value between B3 and B2 of B plug at the harness end with the meter
Yes Is the ohmic value between 500 and 100K?
B2
B3
No B3 and B2 metal plug-in card inside B plug are in poor contact with the controller socket;
1. Harness or metal plug-in connected with B3 and b2 is in poor condition; 2. The vehicle temperature sensor is in poor condition.
No.274 The vehicle exterior temperature sensor is in poor condition; (code display 02) Yes Power on and test if the voltage between A12 and A11 is 0.5V≤Vi≤4.8V
No The a/c controller is in poor condition
Pull out A plug Aehind the control panel
Vehicle exterior temperature sensor
Test the ohmic value between A12 and A11 of A plug at the harness end with the meter
Yes Is the ohmic value between 500K and 100K?
A11
A/C controller
A12
No 1. Harness or metal plug-in unit connected with A12 and A11 is in poorcondition; 2. The vehicle exterior temperature sensor is in poor condition.
376
A12 and A11 metal plug-in card inside A plug are in poor contact with the controller socket;
Common Malfunction Diagnosis Flow of Geely Automobile
No.275 The evaporator temperature sensor is in poor condition. (code display 03) Yes Power on and test if the voltage between B4 and B1 is 0.5V≤Vi≤4.8V
No The A/C controller is in bad condition
Pull out B plug behind the control panel
Vehicle exterior temperature sensor
Test the ohmic value between B4 and B1 of B plug at the harness end with the meter
Yes Is the ohmic value between 500 and 100K?
B2
B3
B3
No B4 and B1 metal plug-in card inside B plug are in poor contact with the controller socket;
1. Harness or metal plug-in unit connected with B4 and B1 is in bad condition; 2. The evaporator temperature sensor is in bad condition. A/C controller
No.276 The temperature adjustment performer is in poor condition; (code display 04) 1. Turn the ignition switch to "ON"; 2. Remain the environment temperature at about 25℃ (or unplug the temperature sensor inside and outside the vehicle); 2. Test the voltage between B9 and B2 (ground lead) pins with a meter; 3. Adjust the TEMP+ or the TEMP- key on the control panel.
Does the voltage between B9 and B2 continuously changed between 1.1V and 4.0V when the design temperature varies continuously between HI and LO?
No Yes Does the voltage remain constant?
A/C controller
value
Yes The A/C controller is in bad condition
No
1. The temperature adjustment performer is in bad condition; 2.The A/C controller is in poor condition
377
1. B10, B9 and B13 wires inside B plug are in poor contact with the performer or broken; 2. The temperature adjustment performer is in bad condition or the mechanism is seized; 3. The A/C controller is in bad condition.
Common Malfunction Diagnosis Flow of Geely Automobile
No.277 The sun sensor is in poor condition.(code display 05)
Yes
Power on and test if the voltage between B2 and B5 is0.7V≤Vi≤4.85V No
1. Pull out B plug behind the control panel; let the light sensitive head fully exposed under the sun; 2. Connect B5 pin at the harness end B plug with the digital multimeter red pen and connect B2 (ground lead) with the black pen.
1.Pull out B plug behind the control panel; 2.Cover the light sensitive head of the sun sensor with a light-tight object.
A/C controller
Yes Test if the ohmic value between B5 and B2 is reduced apparently?
Test the ohmic value between B2 and B5 of B plug at the harness end with the meter
No Yes
Is the ohmic value less than 100K?
The sun sensor is in poor condition.
No 1. Harness or metal plug-in unit connected with B2 and B3 is in poor condition; 2. The sun sensor is in poor condition.
The a/c controller is in poor condition
No.278 The fan governing module is in poor condition; 故障6(code display 06) 40A
800 power line (2)
Fan relay
3BW
GAUSE meter
Test the voltage between B7 and B2 with a meter from gear 1 to gear 5. The normal voltage shall be as follow: 3.9V at gear 1; 4.0V at gear 2 and 4.3V at gear 3; 4.5V at gear 4; 4.8V at gear 5.
black blue/brown
grey/brown
blue/black
speed regulation module
Blower
High speed realy
M
1.Turn the ignition switch to "ON"; 2.Adjust the "air volume plus" key on the control panel. There has no air or abnormal air volume variation from gear 1 to gear 5; the air volume is in normal condition at the Max. gear 6.
Blue
E
Fan ground lead
Is the voltage value in normal condition?
Yes
No 1.The harness connected with B7 and the plug-in unit are in poor condition; 2.The a/c controller is in poor condition.
A/c controller
378
1The governing module is in poor condition; 2.The plug-in unit at DS end of the governing module is in poor contact.
Common Malfunction Diagnosis Flow of Geely Automobile
No.279 The high speed relay is in poor condition; (code display 07) 1. Turn the ignition switch to gear "ON"; 2. Adjust the "air volume plus" key on the control panel. There has no air or abincreaseunsharpness air volume variation from gear 1 to gear 5, the air volume does not increase apparently at the Max. gear 6.
Fan relay
GAUSE meter
Blue M Test the voltage value between B6 and B2 with a meter. The normal value shall be 13V at gears excepet gear 6 and no more than 1V at gear 6.
Yes Is voltage value at gear 5 or gear 6 close to 0V? black blue/brown
blue/black
grey/brown
speed regulation module
Blower
A/c controller
No
E Fan ground lead
1.The GAUSE meter wire is in bad condition; Yes
Is the voltage value at gear 6 ≤ 1V?
2. The high-speed relay socket is in bad contact; 3. The high-speed relay is in bad condition.
No
1. The controller card connected with B6
1. The high-speed relay socket is in bad
is in bad contact;
contact; A/c controller 2. The high-speed relay is in bad condition.
2. The a/c controller is in bad condition;
No.280 The rear defrosting function is invalid 800 powe line (2) 1. Turn the ignition switch to gear "ON"; 2. Operate the "rear defrosting" key on the control panel; the defrosting lamp will light up after pressing the key once and will go out after pressing it again.
2# 30A
Rear defrosting control
Test the voltage value between A3 and the ground with a meter. The normal value shall be 13V at light off and ≤ 1V at light on.
Green/White
Is the voltage value at light on or ligh off close to 0V?
1. The GAUSE meter wire is broken; Is the voltage value no more than 1V when the light is on?
2. The rear defrosting relay socket is in bad contact; 3. The rear defrosting relay is in bad condition;
A3 A/C controller 1. The A3 plug-in unit is in bad contact with the controller socket; 2. The a/c controller is in bad condition;
379
1. The rear defrosting relay socket is in bad contact; 2. The rear defrosting relay is in bad condition; 3. The rear defrosting heater and concerned harness problem.
Common Malfunction Diagnosis Flow of Geely Automobile
No.281 The display screen has no display
No.282 The internal and external circulation regulation is invalid
380
Common Malfunction Diagnosis Flow of Geely Automobile
No.283 The wind direction adjustment is abnormal
No.284 The blower is in poor operation
381
Common Malfunction Diagnosis Flow of Geely Automobile
No.285 Vehicle interior air conditioning is in poor condition
382
Common Malfunction Diagnosis Flow of Geely Automobile
No.286 Vehicle interior central heating is in poor condition
No.287 Night light regulation function of the a/c controller is invalid
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Common Malfunction Diagnosis Flow of Geely Automobile
No.288 The compressor is out of service
No.289 Effect of the air conditioning is in poor condition (check it per the content in the following table) Phenomena and state
Both high pressure and low pressure are too high
Analysis of causes
Solution
1. There is too much air mixed in the system.
Vacuumize again and refill the refrigerant.
2. Too much refrigerant filled.
Discharge the surplus refrigerant.
3. Too much lubrication oil.
Check or replace, discharge the surplus lubrication oil.
4. The heat emission effect of condenser is poor.
Clean the dirt on the condenser surface or replace with a new condenser.
5. The cooling fan common used by the condenser and Check it or replace with a new cooling fan. the water tank is abnormal.
Both high pressure and low pressure are too low
The high pressure is normal and the low pressure is too high
The high pressure is normal and the low pressure is too low
1. There is insufficient refrigerant filled.
Add the filling volume of the refrigerant.
2. The refrigerant is leaking.
Make the leak check and replace the leaked spare.
3. The O-ring is damaged.
Replace the O-ring.
1. The expansion valve is in over size opening or is damaged.
Adjust the opening of the expansion valve or replace with a new expansion valve.
2. Too much refrigerant filled.
Discharge the surplus refrigerant.
3. Something wrong with the compressor.
Replace the compressor.
1. Insufficient refrigerant filled.
Add the filling volume of the refrigerant.
2. The expansion valve is ice blocked.
Replace with a new liquid storage drying bottle.
3. Dirt on the evaporator surface or has clogging inside Clean the evaporator surface or replace the evaporator. with a new evaporator.
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Common Malfunction Diagnosis Flow of Geely Automobile
The high pressure is low yet the the low pressure is high
1. The compressor efficiency is decreased.
Check it or replace compressor.
with a new
2. Opening of the expansion valve is too big.
Adjust the opening of the expansion valve or replace with a new expansion valve.
1. The low pressure increase fast after the power off- the Replace with a new liquid storage drying bottle. The high pressure is low system is ice blocked. yet the the low pressure is of negative pressure 2. The low pressure increase slowly after the power off Clean the system. the system is blocked.
The air volume is insufficient
The voltage normal
is
1. The inlet air filter is blocked.
Replace with a new inlet air filter cartridge.
2. The air duct is blocked.
Clear the air duct.
3. There is dirt on the evaporator surface.
Clean the evaporator surface.
4. The blasting motor is in sluggish operation.
Check or replace with a new blasting motor.
1. Supply voltage of the entire car is unsteady. The voltage is inadequate 2. The power ground is out of order. The high pressure can only 1. The clutch or the belt is slippery. reach a certain value.
Check .
Check or replace the clutch or the belt.
1. The evaporator temperature sensor is in poor Replace the sensing head or check if its condition. position is correct. 2. Harness and plug-in unit of the evaporator Check temperature sensor are in poor condition. The evaporator is frozen
3. Too much refrigerant
Discharge a portion of the refrigerant
4. Air capacity passing through the evaporator is Inspect if the fan rotation speed is inadequate. normal. 5. Failure expansion valve
Replace it
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Common Malfunction Diagnosis Flow of Geely Automobile
No.290 Installation and Commissioning of the Air Conditioning Commissioning
Inspect the leaking point
Leak detection by nitrogen positive pressure No felling back occurs when the filling pressure is 3.0Mpa Vacuumizing
Leak detection
Remain it for at least 72 hours after the vacuum degree is 745mmHg Close the manifold pressure gauge and watch for 5 minutes without felling back being occurred
Fill in the refrigerant
The liquid refrigerant can be filled from the high pressure side per the regulation before the system start-up; gaseous refrigerant must be filled from the low pressure side after the system start-up.
Watch the window until the filling volume is appropriate
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Common Malfunction Diagnosis Flow of Geely Automobile
Cautions for installation safety ·Installation staffs of air conditioning must wear protective glasses. ·During the operation and the commissioning of the air conditioning unit, hands of the loading staffs shall be kept away from various fans and water tank fans. · The high pressure and low pressure pipes shall be checked carefully before charging the cooling medium to avoid the explosion. · Open flame is strictly prohibited to touch the refrigerant to avoid the choking caused by the toxic gas generated by the burning. · The radiator fin shall be taken care not to scuff the hand skin when the radiator is operated. · Metal ornament is strictly prohibited when the air conditioning is installed to avoid the injury caused by the short circuit. Treatment to the installation accident · If the refrigerant touches the eyes, a great deal cold water shall be used to flush the eye not less than 10 minutes. · If a great deal of refrigerant is leaked and the skin is frostbite, the frostbite location must be warmed up and then the injury shall be sent to the hospital. Installation notice · Usage of the compressor oil. · Usage of the seal. · Installation of the pipeline: · The pipeline installation must be clean and dry; plugging material on the pipeline could be removed only when the pipe is installed. ·R134a pipeline adopted by our company is of the sausage type sealing so the nut shall be tightened only afte the pipeline connection is ensured to have been inserted totally; the nut must be tightened by hand and then by two wrenches. ·The refrigeration oil must be dripped before the screwed joint is connected to prevent the thread from stripping and ensure the sealing property. ·Sharp transition is not permitted for the pipeline installation especially for the low pressure pipe installation.
Incorrect (the pipeline should be put naturally)
Correct
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Common Malfunction Diagnosis Flow of Geely Automobile
Special repair kit for air conditioning The special repair kit for air conditioning is composed of the magnetic thickness gauge, the gas leak tester, the spare gas bottle, the service valve wrench, the refrigerant filling valve, the filling hose gasket and the service valve gasket, etc. Above tools are special tools used to repair the vehicle air-conditioning. Tools in the kit shall be used as much as possible during the repair process to ensure the check quality. Usage of the refrigerant filling valve The filling valve is as Fig. 4-6 1). Anti-clockwise rotate the filling valve handle until the valve needle is withdrawn. 2). Install the filling valve on the refrigerant tank and anti-clockwise rotate the sheet nut until it reaches the top position, then clockwise rotate the refrigerant filling valve until the filling valve is embedded into the refrigerant sealing plug. 3). Clockwise rotate the sheet nut to the end and fix the intermediate hose of the manifold pressure gauge into the connection of the filling valve. 4). Tighten the sheet nut. 5). Clockwise rotate the handle until the valve needle pierces into the sealing plug. 6). Provided the refrigerant is to be filled, the handle shall be rotated anti-clockwise to uplift the valve needle and at the same time the hand valve on the manifold pressure gauge is opened. 7). Provided it is to stop adding the refrigerant, clockwise rotate the handle so that the valve needle will enter into the sealing plug once again to play the sealing effect, and meanwhile close the hand valve on the manifold pressure gauge. Usage of the manifold pressure gauge The manifold pressure gauge is also called the manifold pressure meter, which is connected with the refrigeration system to carry out the vacuumizing, filling in the refrigerant and diagnosing the failure of the refrigeration system. Fig. 4-2 shows the structure of the manifold pressure gauge. It consists of the high pressure gauge, low-pressure gauge, manual low pressure valve, manual high-pressure valve, valve body, high pressure connection, low-pressure connector and refrigerant vacuumizing connector. During the operation, high and low pressure connectors are connected with high and low pressure fill in valves of the system respectively via the hose and the intermediate connector is connected with the suction pump or the refrigerant (HR134a) cylinder. The connector connecting the hose and the manifold pressure gauge could only be tightened by hand instead of by wrench, or else the connection thread may be damaged. Air inside the hose must be drained away during the usage. Detailed steps are as follows: 1). When the manual low pressure valve is opened and the manual high pressure valve is closed, the low pressure line is connected with the intermediate pipeline and the low pressure gauge. At that time the refrigerant can be filled or discharged from the low pressure side, and meanwhile pressures at both the high pressure side and the low pressure side can be detected. 2). When the manual low pressure valve is closed and the manual high pressure valve is opened, the pressure line is connected with the intermediate pipeline and the high pressure gauge. At that time the refrigerant can be filled or discharged from the high pressure side, and meanwhile pressures at both the high pressure side and the high-tension side can be detected. 3). Detection to pressures at high and low pressure sides can be made when both the manual high pressure valve and the low pressure valve are closed. 4). Refrigerant filling, vacuumizing and detecting to pressures at both the high pressure and low pressure sides can be carried out when both the manual high and low pressure valves are opened.
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Common Malfunction Diagnosis Flow of Geely Automobile
Open Open Fig 4-2 Structure of manifold pressure gauge 1 high pressure gauge 2 low-pressure gauge, 3 manual low pressure valve, 4 manual high-pressure valve, 5 valve body, 6 high pressure connection, 7 refrigerant vacuumizing connector 8 low-pressure connector Usage of the refrigerant charging valve A charging valve is installed on the inlet and the exhaust pipes of the sedan air conditioning compressor. Its operating principle is identical to that of the valve core on the tire. During the usage, tighten the quick joint of the charging hose into the port of the charging valve so that the needle is pressed open; the air-conditioning system is connected with the detection used hose with the refrigerant flows into it; the charging valve can be closed automatically when the detection used hose is removed. Routine method to check the leakage of air conditioning refrigerant Leak-detection methods generally used in the vehicle air conditioning refrigeration system are nitrogen supercharging leak detection, vacuum leak detection, charging leak detection, instrument leak detection and appearance leak detection. 1). Nitrogen supercharging leak detection: charging the nitrogen into the refrigeration system and apply the soap water at the leak detection position. The soap bubble will be generated when there is the leakage. The compressed air is strictly prohibited when the supercharging leak detection is adopted. This is because there is moisture in the compressed air and will cause the ice block at the thermal expansion valve when the moisture enters into the system along with the air. The industry nitrogen is non-corrosive, moisture-free and low in price, yet bottle high pressure nitrogen gas must be provided with a decompression adjuster to adjust the air out pressure. When the system reaches the specified 1.0 Mpa, apply the soap bath at each joints and welding points of the system to observe the leakage carefully. There is tiny sound at large leakage area with big foam and there is discontinuous small foam at small leakage area. The leak detection must be made carefully and repeated for 3 to 5 times. The leaking position shall be marked and restored in time, then the leak detection can be made at other joints until the leakage is eliminated totally. The leak-off-test shall be made after the leakage is restored, i.e. the system is kept the pressure for more than 0.5 hours. The leak-off-test is accepted when the pressure does not reduce; the leak detection must be made once again if the pressure reduces greatly until the leaking area is found and restored. Leak-off-test pressure of the refrigeration system is 1.5 ~ 1.7Mpa. Take care when checking the leak. 2). Vacuum leak detection: it shall be made adopting the vacuum pump. The vacuum pressure shall be lower than 100Pa and constant. It is acceptable when the vacuum pressure is not increased remarkably during relatively long time. 3). Filling leak detection: it can be made following the vacuum leak detection. The leak detection is carried out by the electronic leak detector after little refrigerant is charged. The indicator will light up and give out an alarm when the refrigerant is leaking. 4). Appearance leak detection: normally there is the refrigeration oil leaked out at the refrigerant leaking 389
Common Malfunction Diagnosis Flow of Geely Automobile
locations. A clean plain paper can be used to wipe it off or the hand can be used to inspect it directly. It means the refrigerant leakage when the oil stain keeps on leaking. Locations where air conditioning refrigerant leakage often occurs Operating condition of the air conditioning is normally rough. Its refrigeration system keeps on vibrating along with the vehicle operation, hence the pipeline is easy to be damaged and the joint is loose thus causing the refrigeration leakage. The general leaking locations are shown as the following table. Locations where air conditioning refrigerant leakage often occurs Assembly
Condenser
Leaking parts Connection of the condenser air inlet pipe and the liquid outlet pipe Welding of the condenser flat pipe and the collector pipe
Evaporator
Connection of the evaporator air inlet pipe and the liquid outlet pipe Each welding of the evaporator
Thermo expansion valve
Gas phase head Fusible plug
Liquid storage dryer Connection of the evaporator liquid inlet pipe and the liquid outlet pipe High and low pressure hoses Refrigerant line Connections of high and low pressure hoses Compressor shaft seal Compressor
Connection of inlet and outlet Sealings of front and rear cover Air intake and exhasut valves of the compressor
How to carry out the vacuumizing, leak detection and refrigerant filling to the vehicle air conditioning There are three purposes of making the vacuumizing by the vacuum pump: the first, to drain out the air and the moisture in the air-conditioning system; the second, to inspect the leakage in the system; the third, to dry the system. The refrigerant can be filled only after the system is vacuumized. The vacuumizing can reduce the boiling point rather than drain the water out from the refrigeration system directly after the vacuum is realized. The water is drained out from the refrigeration system only after it is transferred into the water vapor. Connection of the vacuumizing pipeline is shown in Fig.4-3. Detailed steps are as follows: 1). Connect both high and low pressure hoses of the manifold pressure gauge with high and low pressure charging valve interface of the system (note: for the sedan air-conditioning system, most high and low pressure charging valves are on the high and low pressure hoses, while very few hoes are on the compressor); connect the intermediate hose on the manifold pressure gauge with the vacuum pump. 2). Open the manual high and low pressure valves on the manifold pressure gauge and start the vacuum pump; vacuumize the systemic pressure to below 100pa and keep constant. 3). Close the manual high and low pressure valves on the manifold pressure gauge and see if the pressure shown by the gauge indicator is recovered; the pressure recover means the system leakage, then the leak detection and repair shall be made by this time. Provided the gauge indicator keeps still, the hand valve shall be opened to startup the vacuum pump and keep on vacuumizing until pointer of the if is constant.
390
Common Malfunction Diagnosis Flow of Geely Automobile
1 compressor 2 vacuum pump 3 air 4 low pressure gauge 5 high pressure gauge 6 manual low pressure valve opening 7 manual high pressure valve opening Fig 4-3 Vacuumizing of air conditioning refrigeration system 4). simultaneously close the manual high and low pressure valves after the vacuumizing. 5). Screw down the intermediate hose of the manifold pressure gauge from the vacuum pump joint and switch over a refrigerant cylinder joint. 6). Unscrew the intermediate hose joint on the manifold pressure gauge and slightly open the refrigerant cylinder valve to send away the air in the intermediate hose by the refrigerant. It is OK just being opened for 2~3 seconds. 7). Open the manual high and low pressure valves and the refrigerant cylinder valve so that small volume of the refrigerant can enter into the refrigeration system until the gauge indicator points into 1000pa. Close the manual high and low pressure valve as well as the refrigerant cylinder valve and remain for several hours. 8). If there is no variation in the systemic pressure, it means the system has no leakage; provided the systemic pressure is reduced, it means there is leakage in the system, then the leaking location shall be found out and precluded. 9). Open the refrigerant cylinder valve and the manual high-pressure valve so that the refrigerant can be entered into from the high pressure side after the system is confirmed having no leakage. By this time the refrigerant cylinder can be inverted to increase the charging rate, however the air conditioning is not permitted to startup. 10). The refrigerant can also be filled from the low pressure side. The method is that the manual high-pressure valve is closed and the refrigerant cylinder is kept upright, then the air conditioning compressor is turned on to operate. Slowly open the manual low pressure valve so that the refrigerant can enter into the suction compressor in gaseous state from the low pressure side; when the refrigerant charging volume achieves the requirement, the manual low pressure valve and the refrigerant cylinder valve are closed. 11). Watch it from the sight glass to ensure there is no bubble or surplus refrigerant inside the system. Then adjust the engine speed to 2000r/min and turn the cold air machine air volume to the top gear. Provided the air temperature is between 30℃ and 35℃, pressure at low pressure side of the system shall be about 0.15 ~ 0.20Mpa and that at high pressure side shall be about 1.3 ~ 1.8Mpa. 12). Stop the engine after the charging is finished. Remove the manifold pressure gauge from the compressor quickly to prevent surplus refrigerant from being discharged. Operation and notice of filling or adding the refrigeration oil to the air conditioning, judgment to the refrigeration oil quality 1) Generally it is not required to fill the refrigeration oil when the air conditioning refrigeration system is 391
Common Malfunction Diagnosis Flow of Geely Automobile
maintained. However, the refrigeration oil must be added when parts of the refrigeration system are replaced and severe leakage of the system is precluded. There are two methods to fill the refrigeration oil as follows: (1) Shut down the air conditioning and fill the refrigeration oil utilizing the filling port on the compressor; screw out the filling port bolt and pour the required refrigeration lubrication oil into the filling port and then tighten the filling port bolt. (2) Detailed operation methods of charging the refrigeration oil when the vacuumizing is made are as follows:
Fig. 4-4 Filling the refrigeration lubrication oil with vacuumizing method 1- the manual low pressure valve is closed 2- the manual high pressure valve is opened 3- exhaust the air 4- vacuum pump 5- refrigeration lubrication oil a. Select a graduated cylinder to contain the refrigeration oil of the volume more than required. b. Screw down the hose connected with the low pressure charging valve from the manifold pressure gauge and insert it into the measuring cylinder containing the refrigeration oil. As shown in Fig.4-4. c. Startup the vacuum pump and open the manual high pressure valve on the manifold pressure gauge. Added refrigeration oil will be sucked into the compressor through the suction pipe via the charging valve at the low pressure side. Stop the suction of the vacuum pump and close the manual high pressure valve when the refrigeration oil volume has reached the specified volume. d. After the refrigeration oil is added per the vacuumizing method, the refrigeration system shall be vacuumized and the refrigerant shall be added. 2) The following notices shall be taken care when the refrigeration oil is used: (1). The refrigeration oil is easy in water absorption so the lid must be tightened right after the refrigeration oil is used (2). Deteriorate turbid refrigeration oil is not allowed, or else it will influence the normal operation of the compressor. (3). Excess refrigeration oil is not allowed to be added into the system, or else it will influence the refrigerating capacity of the vehicle air conditioning refrigeration system. (4) The refrigeration oil must be of the grade specified in the compressor instruction of that model. 3) Correlation method and dripping method can be adopted to judge the quality of the refrigeration oil: (1). Correlation method: put clean and standard refrigeration oil into a test tube as the standard oil and put the oil to be checked into another test tube of the same size to make the comparison. Provided the oil to be checked is of light yellow or of saffron yellow, it can be used, however the turbid solution of rufous color can not be used. (2). Dripping method: drip one drib of the refrigeration lubrication oil to be checked on a clean plain paper and watch its color. It means there is no impurity in the oil if its color is light and even; the oil can be used. 392
Common Malfunction Diagnosis Flow of Geely Automobile
How to inspect the refrigeration oil volume in air conditioning compressor The vehicle air conditioning compressor is a high-speed operation device. Its normal condition depends on the sufficiency of the refrigeration oil, however excess refrigeration oil will influence the refrigerating effect. Oil volume inside the compressor must be checked when the compressor or part of the refrigeration system are replaced. The inspection methods are as follows: Fig.4-5 shows the inspection to the refrigeration oil volume. Discharge the oil charge plug 1, watch it via the oil charge taphole and rotate the clutch foreplate; Wipe clean the oil dipstick with the cotton yarn and insert it into the compressor until end of the oil dipstick touches inner casing of the compressor; take out the oil dipstick and observe its immersion depth; oil level inside the compressor shall be between scale 4 and scale 6 if the oil charging is appropriate. Add it if it is inadequate and drain if it is excessive, then tighten the filling port plug.
Fig. 4-5
inspection to the refrigeration lubrication oil volume of the sedan air conditioning compressor 1- oil filling plug 2- Filling port 3- oil dipstick Provided there is no oil filling plug hole in the compressor, the oil shall be poured into a measuring cup to make the comparison with the oil charge volume specified in the instruction to judge if the compressor is required to add the oil. Generally oil content in the compressor shall not be less than 1/3 oil charging volume specified in the instruction, or else the oil shall be added. Compressor provided with the oil charging plug hole can also adopt this method, but the compressor assembly must be removed from the air-conditioning system.
393
Common Malfunction Diagnosis Flow of Geely Automobile
Fig 4-6 Refrigerant filling valve 1 refrigerant reservoir 2 plate nut 3 upper connector of filling valve 4 rotation lever 5 valve pin How to add the refrigerant to the vehicle air conditioning When the pressure in the refrigeration system is abnormal, the bubble will appear in the sight glass. It means the refrigerant is inadequate and shall be added; The vacuumizing is not required when adding the refrigerant. The refrigeration system can be added directly with the operational methods as follows: Connect both high and low pressure hoses of the manifold pressure gauge with interfaces of the high and low pressure charging valves; connect the intermediate hose of the manifold pressure gauge with the refrigerant cylinder valve. Carry it out according to the operation method related to 4.8. Close the manual high and low pressure valves and upright the refrigerant cylinder, then start the engine and turn on the air conditioning compressor to operate; Slowly open the manual low pressure valve so that the refrigerant can enter into the suction compressor in gaseous state from the low pressure side; when the refrigerant charging volume achieves the specified volume, close the manual low pressure valve and the refrigerant cylinder valve. How to check and eliminate the blocking failure of air-conditioning system When the refrigeration system is blocked, it shows inadequate refrigerant volume or no refrigerating, and meanwhile high pressure and low pressure inside the system are abnormal. The block often occurs at the liquid storage dryer and the expansion valve. Temperature difference of the part before and after the blocking is apparent. The dirty block failure can be eliminated according to the following method: 1). Drain out the refrigerant inside the refrigeration system. 2). Remove the blocked part of the refrigeration system for the cleaning and the replacement. 3). When there is severe block, the refrigeration system shall be dismantled entirely for subsection cleaning. Spares after the cleaning shall be blown-dried and oven-dried. How to check and eliminate the icing failure of vehicle air-conditioning thermo expansion valve The system is poor in the refrigerating effect and low bias in both high and low pressure after the refrigeration system is iced; the refrigeration is intermittent. The icing generally occurs at the valve seat of the thermo expansion valve because excessive water vapor contained in the system is iced at valve base of the thermo expansion valve. When the thermo expansion valve occurs ice block, the refrigerating capacity will be reduced that causes the temperature rise to melt down the ice at the valve port so the system recovers normal operations to increase the refrigerating capacity, at that time excessive moisture will be iced again at the valve port. Methods of eliminating the icing failure of the refrigeration system are as follows: 1). Drain out the refrigerant inside the system. 2). Replace the dry reservoir in the refrigeration system. 3). Inspect the refrigeration system for any leakage and stop it. 4) Make the vacuumizing with the vacuum pump and remove the water vapor inside the system. 5) Add qualified refrigerant. How to check and eliminate the air inside the air-conditioning system Air in the system is stored at upper part of the condenser or the dry reservoir owing that it is incapable of being condensed and is lighter than the refrigerant. Air in the system will influence the cooling and heat emission 394
Common Malfunction Diagnosis Flow of Geely Automobile
effect of the condenser thus cause the condensing pressure and temperature over high, simultaneously low pressure of the system is high that causes the refrigerating capacity of overall system being reduced, so that air in the system shall be removed timely with the preclusion methods as follows: 1). Drain out the refrigerant inside the system. 2). Inspect the refrigeration system for any leakage and eliminate it. 3). Pump out the air in the system repeatedly with the vacuum pump. How to dismount the sedan air conditioning compressor When the air conditioning compressor is breakdown, most failure parts shall be dismounted to carry out the repair or the replacement except very few failure parts can be maintained on the vehicle instead of dismounting the compressor. The dismounting steps and requirements are as follows: Steps of dismounting the compressor from the compressor frame: (1). Dismount the connecting wire of the electromagnetic clutch. (2) Drain out the refrigerant from the refrigeration system. (3) Remove the hoses at intake and exhaust port of the compressor; the hose as well as intake and exhaust ports of the compressor shall be covered to prevent the dust and the water vapor from being entered into the system. (4) Dismount the driving belt of the compressor. (5) Remove the compressor fastening screw and the compressor from the compressor frame. (6) Pour out the oil inside the compressor and measure the oil output with the measuring cylinder to judge if it is required to add the oil and inspect the oil for any discoloration as well as any impurities in the oil. Inspection to the air conditioning control system The air conditioning control system can be checked according to the following methods: power→ ignition→ switch→ fuse cutout→ relay→ air conditioning switch ( fan switch, temperature detect switch)→temperature control circuit→pressure switch circuit→electromagnetic clutch→fan→electric machine. After the ignition switch is turned on, the current flows into the air conditioning switch through the fuse cutout and is branched. One branch flows into the evaporator blower motor and the other branch flows into the compressor electromagnetic clutch through the temperature controller and the pressure switch circuit. When malfunction is found in the auto security protection, the fuse shall be checked first for any burn-out; If it is in normal condition, control switch of the blower shall be turned on to inspect if the blower plug is in good contact, the blower governing resistance is in open circuit and the blower motor is damaged; If the blower is in normal operation, then finally check the control circuit of the electromagnetic clutch, the high and low pressure switch, the temperature controller as well as the electromagnetic clutch for any failure; eliminate any failure existed. How to inspect the vehicle air conditioning thermo expansion valve Inspection steps of the vehicle air conditioning expansion valve (take F type thermo expansion valve as an example) are as follows: 1). Eliminate the refrigerant in the system and remove the thermal expansion valve from the refrigeration system. 2). Supply the nitrogen with certain pressure (e.g. 0.05Mpa) at the high pressure inlet side of the thermal expansion valve. If there is no gas flowing out from the low pressure outlet side, it means the thermal expansion valve is out of service. 3). Then immerse the thermo bulb of the thermal expansion valve into warm water and enhance the water temperature; opening of the thermal expansion valve shall be increased (pressure at the low-pressure side is increased, i.e. the gas flow rate is increased), or else it means media inside the thermal expansion valve power head is leaked or the thermal expansion valve is blocked by impurities, then the thermal expansion valve shall be replaced. 4) The blocked thermal expansion valve shall be disassembled to determine the impurity nature. Other notices in repairing the vehicle air conditioning 1). Operation environment: cleanness and moistureproof shall be paid attention to when the air conditioning is 395
Common Malfunction Diagnosis Flow of Geely Automobile
checked. Dirt, dust and moisture shall be prevented from entering into the air-conditioning system. Areas around the assembling unit and the joint shall be cleaned out and rainy day maintenance shall be avoided. 2). Usage of the refrigerant: the refrigerant shall be stored in places of low temperature and dry when the refrigerant cylinder is stored and transported. It shall not be brought into locations with open flame such as the welding, nor exposed under the sunshine. Directly heating to the refrigerant cylinder or putting it into the hot water over 40 Celsius degree is strictly prohibited. The protective glasses shall be worn when the refrigerant is filled to avoid the eye frost damage. Please be noted that it shall not be contact with the skin. Provided the refrigerant is contacted with accidentally, a great deal of fresh water shall be used to rinse the contact area quickly to prevent the frost damage and ask for medical care as soon as possible. Manual high pressure valve on the manifold pressure gauge is strictly prohibited to open when the engine is in operation. The refrigerant will back flow into the refrigerant tank that cause the explosion. When the gaseous state refrigerant is charged from the low pressure side during the engine running, the refrigerant cylinder is not allowed to upend to avoid the compressor "cylinder slugging". The manifold pressure gauge shall be used to drain out the refrigerant inside the system from the low pressure side. The refrigerant shall be exhausted slowly with the time interval not less than 15 minutes to prevent the refrigeration oil from being drained out along with the refrigerant. 3). Operation to the refrigeration system pipeline: the pipeline or the joint shall be capped after the pipeline is dismounted to prevent the moisture and the dust from entering into it. The bending radius shall be as large as possible when the pipe is bent; the pipe orifice shall be remained leveling and clean when the pipe is cut and scraps inside the pipe shall be cleaned out; The trichloroethylene liquid shall be used to clean the pipeline, and the pipeline shall be dried sufficiently; The refrigeration oil shall be applied at the joint and the O-ring when the pipeline is connected; two wrenches shall be used to tighten or unscrew the pipeline joint. 4). Operation to the control wire: the battery ground wire (negative wire) shall be dismounted when the repair work is made to the air conditioning to prevent the circuit short circuit during the refrigeration system repair. Replaced wires shall be fixed by the adhesive tape and the original fasteners; wires of original color and original diameter shall be preferred; the wire is not allowed to close to high temperature objects such as the engine. There is several methods of judging the constant malfunction of the vehicle air conditioning as follows: 1). Hand feeling inspection: the failure is judged mostly by feeling the temperature of the parts by hand. High pressure loop (from the compressor outlet, the condenser and the dry reservoir to the thermal expansion valve outlet) shall be in a thermal behavior (50℃~ 70℃) when it is touched; if certain location is exceptionally hot or there is apparent temperature difference between the inlet and the outlet, it means there is the blocking. The low pressure loop (from the thermal expansion valve outlet, the evaporator and the compressor inlet) shall be cool (0℃~ 5℃) when it is touched. Provided there is no apparent temperature difference between the high pressure side and the low pressure side, it means there is the leakage in the system or the compressor is broken down. 2). Visual examination: inspect each pipeline joint, compressor shaft seal, condenser and evaporator surface for any oil stain; the system has the leakage if there is any oil stain. 3). Sight glass inspection: observe and inspect the refrigerant state via the sight glass installed on the dry reservoir or the pipeline. The refrigerant shall be clear and bubble free, and the evaporator air outlet shall be cold under normal condition. It means that the refrigerant is highly inadequate when it is clear and bubble free yet the air outlet is not cold; is means that the refrigerant is inadequate when it is clear and has bubble in it, yet the air outlet is not cold enough. 4). Leak detection made by the electronic leak detector: electronic leak detector is used to inspect each joint of the overall system for any leakage. 5). Inspection made by the multi-meter: the multi-meter can be used to check out the air conditioning circuit breakdown and judge the broken circuit or the short circuit. 6). Manifold pressure meter: connect the manifold pressure meter with the system high and low pressure 396
Common Malfunction Diagnosis Flow of Geely Automobile
valves to judge the breakdown of the refrigeration system. The inspection shall be made when the air temperature is between 30 ~35oC and the engine speed is 2000r/min. The fan wind speed is adjusted to the high gear and the temperature is adjusted to the Max. refrigerating gear. The normal condition is that: the pressure at the high-pressure side is 1.2Mpa ~ 1.8Mpa and that at the low-pressure side is 0.15 Mpa ~ 0.20Mpa; the system may have a failure if it is out of this scope. 7). Other inspection methods (1) Condenser: the thermometer is used for thermometer under normal operation. When the condenser air-in temperature is about 35oC, the air-out temperature shall be about 55oC. (2) Continual reduction of the air volume at the air outlet means the frosting on the evaporator surface. (3) Dry reservoir: inconsistency of the temperature on upper and lower side of the dry reservoir shell means there is the block inside the dry reservoir.
Maintenance and diagnoses of electronic power-assisted steering system
No.291 Line inspection of "EPS" indicating lamp (the "EPS" indicator does not light up when the ignition switch is opened) 1. Battery 2. Main fuse 3. Ignition switch 4. Circuit fuse (15A) 5. Control module 6. EPS lamp 7. Main fuse 8. Control box socket 9. Connector Step
1
2
3
4
5
Operation
Yes
No
Are the main fuse and the line fuse in good condition Go to step 2 or not ?
The main fuse and the line fuse is broken
1. Turn on the ignition switch 2. Inspect the voltage between the terminal "A6" and the module case earthing 3、Is it the battery voltage?
Go to step 3
“B/W” wire is broken or short circuit
1. Check the voltage between the terminal "A8" and Go to step 4 the module case earthing 2. Is it the battery voltage?
"B/R" wire is broken or short circuit
1. Turn off the ignition switch and disconnect the Go to step 5 connector 8 from the control module 2. Disconnect the body ground terminal "A3" on the connector "8" body 3. Turn on the ignition switch again, is the "EPS" lamp light up?
The bulb is burnt out or the "V/G" wire is broken
1. Is the connection between the connector "8" and Terminal “A6”，“A7” Poor connection the control module firm? " A3 " or " A8 " is in poor contact; the control module case is in poor earthing; "B" wire +12V is broken
397
Common Malfunction Diagnosis Flow of Geely Automobile
No.292 Inspection to "EPS" indicator line ("EPS" indicator does not light up or keep on lighting up when the cross-line connection is made between the diagnoses switch terminal and the ground terminal) Step
Operation
Yes
1
1. If terminal "A2" of the connector "9" is perfectly connected to Go to step 2 the control module
2
1. Earth the "A2" terminal by wire under the condition that the connector is connected with the control module 2. Turn on the ignition switch, is the "EPS" lamp flicking?
No Poor contact
1、The maintenance line Recheck it with replaced control module is broken 2、. "B/W" line is broken or "B" line is in poor earth
No.293 Main line of DTC11 torque sensor (the main line is broken or short circuit) Step
1
2
Operation
Yes
No
1、Remove the protective cover of the steering column hole 2、 Turn on the ignition switch and put the steering wheel towards the right front direction of the vehicle, and check if the terminal voltage of the torque sensor bar foot center "B5" wire is about 2.5V.
1. "W" wire is broken Go to step 2 2. Terminal "B5" is in poor connection 3. Recheck it with replaced control module if the above conditions are normal
1. Close the master switch and disconnect the torque sensor rod head 2. Check the resistance between terminals "B5" and "B2" of the torque sensor 3. Whether it is about 0.96kΩ
1. "W" wire to the battery is The torque sensor has short circuit or earthed defects 2. The torque sensor connector is in poor contact with the line
No.294 DTC13 torque sensor (there is big difference between the auxiliary line outputs of the main line and the torque sensor) Step 1
Operation
Yes
No
1"W" or "B" lines are in The 1. Remove the protective cover of the steering column hole torque poor condition 2. Turn off the ignition switch and disconnect the torque sensing unit sensor is 3、 Inspect the resistance between the torque sensor side plug-in unit 2. Terminals "B5" or broken down "B4" are in poor terminals according to the following state connection The steering wheel faces 3. Recheck it with About 0.96 KΩ towards right ahead replaced control module if the above conditions The steering wheel steers are normal “R—B”
“R—W”
About 0.48 KΩ
entirely right
About 1.02 KΩ
The steering wheel steers entirely Left
About 0.96 KΩ
The steering wheel face towards right ahead
398
Common Malfunction Diagnosis Flow of Geely Automobile
About 1.02 KΩ
The steering wheel steers entirely Right
About 0.48 KΩ
The steering wheel steers entirely left
No.295 DTC14 torque sensor (power supply voltage of the torque sensor is too high or too low) Step
Operation
Yes
No
1
1）Remove the protective cover of the steering column hole Recheck it with replaced control Go to step 2 2）Turn on the ignition switch and check the voltage between module "R" wire of the torque sensor connector and the terminal ground 3）Is it about 5V?
2
1）Turn off the ignition switch and disconnect the torque 1） Terminal "B2" or "B3" is in The torque sensor is broken down sensor connector poor connection 2） Check the resistance between "R" wire of the torque 2） Harness of the torque sensor sensor connector and the terminal ground plug-in unit is in poor contact 3) "R" or "G" line is disconnected 3）Is it about 1.09 KΩ? 4） "R" or "G" line is grounded and the battery are short
No.296 Auxiliary line of DTC15 torque sensor (the auxiliary line is disconnected or short circuit) Step
Operation
Yes
No
1
1）Remove the protective cover of the steering column hole 2） Turn on the ignition switch and put the steering wheel to the front moving position of the vehicle; check the voltage of "B" terminal on the torque sensor connector. 3）Is it about 5V?
1）"B" wire is disconnected 2）Terminal "B4" is in poor contact 3）Recheck it with replaced control Go to step 2 module if the above conditions are normal
2
1）Turn off the ignition switch and disconnect the torque sensor connector. 2）Check the resistance between "R" wire and "W" wire or between "R" and "B" terminals on the torque sensor connector 3）Is it about 0.96 kΩ?
1）"B" wire is ground or the battery is short The torque sensor 2）The torque sensor connector is is broken down in poor contact with the harness
No.297 DTC22 engine speed signal (no engine signal input) Step 1
Operation
Yes
Does the tachometer display the engine speed Go to step 2 signal? 0-1V
399
No 1）The connector is in poor connection or the line is broken 2 ） There is no rotation speed signal output in ECU
Common Malfunction Diagnosis Flow of Geely Automobile 2
1 ） Remove the control module and connect the control module connector when the ignition switch is off. 2）Check the voltage between "A4" terminal of the control module and the earthing when the ignition switch is on; check the resistance between "R" line of the torque sensor connector and the terminal ground 3）Is it 8~12V?
400
"A4" is in poor connection; "Br" line is broken replace with a good control module if the connection is normal
Common Malfunction Diagnosis Flow of Geely Automobile
No.298 Vss line (Vss line is disconnected or short circuit) DTC21Vss line (the engine runs at 2500 R.P.m or higher for continuous 60 seconds (the rotation speed is 4000 R.P.m or higher when the engine is started) and there is no vehicle high speed signal input) DTC23Vss line (the engine runs at 2500 R.P.m or higher for continuous 60 seconds (the rotation speed is 4000 R.P.m or higher when the engine is started) and there is no vehicle high speed signal input) DTC24Vss line (the engine is beyond the standard level for continuous 5 seconds/there is no vehicle speed input) DTC14 torque sensor (supply voltage of the torque sensor is too high or too low) Step
Operation Does the speedometer display the speed signal?
1
Yes
No
Replace with a good 1）"A5" is in poor connection with "V" vehicle speed sensor harness 2）Replace the control module to recheck if the connection is all right
No.299 DTC41 motor (the motor voltage is too high or too low) DTC43 motor (the motor current is too high) DTC42 motor (current displayed on the control module is of great difference from the current actually flowing into the motor) DTC44 motor (there is output signal in the control module, yet the motor doesn't start) DTC45 motor (current actually flowing into the motor is lower than that outputed by the control module) DTC14 torque sensor (supply voltage of the torque sensor is too high or too low) Step
Operation
Yes
No
1
Is there DTC?
Motor failure
Go to step 2 Motor failure
2
1）Dismount the hole cover of the steering column Go to step 3 2）Disconnect the motor and the clutch connector when the ignition switch is OFF 3）Check the conductivity between terminals of the motor 4）Is it conductive?
3
1) Check the resistance between the motor and 1）"R" or "B" line is disconnected Motor failure the clutch as well as the body ground 2）"R" or "B" line is short to 2) Is it infinite? ground 3 ） The connector is in poor contact 4）Replace with a perfect control module to recheck provided the above phenomena are normal
No.300 DTC51 clutch line (the clutch line is disconnected or short) Step
Operation
Yes
401
No
Common Malfunction Diagnosis Flow of Geely Automobile
1
1) Remove the hole cover of the steering column 2) Disconnect the motor and the connector when the ignition switch is OFF 3) Check the conduction between terminals of the clutch connector 4）Is it conductive?
Go to step 2
Clutch failure
1) Check the resistance between the motor and the clutch connector as well as between the motor and the ground 2) Is it infinite?
1）"B/B1" or "B/R" line is disconnected 2）"B/B1" or "B/R" to ground is short 3）The motor and the clutch connectors are in poor contact 4）"A9" and "A10" terminals are in poor contact 5）Replace with a perfect control module to recheck provided the above phenomena are normal
Clutch failure
2
No.301 Power circuit of DTC54 control module (low voltage of the battery) Step
Operation
1
Yes
1）Remove the control module and connect the control module connector when the ignition switch is off. 2）Check the voltage between "A7" terminal of the control module and the ground when the ignition switch is ON. 3）Is it 10-14V?
No
1）"A7" terminal is in poor contact Battery failure 2) Replace with a perfect control module to recheck provided the above phenomena are normal.
No.302 DTC52 and DTC55 control modules (failure of control module) Replace with a good control module and recheck; Inspection to the control module and its line: the control module and its line can be inspected by measuring the voltage and the resistance of the module connector; The multi-meter is strictly prohibited to measure the control module under the condition of disconnecting the module connector.
No.303 Voltage inspection 1）Remove the control module from the body when the ignition switch is OFF 2）Connect the control module connector to the control module 3）Inspect each terminal voltage of the connector according to the following table 4）Voltage of the battery is confirmed to be 11V or higher when the ignition switch is in ON position Terminal
Line
Normal voltage
Malfunction symptom
A6
Voltage of the ignition switch control
10-14V
Engine operates at idle speed
A5
Vss
0-1V and 4-6V
The front left tire rotates greatly under the condition of ignition switch being ON and the front wheel being locked
B2
Power supply of the torque sensor
About 5V
Inspect the voltage between "B2" and B3 when the ignition switch is ON
B1
Blank
——
——
A3
"EPS" failure indicating lamp
0-2V, 10-14V
"EPS" lamp lights up or off when the engine operates at idle speed
402
Common Malfunction Diagnosis Flow of Geely Automobile A9
Clutch plus
10-14
The engine operates at idle speed and the steering wheel is fixed in straight ahead position of the vehicle
A4
Engine signal
——
——
B3
Torque sensor (GND)
0V
B4
Torque sensor plus
About 2.5V
The engine operates at idle speed, direct moving direction, the voltage between "B4" and "B3" terminals
B5
Torque sensor minus
About 2.5V
The engine operates at idle speed, direct moving direction, the voltage between "B4" and "B3" terminals
Clutch minus
0V
——
Disconnect to the terminal
5V
Ignition switch ON
A11
Motor output plus
5-7V
The engine operates at idle speed, the steering wheel is fixed to direct moving position of the vehicle
A12
Motor output minus
5-7V
The engine operates at idle speed, the steering wheel is fixed to direct moving position of the vehicle
A7
Power supply plus
10-14V
Engine operates at idle speed
A8
Power supply minus
0V
——
A1
Blank
——
——
A10 A2
No.304 Introduction of mechanical assembly 1）The steering column assembly can not be disassembled. Provided any part is found to have defect, the whole assembly shall be replaced. 2）It must be noticed not to cause the impact when the steering column assembly is replaced. Chart of connector functions
403
Common Malfunction Diagnosis Flow of Geely Automobile
SN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Line No. B1 B2 B3 B4 B5 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12
Name Blank +5V GND Torque signal 1 Torque signal 2 Blank Diagnosis control Indicating lamp Engine speed Speed signal ON switch 12V power Power ground Clutch plus Clutch minus Motor plus Motor minus
Load — 5~10mA 5~10mA <5mA <5mA — <10mA 5~20mA <10mA <10mA <10mA <32A <32A <1A <1A <30A <30A
404
Color — R G B W — B1/W V/G Br V B/W B/R B B/B1 B/r R B1
Dia. — 0.5mm2 0.5mm2 0.5mm2 0.5mm2 — 0.5mm2 0.5mm2 0.5mm2 0.5mm2 0.75mm2 2.5mm2 2.5mm2 0.75mm2 0.75mm2 2.5mm2 2.5mm2
Common Malfunction Diagnosis Flow of Geely Automobile
No.305 Diagnoses to the ABS system failure Flow chart of ABS malfunction diagnosis Start
Connect the malfunction diagnosis instrument under the power off condition
Turn the key switch to "ON"
Enter into the ABS system at the address location
No Can it communicate?
Carry out the inspection refer to the malfunction code free malfunction
Yes
Enter into the malfunction inquiry system at the function location
Continuous malfunction
Incidental malfunction
Record the malfunction code
Clear the malfunction code
Carry out the maintenance by reference to the malfunction code malfunction diagnostic gist
Carry out the maintenance by reference to the incidental trouble diagnostic gist
Clear the malfunction code
The key switch is power off, dismount the malfunction diagnosis instrument
Real car driving inspection
Normal End
405
Common Malfunction Diagnosis Flow of Geely Automobile
No.306 Quick index list of malfunction clearance Index of malfunction code malfunction check list Diagnostic code
Malfunction description
Diagnostic content
65535
Electronic control unit
Damaged
01276
ABS hydraulic pump
The motor is out of service
1
00283
Left front wheel sensor
00285
Right front wheel sensor
Electro and mechanical failure
2, 3, 4
00290
Left rear wheel sensor
00287
Right rear wheel sensor
01044
ABS code error
5
00668
Power supply terminal 30
6
01130
Abnormal in ABS operation
The signal is unreasonable
Check list No.
7
No.307 Index of malfunction code free malfunction check list Malfunction status
Check list No.
Turn the ignition switch to "ON" (the engine is in stall state) and the ABS alarm lamp does not light up
1
The alarm lamp does not light off when the engine starts up
2
Braking forces at both sides are unequal The braking force is inadequate
ABS is operation
in
ABS is in operation when the brake pedal is stamped slightly (the vehicle is abnormal in stationary state) 3 ABS is in operation when the brake pedal is stamped slightly (the vehicle is in driving state) The brake pedal vibrates violently when the ABS is in operation
The brake pedal stroke is too long
4
Very big force is required to stamp the brake pedal
5
There is no malfunction code output (communication with the malfunction diagnosis instrument is 6 unavailable)
406
Common Malfunction Diagnosis Flow of Geely Automobile
No.308 Malfunction check list of malfunction code 1
Malfunction code: 01276
Possible cause
z [Description] When the speed exceeds 20km/h, the ABS ECU will monitor abnormal z operation of the motor, then a malfunction code will be recorded. [Prompt] When this malfunction code is displayed, it means the harness between the z motor and ECU is loose. Function test of the hydraulic unit of the failure diagnosis instrument can be used to drive the motor to carry out the test.
The power is broken or earthed The motor harness is loose The motor is damaged
Note: The motor is incapable of being driven if the battery is of excess discharging, so the battery voltage must be confirmed to be normal before the motor driving test is made. The vehicle must be at the stationary state when the motor driving test is made. Unplug the motor harness and connect the battery power directly to the motor plug, does the motor still operate?
Abnormal Replace the hydraulic control unit
Normal Abnormal Inspect the fuse and the ABS ECU joint
Replace the fuse or the harness
Normal Connect the motor harness Turn the ignition switch to "ON" Clear the trouble code Carry out the hydraulic control unit diagnostic using the failure diagnosis instrument
No Yes Does the failure recur?
Replace the electronic control unit
Refer to "gist of incidental trouble maintenance"
407
Common Malfunction Diagnosis Flow of Geely Automobile
No.309 The malfunction codes are 00283, 00285, 00290 and 00287 (mechanical malfunction) 2
Malfunction codes: 00283, 00285, 00290 and 00287 (mechanical malfunction)
Possible cause
[Description] The malfunction code will appear when open circuit of the return can not be checked out and there is no signal output when the speed is above 20km/h. [Prompt] It may be caused by miss installation of the sensor, short of the sensor coil or the harness, ultra large air gap between the sensor and the tooth ring, or the damage or the tooth ring.
z z z z z
Miss installation of the sensor Short of the sensing coil or the harness Ultra big of the air gap between the sensor and the tooth ring Miss installation of the tooth ring Malfunction of ABS ECU
No Is the sensor installation correct?
Yes
Install it correctly
Inspect if the sensor resistance is normal
Inspect the sensor output voltage at Abnormal the ABS25 core socket
Abnormal Inspect each sensor
Replace it
Normal Normal Replace ABS ECU
Abnormal Inspect each sensor tooth ring
Replace it
Normal Inspect the clearance
wheel
bearing
Normal Inspect the sensor output voltage at the ABS25 core socket
408
Abnormal Repair or replace
Common Malfunction Diagnosis Flow of Geely Automobile
No.310 Malfunction codes: 00283, 00285, 00290 and 00287 3
The malfunction codes are 00283, 00285, 00290 and 00287
Possible cause
[Description] The malfunction code will appear if the sensor signal is out of tolerance when the speed is larger than 20km/h. [Prompt] The probability is that the weak sensor signal is cause by the intermittent poor contact or the short of the sensing coil or the harness, damage of the tooth ring teeth and ultra large of the air gap between the tooth rings.
z z z z z
Intermittent poor contact or short of the sensing coil or the harness Ultra big or ultra small of the air gap between the sensor and the tooth ring Damage of the tooth ring teeth Ultra big of the bearing clearance Malfunction of ABS ECU
Incorrect Is the sensor installation correct?
Install it correctly
Correct
Inspect the sensor output voltage at Abnormal the ABS25 core socket
Inspect each wheel sensor
Abnormal Replace
Normal Normal Replace ABS ECU
Abnormal Inspect the tooth ring of each wheel sensor
Replace
Normal Inspect the clearance
wheel
bearing
Normal Inspect the harness between the sensor and ABS ECU
409
Abnormal Repair or replace
Common Malfunction Diagnosis Flow of Geely Automobile
No.311 Malfunction codes are 00283, 00285, 00290 and 00287 (electric failure) 4
Malfunction code: 00283, 00285, 00290 and 00287 (electric malfunction)
[Description] The malfunction code wil appear when there are failures such as the recognizable open circuit or short circuit existed in the sensor. [Prompt] It is likely that the sensor is in poor contact, the coil or the harness is short, or there is a failure in the sensor signal treatment circuit in ABS ECU. Inspect the corresponding sensor with failure Normal Remove the ABS ECU plug Inspect if the resistence value between the following terminals of ABS ECU meets the standard value? Standard value:
1.0 ~ 1.3 k
Possible cause
z z z z
Inspect if the harness is normal and watch if the failure will recur
Abnormal Inspect the sensor plug
corresponding
Normal No Does the malfunction recur?
measuring the resistance. MK20 I:
Yes
Left front: 4 - 11 Right front: 3 - 18 Left rear: 2 - 10
Abnormal Repair the connector
Shake the sensor harness and the joint simultaneously when
Connector or coil of the sensor is of open circuit The sensing coil is short The sensor plug, the harness, the earth or the power is short Treatment circuit of ABS ECU sensor signal is out of order
Inspect the harness between the sensor and ABS ECU
Right rear: 1 – 17 MK20 I/E： Left front: 1 - 2 Right front: 19 - 20 Left rear: 5 - 6 Right rear: 22 – 23
Normal Replace ABS ECU
410
Refer to the gist of the incidental trouble maintenance
Common Malfunction Diagnosis Flow of Geely Automobile
No.312 Malfunction code: 01044 5
Malfunction code: 01044
Possible cause
The malfunction code will appear when the ECU software z z code is different from the hardware jumper connection of ABS harness. [Description]
Use the failure diagnosis instrument to check if the code of ABS ECU software is correct Correct value: see relative ABS electric wiring diagram
Error of jumper connection in ABS harness Error of ABS ECU code
Incorrect Recode it
Correct Check if the joint of ABS harness slip stitch is conductive Joint of correct slip: see relative ABS electric wiring diagram
Abnormal Repair the harness
No.313 Malfunction code: 00668 6
Malfunction code: 00668
[Description]
Possible cause
The malfunction code will appear when there is no
voltage or over high voltage on the power supply terminal 30.
411
z
Fuse of ABS system is blown out
z
The battery voltage is over low or over high
z
Connector of ABS harness is damaged
z
ABS ECU is damaged
Common Malfunction Diagnosis Flow of Geely Automobile Inspect 30A fuse of ABS system
Abnormal Replace the fuse
Normal Abnormal
Abnormal
Disconnect the connection between ABS harness and ECU, turn the ignition switch to "ON" and measure the voltage between the following terminals of ABS harness Terminals 8 and 9: 9.5 – 16.5V Terminals 24 and 25: 9.5 - 16.5V MK20 I: Terminals 8 and 23: 9.5 –16.5V MK20 I/E: Terminals 8 and 4: 9.5 –16.5V
Inspect ABS harness connector
Repair connector
the
Normal Refer to the incidental trouble No Retry. Does the abnormal condition recur?
Check the voltage
battery
Yes Check battery voltage
Normal Replace ABS ECU
No.314 Malfunction code: 01130 7
Malfunction code: 01130
[Description]
Possible cause
The malfunction code will appear when ABS is
z
High frequency electromagnetic interference
z
The sensor or the sensor harness is
interfered by the high frequency electromagnetic wave or the microprocessor regards the input speed signal as false.
damaged z Abnormal Inspect output voltage of the sensor
Inspect the sensor Normal
Normal
Replace ABS ECU
Inspect the harness between the sensor and ECU
412
ABS ECU is damaged
Abnormal
Replace the sensor
Common Malfunction Diagnosis Flow of Geely Automobile
No.315 Malfunction check list of malfunction free code 1
The ignition switch is in ON position (the engine is in stall state) while the ABS alarm lamp does not light up
[Description] ABS alarm lamp does not light up. It might be caused by the open circuit of the alarm lamp power return, burnt out of the bulb or damage of the alarm lamp controller.
Possible cause
The fuse is burnt Bulb of ABS alarm lamp is burnt z The power circuit is broken z ABS alarm lamp controller is damaged
z z
Abnormal
Check the ABS alarm lamp fuse in the central electric appliance box
Replace it
Normal Abnormal Inspect the fuse socket of the central electric appliance box
Repair the fuse socket
Normal Remove the ABS ECU joint, and the ignition switch is ON Does the alarm lamp light up?
No
Inspect if bulb of ABS alarm lamp is burnt
Yes Replace it
No Yes Inspect if the wire connecting ABS alarm lamp controller and ECU in ABS harness is short or earthed
Inspect if the power return and the earth return of the alarm lamp in ABS harness is open
Abnormal Replace the harness
Normal Yes Replace the harness
Inspect the connector of the alarm lamp power return and the earth return
Abnormal Repair the connector
Normal No Does the failure recur? Yes Replace the controller
alarm
413
lamp
See the maintenance importance of incidental trouble
Common Malfunction Diagnosis Flow of Geely Automobile
No.316 The ABS alarm lamp is normally open after the engine starts 2
The ABS alarm lamp is normally open after the engine is started.
Possible cause
[Description] The possible cause is that ABS alarm lamp controller is damaged or the ABS alarm lamp return is open.
z z z
The alarm lamp controller is damaged Return of ABS alarm lamp controller is open ABS ECU is damaged
Note: this failure mode confines to the condition of the system being capable of communicating with the failure diagnosis instrument (power supply of ABS ECU is normal) and no malfunction code appeared. Inspect if the wire between ECU and ABS alarm lamp controller is open
Yes Replace the harness
No Inspect the ABS alarm lamp controller
Abnormal Replace it
Normal Replace ABS ECU
No.317 ABS is in abnormal operation 3
ABS is in abnormal operation
Possible cause
[Description] This problem is closely related to the driving condition and the road surface, therefore the failure diagnosis is difficult to be made. However the following inspections can be made provided there is no malfunction code memory.
414
z z z z z z z z
The sensor is of improper installation There is something wrong with the sensor harness The sensor is damaged The tooth ring is damaged The sensor is stained with foreign materials The wheel bearing is damaged ABS HCU (hydraulic unit) is damaged ABS ECU (electric control unit) is damaged
Common Malfunction Diagnosis Flow of Geely Automobile Is the sensor installation correct?
Install it correctly
Yes Abnormal Inspect output voltage of the sensor
Abnormal Inspect each sensor
Replace it
Normal Normal
Abnormal Replace it
Inspect each sensor tooth ring Carry out the hydraulic control unit diagnostic using the failure diagnosis instrument
Normal Inspect the clearance
wheel
Abnormal
bearing
Repair or replace it
Abnormal Replace ABS HCU
Normal
Abnormal
Inspect ABS ECU socket and the central connector
Repair the joint
Normal No Does the failure recur?
Refer to the maintenance gist of incidental trouble
Yes Remove ABS ECU and inspect ABS Does the resistence value between the following terminals of the harness meet the standard value? Standard value: 1.0 ~ 1.3 k; shake the sensor harness and the connector simultaneously during the measurement MK20 I MK20 I/E front left: 4 – 11 1 – 2 front right: 3 – 18 19 – 20 rear left: 2 – 10 5–6 rear right: 1 – 17 22 – 23 Normal Replace ABS ECU
Replace ABS ECU
415
Abnormal Repair the connector
harness
or
the
Common Malfunction Diagnosis Flow of Geely Automobile
No.318 The brake pedal stroke is too long 4
The brake pedal stroke is too long
Possible cause
[Description] Visually inspect if there is any exterior leakage or mechanical failure. Check if there is air in the system by the air exhausting method. Check if the normally closed valve is leaked with the function test of failure diagnosis hydraulic unit.
Visually inspect if the hydraulic pipe joint is leaked
z z z z z
The braking fluid is leaked The normally closed valve is leaked There is air in the system The brake disc is of heavy wear The hand braking is improper adjusted
Abnormal Tighten the pipe joint as required
Normal Inspect worn condition of the brake disc
Abnormal Replace the brake disc
Normal Inspect the hand braking adjust device
Abnormal Replace the hand braking adjust device
Normal Abnormal Air exhaust inspection
Carry out the air exhaust again
Normal Diagnostic and inspect the sealing property of the normally closed valve with the failure diagnosis hydraulic control unit
Abnormal Replace HCU (hydraulic control unit)
416
Common Malfunction Diagnosis Flow of Geely Automobile
No.319 Large force is required to stamp the pedal 5
Large force is required to stamp the pedal
Possible cause
[Description] Inspect the stroke of the booster and the brake pedal with conventional z method. Failure of the normally open valve can be inspected with the function test of the failure diagnosis hydraulic pressure unit. z
Diagnostic and inspect the normally open valve with the failure diagnosis hydraulic control unit
There is something wrong with the booster There is something wrong with the normally open valve
Abnormal Replace HCU (hydraulic control unit)
Normal
Inspect the stroke of the booster and the pedal according to the conventional method of vehicles without ABS
No.320 There is no diagnostic code output 6
There is no malfunction code output (communication with the failure diagnosis instrument is unavailable)
[Description]
ABS ECU power return or the diagnostic line return is open
when the communication with the failure diagnosis instrument is unavailable.
Possible cause
z
The fuse is burnt
z
The diagnostic line is broken or the joint is loose
z
ABS ECU is damaged
z
There is something wrong with the failure diagnosis instrument
417
Common Malfunction Diagnosis Flow of Geely Automobile Is the failure diagnosis instrument capable of communicating with MK20 ABS ECU on other vehicles
No
There is something wrong with the failure diagnosis instrument Carry out the inspection after the repair
Yes Abnormal Inspect ABS power fuse
Replace it
Normal Does there is display on the screen of the failure diagnosis instrument No
Inspect the power line, earth wire, diagnostic wire and its connection of the diagnostic connector
Abnormal
Yes Remove ABS ECU joint Inspect if ECU relative terminal in ABS harness (MK20I is terminal 13, MK20I/E is terminal 7) and the diagnostic connector (terminal 7 in the failure diagnosis instrument) are conductive
No
Repair the diagnostic connector or ABS harness
Conductive Replace ABS ECU
418
Repair diagnostic connector harness
the or
Common Malfunction Diagnosis Flow of Geely Automobile
No.321 ABS system inspection Inspection items
Ignition switch gear
Terminal MK20 I
Standard value
Unit
V
MK20 I/E
Battery voltage (motor)
OFF
25 – 8
10.1 – 14.5
Battery voltage (electromagnetic valve)
↑
9 – 24
↑
Power insulation property
↑
Earth insulation property
↑
Supply voltage
ON
8 – 23
8–4
V
0.00 – 0.5
V
↑
V
10.0 –14.5
V
Alarm lamp off
Visual inspection
ON
Alarm lamp on
Visual inspection
OFF
Alarm lamp off
Visual inspection
8 – 24 8 – 23
8–4
OFF ECU not connected
ABS alarm lamp
ECU connected The alarm lamp lights up, and lights off after Visual inspection 1.7 seconds
ON
Function of brake lamp switch Pedal not stampped down
Function of brake lamp switch Pedal stampped down
Diagnostic joint
Resistance value of left front wheel speed sensor
ON
8 – 12
8 – 18
0.0 – 0.5
V
ON
8 – 12
8 – 18
10.0 – 14.5
V
OFF
Diagnostic joint K and 13
Diagnostic joint K and 7
0.0 – 0.5
OFF
11 – 4
1–2
1.0 – 1.3
k
419
Common Malfunction Diagnosis Flow of Geely Automobile
Resistance value of right front wheel speed sensor
OFF
18 – 3
19 – 20
1.0 – 1.3
k
Resistance value of left rear wheel speed sensor
OFF
2 – 10
5–6
1.0 – 1.3
k
Resistance value of right rear wheel speed sensor
OFF
1 – 17
22 - 23
1.0 – 1.3
k
Output voltage of left front wheel sensor
OFF
11 – 4
1–2
3.4 – 14.8
mV/ Hz
Output voltage of right front wheel sensor
OFF
18 – 3
19 – 20
3.4 – 14.8
mV/ Hz
Output voltage of left rear wheel sensor
OFF
2 – 10
5–6
>12.2
mV/ Hz
Output voltage of right rear wheel sensor
OFF
1 – 17
22 - 23
>12.2
mV/ Hz
Output voltage ratio of sensor
Model identification
Max. peak voltage Min. peak voltage ≦2
OFF
For example: 15 – 21 (Jetta 5V) 6 – 22(Santana 2000) The detail refer to relative ABS electric wiring diagram
420
0.0 – 1.0
Common Malfunction Diagnosis Flow of Geely Automobile
Inspection items
Key switch gear
Operation
Standard value
Remark
Note: there must have the vacuum acting on the vacuum booster when the following inspections are made. The pedal does not go down ON
Pedal
when the left front wheel is
Tightness of left front
Inspection to the normally closed valve
incapable of rotating
wheel normally open valve and normally
ON
closed valve
(two valves and the pump power on
The pedal does not go down Pedal
when the left front wheel is capable of rotating freely
simultaneously)
The pedal does not go down ON
Inspection to normally open valve
Pedal
when the right front wheel is
Tightness of normally
Inspection to the normally closed valve
incapable of rotating
open valve and normally closed valve of
ON
front right wheel
(two valves and the pump power on
The pedal does not go down Pedal
when the right front wheel is capable of rotating freely
simultaneously)
The pedal does not go down ON
Inspection to normally open valve
Pedal
when the left rear wheel is
Tightness of normally
Inspection to the normally closed valve
incapable of rotating
open valve and normally closed valve of rear left wheel
ON (two valves and the pump power on
The pedal does not go down Pedal
when the left rear wheel is capable of rotating freely
simultaneously)
The pedal does not go down ON
Inspection to normally open valve
Pedal
when the rear right wheel is
Tightness of rear right
Inspection to the normally closed valve
incapable of rotating
wheel normally open valve and normally
ON
closed valve
(two valves and the pump power on
The pedal does not go down Pedal
when the rear right wheel is capable of rotating freely
simultaneously)
421
Inspection to normally open valve
Common Malfunction Diagnosis Flow of Geely Automobile
No.322 ECU code When replacing HECU or ECU, code new ECU, otherwise ABS warning lamp will flash and the system can not operate normally. Code ECU with diagnosis scanner as following procedures: Connect diagnosis scanner and diagnosis socket
Enter controller code at address (Addresswort eingeben)
Input 01 and press F1 at function select (Funktion anwählen)
Input relevant vehicle code at code input (see ABS elementary diagram MK20, No.01901, and MK60, No.0004097)
Display input number, press →
Input 01 at function select (Funktion anwählen), press F1
End
422
Common Malfunction Diagnosis Flow of Geely Automobile
No.323 Fluid filling and air exhaust Wet HCU When equipped with wet HCU, implement fluid filling and air exhaust according to the requirements of normal brake system after HCU replaced.
Dry HECU When equipped with dry HECU, after replacing HECU, not only implement fluid filling and air exhaust according the requirements of normal brake system, but also implement air exhaust to 2nd circuit of HECU. The procedures when operating with diagnosis scanner are as follows: Implement fluid filling and air exhaust, until there is no bubble in transparent pipe.
Connect diagnosis scanner and diagnosis socket
At address (Addresswort ein-geben) basic setting, press F1
Ehnter 01 at function select (Funktion anwählen), press F1
Enter 01 at group number input (Anzeigegruppen-nummer eingeben), press F1
Turn to next page
423
Common Malfunction Diagnosis Flow of Geely Automobile Continued from previous page
Pedal betätigung und halten… Press brake pedal and hold, hydraulic pump operates, pedal rebound
Pedal lösen, VR/ VL, Entlüfter-schraube, auf <↑> Loose brake pedal, and air drain screws on left and right brake caliper， press ↑
Pedal
10×betätigung,
Ent-lüfterschraube,zu
<↑>
Press brake pedal 10 times and tighten the air drain screws on left and right brake caliper, press ↑
Repeat step I, II, and III for 7 times.
Teilentlüftung beendet… Screen display, air exhaust finished, press → and return to function select menu.
Enter 02 at function select (Funktion anwählen), press F1
End
424
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